“Motorlab” Dynamics and Controls System
Motor
amplifier
“Motorlab”
Apparatus
Power
supply
Mechanical
System
Detail
Interface to motion
control card
Load
encoder
Load
inertia
Load lock
down screw
Motor
encoder
Brushless motor
Spring coupling
System Description
Below is a schematic representation of the motorlab system in a closed-loop position or velocity control
configuration. There are two position sensors on the apparatus. The position of the motor inertia is measured using
the motor encoder and the position of the load inertia is measured using the load encoder. This is done using
hardware on the DSP motion control card that counts the pulses from the encoders. Each pulse corresponds to a
certain increment of rotation. The velocities of the two inertias are measured using hardware on the MC4000
motion control card that measures the time between pulses coming from the encoders. The motor amplifier has a
control loop that measures and controls the electric current in the motor windings. This results in what is commonly
known as a “torque controlled” motor, since the magnetic torque is proportional to the current in the windings. The
DSP motion control card is interfaced to the motor amplifier through a +/-10V analog signal from a digital to analog
converter (DAC) on the card. By varying the magnitude of this voltage from the DAC the current in the motor is
varied. This voltage, which is proportional to the controlled current, serves as a current command for the current
control loop in the amplifier. An additional sensor, not shown below, is the current sensor in the amplifier. This
sensor is also read by the DSP card, using an analog to digital converter (ADC) to read the actual current measured
by the amplifier. Although this signal is not used in the control loops on the DSP card, it is recorded for data
analysis.
R
ic
P
DS
C
ard
24 V Supply,
and Motor
Amp with
Current Control
V
i
L
T = kt i
+
k bω 1
_
θ1,θ 2 ,ω1,ω2
1
θ2
θ1
J1
J2
b1
ks
b2
Several different configurations of the system can be utilized in experiments. Either sensor, the motor or load
encoder, can be used for the feedback of the control loop. The selection is made in the software interface. The
motor encoder is known as a “collocated” sensor since it is co-located with the input to the mechanical system, the
motor torque. The load sensor is separated from the input to the system by a spring and is therefore known as a
“non-collocated” sensor. In addition to varying which sensor is used, the mechanical system can be changed with
the lock down screw and the spring coupling. Also, a choice can be made between velocity control or position
control by selecting the appropriate control program. Any of the following mechanical models may be realized
using the motorlab hardware and software.
T
θ2
θ1
J1
T
ks
b1
b2
T
ω2
ω1
J1
J2
b1
ks
Third order system
ω1
J1
J1
b1
b2
Second order system
with a free integrator
T
ω1
T
b1
ks
Second order system
Fourth order system
with a free integrator
θ1
J1
J1
J2
b1
T
θ1
ks
Second order system
with a free differentiator
b1
First order system
Software
The software can be found in the “c:\motorlab” directory on the laboratory machines. All the needed functions
and shortcuts to the executables can be found here. The “c:\motorlab\student data” directory can be used to store
data files and gain files temporarily. It should be cleaned out at the end of the lab session. Students have
read/write/delete access to this directory.
Control Software
There are three different programs used to control the motorlab hardware. Each program consists of a GUI
interface that runs on the host PC and a low-level control program that runs on the DSP microprocessor on the
MC4000 motion control card. The PC’s processor and the DSP communicate over the PCI bus in the host computer.
For the two programs that implement closed loop control, a PID controller is used. In addition the user has the
option of including feedforward velocity and acceleration gains. Each of the three programs may be run by
executing the host program, which loads the appropriate DSP program onto the motion control card and begins its
execution. WARNING: The software will not function properly if more than one host program is running. The
three programs are described below.
MotorLabOL.exe
This is the open loop program. The feedback sensors (encoders) are not actually used for
closed loop control. The DAC output from the motion control card to the motor amplifier is
determined directly by the wave command buttons and the jog buttons.
MotorLabPosition.exe
This is the position control program. The feedback sensors (encoders) are used to close
the position control loop. The DAC output from the motion control card to the motor
amplifier is determined by the controller algorithm, while the position command is
determined by the wave command buttons and the jog buttons.
2
MotorLabVelocity.exe
This is the velocity control program. The feedback sensors (encoders) are used to close
the velocity control loop. The DAC output from the motion control card to the motor
amplifier is determined by the controller algorithm, while the velocity command is
determined by the wave command buttons and the jog buttons.
Menus for:
•trapezoidal velocity
profile parameters
•controller gain
changes
•gain file saves
•gain file loads
Jogging
buttons
Choice of
sensors for
feedback loop
Real time
display of status
Amplifier
power control
Encoder zeroing
button
Motion
command
buttons
Parameters for:
•jogging
•motion commands
•and data storage
Data
acquisition
control
Position Control Host-Computer Interface
Velocity Control Host-Computer Interface
Showing Gain-Change Dialog
Open Loop Host-Computer Interface
3
Data Acquisition
When the “Store Data” button is pressed in the host GUI the software stores data from the dynamic system in a
circular buffer. The buffer is 2048 data samples in length. After 2048 sample periods the buffer begins to be
overwritten, and will continue to be overwritten as long as the “Store Data” button is depressed in the host program.
Pressing either the “Save Data” button or the “Store Data” button again will stop data storage, leaving the last 2048
data samples in the buffer. If for example the sample rate is set to 500 Hz, then the last 2048/500=4.096 seconds of
data will be saved in the buffer. The data is saved to a file by pressing the “Save Data” button.
The exception to the sampling scheme above occurs when one of the command buttons in the “One Shot
Commands with Auto Save of Data” is pressed. In this case the command generation and the data storage execute
until the buffer fills. Then the data is automatically stored to a data file named with the time and date from the
computer clock.
