SPiiPlus PCI-DDM4 Multi-Axes Motion Controllers with Digital Drive Interface
Hardware and Setup Guide
Document part no. TM-0DDM4-PCI Document revision no. 1.20
Document revision no. 1.20 (March 2002) Document part no. TM-0DDM4-PCI COPYRIGHT Copyright © 2001 - 2002 ACS-Tech80 Ltd. Changes are periodically made to the information contained in this guide. The changes are published in release notes and will be incorporated into future revisions of this guide. No part of this guide may be reproduced in any form, without permission in writing from ACS-Tech80. TRADEMARKS ACS-Tech80, PEG, SPii, and SPiiPlus are trademarks of ACS-Tech80 Ltd. JST is a trademark of JST Corp. Visual Basic and Windows are registered trademarks of Microsoft Corp. 3M is a registered trademark of 3M Corp. The names of actual companies and products mentioned herein may be the trademarks of their respective owners. Website: http://www.acs-tech80.com/ E-mail:
[email protected] [email protected]
ACS-Tech80 Inc. 7351 Kirkwood Lane North, Suite 130 Maple Grove, MN 55369 USA Tel: (1) (763) 493-4080 (800-545-2980 in USA) Fax: (1) (763) 493-4089
ACS-Tech80 BV Antonie van Leeuwenhoekstraat 18 3261 LT Oud-Beijerland THE NETHERLANDS Tel: (31) (186) 623518 Fax: (31) (186) 624462
ACS-Tech80 Ltd. Ramat Gabriel Industrial Park POB 5668 Migdal Ha'Emek, 10500 ISRAEL Tel: (972) (4) 6546440 Fax: (972) (4) 6546443 NOTICE Information deemed to be correct at time of publishing. ACS-Tech80 reserves the right to change specifications without notice. ACS-Tech80 is not responsible for incidental, consequential, or special damages of any kind in connection with this document.
Refer connection, installation, maintenance, adjustment, servicing, and operation to qualified personnel.
RE C ENT CH AN G E S T O T HI S G UI D E
I
RECENT CHANGES TO THIS GUIDE Rev.
Date
Section
1.10 Oct/01
Change
ECR
Remove interrupts section which is fully contained in SPiiPlus ACSPL+ Programmer’s Guide
1.10 Oct/01
All
Apply new template
1.10 Oct/01
5.15.2
Update drawing labels
1.10 Oct/01
4.1
Update main drawing
1.20 Jan/02
3.2
Update Specifications and add to a table
1382 1419
1.20 Jan/02
4.2
Update J11 External Power Supply Connector section
1382
1.20 Jan/02
4.3
Update J2 Encoder, Digital, and Analog I/O Connector 1382 section
1.20 Jan/01
1
Integrate preface into Introduction chapter per new temp 1410
1.20 Jan/02
TABLE 4-4 Update table per product revisions
1382
1.20 Jan/02
TABLE 4-6 Update table per product revisions
1382
1.20 Jan/02
TABLE 4-7 Update table per product revisions
1382
1.20 Feb/02
4.2
Change connector # on PCB from J8 to J11
1.20 Feb/02
4.6
Change connector # on PCB from J6 to J8
1.20 Feb/02
4.7
New J6 Z-Axis P/D Drive or HSSI Connector on PCB
1.20 Feb/02
4.14
New Test Points section
1.20 Feb/02
4
Expand, revise, and edit user interface sections
1.20 Feb/02
4.1
Update main drawing
1.20 Feb/02
6.3
Add MPU drawing for RS-232 connection
1.20 Mar/02
7
Update and improve Control Loops chapter
1413
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CO NT E NT S
II I
CONTENTS
FIGURES
VII
TABLES
IX
1.
1-1
INTRODUCTION
1.1.
ORGANIZATION OF THIS GUIDE
1-2
1.2.
RELATED SPIIPLUS DOCUMENTATION
1-2
1.3.
RELATED SPIIPLUS TOOLS
1-3
1.4.
CONVENTIONS USED IN THIS GUIDE
1-3
2.
SAFETY AND EMC GUIDELINES
2-1
2.1.
GENERAL SAFETY GUIDELINES
2-1
2.2.
GENERAL WIRING AND ELECTROMAGNETIC COMPATIBILITY (EMC) GUIDELINES
2-2
3.
FEATURES AND SPECIFICATIONS
3-1
3.1.
FEATURES
3-1
3.2.
SPECIFICATIONS
3-3
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IV
4.
C O NT E NT S
USER INTERFACE
4-1
4.1.
MECHANICAL STRUCTURE
4-1
4.2.
J11 EXTERNAL POWER SUPPLY CONNECTOR
4-3
4.3.
J2 ENCODER, DIGITAL, AND ANALOG I/O CONNECTOR
4-4
4.4.
J3 DRIVE INTERFACE CONNECTOR
4-7
4.5.
J5 DIGITAL AND SPECIAL I/O CONNECTOR
4-10
4.6.
J8 X, A, Y, AND B RAW SIGNAL LIMIT INPUTS OR A-AXIS ENCODER OUTPUT
4-11
4.7.
J6 Z-AXIS P/D DRIVE OR HSSI CONNECTOR
4-12
4.8.
J7 ADDITIONAL FUNCTIONS OUTPUT CONNECTOR (SPIIPLUS PCI-DDM4A ONLY)
4-13
4.9.
J1 HSSI (HIGH-SPEED SYNCHRONOUS SERIAL INTERFACE) CONNECTORS
4-14
4.10.
J4 HSSI AND DEDICATED OUTPUT CONNECTORS
4-16
4.11.
J9 JTAG CONNECTOR
4-19
4.12.
JP1 JUMPER
4-19
4.13.
JP2 JUMPER
4-20
4.14.
TEST POINTS
4-20
4.15.
LED INDICATOR
4-20
5.
DDM4-DR AND DDM4-PS INTERFACE
5-1
5.1.
BRUSHLESS MOTOR CONNECTION
5-1
5.2.
BRUSH MOTOR CONNECTION
5-2
6.
COMMUNICATIONS
6-1
6.1.
SIMULATOR
6-2
6.2.
PCI BUS CONNECTION
6-3
6.3.
SERIAL RS-232 COMMUNICATION
6-5
6.4.
ETHERNET NETWORK COMMUNICATION
6-9
6.5.
ETHERNET POINT-TO-POINT COMMUNICATION
6-12
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CO NT E NT S
7.
CONTROL LOOPS
V
7-1
7.1.
CONTROL LOOPS BLOCK DIAGRAMS
7-1
7.2.
POSITION LOOP
7-6
7.3.
VELOCITY LOOP
7-7
7.4.
VELOCITY LOW PASS FILTER
7-7
7.5.
VELOCITY LOOP PROPORTIONAL-INTEGRAL (PI) FILTER
7-9
7.6.
VELOCITY LOOP NOTCH-FILTER
7-11
7.7.
CURRENT COMMAND AND COMMUTATION
7-14
7.8.
CURRENT LOOP
7-14
WARRANTY
8-1
8.
