Oregon Micro Systems PC46 family User manual

USER’S MANUAL
INTELLIGENT MOTOR CONTROLLERS
PC46 FAMILY
OREGON MICRO SYSTEMS, INC.
TWIN OAKS BUSINESS CENTER
1800 NW 169th PLACE, SUITE C100
BEAVERTON, OR 97006
PHONE [phone]
FAX [phone]
EMAIL [email protected]
WEB SITE www.OMSmotion.com

COPYRIGHT NOTICE
© 2001 Oregon Micro Systems, Inc., A Pro-Dex Company ALL RIGHTS RESERVED
This document is copyrighted by Oregon Micro Systems, Inc. You may not reproduce, transmit, transcribe, store
in a retrieval system, or translate into any language in any form or by any means, electronic, mechanical,
magnetic, optical, chemical, manual, or otherwise, any part of this publication without the express written
permission of Oregon Micro Systems, Inc.
TRADEMARKS
IBM, IBM PC, IBM PC/XT, IBM PC/AT, IBM PS/2 and IBM PC DOS are registered trademarks of International
Business Machines Corporation.
DISCLAIMER
Oregon Micro Systems, Inc. makes no representations or warranties regarding the contents of this document.
We reserve the right to revise this document, or make changes to the specifications of the product described
within it at any time without notice and without obligation to notify any person of such revision or change.
3301-0500000
Revision F

TABLE OF CONTENTS 1. GENERAL DESCRIPTION
PC46 User’s Manual i
TABLE OF CONTENTS
1. GENERAL DESCRIPTION
INTRODUCTION ............................................................................................. 1-1
FUNCTIONAL DESCRIPTION......................................................................... 1-1
VELOCITY PROFILES .................................................................................... 1-3
2. GETTING STARTED
INTRODUCTION ............................................................................................. 2-1
JUMPERS........................................................................................................ 2-2
HARDWARE INSTALLATION ......................................................................... 2-4
SOFTWARE INSTALLATION.......................................................................... 2-5
MOTOR CONTROL CONNECTOR ................................................................. 2-5
3. I/O CHANNEL INTERFACE
I/O CHANNEL.................................................................................................. 3-1
PC/AT DATA BUS................................................................................ 3-1
PC/AT ADDRESS BUS ........................................................................ 3-1
MEMORY AND I/O CONTROL............................................................. 3-1
INTERRUPT REQUEST....................................................................... 3-1
CLOCK AND OSC LINES .................................................................... 3-2
RESET DRV......................................................................................... 3-2
I/O CH RDY.......................................................................................... 3-2
I/O CH CK ............................................................................................ 3-2
ADDRESS SELECTION .................................................................................. 3-3
USING INTERRUPTS...................................................................................... 3-5
I/O REGISTERS .............................................................................................. 3-5
DATA REGISTER ................................................................................ 3-5
DONE FLAG REGISTER ..................................................................... 3-5
INTERRUPT CONTROL REGISTER ................................................... 3-6
STATUS REGISTER............................................................................ 3-6
POWER SUPPLY REQUIREMENTS............................................................... 3-7
4. DRIVER INTERFACE
OUTPUT CONNECTIONS............................................................................... 4-1
MULTI-AXIS SYNCHRONIZATION ................................................................. 4-4
LIMIT AND HOME LINES ................................................................................ 4-5
FUSED PROTECTION .................................................................................... 4-5
5. ENCODER OPTION
INTRODUCTION ............................................................................................. 5-1
MODES OF OPERATION................................................................................ 5-1
ENCODER SELECTION AND COMPATIBILITY ............................................. 5-1