Nine pieces of data are stored at each time step (each sample period):
TIME(sec) Command(deg/RPM/Amps) Theta1(deg) Theta2(deg) Vel1(RPM) Vel2(RPM) U(Amps) I(Amp) Extra(??)
The TIME data begins at zero with the oldest data point in the buffer. The units of the Command depend upon
which program is running: closed-loop position control, closed-loop velocity control, or the open loop program. The
U variable is the commanded current to the amplifier, and the I variable is the measured current. The Extra variable
is reserved for future use.
Associated MATLAB functions for data analysis
File: mlimport.m function data = mlimport(); Opens a dialogue to select a data file generated by the motor lab
software. Returns the data in the selected file through a matrix with 9 columns and 2048 rows. The 9 columns of
the matrix contain the following data:
TIME(sec) Command(deg/RPM/Amps) Theta1(deg) Theta2(deg) Vel1(RPM) Vel2(RPM) U(Amps) I(Amp) Extra(??)
example: data = mlimport;
File: mlolplots.m function mlolplots(data,Iscale); Uses data generated by the motorlab openloop control software
and imported using mlimport.m. Plots the motion variables along with the current command to the amplifier. If an
"Iscale" argument is supplied then the commanded current values are scaled by the Iscale value in the plots.
example: mlolplots(data); Does not scale the current command.
example: mlolplots(data,Iscale); Multiplies commanded current values by Iscale.
File: mlposplots.m function mlposplots(data); Uses data generated by the motorlab position control software that
has been imported using mlimport(). Plots this data in several plots. example: mlposplots(data);
File: mlvelplots.m function mlvelplots(data); Uses data generated by the motorlab velocity control software that
has been imported using mlimport(). Plots this data in several plots. example: mlvelplots(data);
File: trapprof.m function [x,v,t] =trapprof(DX,Vmax,Amax,DT) Trapezoidal-velocity motion profile generation
Outputs: x=position vector, v=trapezoidal velocity vector, t=time vector
Inputs: DX=distance to move, Vmax=maximum velocity, Amax=maximum acceleration, DT=time step for outputs
example: [x,v,t] =trapprof(DX,Vmax,Amax,DT)
Associated EXCEL programs
Three EXCEL files/programs are also included in the motorlab directory: “Open Loop Plots.xls,” “Position
Control Plots.xls,” and “Velocity Control Plots.xls.” Each of these files contains a Visual Basic GUI interface in
the “HeaderSheet” sheet of the file. The GUI’s are used to import data files for the plot sheets. These files
essentially implement the same plots as the three plot functions for MATLAB discussed above.
4
Hardware Specifications
Important Scaling Considerations
• Motor Amplifier Scaling = 1 Amp/Volt (i.e. one volt from the DAC on the MC4000 is a one Amp command to
the current loop in the motor amplifier). The plotting routines provided take this scaling into consideration.
• Position is measured in degrees and velocity is measured in RPM. The output of the controller algorithm on the
MC4000 is the DAC voltage, and is measured in Volts. Therefore, for example, the units of the proportional
and derivate gains in the position controller would be Volts/deg and Volts*sec/deg, respectively. When
multiplied by the amplifier scaling (1 Amp/Volt) these gains become Amps/deg and Amps*sec/deg. The units
of the proportional gain in the velocity controller would be Volts/RPM (or Amps/RPM if amplifier scaling is
included).
Inertias
Object
Approx. Inertia (g-cm2)
Motor Rotor and
Motor Encoder
110
Stainless Steel
Coupling Collar
13.04
Stainless Steel
Load Shaft
1.423
Aluminum
Spacer for Load
0.079
Aluminum
Load Inertia
81.91
Load
Encoder
0.83
A Few Other Details
• Max motor velocity with the amplifier used is about 4000 rpm
• Max Data Acquisition Sample Rate = 10 kHz (the servo update rate of the DSP software)
• Motor Encoder Resolution = 360/1600 = 0.225 deg/count
• Load Encoder Resolution =360/2000=0.180 deg/count
Velocity measurement
The velocity is measured on the DSP motion control card using a timer to measure the time between encoder pulses
( ω ≅ ∆θ / ∆t ). This results in a time delay in the velocity measurement that can become very significant at low
velocity. This time delay can have a significant affect on a velocity controller and on the derivative term in a PID
position controller. If for example the motor encoder is spinning at 20 rpm then the time delay would be
0.225 deg
rev
60 sec
∆t = ∆θ / ω =
⋅
⋅
= 0.002 sec
20 rev/min 360 deg min
Theoretically, it is not possible to measure zero velocity.
Specs from Motor Manufacturer’s Data Sheet
LA052-040E Motor Dynamic Specs From Shinano Kenshi
RATED POWER
RATED VOLTAGE
RATED SPEED
RATED TORQUE
RATED CURRENT
TORQUE CONSTANT
BACK EMF CONSTANT
PHASE RESISTANCE
PHASE INDUCTANCE
INSTANTANEOUS PEAK TORQUE
MAX SPEED
ROTOR INERTIA
POWER RATE
MECHANICAL TIME CONSTANT
ELECTRICAL TIME CONSTANT
MASS
5
UNITS
W
VDC
rpm
N-cm
kgf-cm
A
N-cm/A
kgf-cm/A
V/krpm
Ohm
mH
N-cm
rpm
g-cm2
kW/s
ms
ms
kg
Value
40
24
3,000
12.7
1.3
2.5
5.0
0.51
5.2
1.18
4.4
38.2
5,000
110
1.48
5.2
3.7
0.6
Current Control Loop Model
The motor amplifier has a current control loop. As configured in the Motorlab apparatus this loop has a
bandwidth of approximately 400 Hz. Using data acquired from step and sinusoidal responses the following two
closed loop transfer functions have been identified as approximate models for the closed-loop current control
dynamics.
z = 170 ⋅ 2π (rad/sec)
2
2
ω n = 230 ⋅ 2π (rad/sec)
ω n (s + z)
ω n (s + z)
Ti =
and Tidelay =
e −td s where
2
2
2
2
ς = 0.8
z ( s + 2ςω n s + ω n )
z ( s + 2ςω n s + ω n )
t d = 0.0002 (sec)
One of the models above contains a time delay while the other does not. In the following two figures the responses
of these two models are compared with actual data acquired from one of the Motorlab systems. Both the step
response and the frequency response models are shown.