INDEX
1
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FIG U R E S
V II
FIGURES
FIGURE 2-1 Cable Spacing......................................................................................................... 2-2 FIGURE 2-2 Shielded Cable........................................................................................................ 2-2 FIGURE 2-3 Improved Shielding ................................................................................................ 2-3 FIGURE 4-1 Mechanical Dimensions and Connector Placement ............................................... 4-2 FIGURE 4-2 Encoder Interface ................................................................................................... 4-6 FIGURE 4-3 Emergency Stop (ES) Input.................................................................................... 4-6 FIGURE 4-4 RS-422 Output Port Interface................................................................................. 4-7 FIGURE 4-5 RS-422 Input Interface ........................................................................................... 4-7 FIGURE 4-6 Drive Enable Output............................................................................................... 4-9 FIGURE 4-7 Drive Fault Input .................................................................................................... 4-9 FIGURE 4-8 FSTATUS Fault Input ............................................................................................ 4-9 FIGURE 4-9 Analog Inputs for Current Feedback ...................................................................... 4-9 FIGURE 4-10 Isolated Outputs 5 and 6..................................................................................... 4-11 FIGURE 4-11 HSSI Connection Diagram................................................................................. 4-17 FIGURE 4-12 Timing Sequence of HSSI Control Signal.......................................................... 4-18 FIGURE 4-13 Data Read/Write Operation ................................................................................ 4-18 FIGURE 4-14 HSSI Control Signal........................................................................................... 4-19 FIGURE 5-1 Brushless Motor Connection .................................................................................. 5-1 FIGURE 5-2 Brush Motor Connection ........................................................................................ 5-2 FIGURE 6-1 Communication Window for Simulator Connection............................................... 6-3 FIGURE 6-2 Communication Window for PCI Bus Connection ................................................. 6-4
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VI II
F IG U R E S
FIGURE 6-3 PC104+ with 133MHz Processor (SPiiPlus PCI-DDM4A default MPU)..............6-5 FIGURE 6-4 RS-232 RX/TX Connection....................................................................................6-6 FIGURE 6-5 Communication Window for Serial Connection .....................................................6-7 FIGURE 6-6 Communication Parameters.....................................................................................6-8 FIGURE 6-7 Configuration Parameters Changed, Save to Flash Warning .................................6-8 FIGURE 6-8 Network Settings Window for Windows 95, 98, NT, and 2000...........................6-10 FIGURE 6-9 Communication Window for Ethernet Network....................................................6-11 FIGURE 6-10 SPiiPlus MMI Communication Parameters Dialog Box ....................................6-12 FIGURE 6-11 Network Settings Window for Windows 95,98, NT, and 2000..........................6-14 FIGURE 6-12 TCP/IP Properties Window for Ethernet Point-to-Point ....................................6-15 FIGURE 6-13 Communication Window for Ethernet Point-to-Point.........................................6-16 FIGURE 7-1 SPiiPlus PCI-DDM4 Control Algorithm Block Diagram (Single Loop) ...............7-2 FIGURE 7-2 SPiiPlus PCI-DDM4 Control Algorithm Block Diagram (Dual Loop)..................7-3 FIGURE 7-3 Position Loop Block Diagram ................................................................................7-4 FIGURE 7-4 Velocity Low Pass Filter Block Diagram...............................................................7-4 FIGURE 7-5 Velocity PI Filter Block Diagram...........................................................................7-5 FIGURE 7-6 Velocity Notch Filter Block Diagram ....................................................................7-5 FIGURE 7-7 Current PI Filter Block Diagram ............................................................................7-5 FIGURE 7-8 Bode Plot of Velocity PI Filter ...............................................................................7-9
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T AB LE S
IX
TABLES
TABLE 1-1 Related SPiiPlus Documentation ............................................................................. 1-2 TABLE 1-2 Related SPiiPlus Tools............................................................................................. 1-3 TABLE 1-3 Conventions Used in this Guide .............................................................................. 1-3 TABLE 2-1 Topics Covered in Chapter 2 ................................................................................... 2-1 TABLE 3-1 Controller Specifications ......................................................................................... 3-3 TABLE 4-1 Topics Covered in Chapter 4 ................................................................................... 4-1 TABLE 4-2 Connector Signal Abbreviations .............................................................................. 4-3 TABLE 4-3 J11 External Power Supply Connector .................................................................... 4-4 TABLE 4-4 J2 Encoder, Digital, and Analog I/O Connector ...................................................... 4-5 TABLE 4-5 J3 Drive Interface Connector ................................................................................... 4-7 TABLE 4-6 J5 Digital and Special I/O Connector .................................................................... 4-10 TABLE 4-7 J8 X, A, Y, and B Raw Signal Limit Inputs or A-Axis Encoder Output ............... 4-11 TABLE 4-8 J6 Z-Axis P/D Drive or HSSI Output Connector................................................... 4-12 TABLE 4-9 J7 Additional Functions Output Connector ........................................................... 4-13 TABLE 4-10 HSSI Signal Description ...................................................................................... 4-14 TABLE 4-11 J1 (Top) HSSI Interface Connector (SPiiPlus PCI-DDM4A).............................. 4-14 TABLE 4-12 J1 (Bottom) HSSI Interface Connector (SPiiPlus PCI-DDM4A) ........................ 4-15 TABLE 4-13 J1 (Bottom) HSSI Interface Connector (SPiiPlus PCI-DDM4)........................... 4-15 TABLE 4-14 J4 Connector for HSSI and Dedicated Digital Outputs ....................................... 4-16 TABLE 4-15 HSSI Timing Information .................................................................................... 4-18 TABLE 4-16 Test Points............................................................................................................ 4-20
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X
T AB L E S
TABLE 6-1 Topics Covered in Chapter 6....................................................................................6-1 TABLE 6-2 Communication Options ..........................................................................................6-1 TABLE 6-3 Pin-out of RS-232 COM Ports Located on the MPU...............................................6-5 TABLE 7-1 Position Loop Parameters ........................................................................................7-6 TABLE 7-2 Velocity Second-Order Low-Pass Filter Parameters ...............................................7-9 TABLE 7-3 Velocity Loop PI Filter Parameters........................................................................7-10 TABLE 7-4 Velocity Notch Filter Parameters...........................................................................7-13 TABLE 7-5 Velocity Notch Filter Parameters...........................................................................7-15
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INT RO D UCT IO N
1.
1-1
INTRODUCTION
The SPiiPlus™ PCI-DDM4 are powerful multi-axes motion controllers designed to work with the SPiiPlus DDM4-DR digital drives board and the SPiiPlus DDM4-PS power supply board. The drives and power supply are described separately in the DDM4 Multi-Axes Digital Drive Module Hardware Guide. ACS-Tech80™ motion controllers meet stringent safety and EMC standards and are CE compliant. SPiiPlus PCI-DDM4 motion controllers are manufactured according to ISO 9001 certified quality management system. SPiiPlus PCI-DDM4 controllers feature the following characteristics: •
Cutting edge technology developed by ACS-Tech80
•
The world’s newest and most advanced generation of motion control technology available
•
Based on the best and most cost-effective hardware and software platforms available
•
Advanced, unprecedented features and capabilities in motion generation, servo-control flexibility, and programming
•
The SPiiPlus PCI-DDM4 is Windows® 95/98/NT/2000 compatible
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1- 2
I NT RO D UCT I O N
1.1. Organization of this Guide The SPiiPlus PCI-DDM4 Hardware and Setup Guide describes how to mount, connect, tune, and operate SPiiPlus PCI-DDM4 motion controllers. Regarding operation, only an introduction to the ACS-Tech80 programming language, ACSPL+, is provided. For a detailed description of ACSPL+, refer to the SPiiPlus ACSPL+ Programmer’s Guide. The information in this guide is organized sequentially according to the steps involved in installing and setting up the control module. Chapter 2 Safety and EMC Guidelines: General Safety, EMC recommendations, and customer installed protective devices. Chapter 3 Features and Specifications: Outline of features and specification of the controller. Chapter 4 User Interface: Mounting dimensions, connector descriptions, tables of pin characteristics, and schematics. Chapter 5 DDM4-DR and DDM4-PS Interface: Physical connections to different types of motors. Chapter 6 Communications: Guide to setting up Ethernet or serial port connection with the controller. Chapter 7 Control Loops: Description of control algorithm and control loop theory.
1.2. Related SPiiPlus Documentation TABLE 1-1 Related SPiiPlus Documentation Document
Description
DDM4 Multi-Axes Digital Drive Module Hardware Guide
Electrical interface between the SPiiPlus PCI-DR (Driver) and the SPiiPlus PCI-PS (Power Supply).
SPiiPlus ACSPL+ Programmer's Guide
Command set, programming language, and advanced functions of SPiiPlus controllers.
SPiiPlus MMI User’s Guide
Multipurpose visual interface for configuring and adjusting the controller, managing ACSPL+ programs, and analyzing controller performance.
SPiiPlus MultiDebugger User’s Guide
Multiprogramming and Debugging environment for ACSPL+ programs.
SPiiPlus C Library Reference Guide
C++ and Visual Basic® libraries for host driven applications.
HSSI Expansion Modules Guide
High-Speed Synchronous Serial Interface (HSSI) expansion modules description, installation, and operational procedures.
SPiiPlus Utilities User’s Guide Firmware upgrading and recovery procedures.
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INT RO D UCT IO N
1.3.
1-3
Related SPiiPlus Tools TABLE 1-2 Related SPiiPlus Tools Tool
Description
SPiiPlus MMI
A multipurpose user interface with the controller including: Program management, Motion management, Communication terminal, Four channel digital oscilloscope, Safety and I/O signals monitor, Signal tuning and adjustment, and a fully interactive simulator.
SPiiPlus MultiDebugger
An interactive tool for SPiiPlus ACSPL+ multiprogramming that includes: Progress window for monitoring the status and simultaneous debugging of up to 10 programs, normal and stepby-step execution, programmable breakpoints, and a fully interactive simulator.
SPiiPlus C Library
A DLL (Dynamic Link Library) that supports host application programming in a variety of languages including C/C++ and Visual Basic plus a fully interactive simulator.
SPiiPlus SPiiDebugger
A developing and debugging environment for real-time motion control algorithms inside of SPii processor.
SPiiPlus Utilities
The SPiiPlus Upgrader allows upgrading or downgrading of the controller firmware. The SPiiPlus Emergency Wizard allows firmware recovery in case of damage or loss of communication to the controller.
1.4. Conventions Used in this Guide Several text formats and fonts are used in the text to convey information about the text. TABLE 1-3 Conventions Used in this Guide Text
Description
Bold
ACSPL+ command names. Software tool menus, menu items, dialog box names, and dialog box elements.
Italic
Emphasis or an introduction to a key concept. In a command syntax, specifies a variable name or other information that the user provides.
Monospace
Code examples.
Italic monospace
Information in code examples that the user provides.
ALL CAPS
Names of keys on the keyboard. For example, SHIFT.
blue italic
Names of other documents.
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I NT RO D UCT I O N
Text
Description
blue underlined
Cross references, web pages, and e-mail addresses.
|
Symbol used in nested menu items and dialog box options leading to a final action. For example, the sequence Debug | New Watch | Real-time | Directs the user to open the Debug menu, choose the New Watch command, and select the Real-time option.
1.4.1.
Statement Text and Icons Used in this Guide
WARNING
Highlights an essential operating or maintenance procedure, practice, or condition, which, if not strictly observed, could result in INJURY to, or DEATH of, personnel.
