THORLABS TBD001 User manual

TBD001
T-Cube Brushless DC Servo
Driver
User Guide
Original Instructions

2 HA0265T Rev D Nov 2015
Contents
Chapter 1 Safety ............................................................................................. 4
1.1 Safety Information .................................................................................. 4
1.2 General Warnings .................................................................................. 4
Chapter 2 Overview and Setup .....................................................................5
2.1 Introduction ............................................................................................. 5
2.2 APT PC Software Overview ................................................................... 7
2.2.1 Introduction......................................................................................................... 7
2.2.2 APTUser Utility ...................................................................................................8
2.2.3 APT Config Utility ...............................................................................................9
2.2.4 APT Server (ActiveX Controls) ...........................................................................9
2.2.5 Software Upgrades ...........................................................................................11
Chapter 3 Getting Started ............................................................................12
3.1 Installing APT Software ........................................................................ 12
3.2 Mechanical Installation ......................................................................... 13
3.2.1 Environmental Conditions ................................................................................13
3.2.2 Mounting Options .............................................................................................13
3.2.3 Removing the Baseplate ..................................................................................14
3.3 Electrical Installation ............................................................................. 15
3.3.1 Connecting a Motor ..........................................................................................15
3.3.2 Using The TCH002 Controller Hub ..................................................................15
3.3.3 Connecting To A Standalone Power Supply ...................................................16
Chapter 4 Standalone Operation ................................................................ 18
4.1 Introduction ........................................................................................... 18
4.2 Control Panel Buttons and Indicators .................................................. 18
4.3 Joystick Operation ................................................................................ 19
4.4 Homing ................................................................................................. 19
4.5 External Triggering ............................................................................... 19
4.5.1 Trigger In ..........................................................................................................20
4.5.2 Trigger In Latency .............................................................................................20
4.5.3 Trigger Out .......................................................................................................21
4.5.4 Triggering Out Latency......................................................................................21
Continued...

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Brushless DC Servo Driver T-Cube
Chapter 5 PC Operation - Tutorial ............................................................. 22
5.1 Introduction ...........................................................................................22
5.2 Verifying Software Operation ................................................................23
5.2.1 Initial Setup ...................................................................................................... 23
5.3 Using the APT User Utility ....................................................................24
5.4 Homing Motors .....................................................................................24
5.5 Moving to an Absolute Position ............................................................26
5.6 Changing Motor Parameters ................................................................27
5.7 Jogging .................................................................................................28
5.8 Graphical Control Of Motor Positions (Point and Move) .......................29
5.9 Loading Parameter Settings .................................................................30
5.10 Setting Move Sequences ......................................................................31
5.11 Creating/Loading a Settings File .........................................................34
5.11.1 Introduction ...................................................................................................... 34
5.11.2 Creating a New Settings Group ....................................................................... 34
5.11.3 Automatically Loading a Settings Group on Start Up ....................................... 36
5.12 Creating a Simulated Configuration Using APT Config ........................36
Chapter 6 Software Reference .................................................................... 39
6.1 Introduction ...........................................................................................39
6.2 GUI Panel .............................................................................................39
6.3 Settings Panel ......................................................................................41
6.3.1 Moves/Jogs tab ................................................................................................ 41
6.3.2 Stage/Axis tab .................................................................................................. 45
6.3.3 Advanced - Control Loop SettingsTab ............................................................. 48
6.3.4 Advanced - Misc. Tab ...................................................................................... 52
6.4 Troubleshooting and Restoring Default Parameters ............................58
Appendices
Appendix A Rear Panel Connector Pinout Details .................................... 60
Appendix B Preventive Maintenance ......................................................... 61
Appendix C Specifications and Associated Parts .................................... 62
Appendix D Motor Control Method Summary ........................................... 63
Appendix E Regulatory ................................................................................ 67