Step Response of Current Control Loop
1.2
Current (Amp)
1
0.8
0.6
0.4
Command
Experimental Data
Model w/o Time Delay
Model with Time Delay
0.2
0
0
0.001
0.002
0.003
Time (sec)
0.004
0.005
Frequency Response of Current Control Loop
2
Magnitude (dB)
0
-2
-4
-6
-8
Phase (deg)
-10
0
-45
-90
Experimental Data
Model w/o Time Delay
Model with Time Delay
-135
-180 0
10
10
1
10
Frequency (Hz)
6
2
10
3
Schematic For the “Motorlab” Apparatus
7
Manual for the Motor Amplifier
Model 503
DC Brushless Servo Amplifier
FEATURES
• CE Compliance to
89/336/EEC
•
Recognized Component
to UL 508C
• Complete torque ( current ) mode
functional block
• Drives motor with
60° or 120° Halls
• Single supply voltage
18-55VDC
• 5A continuous, 10A peak more
than double the power output of
servo chip sets
• Fault protected
PRODUCT DESCRIPTION
Short-circuits from output to
output, output to ground
Over/under voltage
Over temperature
Self-reset or latch-off
• 2.5kHz bandwidth
• Wide load inductance range
0.2 to 40 mH.
• +5, +15V Hall power
• Separate continuous, peak, and
peak-time current limits
• Surface mount technology
APPLICATIONS
•
•
•
•
X-Y stages
Robotics
Automated assembly machinery
Component insertion machines
THE OEM ADVANTAGE
• NO POTS: Internal component
•
•
header configures amplifier for
applications
Conservative design for high
MTBF
Low cost solution for small
brushless motors to 1/3 HP
Model 503 is a complete pwm servoamplifier for applications using DC
brushless motors in torque ( current ) mode. It provides six-step commutation of three-phase DC brushless motors using 60° or 120° Hall
sensors on the motor, and provides a full complement of features for
motor control. These include remote inhibit/enable, directional enable
inputs for connection to limit switches, and protection for both motor and
amplifier.
The /Enable input has selectable active level ( +5V or gnd ) to interface
with most control cards.
/Pos and /Neg enable inputs use fail-safe (ground to enable) logic.
Power delivery is four-quadrant for
bi-directional acceleration and deceleration of motors.
Model 503 features 500W peak power output in a compact package
using surface mount technology.
An internal header socket holds components which configure the various
gain and current limit settings to customize the 503 for different loads and
applications.
Separate peak and continuous current limits allow high acceleration
without sacrificing protection against continuous overloads. Peak current
time limit is settable to match amplifier to motor thermal limits.
Header components permit compensation over a wide range of load
inductances to maximize bandwidth with different motors.
Package design places all connectors along one edge for easy connection and adjustment while minimizing footprint inside enclosures.
High quality components and conservative ratings insure long service life
and high reliability in industrial installations.
A differential amplifier buffers the reference voltage input to reject
common-mode noise resulting from potential differences between
controller and amplifier grounds.
Output short circuits and heatplate overtemperature cause the amplifier
to latch into shutdown. Grounding the reset input will enable an autoreset from such conditions when this feature is desired.
Corporate Offices: 410 University Avenue
Westwood, MA 02090
Telephone: (781) 329-8200
Fax: (781) 329-4055
E-mail: sales@copleycontrols.com
http://www.copleycontrols.com
221
Model 503
DC Brushless Servo Amplifier
FUNCTIONAL DIAGRAM
MOMENTARY SWITCH RESETS FAULT
WIRE RESET TO GROUND FOR SELF-RESET
3
SHORT/O.T.
POWER FAULT
NORMAL
CH2
1.5 NF
RH1
499K
LED'S
R
R
G
8
STATUS
&
CONTROL
LOGIC
4
5
+5V
6
1nF
7
REF AMP
10K
10K
RH7
REF(-) 10
-
REF(+) 11
+
470 PF 2.2 MEG
CURRENT LIMIT
SECTION
100K
1
-
RH6
10K
PEAK
RH3
RH5
PEAK
TIME
1nF
RH4
+NORMAL
NEG ENABLE
POS ENABLE
ENABLE
ENABLE POL
GND
100 PF
J2 SIGNAL CONNECTOR
+
10K
J2 SIGNAL CONNECTOR
RESET
50K
CURRENT
ERROR
AMP
J1 MOTOR & POWER CONNECTOR
RH3
RH5
CONT
Gv = 1
CURRENT 9
MONITOR
OPEN = 120 DEG.
GND = 60 DEG.
