PMC MultiFlex PCI 1000 Series User manual

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MultiFlexPCI
1000 Series
PCI Motion Controller - User’s Manual
Revision 2.5
Precision MicroControl Corporation
2075-N Corte del Nogal
Carlsbad, CA 92009 * USA
Tel: [phone]
Fax: [phone]
www.pmccorp.com
Information: [email protected]
Technical Support: [email protected]
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Precision MicroControl Corp.
LIMITED WARRANTY
All products manufactured by PRECISION MICROCONTROL CORPORATION are guaranteed to be free
from defects in material and workmanship, for a period of 2 years from the date of shipment. Liability is
limited to FOB Factory repair, or replacement, of the product. Other products supplied as part of the
system carry the warranty of the manufacturer.
PRECISION MICROCONTROL CORPORATION does not assume any liability for improper use or
installation or consequential damage.
© Copyright Precision Micro Control Corporation, 2004-2012. All rights reserved.
Information in this document is subject to change without notice.
Intel is a registered trademark of Intel Corporation.
Microsoft®and Windows®are registered trademarks of Microsoft Corporation.
Acrobat®and Acrobat Reader®are registered trademarks of Adobe Corporation.
Precision MicroControl Corp.
2075-N Corte del Nogal
Carlsbad, CA 92011 • USA
Tel: [phone]
Fax: [phone]
Web: www.pmccorp.com
Email: [email protected]
[e-mail]
[email protected]
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MultiFlex PCI 1000 Series User's Manual
i
Table of Contents
Prologue.......................................................................................................................................................3
Introduction .................................................................................................................................................5
Motion Control Primer..............................................................................................................................11
Axis I/O....................................................................................................................................................15
The Command Set - the heart of the motion controller...........................................................................16
Executing Operations with MCCL ...........................................................................................................17
Closed loop, open loop, and position verification....................................................................................20
Why does a servo need to be tuned?......................................................................................................22
Position Feedback - Quadrature Incremental Encoder...........................................................................24
Servo Amplifiers: Current Mode versus Velocity Mode...........................................................................25
Stepper Motors - Full Step versus Micro Step ........................................................................................26
Homing - Why, When, and How..............................................................................................................27
Software, Programming and Utilities......................................................................................................29
Controller Interface Types.......................................................................................................................30
Building Application Programs using Motion Control API .......................................................................31
MCSpy - application program diagnostic tool..........................................................................................36
PMC Sample Programs...........................................................................................................................37
Motion Control API On-line Help.............................................................................................................38
Motion Integrator .....................................................................................................................................40
PMC Utilities............................................................................................................................................43
Connecting to the Controller ...................................................................................................................47
+/- 10V Analog Servo Command Connections .......................................................................................48
PWM (Pulse Width Modulation) Command Connections........................................................................49
Pulse Command Connections.................................................................................................................51
Amplifier / Driver Enable Connections - Low Active................................................................................52
Driver Disable Connections - Low Active................................................................................................53
Amplifier / Driver Enable Connections - High Active...............................................................................54
Amplifier / Driver Fault Connections........................................................................................................55
Differential Incremental Encoder Connections........................................................................................56
Single Ended Incremental Encoder Connections....................................................................................57
Over-Travel Limit Connections................................................................................................................58
Home Sensor Connections .....................................................................................................................60
TTL Digital Input Connections.................................................................................................................61
TTL Digital Output Connections..............................................................................................................62
A/D Input Connections wiring example ...................................................................................................63
Watchdog Relay Connections.................................................................................................................64
Motion Control...........................................................................................................................................65
Servo (analog command) Axis Setup......................................................................................................65
Tuning the Servo.....................................................................................................................................68
Moving Servo Axes with Motor Mover.....................................................................................................77
Stepper (pulse command) Axis Setup.....................................................................................................78
Moving Stepper Axes with Motor Mover..................................................................................................85
Contour Motion (arcs and lines)..............................................................................................................91
Electronic Gearing.................................................................................................................................100
Jogging..................................................................................................................................................101
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Table of Contents
Precision MicroControl Corp.