NOTE Highlights an essential operating or maintenance procedure, condition, or statement.
MODEL DEPENDENT
Highlights a specification, procedure, condition, or statement that depends on the product model.
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S AF ET Y AN D EM C G UI DE LI N E S
2.
2- 1
SAFETY AND EMC GUIDELINES
TABLE 2-1 Topics Covered in Chapter 2 Topic
Description
General electrical safety guidelines
End-user installed protective devices and safety precautions
General wiring and electromagnetic compatibility (EMC) guidelines
Suggestions for proper wiring and shielding
2.1. General Safety Guidelines Under emergency situations the unit should be completely disconnected from any power supply. The E-Stop Inputs and Left/Right Limits on ACS-Tech80 products are designed for use in conjunction with customer-installed devices to protect driver load. The end user is responsible for complying with all Electrical Codes.
2.1.1.
Emergency Stop Device
An emergency stop device shall be located at each operator control station and other operating stations where an emergency stop may be required. The emergency stop device shall disconnect any electrical equipment connected to the unit from the power supply. It will not be possible to restore the circuit until the operator manually resets the emergency stop. In situations with multiple emergency stop devices, the circuit shall not be restored until all emergency stops devices are manually reset.
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2.1.2.
S AF ET Y AN D EM C G U ID E L I NE S
Electrical Separation
Electrical separation is required between the control and power supply cables to prevent electrical shock or damage to the equipment.
2.1.3.
Over-Travel Protection
Over-travel limit protection shall be provided where over-travel is hazardous. The over-travel limiting device shall be installed to interrupt the power circuit.
2.2. General Wiring and Electromagnetic Compatibility (EMC) Guidelines 2.2.1.
Routing Signal and Power Cables
Power cables (to the motor, mains outlet, etc.) and signal cables (to I/O, encoder, RS-232, etc.) must be kept as far apart as possible. Keep at least an inch (∼2.5 cm) for each 3 feet (∼1 m) of parallel run. For example, if the motor and encoder cables run parallel for 6 feet (∼2 m), maintain a 2 inch (∼5 cm) separation between them.
Motor Cable
Separation of 1 inch for every 3 feet Encoder / RS232 Cable
FIGURE 2-1 Cable Spacing
It is recommended to use cables that are completely shielded.
COVER
SHIELD
FIGURE 2-2 Shielded Cable
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S AF ET Y AN D EM C G UI DE LI N E S
2.2.2.
2- 3
Cable Length
Use short cables as much as possible and route them as far from other EMI sources as possible.
2.2.3.
Shielding
To reduce EMI radiation, do the following: •
Use shielded cables
•
Install a ferrite core around the cable as close to the unit as possible
FIGURE 2-3 Improved Shielding
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F E AT U R E S AN D S P E CIF IC AT IO N S
3.
3- 1
FEATURES AND SPECIFICATIONS
3.1. 3.1.1.
Features PCI Based
•
Universal 3.3V and 5V operation
•
Operates on 32-bit, 33MHz PCI Bus
•
Standard long-sized PCI card
3.1.2.
Stand-Alone
•
RS-232 high-speed serial communications interface with up to 115,200-baud rate
•
Optional Ethernet communication with TCP/IP and UDP protocol
3.1.3.
Fully Programmable Operation
•
Easy to program using SPiiPlus ACSPL+, a powerful high-level language
•
Multitasking of up to 10, concurrently executed ACSPL+ programs
•
1 MB user programmable controller RAM
•
General-purpose I/Os: 8 inputs and 8 outputs
•
Extendable general purpose digital I/Os via the HSSI-IO16 Expansion Module: 16 additional opto-isolated Inputs and 16 opto-isolated Outputs.
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F E AT U R E S AND S P E CI F I C AT IO N S
•
High-Speed Synchronous Serial Interface (HSSI) for expanding system capabilities such as I/Os, absolute encoder, AD, DA, and other devices
•
Eight, 14-bit analog inputs that can be used for feedback, force, and position control, or for the joystick interface
•
Powerful I/O handling with advanced PLC capabilities
•
Simultaneous communication via all channels
3.1.4.
Special Features for Demanding Applications
•
Master/slave, electronic gearing, and electronic cam operation
•
PEG™ (Position Event Generator) for real-time position compare
•
MARK (High-speed registration) inputs with absolute accuracy and position capture
•
Multi-programming and multi tasking ability
3.1.5.
Outstanding Performance and Capabilities
•
State-of-the-art proprietary Servo Processor (SPii™) technology
•
Fully digital position and velocity control at 20kHz sampling rate, for excellent dynamic and tracking performance
•
The ability of the advanced user to modify the control algorithm
3.1.6.
Comprehensive Safety, Diagnostics, and Protection
•
Flexible, powerful, and fully programmable automatic routines for each fault, error, and exception
•
Real-time data collection and programmable sampling rate
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F E AT U R E S AN D S P E CIF IC AT IO N S
3.2.
3- 3
Specifications TABLE 3-1 Controller Specifications Specification
SPiiPlus PCI-DDM4
SPiiPlus PCI-DDM4A
Axes
Number of Axes
4 with full support plus 4 with limited support
Axes Notation
X, Y, A, and B-axes. A and B have reduced set of features with no MARK, PEG, or 1/T support T, C, and D-axes have no drive interface, independent encoders, and no other I/O interface. Extension support available via fully functional HSSI interface Z-axis has only P/D drive interface
Motor Types
Brush, Brushless, AC Induction, and P/D Stepper
Position Control
Sampling Rate
20kHz
Control Algorithms
Pgain, acceleration feed-forward, automatic velocity feedforward
Trajectory Calculation Rate
Programmable to: 0.5, 1kHz, and 2kHZ. Some settings might require the more powerful MPU option
Position Accuracy
±1 encoder count
Position Feedback Sources
Incremental encoder, analog inputs, external data via HSSI
Velocity Control
Sampling Rate
20kHz
Control Algorithms
PI + second order low pass filter; notch filter from 50 to 2000Hz and anti-reset windup
Range
Up to 1,000,000,000 counts/second
Resolution
1 count/second
Incremental Encoder Count Rate
Up to 32,000,000 counts/second
Velocity Accuracy
Long term
0.005%
Short term
0.01%-0.5% (system-dependent)
Acceleration Range
Up to 1,000,000,000,000 counts/second2
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F E AT U R E S AND S P E CI F I C AT IO N S
Specification
SPiiPlus PCI-DDM4
SPiiPlus PCI-DDM4A
Position Feedback
Types Digital Encoder
User defined devices via HSSI
Digital encoder, analog inputs, user defined devices via HSSI Number
4
Format
Incremental, A, B, & I, Up/Down & I, Pulse/Direction & I
Interface type
Differential, RS-422
Counting speed
< 32*106 counts/sec
Number
0 to 8
Resolution
16, 32, 48, 64-bit
Number
12 (3 PWM commands per axis)
Drive Interface
Drive Commands
P/D for Z-axis Axes
X, Y, A, and B
X, Y, A, B, and Z
Output type
Differential, RS-422
Differential, RS-422, and CMOS for Z-axis
DAC resolution
11.5-bit
Number
4
5
Axes
X, Y, A, and B
X, Y, A, B and Z
Output type
Open emitter 5V for X, Y, A, B-axes and CMOS for Z-axis
Number
4
5
Axes
X, Y, A, and B
X, Y, A, B, and Z
Input type
CMOS Logic with 2k pull-down resistor
Number
4
Axes
X, Y, A, and B
Output type
Open emitter 5V
Dedicated Constant Current Output
Number
1 per card
Output type
Open emitter 5V
Dedicated Fault Status Input
Number
4 per card
Input type
CMOS Logic with 2k pull-up resistor
Drive Enable Output
Drive Fault Input
Motor Break Output
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F E AT U R E S AN D S P E CIF IC AT IO N S
Specification
Pulse Direction Output
Analog Inputs for Current Feedback
SPiiPlus PCI-DDM4
3- 5
SPiiPlus PCI-DDM4A
Output type
LVCMOS 5V tolerant
Maximum frequency
4,000,000 pulse/sec
Number
1 on the Z-axis
Input type
±2.5V differential, second order (10kHz) low-pass input filter
Resolution
14-bit
I/O
Dedicated Emergency Stop Input
Opto-isolated, two terminal, 24V
Dedicated Safety Input Digital Input
Digital Output
Repetition Rate
Uncommitted Analog Input
X, Y, A, B and Z-axis Left and Right limits
Number
8
Input type
7 Differential RS-422 inputs and 1 Opto-isolated, two terminal, 24V
Usable for MARK (position capture input)
Support for X and Y incremental encoder only
MARK registration delay
< 100nsec
Number
8
Output type
6 Differential RS-422 outputs and 2 Opto-isolated, two terminal, 24V
Usable for PEG
4 for X and 2 for Y-axis. Support for incremental encoder only
Position compare accuracy
±1 count at up to 5,000,000 counts/second
Random mode
5 events/0.001second
Incremental mode
up to 3MHz
Delay
< 100nsec
Number
1 (It of A-axis routed to J2 connector)
Input type
Differential, ±10V
ADC resolution
14-bit
Low pass filter
10kHz
Differential, ±2.5V
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F E AT U R E S AND S P E CI F I C AT IO N S
Specification
SPiiPlus PCI-DDM4
SPiiPlus PCI-DDM4A
High-Speed Synchronous Serial Interface (HSSI)
Input
256 (4x16x4)
Output
256 (4x16x4)
Transmit/Receive Type
Differential, RS-422
Sampling and Update Rate
20kHz
Delay
150,000 hours (calculated per Bellcore 3.0 at +25°C)
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4.