HALLSELECT
1K
OUTPUT
CURRENT
SENSE
33NF
+/-5V AT
+/-10A
PWM
STAGE
MOSFET
"H"
BRIDGE
1
2
3
4
Gv = +HV
10
MOTOR
U
V
W
+HV
GND
5
2
U
17
V
HALLS
HALL
LOGIC
16
W
15
+5
+15
GND
+HV
GROUND CASE FOR SHIELDING
+5
14
+15
13
DC / DC
CONVERTER
CASE GROUND
NOT CONNECTED
TO CIRCUIT GROUND
-15
18
POWER GROUND AND SIGNAL GROUNDS ARE COMMON
TYPICAL CONNECTIONS
CONTROLLER
REF(-)
10
W
3
REF(+)
11
SIG GND
J2
12
J1
DC POWER SUPPLY
V
2
MOTOR
U
1
GND
AC
-
5
+
4
J1
AC
+HV
13
J2
14
+15 V
+5 V
15
16
222
SIG GND
1
/NEG ENAB
4
/POS ENAB
5
/ENABLE
6
17
18
J2
Corporate Offices: 410 University Avenue
Westwood, MA 02090
Vcc
W
V
U
GND
HALL
SENSORS
Telephone: (781) 329-8200
Fax: (781) 329-4055
E-mail: sales@copleycontrols.com
http://www.copleycontrols.com
Model 503
DC Brushless Servo Amplifier
APPLICATION INFORMATION
To use the model 503 set up the internal header with the
components that configure the transconductance, current
limits, and load inductance. Current-limits and load
inductance set up the amplifier for your particular motor,
and the transconductance defines the amplifiers overall
response in amps/volt that is required by your system.
COMPONENT HEADER SETTINGS
Use the tables provided to select values for your load and
system. We recommend that you use these values as
starting points, adjusting them later based on tests of the
amplifier in your application.
LOAD INDUCTANCE (RH1,CH2)
Maximizes the bandwidth with your motor and supply
voltage. First replace CH2 with a jumper (short). Adjust the
value of RH1 using a step of 1A or less so as not to
experience large signal slew-rate limiting. Select RH1 for
the best transient response ( lowest risetime with minimal
overshoot). Once RH1 has been set. choose the smallest
value of CH2 that does not cause additional overshoot or
degradation of the step response.
TRANSCONDUCTANCE (RH6,7)
The transconductance of the 503 is the ratio of output
current to input voltage. It is equal to 10kΩ/RH6 (Amps/
Volt). RH6,and RH7 should be the same value and should
be 1% tolerance metal film type for good common-mode
noise rejection.
CURRENT LIMITS (RH3, 4, & 5)
The amplifier operates at the 5A continuous, 10A peak
limits as delivered. To reduce the limit settings, choose
values from the tables as starting points, and test with your
motor to determine final values. Limit action can be seen
on current monitor when output current no longer changes
in response to input signals. Separate control over peak,
continuous, and peak time limits provides protection for
motors, while permitting higher currents for acceleration.
SETUP BASICS
1. Set RH1 and CH2 for motor load inductance (see
following section).
2. Set RH3, 4, & 5 if current limits below standard values is
required.
3. Ground the /Enable (/Enable Pol open), /Pos Enable,
and /Neg Enable inputs to signal ground.
4. Connect the motor Hall sensors to J2 based on the
manufacturers suggested signal names. Note that
different manufacturers may use
A-B-C, R-S-T, or U-V-W to name their Halls. Use the
required Hall supply voltage (+5 or +15V). Note that
there is a 30 mA limit at +5V. Encoders that put-out Hall
signals typically consume 200-300 mA, so if these are
used, then they must be powered from an external
power supply.
5. Connect J1-4,5 to a transformer-isolated source of DC
power,
+18-55V. Ground the amplifier and power supply with an
additional wire from J1-5 to a central ground point.
6. With the motor windings disconnected, apply power and
slowly rotate the motor shaft. Observe the Normal (green)
led. If the lamp blinks while turning then the 60/120°
setting is incorrect. If J2-2 is open, then ground it and
repeat the test. In order to insure proper operation, the
correct Hall phasing of 60° or 120° must be made.
6.Turn off the amplifier and connect the motor leads to
J1-1,2,3 in U-V-W order. Power up the unit. Apply a
sinusoidal reference signal of about 1 Hz. and 1Vrms
between
Ref(+) and Ref(-), J2-10,11.
7. Observe the operation of the motor as the current monitor
signal passes through zero. When phasing is correct the
speed will be smooth at zero crossing and at low speeds. If
it is not, then power-down and re-connect the motor.
There are six possible ways to connect the motor windings,
and only one of these will result in proper motor operation.
The six combinations are listed in the table below. Incorrect
phasing will result in erratic operation, and the motor may
not rotate. When the correct combination is found, record
your settings.
#1
#2
#3
#4
#5
#6
J1-1
U
V
W
U
W
V
J1-2
V
W
U
W
V
U
J1-3
W
U
V
V
U
W
GROUNDING & POWER SUPPLIES
Power ground and signal ground are common ( internally
connected ) in this amplifier. These grounds are isolated
from the amplifier case which can then be grounded for best
shielding while not affecting the power circuits.
Currents flowing in the power supply connections will create
noise that can appear on the amplifier grounds.
This noise will be rejected by the differential amplifier at the
reference input, but will appear at the digital inputs. While
these are filtered, the lowest noise system will result when
the power-supply capacitor is left floating, and each amplifier is grounded at its power ground terminal ( J1-5 ). In
multiple amplifier configurations, always use separate
cables to each amplifier, twisting these together for lowest
noise emission. Twisting motor leads will also reduce
radiated noise from pwm outputs. If amplifiers are more than
1m. from power supply capacitor, use a small (500-1000µF.)
capacitor across power inputs for local bypassing.
Corporate Offices: 410 University Avenue
Westwood, MA 02090
Telephone: (781) 329-8200
Fax: (781) 329-4055
E-mail: sales@copleycontrols.com
http://www.copleycontrols.com
223
Model 503
DC Brushless Servo Amplifier
APPLICATION INFORMATION (CONT’D)
COMPONENT HEADER
HEADER LOCATION
WARNING!
