Atlas DMC Service - Training

1. Atlas DMC Service - Training

Modern Motion Management
MBI - October, 16 1997 - V1.6 - page 1
Atlas DMC Service - Training
A tlas DM C
D igital M otion C o ntroller
L
D M C 5 0 72 0P
NEXT
HOST
Lac

2. DC supplied DMC with Power Supply unit

[A3 : 16] User's Manual
AC BUS
DC BUS
A tla s
D M C
D i g i t a l M o ti o n C o n t r o ll e r
L
MBI - October, 16 1997 - V1.6 - page 2
Atlas DM C
Atlas DMC
Atlas DMC
A tlas DM C
D igital Motion Co ntroller
D igital Motion C ontroller
Digital Motion C ontroller
D igital Motion C ontroller
L
L
L
L
D M C 5 0720P
DM C 50 720P
DM C 50 72 0P
D M C 50 720P
NEXT
HOST
N E XT
H OST
N EXT
H OS T
NEXT
HO S T
Stand-alone PS Unit
3 x 240V / 400V AC
DC Bus voltage
340 / 570V DC
Output Current
4 - 57 Arms
Lac

3. DMC - Numbering System

DMC
3
MBI - October, 16 1997 - V1.6 - page 3
05
15
P
O
[A3 : 15] User's Manual
Option Board
with Internal Power part
max. peak value (15A), for a short time
continuous peak value (5A), specification at 60°C
3 = 340 VDC (3 x 240 VAC)
5 = 570 VDC (3 x 400 VAC)
Lac

4. Standard Digital/Analog I/O Board

MBI - October, 16 1997 - V1.6 - page 4
Standard Digital/Analog I/O Board
D M C Standard I/O
D iEnable
D i10
D i9
D i8
D i7
D i6
D i5
D i4
D i3
D i2
D i1
D ig.Gnd
Ana In1 +
Ana In1 Ana In2 +
Ana In2 + 24 V In
X7A
6
X 7B
29
7
30
8
31
9
32
10
33
11
34
Do6
Do5
Do4
Do3
Do2
Do1
12
13
35
14
36
15
21
16
22
5
23
Rdy. n.o.
Rdy. n.o.
Ana. Gnd
Ana O ut1
Ana O ut2
3
4
24
1
26
2
27
25
28
0 V.
+ 24 V Out
+ 15 V Out
- 15 V O ut
Lac

5. Analog Input Expansion Board (12bit)

D M C O ption M
S train G a uge Transducer
Gnd
M2 +
+/- 50 m V
M2 M1 +
+/- 50 m V
M1 Gnd
X6D
1
X7D
61
2
62
3
63
4
64
5
65
6
66
67
+ 5 V O ut
- 5 V Out
9
68
7
69
70
Analog inputs
* 2 x +/- 50mV
* 1 x +/- 120mV
* 2 x +/- 20mA
* 2 x +/- 10V
* 5V output
MBI - October, 16 1997 - V1.6 - page 5
71
72
73
74
75
76
M7 +
M7 -
+/- 20 m A
M6 +
M6 -
+/- 20 m A
G nd
G nd
+ 12 V O ut
- 12 V Out
M5 +
M5 -
+/- 10 V
M4 +
M4 -
+/- 10 V
M3 +
M3 -
+/- 120 mV
+ 5 V O ut
- 5 V O ut
Lac

6. Encoder Output Emulation Board

MBI - October, 16 1997 - V1.6 - page 6
Encoder Output Emulation Board
D M C O ption H
X6H
1
2
3
4
5
6
7
8
5V
0V
C h. A +
C h. A C h. B C h. B +
Zero +
Zero G nd
G nd
Encoder emulation
* 2 channels + marker pulse
* 5V balanced outputs
* 1024 pulses/electric rev.
Lac

