Delta Computer Systems VMC 186/40 Bedienungsanleitung

Delta Computer Systems, Inc. cannot be held responsible for the performance of any system in which the VMC

186/40 is used in a manner other than that for which it was originally intended, nor of any board which has

been modified by the owner.

Although great effort has been taken to ensure the accuracy of the information in this document, it is intended

to be used only as a guide. Knowledge of motion control, hydraulic servos, electric servos, magnetostrictive

transducers and safety rules is required. Delta Computer Systems, Inc. cannot accept responsibility for

problems resulting from omissions in this document.

VMC 186/40

Motion Controller Module

931104

Contents

Overview....................................................................................................................................................4

Hardware Specifications.............................................................................................................................5

VME Memory Map....................................................................................................................................6

Motion Control Parameters ........................................................................................................................7

Read Only Parameters..................................................................................................................7

Command Position.........................................................................................................7

Target Position...............................................................................................................7

Actual Position...............................................................................................................7

Transducer Counts.........................................................................................................7

Status Word ...................................................................................................................8

Bit Descriptions .............................................................................................................8

Industrial Bus Status Word Bit Map..............................................................................11

Drive..............................................................................................................................12

Target Speed..................................................................................................................12

Null Drive......................................................................................................................12

Reserved Words.............................................................................................................12

Axis Setup Parameters.................................................................................................................12

Clock (Default: N/A,256,2,N/A) ...................................................................................12

VME Status_ID (Default: 0)..........................................................................................12

New Null (Default: 2048) Range: 1844 to 2252...........................................................12

Estop Mask (Default: FFFFH Emergency stop disabled).............................................13

Halt Mask (Default: 0000H Halt enabled)....................................................................13

Interrupt Mask (Default: FFFFH Interrupts disabled) .................................................13

Feed Forward Advance (Default: 0)..............................................................................14

Null Update (Default: 500) Range: 10 - 65535, 0 = disabled........................................14

Minimum Update Time (Default: 1000).......................................................................14

Dither (Default: 0) .........................................................................................................15

Hysteresis (Default: 0)...................................................................................................15

Static Gain (Default: 50)................................................................................................15

Extend Gain (Default: 50)..............................................................................................15

Retract Gain (Default: 50) .............................................................................................15

Integral Gain (Default: 0) ..............................................................................................15

Differential Gain (Default: 0) ........................................................................................16

Extend Feed Forward (Default: 100).............................................................................16

Retract Feed Forward (Default: 100).............................................................................16

Scale (Default: 32768) Range 0 to 65535......................................................................16

Scale Calculation Examples...........................................................................................18

Position Offset (Default: 0)............................................................................................18

Direction (Default: 0) Possible options: 0 and -1 ..........................................................19

Maximum Position Error (Default: 250)........................................................................19

At Command Position (Default: 50)..............................................................................19

Near Command Position (Default: 0) ............................................................................19

Extend Limit (Defaults to actual position on reset).......................................................19

Retract Limit (Defaults to actual position on reset).......................................................20

Dynamic Control Parameters.......................................................................................................20

Mode (Default: 0000H) .................................................................................................20

Acceleration (Default: 1000).........................................................................................21

Deceleration (Default: 1000).........................................................................................21

Requested Speed (Default: 10000)................................................................................21

Requested Position.........................................................................................................22

Command.......................................................................................................................22

How It Works.............................................................................................................................................24

Initialization.................................................................................................................................24

Position Sensing...........................................................................................................................24

Drive Output ................................................................................................................................24

Closing the Loop..........................................................................................................................24

Integral and Differential Gains.....................................................................................................25

Feed Forward ...............................................................................................................................25

Feed Forward Advance................................................................................................................26

Control at Rest .............................................................................................................................26

Control Equations ........................................................................................................................26

Getting Started and Tuning the Axis..........................................................................................................27

Step 1 - Setting Up the Initialization Parameters.........................................................................27

Direction Parameter.......................................................................................................27

Scale Parameter..............................................................................................................27

Position Offset Parameter..............................................................................................28

Step 2 - Moving the Axis.............................................................................................................28

Step 3 - Jogging the Axis.............................................................................................................29

Step 4 - Tuning the Axis..............................................................................................................29

VME Controller Programming Precautions...............................................................................................30

VME Controller Error Handling..................................................................................................30

Key Items to Remember...............................................................................................................30

Front Panel Indicators ................................................................................................................................31

Hardware Configuration Information.........................................................................................................32

Supported VME Bus Address Modifiers .....................................................................................32

Module Jumpers and Removable Resistors .................................................................................32

Magnetostrictive Transducer Interrogation Pulse Polarity ............................................33

Number of Recirculations..............................................................................................33

Dual Port Address Selection..........................................................................................35

Fail Safe Timer Operation .............................................................................................36

Fail Safe Timers Jumpers...............................................................................................36

VME Bus Interrupt Selection ........................................................................................37

Firmware Development .................................................................................................37

Drive Selection.............................................................................................................................38

External Wiring and Site Installation Information.....................................................................................39

Common Problems and Solutions..............................................................................................................41

Repairs and Returns....................................................................................................................................42

Field Module Repair ....................................................................................................................42

Module Returns............................................................................................................................42

Warranty Repairs...........................................................................................................42

Returns...........................................................................................................................42

Glossary......................................................................................................................................................43

ASCII Code Chart......................................................................................................................................44

External Wiring Examples .........................................................................................................................45

VMC 186/40 Motion Control Module Overview

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Overview

The VMC 186/40 motion controller module was designed to provide a complete four axis position control sub-

system for the VME bus. Each axis is controlled by an on-board processor that provides a complete PID loop

in addition to numerous special functions. Coordinated moves and position changes can be made on-the-fly.