TABLE OF CONTENTS 6. COMMAND STRUCTURE
PC46 User’s Manual
ii
ENCODER INTERFACE ..................................................................................5-1
HOME PROCEDURES.....................................................................................5-3
6. COMMAND STRUCTURE
INTRODUCTION..............................................................................................6-1
COMMAND QUEUES.......................................................................................6-2
COMMAND SUMMARY....................................................................................6-2
AXIS SPECIFICATION COMMANDS...............................................................6-6
SYSTEM CONTROL COMMANDS ................................................................6-10
USER I/O COMMANDS..................................................................................6-16
MOVE SPECIFICATION COMMANDS...........................................................6-21
MOVE EXECUTION COMMANDS .................................................................6-29
MOVE TERMINATION COMMANDS .............................................................6-33
LOOP CONTROL COMMANDS.....................................................................6-35
HOME AND INITIALIZATION CONTROL COMMANDS.................................6-40
MOVE SYNCHRONIZATION COMMANDS....................................................6-43
SYSTEM STATUS REQUEST COMMANDS..................................................6-49
USER UNIT COMMANDS ..............................................................................6-55
POSITION MAINTENANCE COMMANDS .....................................................6-56
SLIP AND STALL DETECTION COMMANDS................................................6-60
ENCODER TRACKING COMMANDS ............................................................6-62
ENCODER HOME CONTROL COMMANDS..................................................6-63
ENCODER STATUS REQUEST COMMANDS ..............................................6-64
VELOCITY STAIRCASE COMMANDS...........................................................6-66
CONSTANT VELOCITY CONTOURING........................................................6-69
7. HOST SOFTWARE
INTRODUCTION..............................................................................................7-1
PROGRAM FILES............................................................................................7-1
DRIVER SUPPORT..........................................................................................7-1
DEVICE DRIVER INSTALLATION........................................................7-1
COMMAND LINE OPTIONS .................................................................7-2
BOARD STATUS MESSAGE HANDLING ............................................7-3
OTHER DEVICE DRIVER FEATURES.................................................7-3
INTERFACING TO THE DEVICE DRIVER...........................................7-4
MULTIPLE BOARDS IN ONE COMPUTER..........................................7-6
8. SERVICE
USER SERVICE...............................................................................................8-1
THEORY OF OPERATION ..............................................................................8-1

TABLE OF CONTENTS A. LIMITED WARRANTY
PC46 User’s Manual iii
A. LIMITED WARRANTY
B. TECHNICAL INFORMATION / RETURN FOR REPAIR PROCEDURES
C. SPECIFICATIONS
INDEX

TABLE OF CONTENTS INDEX
PC46 User’s Manual
iv
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1. GENERAL DESCRIPTION INTRODUCTION
PC46 User’s Manual 1-1
1.
GENERAL DESCRIPTION
1.1. INTRODUCTION
The PC46 family of intelligent motion controls can manage as many as 6 axes of motion
in one I/O slot of a PC/AT or compatible computer. They meet the IBM I/O channel
specifications and can be plugged directly into the backplane of these machines. The
PC46-2E can, for example, simultaneously control two axes of step motors while monitor-
ing their actual position with the built in incremental encoder interface. It can manage
coordinated or independent motion on each of the four axes simultaneously.
The PC46 functions as a motion coprocessor within the PC/AT or compatible computer. It
utilizes a 68332 microprocessor and patented proprietary technology (patent number
4,734,847) to control direction of motion, acceleration, deceleration and velocity of an
associated motor. In response to commands from the host computer, the PC46 controller
will calculate the optimum velocity profile to reach the desired destination in the minimum
time while conforming to the programmed velocity and acceleration parameters.
The PC46 family of controllers, when combined with Oregon Micro Systems’ drivers, can
employ ‘microstepping’ techniques for increased position resolution and decreased low
speed resonance. When combined with the appropriate Oregon Micro Systems’ driver
and step motor, the normal step angle can be divided into as many as 128 microsteps per
step.
Commands may be sent to the PC46 by simple I/O commands using virtually any
language on the PC which has the ability to do I/O. It is easily programmed using ASCII
character strings. For a typical motion requirement of 1,000,000 pulses at 400,000
pulses/sec and an acceleration of 500,000 pulses/sec2the following string would be sent
from the host computer to the PC46:
VL400000 AC500000 MR1000000 GO
For additional programming examples see Section 6.
1.2. FUNCTIONAL DESCRIPTION
The PC46, in response to commands from the host computer, provides controlled
acceleration to a predefined peak speed followed by a constant velocity and controlled
deceleration to a stop. This is achieved by calculating the optimum velocity 1024 times
each second (512 times each second on the PC46-21 and PC46-41 models), providing a
very smooth acceleration curve. This calculation is used to control a variable frequency
pulse train which is derived from a crystal oscillator providing very accurate pulse rates.
The 68332 microprocessor calculates this velocity profile for each of the axes providing
independent but synchronized (if desired) profiles for each axis. The PC46 can perform a