4
Chapter 1 Safety
1.1 Safety Information
For the continuing safety of the operators of this equipment, and the protection of the
equipment itself, the operator should take note of the Warnings, Cautions and Notes
throughout this handbook and, where visible, on the product itself.
The following safety symbols may be used throughout the handbook and on the
equipment itself.
1.2 General Warnings
Shock Warning
Given when there is a risk of injury from electrical shock.
Warning
Given when there is a risk of injury to users.
Caution
Given when there is a risk of damage to the product.
Note
Clarification of an instruction or additional information.
Warnings
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired. In particular,
excessive moisture may impair operation.
Spillage of fluid, such as sample solutions, should be avoided. If spillage does
occur, clean up immediately using absorbant tissue. Do not allow spilled fluid
to enter the internal mechanism.
Caution
If your PC becomes unresponsive (e.g due to an operating system problem,
entering a sleep state condition, or screen saver operation) for a prolonged
period, this will interrupt communication between the APT Software and the
hardware, and a communications error may be generated. To minimize the
possibility of this happening it is strongly recommended that any such modes
that result in prolonged unresponsiveness be disabled before the APT
software is run. Please consult your system administrator or contact Thorlabs
technical support for more details.

5
Chapter 2 Overview and Setup
2.1 Introduction
The TBD001 Brushless DC Motor T-Cubes are ideal for motion control applications
demanding high speed (100s of mm/s) and high encoder resolution (<100 nm)
operation. These single channel drivers offer high-precision motion control in a wide
range of applications, and in particular when used along with our DDSM100 fast
translation stage where speeds of up to 500 mm/sec can be achieved. Designed
using latest digital and analog techniques and with high-bandwidth high-power servo
control circuitry, these new drivers are capable of driving a range of rotary and linear
brushless 3-phase DC motors of up to 2 Amp peak coil current.
Integrated into the apt family of products, it offers Thorlabs standard control and
programming interface, allowing easy integration into the customer’s own automated
motion control applications. These units are cable of being reprogrammed in-field,
allowing the option of upgrading the units with future firmware releases as soon as
new programming interfaces (such as microscopy standard command sets) are
added.
Fig. 2.1 T-Cube Brushless DC Servo Motor driver (TBD001)

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Chapter 2
Operation of the TBD001 brushless DC motor unit is fully configurable
(parameterized) with key settings (e.g. PID settings, min and max position values, and
joystick response) exposed through the associated graphical interface panels.
PID control loop values can be adjusted for a particular application, minimum and
maximum position values can be entered to suit different stages as required, and the
response of the key pad joystick can be adjusted for speed or precision. Moreover,
relative and absolute moves can be initiated with move profiles set using velocity
profile parameters. Similarly, home sequences have a full set of associated
parameters that can be adjusted for a particular stage or actuator. For simplicity of
operation, the apt™ software incorporates pre-configured settings for each of the
Thorlabs stages and actuators, while still exposing all parameters individually for use
with other DC motor driven systems.
For convenience and ease of use, adjustment of many key parameters is possible
through direct interaction with the graphical panel. For example a move to the next
position can be initiated by clicking directly on the position display and entering a new
value (see the tutorial in Chapter 5 for further details). Furthermore, all such settings
and parameters are also accessible through the ActiveX® programmable interfaces
for automated alignment sequences.
In the remainder of this handbook, the Tutorial section (Chapter 5) provides a good
initial understanding on using the unit, and the reference sections (Chapter 6) covers
all operating modes and parameters in detail.