7. The Motor...

AC Brushless Servo Motors (Synchronous)
For high dynamic control
Torque range 0,2 to 80 Nm
…..
from 0,2 to 80 Nm
AC Induction Motors (Asynchronous)
Power range from 1 to 14 kW
For lower cost in applications
with less demanding duty cycle.
MBI - October, 16 1997 - V1.6 - page 7
1 to 14kW
Lac

8. Kein Folientitel

Benefits of AC Servo Motors
Electrical Commutation (No Brushes!)
No Commutation Related Speed Limit
Lower Inertia
Windings on Stator (Better Cooling
Characteristics)
High Peak and Rated Torque
Torque = Kt x Current
MBI - October, 16 1997 - V1.6 - page 8
Lac

9. Kein Folientitel

Modern Motion Management
Feedback Types
Resolver (Only type of feedback device
supported by the DMC)
Incremental Encoder
Absolute Encoder
Hall Effect Sensors
MBI - October, 16 1997 - V1.6 - page 9
Lac

10. Kein Folientitel

Modern Motion Management
Resolver Functionality
Position Feedback
Resolver angle information read by controller
The sum of angle changes is equal to position
Speed Feedback
Speed is calculated as the derivative of the
position
Motor Rotor Position Relative to Motor
Stator
MBI - October, 16 1997 - V1.6 - page 10
Used in electrical commutation of motor currents
Lac

11. Resolver Signal Processing

Excitation
Rotation
A Sine
U A
Excitation
B Cosine
U B
Filtered
A resolver can be seen as a rotating transformer. Output signals are rectified
after filtering the excitation. The final signals represent the sine and cosine of the
angle of the resolver (and motor shaft).
MBI - October, 16 1997 - V1.6 - page 11
Lac

12. Kein Folientitel

Analog Power
stage (current loop)
Power part
3 x 240 VAC
or
3 x 400 VAC
.
.
.
MBI - October, 16 1997 - V1.6 - page 12
Servo Motor
SW
D/R
Resolver
Lac

13. Kein Folientitel

DMC CPU & Memory
1 Firmware (system SW)
1 EProm
EProm :
27C256 -70
(32k * 8, 70 ns
--> must be < 90 ns)
static RAM
4 "256 Register"
* 4 Bytes
16 MHz
2 Application code (.pl2)
"only 16 kBytes available",
the rest is "out of memory
map"
Software:
LINE ORIENTED
DIRECT INTERPRETATIVE
MBI - October, 16 1997 - V1.6 - page 13
2
CPU
INTEL
-196 kC
BRam or
EProm
3
E Prom
4
static RAM
every value
will be lost at
"Power off"
RS 232
RS 422
15-pin
high
density
[A5:18] User’s
Manual
CAN BUS
2
64 * 2 Bytes
3 approx.
10% is used and
90% is free for
application
Lac

14. User's Manual

Part A : Hardware reference
USER's MANUAL 3.0
MBI - October, 16 1997 - V1.6 - page 14
Part B : Software reference
Part C : Accessories
Install the ECT Software
a:\ install.exe
+
copy examples on your HD
Lac

15. DMC - System Architecture [B1:3] User's Manual

1 MAX 2047 Line of Code
DMC
2 a : EPROM Version (.eprom)
b : BRAM Version [B1:8] & [B2:13]
Work directly in Atlas DMC
application memory. Use
direct commands
3 .list on [B2:11]
4 Pseudo-machine language, stripped of
all comments and labels
ECT
Editor
Create PL2
textfile in the
PC-editor
ECT
Compiler
2
1
List file
.lss
3
Download binary file to
Atlas DMC application
memory
ECT
Test
Compile the textfile to
create a binary
downloadable file
PL2 textfile
.pl2
Binary file
.hee 4
This way does
not exist
Figure B1-1 Atlas DMC software development cycle
MBI - October, 16 1997 - V1.6 - page 15
Lac
BRam