FUNCTIONAL DESCRIPTION 1. GENERAL DESCRIPTION
PC46 User’s Manual
1-2
smooth coordinated move on up to six axes using linear, parabolic or cosine velocity
profiles. It can manage as many as six independent or coordinated processes.
The PC46 will calculate the optimum velocity profile to generate the desired move, while
conforming to the acceleration and velocity data input by the host computer. This move
will consist of a smooth acceleration, followed by a constant velocity section and a smooth
deceleration to the desired distance. A graph of a typical linear velocity is shown in
Figure 1-1.
FIGURE 1-1 TYPICAL VELOCITY PROFILE
If the move parameters do not allow the motor to accelerate to the desired velocity in the
desired distance, the PC46 will automatically generate an optimum triangular velocity
profile. It can also be commanded to accelerate to a velocity and hold that velocity until
told to stop or change to a new velocity. It will then smoothly decelerate to a stop or
accelerate/decelerate to the new velocity.
Several moves of this type may be chained together to provide a more complex pattern.
The PC46 is able to store up to 124 characters in an input character buffer, plus a
separate 200 command and parameter queue for each axis, allowing several moves to be
made without host intervention. A loop counter is provided to repeat desired sections of a
complex move pattern. Loops may be nested up to four levels deep on all axes.

1. GENERAL DESCRIPTION VELOCITY PROFILES
PC46 User’s Manual 1-3
1.3. VELOCITY PROFILES
The PC46 offers three options for ramping the device to speed. The traditional constant
acceleration or linear velocity ramp (see Figure 1-1) is the default at power up or reset.
The half sinusoid acceleration or half cosine velocity ramp (see Figure 1-3) is selected by
the CN command. Since the acceleration is zero at the velocity inflection points, this
offers very smooth operation. It is used in sensitive applications such as wafer handling
on a vacuum chuck. The third option is a reverse ramp of acceleration or parabolic
velocity curve (see Figure 1-2), which can be selected by the PN command. This ramp is
commonly used to compensate for loss of motor torque at high speeds, i.e. since the
acceleration is reduced at higher speeds the required forces are reduced proportionally.
The parabola may be truncated to allow the user to select, under program control, the
reduction in acceleration (force) appropriate for the application.
LINEAR RAMPS. The OMS controls generate a linear velocity ramp in real time, i.e. while
the stage is in motion. There is no table building prior to the move and thus minimal
latency. The controls will accelerate to the specified velocity and hold that speed until just
enough move distance is left, then decelerate to a stop. If the move distance is too short
to reach speed, a triangular velocity ramp will automatically be generated. The
acceleration is a constant Amand the velocity is then:
vAt
m
=
A useful relationship is the distance required to accelerate at acceleration Amto peak
velocity Vpis:
sV
A
p
m
=
2
2
or the acceleration Amrequired to accelerate to peak velocity Vpin distances sis:
AV
s
m
p
=
2
2
PARABOLIC RAMPS. The parabolic ramp is generated in a similar fashion except the
acceleration is reduced as the stage accelerates to speed thus reducing the velocity
slope, as shown in Figure 1-2.
The acceleration follows the equation:
2
00 T
t
AAa −=
and the velocity is then:
2
2
0
02T
tA
tAv −=

VELOCITY PROFILES 1. GENERAL DESCRIPTION
PC46 User’s Manual
1-4
and the distance traveled in the ramp is:
sAt At
T
=−
0
2
0
3
2
26
where A0is the initial acceleration, tis time during the ramp and T2is total ramp time if
the acceleration had reached zero. The parameter supplied with the PN command is 10
times the ratio t
T2
which can take on values from 3 to 10, allowing the final acceleration to
range from 70% to 10% respectively of the programmed or initial value. When a move is
specified, the controls will fit the resulting velocity curve to the desired acceleration profile.
This insures that the desired acceleration is always reached at the programmed velocity,
as long as the move is long enough for the stage to reach the programmed speed. If the
move is too short to reach the programmed speed the curve is truncated, causing the
shape of the velocity curve to remain the same up to the velocity reached by the specific
move. This is consistent with the desired result of compensating for loss of motor torque.
Since the motor has not reached the programmed speed, less compensation is needed.
The parabolic ramp mode may result in reduced move time at high speeds, since a larger
acceleration may be used.
FIGURE 1-2 PARABOLIC VELOCITY PROFILE
COSINE RAMPS. The cosine ramps are generated in a similar fashion to the parabolic
ramps, except the acceleration is:
aA A
Vt
mm
p
=sin 2
Acceleration
Velocity
Time