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Brushless DC Servo Driver T-Cube
2.2 APT PC Software Overview
2.2.1 Introduction
As a member of the APT range of controllers, the TBD001 DC motor driverdrivers
share many of the associated software benefits. This includes USB connectivity
(allowing multiple units to be used together on a single PC), fully featured Graphical
User Interface (GUI) panels, and extensive software function libraries for custom
application development.
The APT software suite supplied with all APT controllers, including the TBD001 DC
Servo drivers, provides a flexible and powerful PC based control system both for
users of the equipment, and software programmers aiming to automate its operation.
For users, the APTUser (see Section 2.2.2.) and APTConfig (see Section 2.2.3.)
utilities allow full control of all settings and operating modes enabling complete ‘out-
of-box’ operation without the need to develop any further custom software. Both
utilities are built on top of a sophisticated, multi-threaded ActiveX ‘engine’ (called the
APT server) which provides all of the necessary APT system software services such
as generation of GUI panels, communications handling for multiple USB units, and
logging of all system activity to assist in hardware trouble shooting. It is this APT
server ‘engine’ that is used by software developers to allow the creation of advanced
automated positioning applications very rapidly and with great ease. The APT server
is described in more detail in Section 2.2.4.
Aside
ActiveX®, a Windows®-based, language-independent technology, allows a user
to quickly develop custom applications that automate the control of APT system
hardware units. Development environments supported by ActiveX® technology
include Visual Basic®, LabView™, Borland C++ Builder, Visual C++, Delphi™,
and many others. ActiveX® technology is also supported by .NET development
environments such as Visual Basic.NET and Visual C#.NET.
ActiveX controls are a specific form of ActiveX technology that provide both a user
interface and a programming interface. An ActiveX control is supplied for each
type of APT hardware unit to provide specific controller functionality to the
software developer. See Section 2.2.4. for further details.
Caution
On start up, wait until the top panel POWER led is lit bright green and the
ENABLE led stops flashing, before running the APT software.

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Chapter 2
2.2.2 APTUser Utility
The APTUser application allows the user to interact with a number of APT hardware
control units connected to the host PC. This program displays multiple graphical
instrument panels to allow multiple APT units to be controlled simultaneously.
All basic operating parameters can be altered and, similarly, all operations (such as
motor moves) can be initiated. Settings and parameter changes can be saved and
loaded to allow multiple operating configurations to be created and easily applied.
For many users, the APTUser application provides all of the functionality necessary
to operate the APT hardware without the need to develop any further custom
software. For those who do need to further customise and automate usage of the
driver (e.g. to implement a positioning algorithm), this application illustrates how the
rich functionality provided by the APT ActiveX server is exposed by a client
application.
Use of the APT User utility is covered in the PC tutorial (Chapter 5) and in the
APTUser online help file, accessed via the F1 key when using the APTUser utility.
Caution
On start up, wait until the top panel POWER led is lit bright green and the
ENABLE led stops flashing, before running the APT software.

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Brushless DC Servo Driver T-Cube
2.2.3 APT Config Utility
There are many system parameters and configuration settings associated with the
operation of the APT Server. Most can be directly accessed using the various
graphical panels, however there are several system wide settings that can be made
'off-line' before running the APT software. These settings have global effect; such as
switching between simulator and real operating mode, and associating third party
mechanical stages to specific motor actuators.
If a TBD001 driver is used with the DDSM100 Direct Drive Translation stage, all
stage-associated settings are made automatically when the stage is connected to the
driver.
The APTConfig utility is provided as a convenient means for making these system
wide settings and adjustments for third party brushless DC motor driven stages. An
overview of APTConfig is provided in Section 2.2.3. Full details are contained in the
online help supplied with the utility.
2.2.4 APT Server (ActiveX Controls)
ActiveX Controls are re-usable compiled software components that supply both a
graphical user interface and a programmable interface. Many such Controls are
available for Windows applications development, providing a large range of re-usable
functionality. For example, there are Controls available that can be used to
manipulate image files, connect to the internet or simply provide user interface
components such as buttons and list boxes.
With the APT system, ActiveX Controls are deployed to allow direct control over (and
also reflect the status of) the range of electronic controller units, including the TBD001
DC motor drivers. Software applications that use ActiveX Controls are often referred
to as 'client applications'. Based on ActiveX interfacing technology, an ActiveX

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Chapter 2
Control is a language independent software component. Consequently ActiveX
Controls can be incorporated into a wide range of software development
environments for use by client application developers. Development environments
supported include Visual Basic, Labview, Visual C++, C++ Builder, HPVEE, Matlab,
VB.NET, C#.NET
and, via VBA, Microsoft Office applications such as Excel and Word.
Consider the ActiveX Control supplied for the TBD001 APT Brushless DC Servo
driver unit.
This Control provides a complete user graphical instrument panel to allow the motor
unit to be manually operated, as well as a complete set of software functions (often
called methods) to allow all parameters to be set and motor operations to be
automated by a client application. The instrument panel reflects the current operating
state of the driver unit to which it is associated (e.g. such as motor position). Updates
to the panel take place automatically when a user (client) application is making
software calls into the same Control. For example, if a client application instructs the
associated DC motor Control to move a motor, the progress of that move is reflected
automatically by changing position readouts on the graphical interface, without the
need for further programming intervention.