16. Application files

Proj Name
-) ApplName.pl2
include
include
SysUtl
-) Decl201.pl2
-) EEUtl201.pl2
-) ApplUtl.pl2
MBI - October, 16 1997 - V1.6 - page 16
-) Const201.pl2
-) Mac201.pl2
-) Mot201.pl2
-) Res201.pl2
-) Regul201.pl2
Lac

17. Kein Folientitel

Working with the ECT
[B8:2]
Editor for writing PL2 code applications.
Compiler to create Hex file which can be
downloaded to the DMC or burned into an
EPROM.
Terminal with useful tools and ability to
download programs.
MBI - October, 16 1997 - V1.6 - page 17
Lac

18. Kein Folientitel

Using the ECT Terminal
Start ECT by double-clicking on the ECT icon.
Select the “Terminal” option from the “Window”
menu.
All keystrokes typed will be sent to the DMC. All
responses from the DMC will be displayed.
MBI - October, 16 1997 - V1.6 - page 18
Lac

19. PL2 Extended Registers [B5:2]

A Group and its members
Group
Member 1
Member 2
Member n
Overview of the various groups in the DMC controller
RD1
RD2
PG
STACK
MOTOR
Profile
Circular
Motor
REG
Resolver 1
Resolver 2
Generator
Stack
Setup
Regulator
GEAR
TMR
SYSIO
INT
IN
OUT
System
Interrupt
Digital
Digital
Electric
Gear
Timers
IO
system
Input
Output
VECTOR
CAPTURE
ANA
EEPROM
COMM
RD1Corr
Interrupt
Event
Analog
Non volatile
Serial
Resolver
vectors
Capture
IO
storage
communication
Correction
MBI - October, 16 1997 - V1.6 - page 19
Lac

20. Kein Folientitel

Displaying Registers From the Terminal
The “disp” command is used to display
individual registers
“disp R100”
“disp RD1.Ampl”
The “gdisp” command is used to display an
entire extended register group. Group
name must be followed by a period “.”
MBI - October, 16 1997 - V1.6 - page 20
“gdisp RD1.”
“gdisp PG.”
Lac

21. Kein Folientitel

Changing Registers From the Terminal
To change a register value, type the register
name, a comma and the new value.
“R100,12345”
“PG.Speed,-81920”
MBI - October, 16 1997 - V1.6 - page 21
Lac

22. Some PL2 On Line Commands [B7:2]

1. LIST
for a new page
to quit
: <space>
: <Q>
2. DEL
3. RUN
4. NEW
5. CONT
6. DISP
7. GDISP
8. HELP
9. Control-C
10. Control-Z
11. Control-T
MBI - October, 16 1997 - V1.6 - page 22
Lac

23. DMC PL2 SW Flow

Start:
Out.do1 = 0
Out.do2 = 0
Start
Init:
clr Tmr.T0
If ... then ...
If ... then ...
MBI - October, 16 1997 - V1.6 - page 23
; clr timer
Main:
if In.di1 = 1 then Main1 ; Test input 1
if In.di2 = 1 then Main2 ; Test input 2
if Tmr.T0 > 200 then Main3
; Test timer
goto Main
; loop
Init
If ... then ...
; clr output 1
; clr output 2
Subroutine
Subroutine
Subroutine
Main1:
Out.do1 = 1
disp 1
goto Main
Main2:
Out.do2 = 1
disp 2
goto Main
; loop
; loop
; set output 1
; display on screen
; set output 2
; display on screen
Main3:
clr Tmr.T0
; clr timer
Out.do3 = 1 - Out.do3 ; toggle output 3
goto Main
; loop
Lac

24. DMC Firmware Flow [B1:4]

Servo Cycle
Handle Resolver Inputs ...
2 Resolver Input
0
Handle Digital Inputs and
evaluate interrupt flags.
Do all Profile and Gear / Cam
calculations.
Do regulator calculations
Do much more ...
Handle all Analog Outputs and
set the Current references.
Current reference is
updated every ms
(extrapolation)
Admin. Task
Handle the serial communication and DMC LAN
PL 2 code Task
Run the Interpreter and execute
the PL2 code.
MBI - October, 16 1997 - V1.6 - page 24
1 mS
Lac