DISCONNECT POWER WHEN CHANGING HEADER
COMPONENTS. REPLACE COVER BEFORE APPLYING
POWER TO PREVENT CONTACT WITH LIVE PARTS.
( COVER
REMOVED )
RH1
J1
CH2
J2
LOAD INDUCTANCE SETTING
RH3
CONTINUOUS CURRENT LIMIT
RH4
PEAK CURRENT TIME LIMIT
RH5
PEAK CURRENT LIMIT
RH6
RH7
REFERENCE GAIN SETTING
LEDS
NOTE: Components in dotted lines are
not installed at factory
CONTINUOUS CURRENT LIMIT (RH3)
Icont (A)
5
4
3
2
1
RH3 (Ω)
open *
20k
8.2k
3.9k
1.5k
INPUT TO OUTPUT GAIN SETTING ( RH6, RH7 )
Note 1
Example: Standard value of RH6 is 10kΩ, thus G = 1 A/V
PEAK CURRENT LIMIT (RH5) Note 3
Ipeak (A)
10
8
6
4
2
RH5 (Ω)
open *
12k
4.7k
2k
750
LOAD INDUCTANCE SETTING (RH1 & CH2) Note 2
Load (mH)
0.2
1
3
10
33
40
RH1
49.9 k
150 k
499 k
499 k
499 k
499 k
PEAK CURRENT TIME-LIMIT (RH4) Note 4
CH2
1.5 nF
1.5 nF
1.5 nF *
3.3 nF
6.8 nF
10 nF
Tpeak (s)
0.5
0.4
0.2
0.1
RH4 (Ω)
open *
10 M
3.3 M
1M
Times shown are for 10A step from 0A
Notes:* Standard values installed at factory are shown in italics.
1. RH6 & RH7 should be 1% resistors of same value.
2. Bandwidth and values of RH1, CH2 are affected by supply voltage and load inductance. Final selection should be
based on customer tests using actual motor at nominal supply voltage.
3. Peak current setting should always be greater than continuous current setting.
4. Peak times will double when current changes polarity. Peak times decrease as continuous current increases.
224
Corporate Offices: 410 University Avenue
Westwood, MA 02090
Telephone: (781) 329-8200
Fax: (781) 329-4055
E-mail: sales@copleycontrols.com
http://www.copleycontrols.com
Model 503
DC Brushless Servo Amplifier
TECHNICAL SPECIFICATIONS
Typical specifications @ 25°C ambient, +HV = +55VDC. Load = 200µH. in series with 1 ohm unless otherwise specified.
OUTPUT POWER
Peak power
Unidirectional
After direction change
Continuous power
±10A @ 50V for 0.5 second, 500W
±10A @ 50V for 1 second, 500W
±5A @ 50V, 250W
OUTPUT VOLTAGE
Vout = 0.97HV -(0.4)(Iout)
MAXIMUM CONTINUOUS OUTPUT CURRENT
Convection cooled, no conductive cooling
Mounted on narrow edge, on steel plate, fan-cooled 400 ft/min
±2A @ 35°C ambient
±5A @ 55°C
LOAD INDUCTANCE
Selectable with components on header socket
200 µH to 40mH (Nominal, for higher inductances consult factory)
BANDWIDTH
Small signal
-3dB @ 2.5kHz with 200µH load
Note: actual bandwidth will depend on supply voltage, load inductance, and header component selection
PWM SWITCHING FREQUENCY
25kHz
ANALOG INPUT CHARACTERISTICS
Reference
Differential, 20K between inputs with standard header values
GAINS
Input differential amplifier
PWM transconductance stage
X1 as delivered. Adjustable via header components RH6, RH7
1 A/V ( output vs. input to current limit stage )
Output offset current ( 0 V at inputs )
Input offset voltage
20 mA max. ( 0.2% of full-scale )
20 mV max ( for 0 output current, RH6,7 = 10kΩ )
Logic threshold voltage
/Enable
/POS enable, /NEG enable
/Reset
/Enable Pol (Enable Polarity)
HI: ≥ 2.5V , LO: ≤1.0V, +5V Max on all logic inputs
LO enables amplifier (/Enable Pol open) , HI inhibits; 50 ms turn-on delay
LO enables positive and negative output currents, HI inhibits
LO resets latching fault condition, ground for self-reset every 50 ms.
LO reverses logic of /Enable input only (HI enables unit, LO inhibits)
OFFSET
LOGIC INPUTS
LOGIC OUTPUTS
+Normal
HI when unit operating normally, LO if overtemp, output short, disabled, or power supply (+HV) out of tolerance
HI output voltage = 2.4V min at -3.2 mA max., LO output voltage = 0.5V max at 2 mA max.
Note: Do not connect +Normal output to devices that operate > +5V
INDICATORS (LED’s)
Normal (green)
Power fault (red)
Short/Overtemp (red)
ON = Amplifier enabled, no shorts or overtemp, power within limits
ON = Power fault: +HV <18V OR +HV > 55V
ON = Output short-circuit or over-temperature condition
CURRENT MONITOR OUTPUT
±5V @ ±10A (2A/volt), 10kΩ, 3.3nF R-C filter
DC POWER OUTPUTS
+5VDC
+15VDC
30mA (Includes power for Hall sensors)
10mA
Total power from all outputs not to exceed 200mW.
Output short circuit (output to output, output to ground)
Overtemperature
Power supply voltage too low (Undervoltage)
Power supply voltage too high (Overvoltage)
Latches unit OFF (self-reset if /RESET input grounded)
Shutdown at 70°C on heatplate (Latches unit OFF)
Shutdown at +HV < 18VDC (operation resumes when power >18VDC)
Shutdown at +HV > 55VDC (operation resumes when power <55VDC)
PROTECTION
POWER REQUIREMENTS
DC power (+HV)
Minimum power consumption
Power dissipation at 5A output, 55VDC supply
Power dissipation at 10A output, 55VDC supply
+18-55 VDC @ 10A peak.