4- 1
USER INTERFACE
TABLE 4-1 Topics Covered in Chapter 4 Topic
Description
Mechanical structure
Connector abbreviations, dimensions, and connector placement
User interface connections
Wiring details for external connections: RS-232, Encoder, HSSI, PEG, digital I/Os, and Emergency Stop
Pin-outs, Connectors (J#), and Jumpers (JP#)
Outline of connector pin-outs and jumper settings
Indicators
Functional description of the indicators
4.1.
Mechanical Structure
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U S E R INT E RF AC E
? ?? ?????
FIGURE 4-1 Mechanical Dimensions and Connector Placement
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4- 3
TABLE 4-2 outlines the signal abbreviations and describes the specific axis, function, and signal polarity used on the interface connector. TABLE 4-2 Connector Signal Abbreviations Symbol
Description
#
Place holder for axes-X, Y, Z, T, A, B, C, D
$
Place holder for signal polarity (non-inverted “+”or inverted “-”)
#FLT$
Drive Fault Input
#ENA$
Drive Enable Output
#RL and #LL
Right and Left Limit (safety inputs)
VIN+, VIN-, COMM
Pins used for connecting external power supple for safety inputs
ES$
Emergency Stop
#DIR$, #PULSE$
Pulse direction commands (for step motor control)
OUTx$
PEG or digital output
#MARKx$
MARK and digital inputs
#CHA$
Channel A of incremental encoder
#CHB$
Channel B of incremental encoder
#CHI$
Channel Index of incremental encoder
#DACx$
Analog drive command or analog output
NC
Not Connected
4.2.
J11 External Power Supply Connector
Receptacle: JST™ B4B-EH-A Plug: JST EHR-4 with contacts SEH-001T-P0.6
Use 22-AWG# wire When installed into a PC host, the controller is powered via the PCI Bus. When the SPiiPlus PCI-DDM4 is used as a stand-alone controller via serial communications, the external power supply must be connected to the J11 connector.
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TABLE 4-3 J11 External Power Supply Connector
4.3.
Pin
Signal (consumption)
1
+5V (2.5A)
2
+12V (200mA)
3
-12V (200mA)
4
GND
J2 Encoder, Digital, and Analog I/O Connector
Receptacle: MDR 50-pin 3M® Part number: 10250-55H3VC Plug: MDR 50-pin 3M® Part number: 10150-6000EC
The J2 connector includes the following: •
+5VUF supply for encoders ♦ Max current: 800mA ♦ Protected by resettable fuse
•
Three channel encoder interface for X, Y, A, and B-axes and connected in parallel to C, D, Z, and T-axes ♦ X encoder connected in parallel to C-axis ♦ Y encoder connected in parallel to D-axis ♦ A encoder connected in parallel to Z-axis ♦ B encoder connected in parallel to T-axis
•
Four, RS-422 general-purpose digital inputs
•
Five, RS-422 general-purpose digital outputs
•
One analog input: differential ±10V. Connected in parallel to B_IT, where B_IT or AIN cannot be used simultaneously
•
Emergency Stop input, connected in parallel to ES input on J3
•
All signals on the J2 connector contain EMC filters
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4- 5
TABLE 4-4 J2 Encoder, Digital, and Analog I/O Connector Pin
Signal
Pin
Signal
1
AIN+
26
AIN-
2
AGND
27
AGND
3
+5VUF
28
GND
4
X_CHA+/C_CHA+
29
X_CHA-/C_CHA-
5
X_CHB+/C_CHB+
30
X_CHB-/C_CHB-
6
X_CHI+/C_CHI+
31
X_CHI-/C_CHI-
7
Y_CHA+/D_CHA+
32
Y_CHA-/D_CHA-
8
Y_CHB+/D_CHB+
33
Y_CHB-/D_CHB-
9
Y_CHI+/D_CHI+
34
Y_CHI-/D_CHI-
10
A_CHA+/Z_CHA+
35
A_CHA-/Z_CHA-
11
A_CHB+/Z_CHB+
36
A_CHB-/Z_CHB-
12
A_CHI+/Z_CHI+
37
A_CHI-/Z_CHI-
13
B_CHA+/T_CHA+
38
B_CHA-/T_CHA-
14
B_CHB+/T_CHB+
39
B_CHB-/T_CHB-
15
B_CHI+/T_CHI+
30
B_CHI-/T_CHI-
16
IN0.1+/X_M2ARK+
41
IN0.1-/X_M2ARK-
17
IN0.3+/Y_M2ARK+
42
IN0.3-/Y_M2ARK-
18
IN0.4+/Z_MARK1+
43
IN0.4-/Z_MARK1-
19
IN0.5+/Z_M2ARK+
44
IN0.5-/Z_M2ARK-
20
OUT0.7+/Y_PEG_pulse+
45
OUT0.7-/Y_PEG_pulse-
21
OUT0.3+/X_PEG_pulse+
46
OUT0.3-/X_PEG_pulse-
22
OUT0.1+/X_PEG_state1+
47
OUT0.1-/X_PEG_state1-
23
OUT0.2+/X_PEG_state2+
48
OUT0.2-/X_PEG_state2-
24
OUT0.4+/Y_PEG_state0+
49
OUT0.4-/Y_PEG_state0-
25
ES+
50
ES-
Note
RS-422, Receiver 26C32 or compatible
RS-422, Receiver 26C32 or compatible
RS-422, Transmitter 26C31 or compatible
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4.3.1.
Incremental Encoder Feedback
The encoder can be powered via pin-3 (+5VUF) or an external +5V power supply. Pin-3 is protected by 2A polymer resettable fuse. Use external power supply when the total current consumption is more than 400mA. The return of the supply must be connected to any GND pin. Each encoder input port accepts three channel differential, RS-422 compatible, optical encoder, or laser interferometer signals of various programmable formats. The factory defaults are listed below: •
Two-phase quadrature plus index E_TYPE = 3
•
UP-DOWN plus index
E_TYPE = 1
•
CLOCK-DIR plus index
E_TYPE = 0
The input buffer is built around 26C32 line receiver with 220Ω termination resistor. The use of encoders with built-in line drivers, such as AM26C31 or similar, is recommended. IN +
To SP
220R
26C 32
IN -
FIGURE 4-2 Encoder Interface
4.3.2.
Emergency Stop Input
The Emergency Stop input is two-terminal and can be operated with either a 5V or a 24V supply. See also section 2.1.1. WARNING
The motion controller SHOULD NOT be used as the Emergency Stop handler of the entire system. The ES input only indicates to the controller that an emergency situation exists. +5V ES+
R To MPU
ES-
DGND
FIGURE 4-3 Emergency Stop (ES) Input S Pi i Plu s PC I-D DM 4 H ar d w ar e an d S etup G u id e - Do cu m ent r ev i sio n n o . 1 .2 0
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4.3.3.
4- 7
RS-422 I/O Interface #OUT + From SP 26C31
#OUT -
FIGURE 4-4 RS-422 Output Port Interface IN +
To SP
220R
26C 32
IN -
FIGURE 4-5 RS-422 Input Interface
4.4.
