Nutfield Technology USC-1 User manual
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Contents
SURFBOARD USB USERS MANUAL........................................................................................1
Nutfield Technology, Inc. .......................................................................................................1
Introduction........................................................................................................................... 4
Version History ................................................................................................................... 4
Safety.................................................................................................................................. 5
Overview ............................................................................................................................ 5
Position Within The System ................................................................................................6
Features.............................................................................................................................. 6
Board And Connectors ........................................................................................................... 7
USB ..................................................................................................................................... 8
Power, Laser, OptoI/O, RS232............................................................................................. 9
Power .............................................................................................................................. 9
Laser .............................................................................................................................. 10
Opto I/O......................................................................................................................... 13
RS232............................................................................................................................. 14
XY2-100 Interface ............................................................................................................. 14
LED Indicators ................................................................................................................... 14
Installation........................................................................................................................... 15
Marking On The Fly.............................................................................................................. 15
Overview .......................................................................................................................... 15
Encoder Signals................................................................................................................. 16
Principle Of Working......................................................................................................... 16
Connecting The Encoder Signals ....................................................................................... 17
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Configuring USC-1.......................................................................................................... 17
Pin Connection............................................................................................................... 18
Software Settings........................................................................................................... 19
First Steps / Getting Started................................................................................................. 20
Hardware Installation ....................................................................................................... 20
Installation........................................................................................................................ 21
sc_usc_server.exe............................................................................................................. 22
Visible Mode.................................................................................................................. 23
Test................................................................................................................................ 24
Reconnect...................................................................................................................... 24
sc_usc.cfg ...................................................................................................................... 25
sc_usc_card_ids.txt........................................................................................................ 25
MultiCard....................................................................................................................... 26
sc_setup.exe ..................................................................................................................... 27
HardwareSettings .......................................................................................................... 27
Diagnostics .................................................................................................................... 30
Appendix.............................................................................................................................. 31
USC-1 Dimensions............................................................................................................. 31
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Introduction
Figure 1.1: USC-1 USB Scanner Controller V1.2
Version History
Date
Changes
10.01.2008 Chapter Marking On The Fly and chapter Appendix added
26.02.2008
Note concerning the AEB-1 signals added
27.03.2008
Maximum XY2-100 cable length updated
08.09.2008
Index updated
04.11.2008 Chapter Analog Extension updated
09.04.2009
Figures and section USB updated
14.04.2009
Layout changed
02.11.2009 - Output current for Laser Signals and LaserPort added
- Threshold level for MOTF signals added
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26.03.2010
Explanation of Analog Output jumper updated
10.12.2010
Chapter "First Steps / Getting Started" added; Layout changed
12.02.2013
Section "Hardware Installation" to "First Steps" added
Table 1.1: Version history
Safety
The goods delivered by Nutfield are designed to control a laser scanner system. Laser
radiation may affect a person's health or may otherwise cause damage. Prior to installation
and operation compliance with all relevant laser safety regulations has to be secured. The
client shall solely be responsible to strictly comply with all applicable and relevant safety
regulations regarding installation and operation of the system at any time.
The goods will be delivered without housing. The client shall be solely responsible to strictly
comply with all relevant safety regulations for integration and operation of the goods
delivered.
Overview
The USC-1 interface module is designed for controlling a 2-axis galvanometric scanner
system. It supplies also all necessary signals for laser and external control. As an option, the
control of a 3-axis system is also possible.
The controller commands are downloaded via the USB (Version 1.1 or 2.0) interface from
the connected host system. The received commands are stored in a data buffer. When a
block of valid data is available the system enables it for execution while filling additional
buffer blocks with new data transmitted from the host system.
The command size varies from 1 to 6 bytes per command. Depending on the command the
USC-1 can execute 10-30 commands in a 10 us (default) output interval. The maximum
download rate is 1 Mbytes/sec for USB 1.1 and 40 Mbytes/sec for USB 2.0.
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Position Within The System
Figure 1.2: USC-1 integration
Features
The USC-1 has the following key features:
USB 1.1 - 2.0 micro controller on board :
256 Kbytes SRAM for USB data buffering
10 us cycle time
Laser control:
Laser Gate Output:
Laser On and Off delay with 500 ns resolution
Optocouplers TTL level/5 mA output current
Q-Switch output:
Frequency resolution: 41.7 ns (24 MHz clock)
Pulse length resolution: 41.7 ns
Optocouplers TLL level /5 mA output current
First pulse killer output:
Resolution 41.7 ns
Optocouplers TTL level/5 mA output current
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Scanner control:
XY2-100 digital interface
Special digital interface to SCAPS analog board
2 x 8 bit analog channels with 2.5, 5, 10 V output range
1 x 8 bit TTL output port.
External control:
6 opto-insulated outputs
6 opto-insulated inputs (2 - 24 V level)
RS 232 interface
Optional:
digital-analog converter board
control of 3-axis system
MarkingOnTheFly
Power:
Digital and Laser Analog:
+5 V /1.6 A
Board And Connectors
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Figure 2.1: USC-1 jumper
USB
Standard USB Series B Connector, self powered configuration. The maximal cable length
with standard cables is 5 meters, with repeaters up to 25 meters.
