“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: email@example.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: firstname.lastname@example.org 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: email@example.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: firstname.lastname@example.org 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: email@example.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: firstname.lastname@example.org 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.