J3 Drive Interface Connector
Receptacle: 64-pin, male, 2.54mm (.100”), dual row pin header Plug: 64-pin, female, 2.54mm (.100”) •
Three PWM commands for X, Y, A, and B-axes
•
Enable, brake, drive fault for X, Y, A, and B-axes
•
Special fault status inputs (see DDM4 Hardware and Setup Guide section 5.4 Fault Status)
•
Eight analog inputs for current measurement
•
Emergency stop input TABLE 4-5 J3 Drive Interface Connector
Pin
Signal
Pin
Signal
Note
1
X_PWM_0+
2
X_PWM_0-
RS-422
3
X_PWM_1+
4
X_PWM_1-
5
X_PWM_2+
6
X_PWM_2-
Transmitter 26C31 or compatible
7
Y_PWM_0+
8
Y_PWM_0-
9
Y_PWM_1+
10
Y_PWM_1-
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Pin
Signal
Pin
Signal
11
Y_PWM_2+
12
Y_PWM_2-
13
GND
14
A_PWM_0-
15
A_PWM_0+
16
A_PWM_1-
17
A_PWM_1+
18
A_PWM_2-
19
A_PWM_2+
20
B_PWM_0-
21
B_PWM_0+
22
B_PWM_1-
23
B_PWM_1+
24
B_PWM_2-
25
B_PWM_2+
26
GND
27
X_ENA
28
A_ENA
29
Y_ENA
30
B_ENA
31
X_BRAKE
32
A_BRAKE
33
Y_BRAKE
34
B_BRAKE
35
CONST_CURR
36
A_FLT
37
X_FLT
38
B_FLT
39
Y_FLT
40
Reserved
41
FSTATUS0
42
FSTATUS1
43
FSTATUS2
44
FSTATUS3
45
ES+
46
ES-
47
X_IS+
48
X_IS-
49
X_IT+
50
X_IT-
51
Y_IS+
52
Y_IS-
53
Y_IT+
54
Y_IT-
55
AGND
56
A_IS-
57
A_IS+
58
A_IT-
59
A_IT+
60
B_IS-
61
B_IS+
62
B_IT-
63
B_IT+
64
AGND
Note
5V open emitter output
CMOS logic with 2k pulldown resistor
Differential analog inputs ±2.5V Input impedance 10k
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4- 9
+5V SP ENA
GND FIGURE 4-6 Drive Enable Output To SP
Fault
2k
FIGURE 4-7 Drive Fault Input +5V
2k FSTATUS
To SP
FIGURE 4-8 FSTATUS Fault Input
5k
5k
20k
I+ C I-
5k
T o A to D converter
5k
20k AGND
FIGURE 4-9 Analog Inputs for Current Feedback S Pi i Plu s PC I-D DM 4 H ar d w ar e an d S etup G u id e - Do cu m ent r ev i sio n n o . 1 .2 0
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U S ER I NT E R F AC E
4.5. J5 Digital and Special I/O Connector Receptacle: 16-pin, male, 2.54mm (.100”), dual row pin header Plug: 16-pin, female, 2.54mm (.100”) •
Three general-purpose digital inputs, RS-422
•
One general-purpose digital outputs, RS-422
•
Industrial signal level (24V) isolated input, two-terminal
•
Two industrial signal level (24V) isolated outputs, two-terminal, maximum current 50mA
•
All signals on the J5 connector contain EMC filters TABLE 4-6 J5 Digital and Special I/O Connector Pin
Signal name
Note
1
IN0+/X_MARK1+/Z_MARK1+ RS-422
2
IN0-/X_MARK1-/Z_MARK1-
3
IN2+/Y_MARK1+/T_MARK1+
4
IN2-/Y_MARK1-/T_MARK1-
5
+IN6/T_MARK1+
6
-IN6/T_MARK1-
7
OUT0+/X_PEG_state0+
RS-422
8
OUT0-/ X_PEG_state0-
Transmitter 26C31
9
GND
10
GND
11
IN7+/T_M2ARK+
Industrial signal level (24V)
12
IN7-/T_M2ARK-
Isolated Input
13
OUT5+
Industrial signal level (24V)
14
OUT5-
Isolated output 50mA
15
OUT6+
Industrial signal level (24V)
16
OUT6-
Isolated output 300mA
Receiver 26C32
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4- 1 1
OUT+ SP OUT-
GND FIGURE 4-10 Isolated Outputs 5 and 6
4.6. J8 X, A, Y, and B Raw Signal Limit Inputs or A-Axis Encoder Output Receptacle: 10-pin, male, 2.54mm (.100”), dual row pin header Plug: 10-pin, female, 2.54mm (.100”)
The J8 connector may be ordered for X, A, Y, and B Raw Signal Limit Inputs or for A-axis Encoder Outputs (TABLE 4-7). TABLE 4-7 J8 X, A, Y, and B Raw Signal Limit Inputs or A-Axis Encoder Output Pin
PCI-DDM4A Signal
PCI-DDM4 Signal
1
X_LL
A_CHA+
2
X_RL
A_CHA-
3
A_LL
A_CHB+
4
A_RL
A_CHB-
5
Y_LL
A_CHI-
6
Y_RL
A_CHI+
7
+5VUF
+5VUF
8
B_LL
NC
9
0V(GND)
0V(GND)
10
B_RL
NC
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4.6.1.
J8 X, A, Y, and B Raw Signal Limit Inputs
The J8 connector is factory configured for X, A, Y, and B Raw Signal Limit Inputs (TABLE 4-7). •
X, A, Y, and B-Left and Right limits
•
LVCMOS compatible
•
5V tolerant
4.6.2.
J8 A-Axis Encoder Output
The J8 connector may be ordered with A-axis Encoder Output (TABLE 4-7). The A-axis encoder signals (RS-422) are directly coupled to this connector. The J8 connector is connected in parallel with connector J2 (Encoder, Digital, and Analog I/O Connector section 4.3).
4.7.
J6 Z-Axis P/D Drive or HSSI Connector
Receptacle: 10-pin, male, 2.54mm (.100”), dual row pin header Plug: 10-pin, female, 2.54mm (.100”)
The J6 connector may be ordered as Z-axis P/D drive interface or as HSSI (TABLE 4-8). •
LVCMOS signal
•
5V tolerant TABLE 4-8 J6 Z-Axis P/D Drive or HSSI Output Connector Pin
PCI-DDM4A Signal
PCI-DDM4 Signal
1
Z_PULSE
X_CLKCVT
2
Z_DIR
X_DATAIN
3
Z_ENA
X_DATAOUT
4
GND
GND
5
Z_FLT
Y_CLKCVT
6
Z_LL
Y_DATAIN
7
Z_RL
Y_DATAOUT
8
GND
GND
9
NC
NC
10
NC
NC
Description
LVCMOS compatible 5V tolerant
LVCMOS compatible 5V tolerant
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4.7.1.
4- 1 3
J6 Z-Axis P/D Drive Interface
The J6 connector is factory configured for Z-axis P/D Drive Interface (TABLE 4-8). See also 4.9. •
Z-axis P/D drive interface
•
Z-axis Left and Right Limits
4.7.2.
J6 HSSI
The J6 connector may be ordered with HSSI (TABLE 4-8). •
LVCMOS signal
•
HSSI connection to X-SPii and Y-SPii
4.8. J7 Additional Functions Output Connector (SPiiPlus PCI-DDM4A Only) MODEL DEPENDENT
The J7 Additional Functions Output Connector applies to the SPiiPlus PCI-DDM4A only.
Receptacle: 16-pin, male, 2.54mm (.100”), single row pin header Plug: 16-pin, female, 2.54mm (.100”) TABLE 4-9 J7 Additional Functions Output Connector Pin
SPiiPlus PCI-DDM4A
1
X_PWM_MON
2
Y_PWM_MON
3
Z_PWM_MON
4
T_PWM_MON
5
X_SP_OUT0
6
X_SP_OUT1
7
Y_SP_OUT0
8
Y_SP_OUT1
9
Z_SP_OUT0
10
Z_SP_OUT1
Note
CMOS compatible
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Pin
4.9.
SPiiPlus PCI-DDM4A
11
T_SP_OUT0
12
T_SP_OUT1
13
Z_PEG_pulse
14
T_PEG_pulse
15
NC
16
DGND
Note
J1 HSSI (High-Speed Synchronous Serial Interface) Connectors
For HSSI Description and Timing information, see section 4.10.1. For J6 HSSI information, see section 4.7.2. •
Differential RS-422 signal
•
HSSI connection to X-SPii and Y-SPii TABLE 4-10 HSSI Signal Description Symbol
Description
SER_DI
HSSI serial data input
SER_DO
HSSI serial data output
CONTROL
Composite signal that includes start and data synchronization signals
SP (SPii)
Servo Processor
4.9.1.
J1 Top HSSI Interface Connector
The J1 Top uses an RJ-45 connector •
J1 Top connector provides connection to X_SPii
•
All signals on the J1 Top connector contain EMC filters TABLE 4-11 J1 (Top) HSSI Interface Connector (SPiiPlus PCI-DDM4A) Pin
SPiiPlus PCI-DDM4A
1
CLKCVT+
2
CLKCVT-
3
X_DATAIN+
Note
Composite synchronized signal, RS-422, transmitter 26C31 or compatible Data input, RS-422,
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Pin
4.9.2.