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Brushless DC Servo Driver T-Cube
The APT ActiveX Controls collection provides a rich set of graphical user panels and
programmable interfaces allowing users and client application developers to interact
seamlessly with the APT hardware. Each of the APT controllers has an associated
ActiveX Control and these are described fully in system online help or the handbooks
associated with the controllers. Note that the APTUser and APTConfig utilities take
advantage of and are built on top of the powerful functionality provided by the APT
ActiveX Server (as shown in Fig. 2.2).
Fig. 2.2 System Architecture Diagram
Refer to the main APT Software online help file, APTServer.hlp, for a complete
programmers guide and reference material on using the APT ActiveX Controls
collection.
2.2.5 Software Upgrades
Thorlabs operate a policy of continuous product development and may issue software
upgrades as necessary.

12
Chapter 3 Getting Started
3.1 Installing APT Software
3.2 DO NOT CONNECT THE CONTROLLER TO YOUR PC YET
1) Insert the CD into your PC.
2) The CD should run automatically. If your CD does not start, double click the file
‘autorun.exe’, found on the Software CD.
3) A Welcome dialogue screen is displayed. Before installing the software, you are
strongly advised to read the Installation Guide. Click the associated link.
4) Once you are familiar with the installation procedure, click the ‘Install APT
Software’ hyperlink displayed on the Welcome dialogue screen.
5) Follow the on-screen instructions - see the Installation Guide supplied for more
information.
Caution
If your PC becomes unresponsive (e.g due to an operating system problem,
entering a sleep state condition, or screen saver operation) for a prolonged
period, this will interrupt communication between the APT Software and the
hardware, and a communications error may be generated. To minimize the
possibility of this happening it is strongly recommended that any such modes
that result in prolonged unresponsiveness be disabled before the APT
software is run. Please consult your system administrator or contact Thorlabs
technical support for more details.
Caution
Some PCs may have been configured to restrict the users ability to load
software, and on these systems the software may not install/run. If you
are in any doubt about your rights to install/run software, please consult
your system administrator before attempting to install. If you experience
any problems when installing software, contact Thorlabs on +44 (0)1353
654440 and ask for Technical Support.

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Brushless DC Servo Driver T-Cube
3.3 Mechanical Installation
3.3.1 Environmental Conditions
Location Indoor use only
Maximum altitude 2000 m
Temperature range 5oC to 40oC
Maximum Humidity Less than 80% RH (non-condensing) at 31°C
To ensure reliable operation the unit should not be exposed to corrosive agents or
excessive moisture, heat or dust.
If the unit has been stored at a low temperature or in an environment of high humidity,
it must be allowed to reach ambient conditions before being powered up.
3.3.2 Mounting Options
The T-Cube Brushless DC Servo Driver is shipped with a baseplate fitted, ready to be
bolted to a breadboard, optical table or similar surface.
If desired, the baseplate can be removed and the unit can be stood on rubber feet -
see Section 3.3.3.
For multiple cube systems, a USB controller hub (TCH002) is available - see Section
3.4.2. for further details. Full instructions on the fitting and use of the controller hub
are contained in handbook ha0146 T-Cube Controller Hub, shipped with the product.
Warning
Operation outside the following environmental limits may adversely affect
operator safety.
Caution
When siting the unit, it should be positioned so as not to impede the
operation of the control panel buttons.
Ensure that proper airflow is maintained to the rear of the unit.