2.5 W
10W
40W
THERMAL REQUIREMENTS
Storage temperature range
Operating temperature range
-30 to +85°C
0 to 70°C baseplate temperature
MECHANICAL
Size
Weight
3.27 x 4.75 x 1.28 in. (83 x 121 x 33mm)
0.52 lb (0.24 kg.)
Power & motor
Signal & Halls
Weidmuller: BL-125946; Phoenix: MSTB 2.5/5-ST-5.08
Molex: 22-01-3167 housing with 08-50-0114 pins
CONNECTORS
Corporate Offices: 410 University Avenue
Westwood, MA 02090
Telephone: (781) 329-8200
Fax: (781) 329-4055
E-mail: sales@copleycontrols.com
http://www.copleycontrols.com
225
Model 503
DC Brushless Servo Amplifier
OUTLINE DIMENSIONS
Dimensions in inches (mm.)
4.75
(120.7)
(19.1)
(3.0)
0.75
0.17
3.27
(83.1)
2.00
(50.8)
4.50
(114.3)
(14)
0.55
1.28
(32.5)
ORDERING GUIDE
Model 503
5A Continuous, 10A Peak, +18-55VDC Brushless Servoamplifier
OTHER BRUSHLESS AMPLIFIERS
226
Model 505
Same power output as 503. Adds Hall / Encoder tachometer feature for velocity loop
operation.
5001 Series
Six models covering +24-225VDC operation, 5-15A continuous, 10-30A peak.
With optional Hall / Encoder tachometer, and brushless tachometer features.
Model 513R
Resolver interface for trapezoidal-drivemotors. Outputs A/B quadrature encoder signals
and analog tachometer signal for velocity loop operation. +24-180VDC operation, 13A
continuous, 26A peak.
Corporate Offices: 410 University Avenue
Westwood, MA 02090
Telephone: (781) 329-8200
Fax: (781) 329-4055
E-mail: sales@copleycontrols.com
http://www.copleycontrols.com
Data Sheet for the MC4000 DSP Motion
Control Card
MC4000
PCI-Bus
The Versatile
Motion Control Board
with Easy-to-Use Software
The MC4000 is Precision MicroDynamics’ multi-axis, PCI-Bus motion control DSP board. It is ideal
for both Original Equipment Manufacturers (OEMs) and Test and Measurement applications.
PC-BASED MULTI-AXIS
DSP MOTION CONTROL
Four off-the-shelf versions of the
M C 4 0 0 0 a r e o ff e r e d : t h e
MC4000
Version
Servos
Open-loop
Steppers
Closed-loop
Steppers
Analog
Inputs
Position
Cap./Com.
MC4000-PRO, four servos and
PRO
4
4
-
4
4
LITE
4
-
-
-
-
STEP
-
4
4
-
-
DUAL
4*
-
-
4
4
four steppers; the MC4000LITE, four servos; the MC4000STEP, four closed-loop steppers
and four open-loop steppers; and
the MC4000-DUAL, four dualencoder servos.
*Dual Encoder Axes
The MC4000 uses a 32-bit floating-point DSP that performs path planning, feedback regulation and
other real-time computations, freeing the host PC for process application and graphical user interface
(GUI) software.
The MC4000 is supported by powerful development software: MotionSuite™ and MotionSuitePRO™. MotionSuite includes: MCI-SoftLIB™, easy-to-use, thread-safe C-library of motion control
functions; and MotionTools™, easy-to-use GUI for machine tuning and set up.
MotionSuite-PRO provides DSP programming capability for the MC8000.
MotionSuite-PRO
includes: LIBeRTy™ real-time multi-tasking software; CMC-SoftLIB™, a C-library of motion
control routines; SHARC-Trig™, a mathematics C-library; and MotionTools.
Application areas for the MC4000 include: semiconductor processing, material handling and test, CNC
machine tool control, automotive test and measurement, aerospace, medical equipment, industrial
materials processing, and food packaging and processing.
Custom modifications to standard DSP executables and FPGA firmware are performed for qualified
OEMs.
PRECISION
M I C R O
DYNAMICS
07/2001
Precision MicroDynamics, Inc., #3 - 512 Frances Ave., Victoria, B.C., Canada, V8Z 1A1, Tel. 250-382-7249, Fax. 250-382-1830, Web. Http://www.pmdi.com
Hardware
Linkport
MC4000-PRO Overview
The MC4000-PRO is a DSP-based motion control board that
communicates with the Host PC through the PCI bus. The card
supports data rates with the host PC as high as 7.2 MBytes/s . The
core of the MC4000-PRO is its 32-bit floating-point DSP
processor. The standard memory configuration is 48 bits wide and
includes 20K words of on-chip SRAM, 256K words of on-board
SRAM and 330Kwords of FLASH memory.
The MC4000-PRO’s 2 external connectors are arranged into
four groups, with each group having 30 physical contacts.
I/O Type
Number
Encoders
Analog
Digital
In
Details
4
- A, B, Z, A*, B* and Z*
4
- ADC differential line
Out
8
- DAC
In
24
- user programmable
Out
8
High-speed
I/O
16
- user programmable
- Stepper outputs, auxiliary
encoders and registration
Digital Signal Processor
The DSP is Analog Devices’ 32-bit ADSP-21061 SHARC
processor running at 40MHz with 20K words of on-chip memory.