SPiiPlus PCI-DDM4A
4
X_DATAIN-
5
X_DATAOUT+
6
X_DATAOUT-
7
GND
8
GND
4- 1 5
Note
receiver Data output, RS-422, transmitter 26C31 or compatible
J1 Bottom HSSI Interface Connector
The J1 Bottom uses an RJ-45 connector •
J1 Bottom connector provides connection to Y_SPii
•
All signals on the J1 Bottom connector contain EMC filters TABLE 4-12 J1 (Bottom) HSSI Interface Connector (SPiiPlus PCI-DDM4A) Pin
SPiiPlus PCI-DDM4A
Note
Composite synchronized signal, RS-422, transmitter 26C31 or compatible
1
CLKCVT+
2
CLKCVT-
3
Y_DATAIN+
Data input,
4
Y_DATAIN-
RS-422, receiver
5
Y_DATAOUT+
6
Y_DATAOUT-
Data output, RS-422, transmitter 26C31 or compatible
7
GND
8
GND
TABLE 4-13 J1 (Bottom) HSSI Interface Connector (SPiiPlus PCI-DDM4) Pin
SPiiPlus PCI-DDM4
1
RESERVED
2
RESERVED
3
RESERVED
4
IN7+
5
IN7-
6
RESERVED
Note
Industrial signal level (24V), isolated input
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Pin
SPiiPlus PCI-DDM4
7
OUT5+
8
OUT5-
Note
Industrial signal level (24V), isolated output 50mA
4.10. J4 HSSI and Dedicated Output Connectors Receptacle: 30-pin, male, 2.54 mm (.100”), double row pin header, with keying Plug: 30-pin, female, 2.54 mm (.100”) •
Differential RS-422 signal
•
HSSI connection to Z_SPii and T_SPii
•
All signals on the J4 connector contain EMC filters
•
The dedicated digital outputs operated via pin-22 through pin-30 on the J4 connector TABLE 4-14 J4 Connector for HSSI and Dedicated Digital Outputs
Pin
Signal
Pin
Signal
Description
1
XSER_DI+
2
XSER_DI-
HSSI
3
YSER_DI+
4
YSER_DI-
Differential RS-422
5
ZSER_DI+
6
ZSER_DI-
7
TSER_DI+
8
TSER_DI-
9
GND
10
XSER_DO-
11
XSER_DO+
12
YSER_DO-
SPiiPlus PCI-DDM4 only has X and Y SER_DI/DO channels
13
YSER_DO+
14
ZSER_DO-
15
ZSER_DO+
16
TSER_DO-
17
TSER_DO+
18
CONTROL1-
19
CONTROL1+
20
CONTROL2-
21
CONTROL2+
22
GND
23
X_PEG_state_3+/XSP_O+
24
X_PEG_state_3-/XSP_O-
25
Y_PEG_state_3+/YSP_O+
26
Y_PEG_state_3-/YSP_O-
27
Z_PEG_Pulse+/ZSP_O+
28
Z_PEG_Pulse-/ZSP_O-
29
T_PEG_Pulse+/TSP_O+
30
T_PEG_Pulse-/TSP_O-
Ground (pin-22) is common to both HSSI and the dedicated digital outputs Additional PEG and SP (SPii) controlled outputs (dedicated digital outputs). PEG is the default. These signals are not related to HSSI
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4- 1 7
4.10.1. HSSI Description and Timing The HSSI operates via pin-1 through pin-22 on the J4 and via the J1 connectors. There are four general-purpose, high-speed synchronous serial input and output channels. They can be used for high-speed laser interferometers, incremental/absolute encoder position reading, A to D interface, I/O extension, or any other function as required by the user. All signals are differential, RS-422 type. The connection between the SPiiPlus PCI-DDM4 and the remote interface unit is shown in FIGURE 4-11 HSSI Connection Diagram. The timing and control sequence required for the serial interface is show in FIGURE 4-12 Timing Sequence of HSSI and in FIGURE 4-13 Data Read/Write Operation. The reading sequence repeats itself once per servo update cycle, 50µsec at 20kHz. In the sequence shown, the data transfer is as follows: •
The sequence is initiated by START pulse. The START pulse is used to latch and transfer data to parallel shift register.
•
The read/write operation consists of 64-serial clock pulses. These pulses are further divided into four groups, each with sixteen pulses. During read operation the serial data is latched into the SPii from the SER_DI line on the falling edge of SER_CLK. During write operation the data is shifted out on the rising edge of the SER_CLK. The data must be latched into destination shift register on falling edge of the SER_CLK. The first data bit of each group is MSB (DB16). The last data bit of each group to be latched in on the final falling edge is the LSB (D0).
H SSI CONTROL
J1 J4 S P iiPlu s P C I or J6
DATA OUT
R em ote Interface U n it
D A T A IN U ser C on n ecto rs
FIGURE 4-11 HSSI Connection Diagram
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T1 T3
T2
T4 1
2
4
T6
T5 START pulse
3
SER_CLK
16 pulses
FIGURE 4-12 Timing Sequence of HSSI Control Signal T6
T5 SER_CLK
SER_DI
SER_DO
FIGURE 4-13 Data Read/Write Operation TABLE 4-15 HSSI Timing Information Parameter
Time
Comments
T1
50µs
HSSI cycle
T2
800ns
START Pulse Width
T3
400ns
Time between START falling edge to first SER_CLK rising edge
T4
1.4µs
Time between groups of SER_CLK
T5
200ns
SER_CLK High Pulse Width
T6
200ns
SER_CLK Low Pulse Width
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4- 1 9
10µs
10µs
FIGURE 4-14 HSSI Control Signal
4.11. J9 JTAG Connector WARNING The J9 JTAG connector is used for manufacturing and testing purposes only. DO NOT connect anything to this connector.
4.12. JP1 Jumper WARNING
Jumper JP1 is used for manufacturing and testing purposes only. DO NOT change the default jumper setting. The JP1 Jumper is not installed by default.
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U S ER I NT E R F AC E
4.13. JP2 Jumper WARNING
Jumper JP2 is used for manufacturing and testing purposes only. DO NOT change the default jumper setting. The JP2 Jumper is by default connected to pin-1 and pin-2.
4.14. Test Points There are 8 test points, one for every analog input and 1for the analog ground (TABLE 4-16). Test points may be connected after the analog input buffer amplifier’s output. •
Output range ±5V represents full range nominal input voltage (±2.5)
•
Test point is connected to analog input buffer amplifier’s output via 51kΩ TABLE 4-16 Test Points Test Point #
Signal
TP1
X_IS
TP2
Y_IS
TP3
X_IT
TP4
Y_IT
TP5
A_IS
TP6
B_IS
TP7
A_IT
TP8
B_IT
TP9
AGND
4.15. LED Indicator LED Indicator
MP_ON
Description
Green LED. After power is turned on, the MP_ON LED flickers and then remains green indicating that the controller is functioning properly. During normal operation when the control unit receives a command, the LED turns off for a fraction of a second.
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5.
5-1
DDM4-DR AND DDM4-PS INTERFACE
5.1. Brushless Motor Connection #_PWM_0 #_PWM_1
#R
#_PWM_2
SPiiPlus PCI-DDM4 Controller
#_ENABLE #_BRAKE
DDM4 X, Y, &A Amplifiers
#S #T
#Brushless Motor
CONST_ #_FLT #_IS #_IT DGND/AGND
ENCODER
FIGURE 5-1 Brushless Motor Connection
For drivers with differential inputs both + and – wires are connected as above. For drivers with single ended input only the + wires are connected.
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5-2
D DM 4-DR AN D DDM 4-P S I NT E RF ACE
5.2. Brush Motor Connection B_PWM_0 B_PWM_1
BR
B_PWM_2
SPiiPlus PCI-DDM4 Controller
B_ENABLE B_BRAKE
DDM4 B Amplifier
BS
Brush Motor
CONST_ B_FL B_IS B_IT DGND/AGND
ENCODER
FIGURE 5-2 Brush Motor Connection
For drivers with differential inputs both + and – wires are connected as above. For drivers with single ended input only the + wires are connected.
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6.
6-1
COMMUNICATIONS
TABLE 6-1 Topics Covered in Chapter 6 Topic
Description
Simulator
Communication with the SPiiPlus Simulator.
Communications
Communication with the controller via the PCI Bus, RS-232, or Ethernet.
The following steps are basic procedures for establishing communication between the SPiiPlus controller and the PC host. The connection types will very depending on the specific controller ordered. In the Main Panel click Communication TABLE 6-2 Communication Options Connection Type
Cable Required
SPiiPlus PCI
Simulator
None
Standard
PCI Bus
None
Standard
Serial (RS-232)
Null-Modem cable
Standard
Ethernet Network
10/100BASE-T Path-Through cable Optional at time of order
Ethernet Point-to-Point
10/100BASE-T Crossover cable
Optional at time of order
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6.1.
Simulator
The SPiiPlus Installation CD comes with a Simulator that allows the user to work with the SPiiPlus MMI, SPiiPlus MultiDebugger, or SPiiPlus C Library without being physically connected to a controller and/or drives/motors. It is recommended to begin here, before installing the controller or making any electrical connections. After becoming familiar with the Simulator proceed to install the controller and make the necessary electrical connections. Whereas the SPii program is intended for execution inside the controller and cannot be activated on the PC, the Simulator is a PC program and operates in the Windows 95/98/NT/2000 environment. The Simulator provides a powerful tool for use during application development and debugging. The MMI Scope displays motions of the Simulator identical to the real motion, except the Simulator’s motion is free of errors and noise. The SPiiPlus Basic Package includes a demo version of the Simulator. The SPiiPlus ADK (Application Development Kit) includes the full version of Simulator that works without any time limitations. The simulator emulates all functions of the firmware, except for the following: •
Control of a physical motor.
•
Real feedback from the motors, instead the simulator sets the feedback values equal to the reference values, which is equivalent to ideal motors with zero following error.
•
Analog and digital inputs. The simulator allows assignment to the corresponding variables, so that the change of actual signals can be emulated. This provides the ability to emulate the I/O (digital and analog) part of a machine using ACSPL+ programs.
•
Emulation SP (SPii) programs. Emulation of all feedback signals specified above provides an ideal with respect to following the reference position. Feedback position and Reference position are equal (FPOS=RPOS).
•
The simulator is not a real-time program. The simulator emulates the controller time and supplies the TIME variable, but 1 millisecond of TIME is not equal to 1 millisecond of realtime.
•
All hardware related features such as; Index, MARK, PEG, and Analog Inputs/Outputs.
•
Immediate commands; #HWRES, #RESET, #PROTECT, #UNPROTECT, #U, #IR.
•
Saving and Loading Array data by WRITE/READ commands.
•
Saving or Loading an application via the Application Saver or Application Loader.