25. DMC Interrupts [B1:5]

Int.SysmaskInt. 128
Syspend
64
32
16
8
TempERR
SysERR
CtrlC
4096
2048
1
4
2
PosERR
Capture
512
256
(mask values)
ResolvERR
MBI - October, 16 1997 - V1.6 - page 25
BleedERR
int.BleedLim
int.Tempmask
Int.Level
Int.Mask
Int.Pend
64
Input7
int.
int.
32
di6
di10
InputPTC
int.
di7
1024
(mask values)
InputFault
int.
InputEnable
int.
16
di5
Input6
int.Poserr
di4
Input5
int.
int.
di8
Input10
Input9
Input8
4
2
1
di3
Input4
128
di9
int.
8
Cycint
Tmr.Cycint
int.
di2
Input3
int.
int.
di1
Input2
int.
Lac
Input1
int.

26. Digital Input [A5:23]

Power Part
Hardware Enable
In. Enable
SW
SW-Enable
1 ms filter
Di 1 ... Di 10
CPU
Di 1
>25 s
MBI - October, 16 1997 - V1.6 - page 26
SYSIO.Pout
25 s filter
HSI
HSI = High Speed Input
(capture function)
Don’t forget to connect the shield [A5:24]
Lac

27. Analog Inputs [A5:25] / [B4:30] / [B5:37]

1. ana.in1range , 100000
; range = 0 .... 100000
2. ana.in1offs , -50000
; +/- 10V is mapped to +/- 50000
Range = 0
-50000
100000
0
-10V
+10V
1. ana.in2range , -16000
; range = 0 .... -16000
2. ana.in2offs , 8000
; +/- 10V is mapped to -/+ 8000
Range = 0
+8000
-10V
MBI - October, 16 1997 - V1.6 - page 27
+50000
-16000
0
-8000
+10V
Lac

28. Analog Outputs [A5:25] / [B4:30] / [B5:37]

RAW_OUTPUT = ANA.Out1 * 2
MBI - October, 16 1997 - V1.6 - page 28
ANA.Out1SF
+ ANA.Out1Offs
Lac

29. What is Positioning ?

Sending current i to motor windings
produces Torque,
Torque which causes an
Acceleration, generating Speed and finally
resulting in movement ... Position
MBI - October, 16 1997 - V1.6 - page 29
SPEED
TIME
Lac

30. Kein Folientitel

Difference between “Pos Abs”,
Abs “Pos Rel”
Rel and “Pos Inc”
Inc
Pos Rel d
Pos Rel d
d
Pos Abs d
Pos Inc d
MBI - October, 16 1997 - V1.6 - page 30
Pos Inc d
d
2d position [Inc]
Lac

31. Kein Folientitel

What is the Servo Regulator?
Algorithm in the DMC Firmware that controls
how much current (torque) is sent to the
motor.
It compares the actual position and speed of the
motor (measured by the resolver) with the
desired position and speed of the motor.
MBI - October, 16 1997 - V1.6 - page 31
Lac

32. The Traditional Control System

“reg.PGAIN”
Generation
of motion
profile
Pos
set
value
Position
regulator
Speed
set
value
“reg.DGAIN”
Speed
regulator
Torque
set
value
Torque
regulator
Current
set
value
Power
electronics
Servo
Motor
The Control system
MBI - October, 16 1997 - V1.6 - page 32
Position
feedback
Velocity
feedback
Torque feedback
Resolver
Atlas DMC has a parallel PID-structure
with Feed-forward drives
Lac

33. The DMC Control System

The Control system
The Analog
Power stage
(Current
regulator)
Feed
forward
drives
Servo Motor
+ Resolver
Generation
of motion
profile
+S
-
MBI - October, 16 1997 - V1.6 - page 33
PID
regulator
S Torque/Current
Limitation
Position and Velocity feedback
PI
reg.
Current feedback
Lac