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Chapter 3
3.3.3 Removing the Baseplate
The baseplate must be removed before the rubber feet (supplied) can be fitted, or the
unit is connected to the USB controller hub..
Fig. 3.1 Removing The Baseplate
Using a hexagon key, remove the bolts securing the unit to the baseplate. Retain the
bolts for future use if the baseplate is refitted.
1) Invert the unit.
2) Remove the backing paper from the rubber feet (supplied) taking care not to touch
the exposed adhesive surface.
3) Position the feet as desired, then press and hold for a few seconds until the
adhesive has bonded.
4) The unit may now be used freestanding, sitting on its rubber feet.
Detail A Detail B
Baseplate removed and rubber feet fittedBaseplate attachment screws

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Brushless DC Servo Driver T-Cube
3.4 Electrical Installation
3.4.1 Connecting a Motor
Fig. 3.2 Rear Panel Connections
The unit is supplied with a female 15 pin D-type connector as shown above, which is
compatible with the DDSM100 brushless DC driven translation stage (refer to
Appendix A for details of pin outs).
3.4.2 Using The TCH002 Controller Hub
The TCH002 USB Controller Hub provides power distribution for up to six T-Cubes,
and requires only a single power connection (from a separate supply unit TPS006
supplied by Thorlabs). Further details are contained in handbook ha0146T, T-Cube
Controller Hub, supplied with the unit.
Warning
DO NOT PLUG A POWERED UP T-CUBE INTO THE TCH002 USB
CONTROLLER HUB. Always ensure that all power is disconnected from
the Brushless DC Driver T-Cube AND the hub before the T-Cube is
plugged into the hub. Failure to observe this precaution will seriously
damage the T-Cube unit and could result in personal injury.
MOTOR
12345678
9101112131415

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Chapter 3
3.4.3 Connecting To A Standalone Power Supply
Fig. 3.3 Front Panel Power Supply Connector
1) Perform the mechanical installation as detailed in Section 3.3.
2) Using the front panel connector as shown above, connect the unit to a regulated
DC power supply of 15 V, 2A.
Thorlabs offers a compact, multi-way power supply unit (TPS008), allowing up to
eight Driver T-Cubes to be powered from a single mains outlet. A single way wall plug
supply (TPS003) for powering a single Driver T-Cube is also available.
3) Install the APT Software.
4) Connect the Controller unit to your PC.
(Note. The USB cable should be no more than 3 metres in length. Communication
lengths in excess of 3 metres can be achieved by using a powered USB hub).
Shock Warning
The unit must be connected only to a DC supply of 15V, 2A regulated.
Connection to a supply of a different rating may cause damage to the unit
and could result in injury to the operator.
Caution
During items (3) to (6) the instructions should be followed strictly in the
order stated. Problems may occur if the process is not performed in the
correct sequence.
Caution
During item (4) ensure the power supply unit is isolated from the mains
before connecting to the T-Cube unit. Always power up the T-Cube unit
by connecting its power supply to the mains. DO NOT connect the T-Cube
unit to a 'live' external power supply. Doing so (i.e. “hot plugging”) carries
the risk of PERMANENT damage to the unit. Similarly, to power down the
unit, disconnect the power suply from the mains before disconnecting
the T-Cube unit.
TRIG IN
USB
TRIG OUT
DC 15V 2A
_
+
Standard 3.5 mm Jack
Pin Length 9.5 mm

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Brushless DC Servo Driver T-Cube
5) Connect the DC servo motor actuator to the driver unit - see Section 3.4.1.
6) Connect the driver unit to the power supply - see Section 3.4.3.
7) Connect the PSU to the main supply and switch ‘ON’.
WindowsTM should detect the new hardware. Wait while WindowsTM installs the
drivers for the new hardware - see the Getting Started guide for more information
8) Wait until the Enable LED stop flashing (~3s). This indicates that phase
initialisation is complete.
Press and hold the ENABLE button for 3 secs to home the stage.
The ‘Active LED flashes while the motor is homing. The homing move is complete,
when the LED stops flashing and is extinguished...
Note
3-phase brushless DC motors are commutated electronically, i.e. the
controller drives the coils with a precisely controlled waveform, that
depends on the position of the rotor (or, with linear motors, the position
of the coil housing). On power up, the position of the rotor is not known.
The controller establishes this by energising the coils and measuring the
resulting movement. This is why on power up, the stage (motor) makes a
slight buzzing noise and moves about slightly for a few seconds. Phase
initialisation can only take place if the motor can move unobstructed
during this time.
Note
If any problems are encountered during the connection and power up
process, power cycle the unit, which should clear the error.