The user can prepare and debug an application using the Simulator. When the logical correctness of the application is proved, and all motions are checked with the MMI Scope, the switch to the actual controller is supported by the SPiiPlus C Library. Switching to a real controller requires no additional changes in the application. Follow these steps to activate the Simulator:
1. Open Communication | Simulator. 2. Click. Connect. Once communication is established the Communication indicator turns green.
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6-3
FIGURE 6-1 Communication Window for Simulator Connection
3. Close the Communication window. The Communication indicator on the Main Panel remains green and the Stop Programs and Motors button is displayed.
6.2.
PCI Bus Connection
6.2.1.
Physical Connection
Install the SPiiPlus PCI card to the PCI slot of the PC host.
6.2.2.
Configuring the Host
You must have one or more of the SPiiPlus tools installed on your PC host. Any SPiiPlus tool (SPiiPlus MMI, SPiiPlus MultiDebugger, or SPiiPlus C Library) installs a driver that provides communication through the PCI Bus. If the driver is not properly installed, you will not be able to establish communication.
6.2.3.
Establishing PCI Bus Communication
1. Open Communication | PCI Bus. The MMI scans the PCI bus for installed controller cards. If at least one card is found, the Slot field becomes enabled.
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FIGURE 6-2 Communication Window for PCI Bus Connection
2. If multiple controller cards are installed, choose the required card in the Slot field. 3. Click. Connect. Once communication is established the Communication indicator turns green, the Firmware box on the Main Panel displays the controller version and the communication channel being used, and the Stop Programs and Motors button appears. 4. Click Close.
6.2.4.
Configuring the Controller
The SPiiPlus PCI is factory configured for PCI Bus communication. No additional controller configuration is required.
6.2.5.
Troubleshooting PCI Bus Connection
1. Check that at least one SPiiPlus tool is installed on your PC host and that the driver is active. 2. Check that the controller card is properly installed in your PC host.
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6.3.
6-5
Serial RS-232 Communication
•
The system may be equipped with one or more COM ports (COM1, COM2, etc.)
•
The exact placement depends on the type of PC104+ used in the controller
FIGURE 6-3 PC104+ with 133MHz Processor (SPiiPlus PCI-DDM4A default MPU)
6.3.1.
Physical Connection
Receptacle: 10-pin, male, 2.54mm (.100”), dual row header Plug: 10-pin, female, 2.54mm (.100”) TABLE 6-3 Pin-out of RS-232 COM Ports Located on the MPU Pin
Name
Description
1
DCD
Data Carrier Detect
2
DSR
Data Set Ready
3
RX232
RS-232 receive signal
4
RTS
Request To Send
5
TX232
RS-232 transmit signal
6
CTS
Clear To Send
7
DTR
Data Terminal Ready
8
RI
Ring Indicator
9 & 10
GND
RS-232 ground
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When making a serial connection verify that: 1. The PC receive (RX) is wired to the controller’s transmit (TX), pin-5 2. The PC transmit (TX) is wired to the controller’s receive (RX), pin-3 3. The ground (GND) is properly connected, pin-9 and pin-10 NOTE
The user must connect RX232 (pin-3), TX232 (pin-5), and GND (pin-9 and 10) ONLY! See FIGURE 6-4 RS-232 RX/TX Connection. Pin-1, 2, 4, 6, 7, and 8 are not used.
SPiiPlus PCI
PC RS-232 Rx
Rx
Tx
Tx
GND
GND
FIGURE 6-4 RS-232 RX/TX Connection
6.3.2.
Configuring the Host
A typical PC computer has one or more RS-232 ports factory configured. Any of these ports can be connected to the controller.
6.3.3.
Establishing Serial Communication
1. Open Communication | Serial. The MMI scans the PCI bus for the installed controller cards. If at least one card is found, the Slot field becomes enabled.
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6-7
FIGURE 6-5 Communication Window for Serial Connection
2. Specify the communication port (COM1, COM2, etc) in the host computer that the cable is connected to. 3. Set the Rate. The value must be the same as the BAUD parameter specified in the controller. Use the factory default value of 115200 for the first time. If you already configured another rate as described in 6.3.3, then use that configured value. You do not need to change the Timeout setting because the MMI automatically adjusts the timeout to the appropriate value. 4. Click. Connect. Once communication is established the Communication indicator turns green, the Firmware box on the Main Panel displays the controller version and the communication channel being used, and the Stop Programs and Motors button appears. 5. Click Close.
6.3.4.
Configuring the Controller
The controller is manufactured with a default serial communication rate of 115200 baud. Use the default communication rate for establishing the first connection. The following instructions are relevant only when communication is established and you need to change the communication rate. 1. Open Tools | Configurator | Communication Parameters.
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FIGURE 6-6 Communication Parameters
2. Select desired Serial Baud Rate (BAUD). The Baud Rate in the MMI must be the same as the Baud Rate in the controller. 3. Close both the Communication Parameters and Configurator. The following confirmation warning will appear.
FIGURE 6-7 Configuration Parameters Changed, Save to Flash Warning
4. Click Yes. The SPiiPlus MMI saves the new communication rate in the controller nonvolatile (flash) memory after a Restart. The flash memory then retains these parameters after complete power-off. 5. The new value is not active immediately. To make the new value active, you must restart the controller by clicking Tools | Restart (#HWRES) on the MMI Main Panel. 6. When the controller restarts, the SPiiPlus MMI will not be able to communicate with the controller because the controller uses a new communication rate. To reestablish communication use the procedure described in 6.3.3 Establishing Serial Communication.
6.3.5.
Troubleshooting Serial Connection
•
Inspect the cable and connectors.
•
Check that the COM port on the PC host is not being used by another application.
•
Check that the communication port specified in the Port field corresponds to the COM port on the PC host that the cable is connected to.
•
Check that the communication rate specified in the Rate field corresponds to the value configured in the controller. Check that the BAUD rate is correctly specified in the Communication Parameters. The factory default is 115200.
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6-9
6.4. Ethernet Network Communication If your PC host is NOT connected to a local network, establish the Ethernet Point-to-Point Communication first (section 6.5). The system may be equipped with a 10M or 100M Ethernet adapter for a 10/100BASE-T network interface. The Ethernet interface includes one RJ-45 type connector. If your PC host is already connected to a local Ethernet Network, you only need to configure the controller and to connect it to the same network.
6.4.1.
Physical Connection
Receptacle: RJ-45 Ethernet connector Plug: RJ-45 Ethernet connector •
Use a 10/100BASE-T Path-Through cable.
•
Connect the Ethernet connector on the controller to any Ethernet Network connector on the PC host.
6.4.2.
Configuring the Host
Check that the TCP/IP protocol is installed on your PC: 1. From the Start button in the Windows Task Bar choose Settings | Control | Network. 2. Select the TCP/IP Protocol and click OK. 3. If the TCP/IP protocol is not installed, ask your network administrator to properly install it.
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In Windows 95/98 the following dialog box appears:
In Windows NT and 2000 the dialog looks like this:
FIGURE 6-8 Network Settings Window for Windows 95, 98, NT, and 2000 S Pi i Plu s PC I-D DM 4 H ar d w ar e an d S etup G u id e - Do cu m ent r ev i sio n n o . 1 .2 0
COM M UNIC AT I ON S
6.4.3.
6-1 1
Establishing Ethernet Network Communication
1. Open Communication | Ethernet. The MMI scans the PCI bus for the installed controller cards. If at least one card is found, the Slot field becomes enabled.
Enter the TCP/IP address provided by the system Select Network connection
FIGURE 6-9 Communication Window for Ethernet Network
2. Enter the Remote Address. You must enter the TCP/IP address configured in the controller (factory default is 10.0.0.100). The address must be reserved by the network administrator. 3. In the Connection Parameters field select Network. 4. Press Connect. Once communication is established the Communication indicator turns green, the Firmware box on the Main Panel displays the controller version and the communication channel being used, and the Stop Programs and Motors button appears. 5. Click Close.
6.4.4.
Configuring the Controller
The controller cannot automatically obtain a TCP/IP address from the network server. The TCP/IP address must be configured in the controller. Ask your network administrator to reserve a fixed address on the network in order to avoid address overlapping. You must first establish communication with the controller through any available communication channel before you can configure the controller. Use the serial communication for initial configuration of the controller. 1. Ask the network administrator to reserve a fixed TCP/IP address in the network. Write down the reserved address. 2. Follow the same instruction in 6.3.3, Establishing Serial Communication between the SPiiPlus MMI and the controller. 3. Open Tools | Configurator | Communication Parameters.
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FIGURE 6-10 SPiiPlus MMI Communication Parameters Dialog Box
4. In the TCP/IP Address field, enter the address that you received from the network administrator (factory default is 10.0.0.100). 5. Click Close on both dialog boxes. The SPiiPlus MMI writes the new TCP/IP address to controller variable TCPIP. 6. Click Yes. The SPiiPlus MMI saves the new communication rate in the controller nonvolatile (flash) memory. The flash memory retains these parameters after power-off. 7. The new value is not active immediately. To make the new value active, you must restart the controller by clicking Tools | Restart (#HWRES) on the MMI Main Panel.
6.4.5.
Troubleshooting Ethernet Network Connection
•
Check that you are using the Path-Through 10/100BASE-T cable.
•
Inspect the cable and the connectors.