Other SHARC DSP processors available include:
On-board SRAM
80K words
40K words
DSP Type
ADSP-21060
ADSP-21062
Other details
Linkports
Linkports
Nonvolatile Memory
Permanent memory storage for stand-alone operations is
provided. The board comes with 330K words of FLASH memory
for storage of machine parameters and programs.
Quadrature Encoders
The quadrature encoder inputs support single-ended and
differential encoder signals. +5V and 12V are available for
encoder power. The standard encoder input frequency is 10 MHz
edge rate after 4X decoding (20 & 40MHz options are available).
Analog
Each group has a 14-bit (65,536 Levels) differential analog input
and two 16-bit (16,384 Levels) outputs. These signals sample at a
rate of 88kHz. Each group has the following:
Analog
Inputs
Outputs
Quantity
1
2
Resolution
Name
14 bits
ADC
DAC A and B 16 bits
Range
± 10V
± 10V
Digital
Each group has 6 inputs, 2 outputs and 4 high-speed lines for a
total of 48 Digital I/O lines. Unreserved lines can be programmed
to meet OEM requirements. Each group has the following:
Digital I/O*
Inputs
Outputs
High-speed
Quantity
6
2
4
Typical Use
HOME, LIM-, LIM+
AmpEnable
Stepper Motor- Pulse or Dir,
Position Capture or Compare,
and Auxiliary A and B.
*TTL compatible (sink and source 10 mA)
SYNC and WDOG
The SYNC signal can be passed between multiple MC4000PRO boards for synchronization of motion control or data
acquisition. If the WDOG times out, the user can program any
number of discrete events to take place (ex. emergency stop).
PMDi
A ten-pin connector contains the WDOG and SYNC signals,
along with the Linkport connections, enabling communication
between two separate MC4000-PRO DSPs directly (transfer
rates up to 160Mbits/sec). This is an advanced feature available
with theADSP-21060 orADSP-21062 options.
Software
Two development software suites are available for the MC4000.
These are (i) MotionSuite and (ii) MotionSuite-PRO.
MotionSuite
Register Access is offered for Microsoft Windows operating
systems. This library provides functions for reading and writing
the board’s registers.
MotionTools is a GUI application program used to set up, and
tune motion control for the MC4000. Evaluate MotionTools for
free over the Internet. After downloading MotionTools you will
be able to control servomotors directly over the Internet. To learn
more visit http://www.pmdi.com.
MCI-SoftLIB high-level motion control C-library contains a set
of functions that accesses the services of PMDi’s DSP-based
motion control cards.
Initialization File is a text-based file that sets motion control
parameters for use by the MCI-SoftLIB library.
MotionSuite-PRO
MotionSuite-PRO provides all of the features and components of
MotionSuite, but adds the capability of programming at the DSP
level. It is distributed with the additional software components:
CMC-SoftLIB, LIBeRTy and SHARC-Trig.
CMC-SoftLIB is a comprehensive software library of Clanguage routines for motion control application development.
LIBeRTy is PMDi’s real-time, multi-tasking kernel for use
with Analog Devices’ SHARC DSP Processors.
SHARC-Trig is an optimized trigonometry C-library.
Specifications
Computer Compatibility
å PCI Bus, 4.25in. high by 8.25in. long
Digital Signal Processor and Memory
å Analog Devices’ ADSP-2106X SHARC DSP
å 128K words of 48-Bit on-board SRAM
å 330K words of 48-Bit on-board FLASH memory
SYNC
å Synchronizes DAC output, ADC and encoder input
å SYNC generated by on-board timer or software
Programmable Interval Timer
å 0.25m s to 512 seconds with 0.12
m s resolution
å Can generate SYNC signal and/or PC interrupts
Watchdog Timer
å 3.85m s to 125ms
å Forces DAC outputs to 0 Volts on timeout and digital output
to low for emergency shutdown
Quadrature Encoder Input Channels
å 24-bit up-down counters. A,B,Z inputs, invertible for
phasing and universal index pulse, digitally filtered
Precision MicroDynamics, Inc., #3 - 512 Frances Ave., Victoria, B.C., Canada, V8Z 1A1, Tel. 250-382-7249, Fax. 250-382-1830, Web. Http://www.pmdi.com
PMDi
å Preload in hardware by index pulse or by software register
å Each encoder axis input configurable for differential or
single ended termination
å Power for +5V and +12V encoders
å Up to 40MHz maximum input edge rate
Digital Outputs
å Digital outputs, usually used as amp enable and emergency
shutdown.
å TTL Level, 10mA source
Stepper Motor Outputs
D/A Channels (16-bit)
å Pulse and direction bits
å 2MHz max (1 Hz resolution)
å Maximum output rate 88kHz
å Accuracy ±1 LSB
å Voltage output range ±10V
High-Speed Digital I/O
A/D Channels (14-bit)
å Maximum sampling rate 88kHz
å Accuracy ±1 LSB
å Voltage input range ±10V
Digital Inputs
å Digital inputs typically used for machine limits and home
å TTL Level, 10mA sink
å Stepper motor outputs (step and direction)
å Position capture inputs or compare outputs
å Auxiliary encoder inputs (A and B)
å Unreserved high speed I/O for OEMs
å Additional functions for qualified OEM customers
! PWM Outputs
! Temposonics™ Inputs
! Handwheel Inputs
Pin-outs
Four off-the-shelf versions of the MC4000 are available.
These are the MC4000-PRO , MC4000-LITE ,
MC4000-STEP and MC4000-DUAL. Each version has
four standard 60-pin IDC connectors. Each connector is
logically separated into two 30-pin groups, with each
group supporting one motion axis (except for the PRO
and STEP versions that have two axes per group for a total
of 8 axes).
