Robot-Solutions RS160D User manual

Robot-Solutions 2005 RS160D-Servo www.robot-solutions.com
Users Guide
RS160D PMDC Servo Controller
Robot-Solutions, LLC

Robot-Solutions 2005 RS160D-Servo www.robot-solutions.com
Users Guide
Table of Contents
Specifications ................................................................................................................1
Overview.........................................................................................................................2
Factory Default ..............................................................................................................3
Customization..............................................................................................................4
Channel Mixing (x).......................................................................................................5
Input Control Curve (C)................................................................................................5
Variable Brake (B)........................................................................................................5
R/C input dead band (i)................................................................................................5
Minimum Drive (M).......................................................................................................6
Power Slew Rate (s)....................................................................................................6
R/C input calibration.....................................................................................................6
Saving custom settings (w)..........................................................................................7
User Interface.................................................................................................................8
Internal Register Summary ...........................................................................................9
Internal Register Description......................................................................................12
Brake (B)....................................................................................................................12
Baud Rate (b).............................................................................................................12
R/C Input Curve (C)...................................................................................................12
Copy Parameters (c)..................................................................................................12
Derivative (velocity) Gain (D).....................................................................................12
Error Dead Band (d)...................................................................................................13
Back-EMF Factor (E).................................................................................................13
Encoder value (e).......................................................................................................13
Input Factor (F)..........................................................................................................13
Temperature Protection Override (f)..........................................................................14
Integral Gain (I)..........................................................................................................14
R/C Input Dead Band (i).............................................................................................14
Feedback Select (J)...................................................................................................14
Control Input Select (j)...............................................................................................14
Local Echo Option (l) .................................................................................................15
Minimum Drive (M).....................................................................................................16
Servo Mode (m).........................................................................................................16
R/C Pulse High Limit (N)............................................................................................16
R/C Pulse Low Limit (n) .............................................................................................17
Proportional (Position) Gain (P).................................................................................17
Position Set Point (p).................................................................................................17
Factory Preset (Q) .....................................................................................................17
Servo Update Rate (r)................................................................................................18
Power Slew Rate (s)..................................................................................................18
Torque Limit (T) .........................................................................................................18
Torque Set point (t)....................................................................................................18

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Users Guide
Unit Amount Minimum Move (U)................................................................................19
Unit Amount Manual Move (u) ...................................................................................19
Velocity Limit (V)........................................................................................................19
Velocity Set point (v)..................................................................................................19
Write User Memory (w)..............................................................................................19
Channel Mixing (x).....................................................................................................20
Menu Items...................................................................................................................20
Output Drive values.....................................................................................................21
Control Period..............................................................................................................21
Position & Encoder values .........................................................................................21
Velocity.........................................................................................................................21
Torque ..........................................................................................................................21
Tuning, discovering servo PID Gain values ..............................................................22
Off Mode (0):..............................................................................................................22
PWM Mode (1):..........................................................................................................22
Torque Mode (2):.......................................................................................................22
Velocity Mode (3):......................................................................................................22
Position Mode (4):......................................................................................................23
Indicators and Outputs ...............................................................................................23
Status LED.................................................................................................................23
Temp LED..................................................................................................................23
COAST LED (Aux, Left & Right) ................................................................................23
FWD/REV LED (Aux, Left, Right)...............................................................................23
Limitations and Warrantees........................................................................................24
Support.........................................................................................................................24
General Guidelines......................................................................................................24
Appendix A: System Software Updates.....................................................................25
Appendix B: Input methods........................................................................................26
Control Input Methods................................................................................................26
Serial ......................................................................................................................26
R/C control .............................................................................................................26
Analog Signal .........................................................................................................26
Step & Direction .....................................................................................................26
Feedback Input Methods............................................................................................27
Encoder..................................................................................................................27
Analog Signal .........................................................................................................27
Appendix C: Interface Wiring Information.................................................................28
Analog........................................................................................................................28
Step & Direction.........................................................................................................29
Incremental Encoder..................................................................................................30
Manual Move .............................................................................................................31
Appendix D: Example applications............................................................................32

Robot-Solutions 2005 RS160D-Servo www.robot-solutions.com
Users Guide
Factory Default...........................................................................................................32
Giant R/C Servo.........................................................................................................33
Set Up & Tuning .....................................................................................................33
CNC (Stepper motor) servo .......................................................................................35