34. Feed - forward

External force
Static/Dry friction
speed
torque
MBI - October, 16 1997 - V1.6 - page 34
speed
torque
Viscous friction
Inertia
speed
torque
+
time
speed
torque
+
+
time
time
time
Total torque
speed
torque
time
Lac

35. External force and Friction adjustment

Run the motor in positive direction with a low speed (S1=1%) and calc. a mean value of torque (tP1) for several samples.
Then run with a high speed (S10= 10%) and calc. a mean value (tP10) .
Do the same in negative direction (tN1 and tN10 ).
torque
tP10
15
Ext.force =
viscous
friction
tP1 7
-
5
dry friction
external force
MBI - October, 16 1997 - V1.6 - page 35
visc =
3
9
4
20
1 S1
S10
|tP1| - |tN1|
2
|tP10|+|tN10| - |tP1|+|tN1|
2
2
= 0.5
S10 - S1
+
speed
dry =
= 3.0
|tP1| + |tN1|
2
- visc * S1 = 2.0
tN10
Lac

36. Kein Folientitel

Reg.perrlim
Pg.apos
+
[inc]
S
-
Reg.Pgain
1024
Z-1
min.
Test Signal
Rd1.rpos
DMC Position Controller
max.
Reg.poserr
modebit 2=1
(or .mode,4) closes
switch
+
+
Reg.torqplim Reg.torqnlim
Reg.ierrlim
S
+
+
max.
S
Reg.ierr Reg.Igain
1024
modebit 3=1
(or .mode,8) closes
switch
min.
8191 = max. torque limit
Reg.torqlim
Test Signal
S
6=1
Reg.torqclim ,modebit
Reg.torqtime
(or .mode,64) ,activates timer
plimfunction
modebit 0=0 ind.
+clim pos. lim.
-clim
modebit 1=0 ind.
neg. lim.
nlim
Rd1.speed
4
.siscale
[inc/S]
Pg.aspeed +
2
Reg.spderr
-
S
1
1000
[inc/mS]
Reg.Dgain
1024
Reg.zero
min.
Reg.inertiap
Reg.inertian
Pg.adecel
Reg.inertiap(n)
2
[inc/S2 ]
|G|
max.
Test Signal
d
dt
Reg.pole
Reg.derrlim
Reg.inertiSF 16
2
modebit 4=1
(or .mode,16)
opens switch
Reg.torque
Reg.viscfric
2
Reg.viscSF
1000
Reg.statfric
+F
modebit 7=1
(or .mode,128)
opens switch
+/- 32767 eq. +/max. torque
0
Reg.settorq
MBI - October, 16 1997 - V1.6 - page 36
Test Signal
-F
Lac

37. Kein Folientitel

Regulator Registers
Reg.Mode = Determines what type of servo loop is to be implemented.
Reg.Pgain = Determines how much torque is output for each count of position
error.
Reg.Perrlim = Determines the max amount of position error used in computing
output torque.
Reg.Igain = Determines how much torque is output for each count integrated
position and/or speed error.
Reg.Ierrlim = Determines the max integrated error used in computing output
torque.
Reg.Dgain = Determines how much torque is output for each count of speed
error.
Reg.Derrlim = Determines the max speed error used in computing output
torque.
Reg.SiScale = Determines scaling of speed error when using integrated speed
error in the servo loop.
MBI - October, 16 1997 - V1.6 - page 37
Lac