18
Chapter 4 Standalone Operation
4.1 Introduction
The Brushless DC Driver T-Cube has been designed specifically to operate with the
range of Thorlabs Brushless DC motorised opto-mechanical products. The unit offers
a fully featured motion control capability including velocity profile settings, limit switch
handling, homing sequences and, for more advanced operation, adjustment of PID
settings, allowing support for many different actuator configurations. These
parameters can be set via the APT Server software - see Chapter 5. Furthermore,
many of these parameters are automatically set to allow “out of the box” operation
with no further “tuning” required.
The following brief overview explains how the front panel controls can be used to
perform a typical series of motor moves.
4.2 Control Panel Buttons and Indicators
Fig. 4.1 Panel Controls and Indicators
MOVE Controls - These controls allow all motor moves to be initiated.
VELOCITY Joystick - Used to drive the motor at a varying speed in either forward
or reverse directions for full and easy motor control - see Section 4.3.
HIGH/LOW - Used to control the gain (responsivness) of the VELOCITY joystick.
When set to HIGH, the HIGH LED is lit - see Section 4.3. for more details.
ENABLE - Used to connect and disconnect the drive power to the motor. The LED is
lit when the drive power is enabled. When the motor is disabled (ENABLE led not lit),
it is possible to move the motor manually. In this mode the feedback mechanism is
inactive and will not attempt to maintain motor position.
POWER
ENABLE
ACTIVE
HIGH
HIGH/LOW
apt - brushless servo controller
VELOCITY

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Brushless DC Servo Driver T-Cube
Active LED - The Active LED flashes when the Ident button is pressed in the GUI
panel. It can also be lit when the motor is moving. - see Section 6.3.3. for further
details.
POWER LED - Lit when power is applied to the unit.
4.3 Joystick Operation
The VELOCITY joystick is a sprung potentiometer, such that when released it returns
to its central position. In this central position the motor is stationary. As the slider is
moved away from the centre, the motor begins to move. Bidirectional control of the
motor is possible by moving the slider in both directions. The speed of the motor
increases by discrete amounts as a function of slider deflection.
The gain of the velocity control can be switched between HIGH and LOW by pressing
the associated button. When HIGH is selected, the LED is lit.
These speed settings are entered in real world units (mm or degrees) in the ‘Joystick’
parameter in the ‘Advanced’ settings tab - see Section 6.3.3.
4.4 Homing
A ‘Home’ move is performed to establish a datum from which subsequent absolute
position moves can be measured (see Section 5.4. for further information).
To initiate a ‘Home’ move, press and hold the ENABLE button for 3 seconds.
The ‘Active LED flashes while the motor is homing. The homing move is complete,
when the LED stops flashing and is extinguished.
4.5 External Triggering
Fig. 4.2 Front Panel Power Supply Connector
External triggering is facilitated by the ‘TRIG IN’ and ‘TRIG OUT’ connectors on the
front panel of the unit as shown above. These connectors are controlled via the APT
software (see Section 6.3.4.) and provide a 5V logic level input/output that can be
configured to support triggering from and to external devices.
TRIG IN
USB
TRIG OUT
DC 15V 2A
_
+
Standard 3.5 mm Jack
Pin Length 9.5 mm

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Chapter 4
4.5.1 Trigger In
Fig. 4.3 TRIG IN Connection Detail
The TRIG IN input contains a pull up resistor to an internal +5V supply, allowing it to
be operated by passive devices (e.g. a switch or relay contact) as well as standard
logic outputs. The protection circuit also allows the external signal to be in the ±10 V
voltage range.
The input logic threshold levels are compatible with most TTL and CMOS logic circuits
(input <0.8V is low and >2.4 V is high). Do not exceed the maximum voltage range of
-10V to 10V.
4.5.2 Trigger In Latency
The trigger input will not accept another trigger request until the current move has
completed, which imposes a restriction on how frequently moves can be triggered. In
addition, there is a communications latency between the microcontroller and the
motion processor of up to 100 msec. This means that the maximum frequency at
which triggered moves can be commanded is approximately 100 msec plus the
duration of the move itself.
10K
10K
0V
5V
SMA
Connector
Protection
TTL Buffer