ii
Defining Motion Limits...........................................................................................................................102
Homing Axes.........................................................................................................................................105
Motion Complete Indicators...................................................................................................................117
On the Fly changes ...............................................................................................................................119
Feed Forward (Velocity, Acceleration, Deceleration)............................................................................120
Save and Restore Axis Configuration Settings.....................................................................................122
Application Solutions.............................................................................................................................123
Backlash Compensation........................................................................................................................123
Emergency Stop....................................................................................................................................125
Encoder Rollover...................................................................................................................................127
Flash Memory Firmware Update...........................................................................................................128
Saving and Restoring Axis Configuration Settings................................................................................129
Learning/Teaching Points......................................................................................................................133
Building MCCL Macro Sequences ........................................................................................................135
MCCL Multi-Tasking..............................................................................................................................137
Position Capture....................................................................................................................................140
Position Compare..................................................................................................................................141
Position Verification of an Open Loop Pulse Axis.................................................................................143
PWM Servo Command..........................................................................................................................147
Record Motion Data...............................................................................................................................150
Resetting the Controller.........................................................................................................................151
Single Stepping MCCL Programs .........................................................................................................152
Torque Mode Output Control.................................................................................................................154
Turning off Integral gain during a move.................................................................................................156
Defining User Units................................................................................................................................159
Watchdog Circuit...................................................................................................................................163
General Purpose I/O................................................................................................................................165
Digital I/O...............................................................................................................................................165
Configuring and Exercising the Digital I/O.............................................................................................167
Using the Digital I/O...............................................................................................................................168
A/D Inputs..............................................................................................................................................170
Specifications..........................................................................................................................................173
Motion Control Board.............................................................................................................................173
Analog Command Axis Specifications...................................................................................................174
Pulse Command Axis Specifications.....................................................................................................175
Connectors, I/O and Schematics...........................................................................................................177
VHDCI Connectors................................................................................................................................178
Controller Status LED Indicators...........................................................................................................179
Controller Potentiometers......................................................................................................................180
Connector Pinout – MultiFlex PCI 1440................................................................................................181
Connector Pinout – MultiFlex PCI 1040................................................................................................185
Signal Descriptions................................................................................................................................190
Motor Command Signals.......................................................................................................................190
Encoder Feedback Signals....................................................................................................................191
Default Axis Inputs.................................................................................................................................191
Default Axis Outputs..............................................................................................................................193
Default Configuration of General Purpose I/O ......................................................................................195
Circuit Schematics.................................................................................................................................197
Troubleshooting......................................................................................................................................201
Controller Error Codes...........................................................................................................................211
Motion Control API Error Codes............................................................................................................212
MCCL Error Codes................................................................................................................................213
Glossary...................................................................................................................................................215
Appendix..................................................................................................................................................219
Default Axis Configuration Settings.......................................................................................................219
Index.........................................................................................................................................................221
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MultiFlex PCI 1000 Series User's Manual
3
Prologue
This document provides configuration, programming and application information for the MultiFlex PCI
1000 Series motion controllers. Documentation for this product line includes the following documents:
MultiFlex PCI 1000 Series Quick Start Guide
MultiFlex PCI 1000 Series User’s Manual (this document)
Motion Control API (Application Programming Interface) Reference Manual
Motion Control Command Language (MCCL) Reference Manual
The latest versions of these documents can be downloaded from the Support section of PMC’s web site
at: www.pmccorp.com/support/mfxpci1000.php.
This user manual applies to all MultiFlex PCI 1000 Series models, which include the following:
Table 1. MultiFlex PCI 1000 Series Models
Model Total Analog Step/Dir or Encoder Analog
Axes and/or CW/CCW Channels Inputs
PWM Axes Pulse Axes (standard / (optional)
(Servo) (Stepper/Servo) optional)
MultiFlex PCI 1040 4 - 4 0 / 4 8
MultiFlex PCI 1400 4 4 - 4 8
MultiFlex PCI 1440 8 4 4 4 / 8 8
MultiFlex PCI 1802 8 8* - 8 8
* PWM onlly
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Precision MicroControl Corp.
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MultiFlex PCI 1000 Series User's Manual
5
Introduction
Figure 1. MultiFlex PCI 1000 Series Board Layout
The MultiFlex PCI 1000 Series are programmable, board-level, PCI-bus motion controllers designed for
high-performance multi-axis control of servo and stepper motors and I/O. Features offered by models in
this series include:
Plug & play PCI universal (3.3 & 5V) half-length card
64-bit floating-point RISC CPU for high precision and dynamic range
Customizable FPGA-based I/O architecture
Up to 8 total axes
4 axes analog servo control (models MultiFlex PCI 1400, 1440)
8 axes PWM servo control (model MultiFlex PCI 1802)
Up to 4 axes Step/Dir/CW/CCW pulse control (models MultiFlex PCI 1040, 1440)
Coordinated motion - interpolation, contouring, spline, master/slave, gearing
Trapezoidal, S-curve and parabolic velocity profiles
Chapter
1
I/O Connectors
J1 & J3 LED Status Indicator Lights
Analog Adjustment
Potentiometers Watchdog Relay Contacts
Encoder Receivers with
Failure Detection Circuits
I/O Connectors
J2 & J4
Digital I/O
Buffer Circuitry
Universal (3.3 & 5V)
PCI-bus Connector 64-bit Floating Point RISC CPU 16 MB DRAM
FPGA
Analog I/O
Circuitry
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Introduction
Precision MicroControl Corp.