Note:
Connection problems can also result from ground loops. To avoid these loops there is a
solder jumper on the bottom side of the USC-1. If the jumper is closed (by default), the cable
shield is connected to the USC-1 ground. Open the jumper to disconnect USC-1 ground and
cable shield.
Figure 2.2: USB cable shield closed (default)
Figure 2.3: USB cable shield open
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Power, Laser, OptoI/O, RS232
This connector provides all signals commonly used to control laser interfaces and allows to
connect external control units like SPS, PC etc. over opto-insulated IO lines. It also provides
the power lines when driving the unit in self powered mode.
Figure 2.4: 37-pin connector assignment
Power
The USC-1 can operate in USB bus powered or self powered mode.
Bus Powered
The USB specification allows drawing 500 mA from the USB power line. The power
consumption of the USC-1 depends on several conditions and can exceed significantly this
upper limit. Although the most USB host systems allow drawing much more power over the
USB line, this mode should be only used for test and evaluation purpose. Next to the
allowed power rate only shorter USB cables should be taken in account since due to the
cable resistance the available voltage on the board itself could go below internal allowed
values.
Self Powered
Self powered mode can be achieved by applying +5 V on VCC pin (pin 24) with respect to
the GND pins (pin 25, 14, 15).
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Figure 2.5: USC-1 power connection
Warning:
To avoid conflicts with the USB power line, Jumper 4 must be removed.
Laser
Gate, LaserA, LaserB
All 3 outputs can operate in opto-insulated mode. For this the LASER_OPTO_VCC (pin 11)
and LASER_OPTO_GND (pin 30) must provide the supply. LASER_OPTO_VCC may not
exceed +5 V with respect to LASER_OPTO_GND.
The maximum output current is 17 mA.
As default the optocouplers take their supply from internal VCC, which causes to eliminate
the opto insulation. In this case the voltages of all 3 outputs are TTL compatible in respect
to GND. The mode can be selected by jumpers JP1 (GND), JP2 (VCC) as shown in figures 2.6a
and 2.6b.
Figure 2.6a: Laser signal optocouplers external supply
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Figure 2.6b: Laser signal optocouplers internal supply (default)
The polarity of the Gate, Laser A and Laser B outputs is selected with jumper JP3 as shown
in figures 2.7a and 2.7b.
Figure 2.7a: Laser signal polarity active low (default)
Figure 2.7b: Laser signal polarity active high
Note:
During startup and when the laser signals are disabled by software, the Gate, LaserA and
LaserB outputs will go into tri-state. It must be sure that the Laser defaults to a safe
operation in this case.
For YAG style laser mode the output timing (active low mode) is as follows:
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Figure 2.8: YAG laser control signals
Analog A And Analog B
Analog A and Analog B are the outputs of the internal 8 bit D/A converters and provide
signals in the range from 0..2.5 V (position 1), 0..5 V (position 2) or 0..10 V (position 3) with
respect to GND with a current of max. 10 mA. The supply for this circuit is generated on
board from the +5 V main supply.
Figure 2.9: Analog output range selection
The output range can be selected by jumpers J5 (Analog A) and J6 (Analog B). The above
example shows the settings for the +5 V range for both outputs (default).
Parallel Port LP0 - LP7
The 8 bit parallel port LP 0...LP 7 provides TTL output signals. All levels are defined in
respect to GND.
The maximum output current is 30 mA.
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Opto I/O
The I/O section provides opto-insulated In/Outputs and can be used to work with attached
machinery/footswitches for triggering and so on.
By default following I/Os are used:
Opto input 0 for external start triggering (mark start, rising edge starts marking if
software enabled this behavior)
Opto input 1 for external stop triggering (mark stop, rising edge stops a currently
running marking process)
Opto output 0 as marking signal (mark in progress, signal goes to high as long as
marking is in progress)
The optocouplers need an external supply OPTO_V+ (pin 5) , OPTO_GND (pin 6).
OPTO_V+ must be in the range of +5 V to +24 V in respect to OPTO_GND.
By connecting the pins VCC (pin 24) with OPTO_V+ and GND (pin 25) with OPTO_GND the
circuit is supplied with the internal +5 V. OPTO_OUT0 is used as Mark in Progress flag and is
parallelly driven with the Mark In Progress indicator LED.
The input activate threshold point is at +2 V. To increase it an approriate external resistor
RExt must be added. The voltage on OPTO_IN(0..5) may not exceed +24 V in respect to
OPTO_GND.
Figure 2.10: schematic optocoupler input and output circuit
Note:
WaveRunner uses OPTO_IN0 for external trigger start and OPTO_IN1 for stop. OPTO_OUT0
is reserved for mark in progress.
The current consumption of the optocouplers is about 10 mA.
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RS232
The RxD and TxD lines are defined in respect to the connected device. So the USC-1 RxD pin
should be connected to the device RxD pin and the same for the TxD pins. The baud rate
can be defined between 2400 and 57600.
XY2-100 Interface
The connector X4 provides the standard XY2-100 Interface.