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Users Guide - 1 -
Specifications
The RS160D servo uses custom software to implement a 2.5 channel high-powered
servo system. The servo uses a quadrature encoder feedback mechanism to control
torque, velocity, and position of the output.
•Enclosure size: 8.80” x 4.80” x 2.40” 3.40” high including fan
•Weight with enclosure: 2.5 lb.
•Three 5 pin finger latching encoder inputs.
•Dual main channels 160 Amps each
•Current limiting on both main channels.
•Thermal protection.
•Connector for external power driver module for third channel operation.
•4-42v battery operation1.
•Large power connector accepts up to 0 AWG wires.
•Full RS232 serial command and setup.
•Standard RS232 communications N81- 4800,9600,19200 or 38400 baud.
•Serial boot loader for future RS232 servo software updates (no special
programming hardware required). See appendix A.
•Multiple-operating modes:
oOff
oNormal PWM
oTorque
oVelocity
oServo-Winch-Position
oServo-Position
•Thermal power monitoring and limiting.
•Manual control inputs (Up/Down) for each channel (Left, Right and Aux) to
facilitate rigging (DB9M). See Appendix B.
•User selected control inputs: Serial Command, Analog Voltage, R/C Pulse or
Step & Direction (CNC).
•User selected servo feedback: Encoder or Analog Voltage
•User adjusted hardware current limiting (Potentiometer adjustment).
•User adjustable software current limiting (Torque limit).
•Robust signal processing for smooth, reliable fail-safe operation.
•Indicator LED’s show direction, power, over-temperature, and board status.
1 If the main battery voltage is over 36V nominal, jumper J7 must be moved to the HV position and a second battery
for the logic supply must be connected to the HV SUPPLY connector. The HV supply can range from 4V to 36V.
Note the GND terminal on the logic supply and the GND terminal on the main power connector are tied together. If
tapping off of the center of a multiple series battery for the logic supply, do not provide a second ground to the logic
connector.

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Users Guide - 2 -
Overview
The RS160D brushed Motor Controller provides a flexible platform for controlling
brushed DC motors. The controller has two power drivers built in and a standard
OSMC connector for a third power driver.
The default factory configuration supports operation with R/C radios for traditional
combat and remote control robotics applications. The factory default is easily modified
and stored in non-volatile (configuration) memory and restored whenever power is
applied. In factory default mode the Left R/C channel controls forward reverse motion
and the Right channel controls steering.
All configuration and control parameters are set via serial menus and configuration
strings. The serial interface supports standard RS232 signaling from 4800 to 38,400
baud using a normal DB9 cable. The entire unit may be configured and controlled via a
PC or Laptop using a terminal emulator (e.g. Hyperterm).
The RS160D supports a variety of servo operation modes (position, velocity, torque &
power) using a variety of input and feedback methods. The RS160D accepts the
following control input signals: serial commands, Analog voltage (0-5v), Radio Control
signaling or Step & direction. For servo feedback the RS160D accepts either analog
voltages (0-5v potentiometer) or quadrature encoders. Inexpensive industrial encoders
can be obtained from www.usdigital.com and the RS160D includes sockets compatible
with US Digital 5 pin finger latching cabling. The relationship between the various
control inputs output are set by serial configuration commands and the serial interface is
always available for adjusting parameters regardless of the operating mode.
Some examples of systems possible with the RS160D
1. A large R/C style servo can be created by combining the R/C control input with
the analog voltage feedback.
2. Using R/C input and encoders enables velocity control which is superior for
handling of remote control robots.
3. Serial input with encoder feedback enables machine controllable subsystems,
such as steering or brake controllers in large vehicles.
4. Step & Direction input with encoder feedback simulates large high powered step
motors with inexpensive PMDC motors. The step & direction interfaces directly
with CNC software.
The RS160D can store up to four unique sets of configuration data. The Controller
automatically loads the last saved or recalled set upon power up, supporting unattended
operation.

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Users Guide - 3 -
Factory Default
As shipped from the factory the RS160D firmware will boot into a default minimal
function mode. The feature set is as follows:
1. Basic PWM control: 95%2reverse to 95% forward power.
2. R/C input control, +/- 10us dead band.
3. Dual stick (no channel mixing).
4. Normal R/C calibration.
5. Mild input curve.
6. 100% brake with neutral command
7. .1 second power slew rate
8. Serial communications set at 38,400 baud.
At any time the user can reset the unit to the factory values with a simple command via
the terminal interface. The RS160D uses a standard DB9 RS232 cable and should
connect to any PC or laptop computer. Newer computers may only have USB
connectors and an inexpensive USB to Serial adapter may be used. Connect a terminal
emulator (Hyperterm) with the following settings:
•38400 baud
•8 bit no parity
•One stop bit
At the prompt type in the following characters:
@0sQ0<cr> (<cr> represents the ENTER key.)
If you desire single stick control type in the following string instead:
@0sQ1<cr>
NOTE: default values are not stored in non-volatile memory by default. You need to
write the values out before they “stick”. The command to do this is:
@0sw0<cr>
The non-volatile store and how to use it is described in a later section.
2For reasons related to the hardware current limiting logic 100% power is not allowed.