38. Kein Folientitel

Regulator
Profile Generator
Din
10+1
Pg.posspeed
In.diX
DOut
6
Pg.rslope
Out.doX
S
7
6
5
4
3
2
1
0
pdata acc,t
CPU-ports
pdata acc,t
pdata acc,t
Sysio.pin
+
+/- 10 V
-
Gear.Camscale
1024
D
A
S
MBI - October, 16 1997 - V1.6 - page 38
Iref S
Feed
Forward
A
Rd1.rpos
S
Ana.Out1
+
12 bit
+/- 10 V
D
A
12 bit
Pg.posOffs
+
S
+
Pdata Array
(cam)
pdata pos,0
Ana.Out2
3
pdata pos,0
pdata pos,0
pdata pos,0
A
Gear. Pos / Gear.Speed
Rd1 (Rd2)
Supply
1 Gear.mode = (+128 for incremental CAM)
0
Sysio.pwm0
(255 - 0)
Rd1
+
Gear Box
Gear.Out
(3 - 13 V)
(1 kHz)
PWM
Sinus
S + Gear.Offset
Gear.Incr
Gear.InAct
Pos Count
32 bit
Rd1.ampl
Gear.mode +4
R
cos
Rd2
Pos Count
32 bit
Rd2.ampl
Timer, 1kHz
Gear.mode +32
sin
D
Gear.In
Rd2.pos
DMC LAN
Interface
Can H Can L
+/- 10 V
D
Rd1.pos
Rd1.speed
pdata pos,0
Serial Port
Rx
Tx
12 bit
D
12 bit
10 bit
10 bit
Iref R
+
Pg.Proscale
1024
pdata pos,0
Ana
In2
A
D
-
pdata pos,0
Ana
In1
D
-
P
I
D
Pos Mod Off (clr)
Gear.Campos
A
Motor.poles
.phalign
.ppr
Pos Mod On (clr)
pdata 0,0
Power On
CPU OK
Led 1
Led 2
Sysio.led
Led 3
Led 4
Led 5
Led 6
Led 7
Led 8
+
S
DMC System
Phase Split
pdata acc,t
LED's
+/- 10 V
+
-
pdata acc,t
pdata acc,t
Sysio.pout
-
Pg.aspeed
Pdata Array
(profile Acc)
7
6
5
4
3
2
1
0
S
+
Pg.apos
Pg.ret
Pg.acc
DMC Position Controller
Gear.SlavePos
Lac
sin
D
R
cos

39. Time profile example

Speed1 = 4 Turn / s
Speed2 = -2 Turn / s
Speed1
Acc1
Di10
Acc1 = 1 Turn / s^2
Acc2 = 2 Turn / s^2
Acc2
Do3
0
Do3
8 sec
time
TIME
Speed2
Input 10 : gosub SRou_Start
Di10
Input 10 : gosub SRou_Stop
MBI - October, 16 1997 - V1.6 - page 39
Lac

40. Master - Slave

Atlas D M C
D ig ita l M o tio n C o n tro lle r
L
D M C 507 20 P
N EX T
Rx 120
Synchr. Box
MBI - October, 16 1997 - V1.6 - page 40
W
with an SEM Motor
DMC
M al e
Fe m.
Ext ern al
R e so lv er
Fem .
M o to r
R e so lv er
M ale
M ast er / S la ve
DMC
Motor +
Resolver
Rx = 27 W (used to adjust the voltage
supply for the ACC Resolver
together with an Elmo Motor)
HO ST
Rx
Resolver
RD2
Lac

41. CAM Function (1)

CAM Function
MBI - October, 16 1997 - V1.6 - page 41
j(t)
6
8
5
4
A tlas D M C
D ig ital M o tion C o n trolle r
7
.
L
D M C 507 20 P
NEXT
HO ST
DMC
M al e
Fe m.
Fem .
M ast er / S la ve
DMC
9
s
M oto r
R e solv er
10
.
3
Ext er nal
R e solv er
11
[B5 : 27] User's Manual
2
M ale
Master
Resolver
RD2
1
12
(1)
Slave Axis
Res. RD1
Lac

42. Questions !!! and Answers ???

Questions !!!
MBI - October, 16 1997 - V1.6 - page 42
and
Answers ???
Lac