6
User selectable 2, 4 and 8 kHz servo update rate each axis
16-bit analog servo command outputs
20 mHz encoder inputs for high-speed, high-resolution moves
5 MHz step/direction/CW/CCW outputs for high-speed microstepping
On-the-fly changes in trajectory, direction and PID values
On-board multi-tasking - frees host PC for other tasks
Eight general-purpose 14-bit A/D input channels (optional)
Up to 60 user-assignable digital I/O channels
Encoder-failure detection circuitry for improved machine safety
Sub-microsecond position capture & compare I/O for rapid event triggering & synchronization
Uses widely available, low-noise twisted-pair shielded SCSI cables for all I/O
Programmable in C/C++/C#/.NET, Delphi, LabVIEW, VB and easy-to-use command language
Drivers and example programs with source code for Windows and Linux
Programming API and commands are compatible across all PMC motion controllers
Graphical setup, tuning, diagnostic and example programs
Custom features and performance enhancements are available upon request
Processor
MultiFlex PCI 1000 series motion controllers feature an advanced 64-bit floating-point MIPS CPU core
coupled with PCI interface logic and internal cache memory to provide a powerful processing engine for
high-performance motion control. An embedded multi-tasking real time kernel executes all motion control
operations with 64 bit floating point precision. 16 MB of DRAM and 4 MB of non-volatile FLASH memory
provide on-board memory space for executing both the intrinsic motion control code as well as user
programs. A high-capacity FPGA interfaces directly with I/O such as encoders, analog inputs, control
signals and general-purpose I/O and provides a great amount of flexibility for tailoring the controller to
specific application and performance requirements.
PC computer minimum requirements
MultiFlex PCI 1000 series controllers can communicate with almost any Windows or Linux based
computer equipped with a 32 bit PCI-bus slot. The controller’s CPU executes motion functions
independently of the host PC, so other than the minimum requirements for the selected operating
environment, the controller does not require the use of any additional PC resources.
Programming
Windows and Linux programmers can create flexible and powerful control programs for PMC motion
controllers in two ways:
1. Writing a high-level program (C/C++/C#/VB/Pascal/LabVIEW) that uses the functions supplied as
part of PMC’s Motion Control API (Application Programming Interface)
and/or
2. Using PMC’s embedded multi-tasking Motion Control Command Language (MCCL)
Programmers can use either, or both, programming methods to command and control the motion
controller. For example, a multi-threaded C/C++/C# host application program can control and coordinate
the execution of motion and I/O, while one or more embedded MCCL routines can run simultaneously as
background tasks on the controller board.
PMC’s WinControl terminal emulator utility (a Motion Control API component) provides a low-level
command interface used to send MCCL commands and routines to the controller for immediate
execution, or to download and save MCCL routines (also called “macros”) to the controller for later
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Introduction
MultiFlex PCI 1000 Series User's Manual
7
execution. Any MCCL command or routine can also be downloaded and called from a high-level program
(C/C++/C#/VB etc) via the appropriate Motion Control API function libraries.
For additional information on Motion Control API and MCCL programming, please refer to the Motion
Control API Reference Manual and the Motion Control Command Language (MCCL) Reference
Manual which are both available for download at: www.pmccorp.com/support/mfxpci1000.php.
Motion Control API example
Function prototypes
C/C++ MCMoveAbsolute(HCTRLR hCtlr, WORD axis, double position);
C#/.NET Mcapi.Error Mcapi.MoveAbsolute(Int16 axis, Double position);
Delphi: procedure MCMoveAbsolute( hCtlr: HCTRLR; axis: Word; position: Double ); stdcall;
VB: Sub MCMoveAbsolute(ByVal hCtrlr As Integer, ByVal axis As Integer, ByVal position As Double)
LabVIEW:
//C/C++ Example, Move Axis 1 to position 85000
MCMoveAbsolute( hCtlr, 1, 85000.0 );
MCCL command example
MA Move Absolute
MCCL command :aMAna = Axis number n = integer or real
applies to: Analog Command Axis, Pulse Command Axis
see also: MR,PM
These MCCL command sequences cause the motion controller to execute a move to absolute position n.
;Example:
1MA1000 ;Axis 1 move to position 1000
2MA-25000 ;Axis 2 move to position -25000
The following example illustrates MCCL multi-tasking. This example shows how a user would monitor the
state of a digital input while an axis is moving in order to ‘automatically’ stop the axis as soon as the input
is activated:
;Example:
AL0,AR10 ;define user register 10 as input #4 active
AL0,AR100 ;define user register #100 as background task
MD100,IN4,MJ101,NO,1JR-3 ;jump to macro 101 when digital input #4 turns on
MD101,1ST,1WS.05 ; macro 101 defined, stop axis #1.
AL1,AR10,ET@100 ;terminate background task
i
There is not necessarily a one-to-one relationship between each Motion Control
API function and eacn MCCL command. Although any MCCL command can be
called directly using the Motion Control API’s pmccmdex() function, most Motion
Control API functions ease the task of programming by encapsulating additional
functionality within each function.
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