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Users Guide - 4 -
Customization
There are a variety of customizations that can be applied to the RS160D:
1. Channel Mixing for single or dual stick operation
2. Calibration of R/C inputs
3. Adjustable control curves
4. Control Dead band
5. Minimum Drive values for output
6. Variable braking when neutral
7. Variable power slew rate
8. Up to four different sets of customizations may be stored and recalled.
What follows are customizations that apply to the default factory configuration. These
registers are described in detail in this section and primarily apply to simple R/C control
of power – a typical remote control robot configuration. There is a complete description
of all customization registers further on in this document under Internal Register
Description.
In general, configuration parameters are entered in the following form:
@{channel}{s,g,a}{register}{value}
Each command starts with the @ character. The second character is a number
indicating which channel. The channels are numbered as follows:
0 Left R/C input or Power output
1 Right R/C input or Power output
2 Aux R/C input or Power output
3 Flip R/C input only
The third character indicates the operation:
s = set the value into the register
g = Get the value stored in non-volatile memory
a = Get the actual current operating value
Note: for some commands the programmed value is not acted upon until the system is
reset, hence the ‘a’ modifier.
The fourth character is the “register” that contains the value being adjusted
The final field is a signed decimal number (i.e. it can be negative). If this number is left
out a ‘0’ will be used instead.
All commands are terminated with a Carriage return (enter) <cr>.

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A typical command might be “Set Left Channel Drive 250” and would look like this:
@0sd250
The command to read the drive for the Left Channel and print it out would look like this:
@0gd
Channel Mixing (x)
Channel mixing is a global value not associated with R/C input channels or PWM output
channels. The “channel” value is ignored. The value can be either 0 (Tank) or 1
(Mixed). Mixing uses the Left channel as throttle and mixes in the Right channel as
steering. This is commonly used to implement single stick control for steering & throttle
in remote control robots.
@0sx0 – Disable Mixing
@0sx1 – Enable Mixing
Input Control Curve (C)
A variable exponential control curve can be applied to the R/C input. The curve value
applies to all channels. The amount ranges from 0, which is flat, to 7, which represents
a fairly aggressive curve.
@0sC{0-7}
The factory default is a mild curve of 3.
Variable Brake (B)
When control sticks are in neutral position the RS160D can apply a variable amount of
braking effort. Braking varies from 0 (coasting) to 31 (100%). Braking is regenerative
and will generate current and re-charge the supply battery. The string to set the brake
amount:
@{0, 1 or 2},sB{0-31}
Braking is specified independently for the Left, Right or Aux channels, hence the 0, 1 or
2 in the first field.
The Factory default is 100% brake
R/C input dead band (i)
Specifying the R/C input dead band can help prevent jitter when control sticks are in
neutral position. The dead band is specified in +/- microseconds.

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@{0, 1, 2, or 3}si{0-63}
Factory default value is +/- 10 microseconds.
Minimum Drive (M)
Often robotic drive systems have significant friction to overcome before the robot
moves. Minimum drive helps compensate for that by boosting the PWM values.
@{0, 1, 2}sM{0-255} Note: 10-25 are normal values
The best way to set this parameter is to use the serial interface to display drive values
and move the trim/stick until the drive train just starts to move; then record the values
and use that as a starting point.
Factory default is 0.
Power Slew Rate (s)
For high power systems suddenly changing power levels can introduce shock and or
large current draws. The former is hard on the mechanical system and the latter can
cause trouble with batteries. The RS160D has a variable power slew function that is
only active in PWM mode. The slew function specifies the time, in 1/10th second units; it
takes to move the output power from –100% to +100% (full reverse to full forward). Too
much slew can make the operation sluggish. For large kinetic energy weapons,
however, a large slew is needed to limit the inrush or regenerative braking currents as
the device accelerates or decelerates.
@{0, 1, or 2}sS{0-100} Note: a typical value is 0 to 10 for drive outputs.
The factory default is 1.
Note: Proper slew rate operation depends upon the default internal update rate of 50 Hz
and works only in the default PWM mode. Please do not modify the update rate if you
use this function. If you do modify the update rate be aware that the slew values will
need to be scaled appropriately.
R/C input calibration
The RS160D can be calibrated for the particular range of R/C pulse widths supplied by
the radio. Calibration can be done explicitly, where the user specifies the minimum and
maximum control pulse widths in microseconds, or calibration can be done by
discovery. In discovery mode the control sticks are moved to their extremes, and the
software records the minimum and maximum values.
There are two ways to enter and exit discovery calibration mode:
1. Press and hold the CAL button for more than 3 seconds.
2. Type in “Cal<cr>” on the serial port.