Group0
1
3
0
2
MC4000
connectors
J17
MC4000-PRO
MC4000-LITE
MC4000-STEP
DESCRIPTION
DESCRIPTION
DESCRIPTION
MC4000-DUAL
DESCRIPTION
PIN
FUNCTION
1
+5V
+5V Power for Encoders
+5V Power for Encoders
+5V Power for Encoders
+5V Power for Encoders
2
GND
Encoder GND
Encoder GND
Encoder GND
Encoder GND
3
A
Encoder Channel A
Encoder Channel A
Encoder Channel A
Encoder Channel A
4
A*
Encoder Channel A Complement
Encoder Channel A Complement
Encoder Channel A Complement
Encoder Channel A Complement
5
B
Encoder Channel B
Encoder Channel B
Encoder Channel B
Encoder Channel B
6
B*
Encoder Channel B Complement
Encoder Channel B Complement
Encoder Channel B Complement
Encoder Channel B Complement
7
Z
Encoder Index Pulse
Encoder Index Pulse
Encoder Index Pulse
Encoder Index Pulse
8
Z*
Encoder Index Pulse Complement
Encoder Index Pulse Complement
Encoder Index Pulse Complement
Encoder Index Pulse Complement
9
+12V
+12V Power for Encoders
+12V Power for Encoders
+12V Power for Encoders
+12V Power for Encoders
10
GND
Digital Ground
Digital Ground
Digital Ground
Digital Ground
11
DIN0
HOME1
HOME1
HOME1
HOME1
12
DIN1
LIM1+
LIM1+
LIM1+
LIM1+
13
DIN2
LIM1-
LIM1-
LIM1-
LIM1-
14
DIN3
HOME2
DIN3
HOME2
DIN3
15
DIN4
LIM2+
DIN4
LIM2+
DIN4
16
DIN5
LIM2-
DIN5
LIM2-
DIN5
17
GND
Digital Ground
Digital Ground
Digital Ground
Digital Ground
18
+5V
+5V from PC
+5V from PC
+5V from PC
+5V from PC
19
DOUT0
Amp Enable 1
Amp Enable 1
Amp Enable 1
Amp Enable 1
20
DOUT1
Amp Enable 2
DOUT1
Amp Enable 2
DOUT1
21
GND
Digital Ground
Digital Ground
Digital Ground
Digital Ground
22
HSD0
Stepper Motor- Pulse 1
NC
Stepper Motor- Pulse 1
Aux. Encoder Channel A
23
HSD1
Stepper Motor- Direction 1
NC
Stepper Motor- Direction 1
Aux. Encoder Channel B
24
HSD2
Position Compare Output
NC
Stepper Motor- Pulse 2
Position Compare Output
25
HSD3
Position Capture Input
NC
Stepper Motor- Direction 2
Position Capture Input
26
AGND
Analog Ground
Analog Ground
NC
Analog Ground
27
DAC B
Analog Output B
NC
NC
Analog Output B
28
DAC A
Analog Output A
Analog Output A
NC
Analog Output A
29
AD+
Analog Input +ve Diferential Line
NC
NC
Analog Input +ve Diferential Line
30
AD-
Analog Input +ve Diferential Line
NC
NC
Analog Input +ve Diferential Line
* Pin-outs shown for Group0 only (Connector J17 pin 1-30).
Functions for Group1 to Group3 are the same.
Precision MicroDynamics, Inc., #3 - 512 Frances Ave., Victoria, B.C., Canada, V8Z 1A1, Tel. 250-382-7249, Fax. 250-382-1830, Web. http://www.pmdi.com
PMDi
System Configuration
WH-60
†
Group0 and 1
2 WH-60 cables connected to
‡
MC4000
2 Breakout60 interconnect boards
Group2 and 3
WH-60
Amplifiers*
Encoders
Sensors
Relays
Servos
Steppers
Switches
†
† also available in shielded version (WHS-60)
‡ regular terminal block available (TERM/60)
* PMDi Linear amplifier available (BTA-XXV-6A)
Ordering Information
MC8000-PRO*
-LITE*
-STEP*
-DUAL*
WH-60
WHS-60
BreakOut60
TERM/60
SYNC/10-ZZ
DNG-9
4 servo axes and 4 stepper axes motion control and data acquisition board
4 servo axes motion control board
4 closed-loop stepper axes and 4 open-loop stepper axes motion control board
4 servo axes dual-encoder motion control and data acquisition board
60 pin ribbon cable assembly (for two axes)
60 pin shielded cable assembly (for two axes)
Breakout board with opto-isolation (for two axes)
60 contact screw-terminal break-out board (for two axes)
10 pin SYNC connector cable, ZZ the number of connectors = number of boards synchronized
Encoder line fault detection circuitry for open-circuit, short-circuit, and voltage level
MotionSuite
MotionSuite-PRO
MotionTools, MCI-SoftLIB, and Register Access libraries
MotionSuite plus LIBeRTy, SHARC-Trig, and CMC-SoftLIB
* Register Access libraries included.
Note: MC8000 boards using Linkports require non-standard DSP chips. Call Precision MicroDynamics for information.
Warranty: The MC8000 is warranted according to the Terms and Conditions of the Sale and is effective for ONE YEAR after shipment.
Representative's Information
PRECISION M I C R O DYNAMICS
# 3 - 5 1 2 F r a n c e s Av e n u e • Vi c t o r i a • B . C .
Canada • V8Z 1A1
Te l . 2 5 0 - 3 8 2 - 7 2 4 9 • F a x . 2 5 0 - 3 8 2 - 1 8 3 0
We b . h t t p : / / w w w. p m d i . c o m E m a i l . i n f o @ p m d i . c o m
©2001 Precision MicroDynamics, Inc., Specifications may change without notice.