•
Check that the network hardware/software (adapter, driver, TCP/IP protocol) is properly installed and configured to the PC host.
•
Check that the TCP/IP address reserved for the controller is unique in the network.
•
Check that the right TCP/IP address is configured in the controller.
•
Check that the right TCP/IP address is selected in the SPiiPlus MMI Communication dialog.
•
If you can communicate with the controller, but an occasional error occurs, check that Network Connection is selected (not Point-to-Point) from the Communication window.
6.5. Ethernet Point-to-Point Communication If your PC host is already included in an Ethernet local network, use the Ethernet Network Communication procedures as described in section 6.4. If you are making a point-to-point connection, make sure that you have an Ethernet card that is dedicated for the point-to-point connection. You CAN NOT use the same Ethernet card that connects to a local network. If you have a connection to a local network, you must install an additional card for point-to-point connections.
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6.5.1.
6-1 3
Physical Connection
Receptacle: RJ-45 Ethernet connector Plug: RJ-45 Ethernet connector •
Use a 10/100BASE-T Crossover cable
•
Connect the Ethernet connector on the controller to the connector of the Ethernet card dedicated to communication with the controller.
6.5.2.
Configuring the Host
1. From the Start button in the Windows Task Bar choose Settings | Control | Network. 2. Select the TCP/IP Protocol and click OK. 3. If the TCP/IP protocol is not installed, ask your network administrator to properly install the TCP/IP protocol. If it appears several times, select the instance related to the Ethernet adaptor card that will be used for connection with the controller.
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COM M UNIC AT IONS
In Windows 95/98 you will see the following dialog box:
In Windows NT and 2000 the dialog box looks like this:
FIGURE 6-11 Network Settings Window for Windows 95,98, NT, and 2000 S Pi i Plu s PC I-D DM 4 H ar d w ar e an d S etup G u id e - Do cu m ent r ev i sio n n o . 1 .2 0
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6-1 5
4. Click Properties. The TCP/IP Properties dialog box opens (Windows NT looks a little different):
FIGURE 6-12 TCP/IP Properties Window for Ethernet Point-to-Point
5. In the IP Address tab Select Specify an IP Address. 6. Enter the number 10.0.0.101 in the IP Address field, and 255.255.255.0 in the Subnet Mask field. NOTE
The controller is manufactured with a default TCP/IP 10.0.0.100. The address entered in this dialog differs from the controller address in the last digit.
7. Set the other tabs as follows (recommended): ♦ WINS Configuration: Disable WINS Resolution ♦ Gateway: Clear all Installed Gateways ♦ DNS Configuration: Disable DNS
8. If the following dialog box appears, click Yes.
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6.5.3.
COM M UNIC AT IONS
Establishing Ethernet Point-to-Point Communication
1. Open Communication | Ethernet. The MMI scans the PCI bus for the installed controller cards. If at least one card is found, the Slot field becomes enabled.
Enter the TCP/IP address provided by the system Select Point-to-Point connection
FIGURE 6-13 Communication Window for Ethernet Point-to-Point
2. Enter the Remote Address. You must enter the TCP/IP address configured in the controller (factory default is 10.0.0.100). The address must be reserved by the network administrator. 3. In the Connection Parameters field select Point-to-Point. 4. Press Connect. Once communication is established the Communication indicator turns green, the Firmware box on the Main Panel displays the controller version and the communication channel being used, and the Stop Programs and Motors button appears. 5. Click Close.
6.5.4.
Configuring the Controller
The controller is manufactured with a default TCP/IP address 10.0.0.100. You do not need to change this address in order to establish Ethernet point-to-point connection.
6.5.5.
Troubleshooting Ethernet Point-to-Point Connection
•
Check that you are using a Crossover 10/100BASE-T cable.
•
Inspect the cable and the connectors.
•
Check that the network hardware/software (adapter, driver, TCP/IP protocol) is properly installed and configured on the PC host.
•
Check that the default TCP/IP address was not changed in the controller and that the proper TCP/IP address 10.0.0.100 is selected in the MMI.
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CONT ROL LOO P S
7.
7.1.
7-1
CONTROL LOOPS
Control Loops Block Diagrams
NOTE
These diagrams are for general description only.
The following chapter describes the block diagrams of the SPiiPlus PCI-DDM4 Control Loops. Servo parameters can be divided to high-level parameters and low-level parameters. High-level servo parameters begin with the letters “SP,” and are set by the user in the Adjuster. Low-level parameters are the internal servo parameters in the DSP program, to which the user has no direct access. FIGURE 7-1 and FIGURE 7-2 describe the general control loops diagrams in case of single loop and dual loop respectively. FIGURE 7-3, FIGURE 7-4, FIGURE 7-5, and FIGURE 7-7 describe each of the control filters, with their low-level parameters.
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Profile Generator
Desired Position +
-
Desired Velocity
+ + -
DAC Command
Phase Advance
Vector Control
S
Derivative
Position Feedback
5242 32768
5242 32768
+ -
-
iB
iA
PWMC
PWMB
PWMA
Position Sensor
-
Current Feedbacks
Phase B Current PI Filter
Phae A Current PI Filter
Not active in case of DC motor (B axis)
+ -
i*B
i*A
Scaling Ipeak=5242
Not active in case of DC motor (B axis)
SW Velocity + + + + PI Sinusoidal Close Loop/ Filter Open Loop Current/Torque Commutation Limit
Velocity Scale Factor VEL_FV Velocity Feedback
2 Order Low -Pass Filter
nd
ACC_FF Acceleration FeedForward
Notch Filter
VEL_FP=VEL_FV
Position Gain
VEL_FP
Velocity FeedForward
S
Derivative
Brushless Motor
DDM4
7-2 C O NT ROL LO OP S
FIGURE 7-1 SPiiPlus PCI-DDM4 Control Algorithm Block Diagram (Single Loop)
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Desired Position +
-
Desired Velocity
+ + -
2 Order Low -Pass Filter
Position Feedback Gear Ratio = Velocity Feedback
DAC Command
Phase Advance
Vector Control
S
Derivative
Position Feedback
5242 32768
5242 32768
+ -
-
-
iB
iA
PWMC
PWMB
PWMA
Secondary Position Sensor
Current Feedbacks
Phase B Current PI Filter
Phae A Current PI Filter
Not active in case of DC motor (B axis)
+ -
i*B
i*A
Scaling Ipeak=5242
Not active in case of DC motor (B axis)
SW Velocity + + + + PI Sinusoidal Close Loop/ Filter Open Loop Current/Torque Commutation Limit
Velocity Scale Factor VEL_FV Velocity Feedback
Notch Filter
nd
ACC_FF Acceleration FeedForward
VEL_FV= Gear Ratio x VEL_FP
Position Gain
VEL_FP
Velocity FeedForward
S
Derivative
Gear
Primary Position Sensor
Brushless Motor
DDM4
CONT ROL LOO P S 7-3
FIGURE 7-2 SPiiPlus PCI-DDM4 Control Algorithm Block Diagram (Dual Loop)
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7-4
C O NT ROL LO OP S Velocity Feed Forward Desired Velocity
VEL_FP
Position Gain Position Error
POS_GA × 2-GF
+
+
Velocity Command
FIGURE 7-3 Position Loop Block Diagram
OUTPUT
INPUT SOF_A
+
+ -
1 Z
Delay
1 Z
Delay
2× ×SOF_B
SOF_C
FIGURE 7-4 Velocity Low Pass Filter Block Diagram
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CONT ROL LOO P S Initial value Proportional Gain
INPUT
FRICTION
Integrator Gain
VEL_GA× × 2-10
INT_GA × 28
7-5
OUTPUT
+
+
+
+
Anti-Windup
1 Z Delay
FIGURE 7-5 Velocity PI Filter Block Diagram INPUT
OUTPUT
NOTCH_B0
1 Z
Delay
-
2× ×NOTCH_B1
+
+
1 Z
+ -
+
1 Z
Delay
1 Z
Delay
2× ×NOTCH_B1
Delay
NOTCH_A2
NOTCH_B2
FIGURE 7-6 Velocity Notch Filter Block Diagram
INPUT
Proportional Gain I_KP
Integrator Gain I_KI
+
OUTPUT +
+
+
Anti-Windup
Bus Limit
1 Z Delay
FIGURE 7-7 Current PI Filter Block Diagram
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7-6
C O NT ROL LO OP S
7.2. Position Loop The position filter consists of a pure proportional gain (FIGURE 7-3), which is set by the highlevel parameter SLPKP. The corresponding low-level parameters are the proportional gain POS_GA and the gain factor GF, which is set to 12. The parameter SLPKP is normalized to be approximately equal to the crossover frequency [rad/sec] of the position loop. This is under the assumption that the crossover frequency of the velocity loop is at least twice. NOTE
If all the servo-loops are well tuned, the bandwidth of the position loop is approximately equal to SLPKP/2π.
The relations between high-level and low-level parameters are:
Filter gain = POS_GA × 2 -GF = POS_GA × 2 -12 POS_GA =
SLPKP × 212 × VEL_FP 20000
The filter output is added to the velocity feed forward term, which is the desired velocity multiplied by the velocity feed forward gain, VEL_FP. The latter is a low-level parameter that is indirectly set by the maximum velocity parameter XVEL: If XVEL