Figure 2.11: XY2-100 interface connector assignment
N.C. : Do not connect
Warning:
Make sure that the scan head and the USC have the same ground potential, to avoid
damages caused by ESD.
LED Indicators
The two LED Indicators have the following function:
Figure 2.12: LED indicators
Device State (green color):
In general when blinking or Off the device is not operational.
Specific:
Blinking with 1 sec period: After device has booted from the on board
EEPROM.
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Blinking with 0.2 sec period: The FPGA program is downloaded via USB.
Staying ON: Device is operational.
Mark In Progress (red color):
This LED is parallel with the opto-insulated OPTO_OUT 0 (pin 3) output of the 37-pin
connector. It is ON during mark.
Installation
For detailed information on installation and setup see chapter First Steps / Getting Started.
Marking On The Fly
Overview
The typical marking on the fly setup is shown below:
Figure 5.1: Marking on the fly setup
The target piece is placed on a moving belt. The movement of the belt is measured by a
rotary encoder. The encoder signals are decoded by the USC-1 logic into a distance
information which in turn is transferred to the Scan head to compensate the target
movement. A photo sensor acts as a synchronization element by delivering a start impulse
to the USC-1. This start impulse typically resets the USC-1 distance counter and initializes
marking.
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Encoder Signals
The USC-1 is designed to handle two 90° shifted encoder signals delivered by standard
commercial encoders. The USC-1 decoder interprets each transition, whether it is on
MOF_CH0 or Channel MOF_CH1, as a count impulse. The up/down information (which
reflects the moving direction of the belt) is taken from the order of transitions and the state
for both channels. If for example MOF_CH0 is high while MOF_CH1 goes from low to high
(Point A) the direction is up. If MOF_CH0 is low while MOF_CH1 goes from low to high
(Point B) the direction is down. Similar rules are valid for other combinations of channel
state and transitions.
Therefore exchanging the MOF_CH0/MOF_CH1 wiring from the encoder to the USC-1 or
inserting inverting elements will not affect the count pulses but will affect the up/down
information encoding.
Figure 5.2: Encoder signals
Principle Of Working
The USC-1 internal logic for decoding the encoder signals MOF_CH0 and MOF_CH1 is
shown below.
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Figure 5.3: Principle of working
The MOF_CH0 and MOF_CH1 signals are filtered by an analog and digital filter unit. The cut
off frequency is 300 kHz leading to 4 times more maximal count frequency of 1.2 MHz After
the decoding a counter counts the incoming count pulses and is incremented or
decremented according to the up and down information. In some applications the belt
movement direction and speed remains constant. In this case the count and up/down
information can be generated by an internal Simulation Generator eliminating the need for
an encoder. The count frequency is fixed to 100 kHz.
In order to calibrate the counter to the scanner field units [typically in bits, mm or inch] the
counter value is multiplied by a user definable signed constant. The resulting distance
information is added to the marking information to form the final scan head control signals.
Connecting The Encoder Signals
Configuring USC-1
In order to use the marking on the fly inputs MOF_CH0 and MOF_CH1, USC-1 jumpers on
the bottom side have to be set as shown in the figures 5.4 and 5.5.
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Figure 5.4: USC-1 board – bottom view
Figure 5.5: Marking on the fly setup
Pin Connection
The encoder signals MOF_CH0 and MOF_CH1 must be connected to the USC-1 37-pin
connector. The signal level may not be below –0.5 V or above +7 V with respect to ground
(GND).
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The threshold level for the signal inputs is 3.4 V.
Software Settings
The marking on the fly settings can be edited within the USC-1 global settings dialog.
Figure 5.6: Software settings
Enable: Generally enables the marking on the fly mode.
Simulation: Takes the internal 100 kHz clock generator as clock source.
Multiplier: Defines the multiply constant for converting Count pulses to field units.
In the above example 1 count equals 1 µm.
For a 100 mm field and the internal 100 kHz clock the marking of the fly speed
is 100 mm / sec.
The multiplier may also have negative sign. This can be used to invert the
compensation direction.
X/Y Channel: Compensate along the Scanner X or Y axis.
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First Steps / Getting Started
Install the latest version of WaveRunner, which can be downloaded here:
WaveRunner Download
Hardware Installation
Installing USC hardware
Stop:
Read the information in this chapter very careful. Wrong power supply or inappropriate
components could result in hardware damage!
Note:
The USC will be delivered without housing, all relevant safety regulations for integration and
operation have to be complied. Mounting the scanner controller in an small housing will
require an extra air ventilation to avoid a critical increase in temperature.
Power supply
It's highly recommended to supply the USC board via an external power supply. By default
the jumper for bus powered mode is closed for first tests and evaluation purpose. This
jumper has to be removed before an external power supply is connected. Please verify to
connect the USC board to the external power supply before the voltage is applied. More
information can be found in the chapter.
Scan head
As a general rule only shielded data cables should be used to connect to scan head to the
scanner controller. It's elemental that the cable shield is aligned to electric shield of the
scanner controller. To avoid electrical damage to the scan head or scanner controller
ensure that both are current less during every connection and disconnection. The potential
difference between the mass potentials of the scanner controller and scan head should not
excess ±7 V.
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