With various options, it is possible to control position using either quadrature encoders, analog slide

potentiometers or magnetostrictive transducers. In its standard configuration, the module provides four

optically isolated magnetostrictive interfaces and four optically isolated ±100 mA ( ±10 volts with resistors

installed) outputs which can be used to drive electric servo motors and hydraulic servo valves.

The VMC 186/40 occupies one slot (two slots if options installed) of the VME rack. Programming of the VMC

186/40 is done using memory reads and writes. The on-board 80186 processor relieves the VME Controller of

the overhead usually associated with servo control. The motion controller module updates the actual position

and drive output every millisecond, assuring accurate positioning even at high speeds.

If more than four axis of control are required, additional VMC 186/40 modules can be installed.

VMC 186/40 Block Diagram

Linear Transducers

Recirculation

& 16 Bit Counter

Logic

VMC 186/40

Isolated

Sensor

Inputs

VME BUS

Isolated

Drive

Outputs

External

Power

Supplies

512 Byte

Dual Port

Memory

-10 volts

-100 mA

VME

Interface

ASBX Analog Board

Analog Inputs (4) QSBX Quadrature Board

SBX 351 RS-232 Board

80186 CPU

& Control

Logic

Quadrature Inputs (4)

Serial Communications

Additional Configurations (one only)

VMC 186/40 Motion Control Module Overview





Hardware Specifications

VMC 186/40

12 MHz 80C186 processor

Addressable 512 byte dual port RAM

Bus interrupt for motion control errors or time interval

iSBX connector for options (Serial I/F, Analog or Quadrature Options)

One millisecond control loop time.

Linear resolution to ±0.0005 inches

Maximum velocity up to 120 inches per second using ±0.002 resolution

65535 position counts

Three hardware fail-safe timers

6U VME

Standard Position Inputs

Four optically isolated magnetostrictive transducer interfaces

1.5V return pulse sensitivity

55.5 MHz counters

1, 2 or 4 recirculations (2 default)

Positive or negative interrogating pulse

Drive Four optically isolated servo drives

Servo Drive - ±100 milliamps (±10 volts with 100 ohm resistors installed in sockets)

12 bit digital to analog converters

Power Requirements

5V @ 2.0 amps VME Bus

5V @ 0.5 amps External Sensor

15V @ 0.5 amps External Sensor

-15V @ 0.5 amps External Sensor

15V @ 0.5 amps External Drive

-15V @ 0.5 amps External Drive

All power supply voltages are to be within 5% of the specified voltage.

Sensor power supplies should be independent of drive power supplies.

VMC 186/40 Motion Control Module Memory Map





VME Memory Map

Axis 1 0D0000H-0D007FH

Memory Map Using Default Address

Axis 2 0D0080H-0D00FFH

Axis 3 0D0100H-0D017FH

Axis 4 0D0180H-0D01FFH Individual Axis Memory Map

Hex Offset Parameter Name Default Value Descriptions

00H Command Position Read Only Requested Position with limits checked

02H Target Position Read Only Calculated position of axis

04H Actual Position Read Only Scaled position measurement

06H Transducer Counts Read Only Raw transducer counts

08H Status Word Read Only Axis error and status

0AH Drive Read Only Output drive in raw A/D counts (12 bit)

0CH Target Speed Read Only Calculated speed

0EH Null Drive Read Only Current value for null drive

10H-39H 24 Reserved words

40H Axis 1 Free Running Clock

Axis 2 Active Bit Interval

Axis 3 Graph Interval

Axis 4 Reserved

Read Only

256

Free running 16 bit counter using millisecond clock

Active Bit toggle interval in milliseconds (Status Word axis 1)

Data capture interval (two millisecond increments)

42H VME Status_ID 0 VME status code for interrupt

44H New Null 2048 (Write Only) Entry for preset drive offset

46H Estop Mask FFFFH Enables emergency stop on errors (Bit = 0 = Enabled)

48H Halt Mask 0000H Enables ramped stop on errors (Bit = 0 = Enabled)

4AH Interrupt Mask FFFFH Enables VME interrupt based on Status Word (Bit = 0 = Enabled)

4CH Feed Forward Advance 0 Time shift in milliseconds for Feed Forward term

4EH Null Update 500 Null calculation interval in milliseconds

50H Minimum Update Time (Axis one only) 1000 Minimum time in microseconds between sensor readings

52H Dither 0 Static friction drive in percent of full drive

54H Hysteresis 0 Deadband compensation

56H Static Gain 50 Proportional gain at rest

58H Extend Gain 50 Proportional gain when extending

5AH Retract Gain 50 Proportional gain when retracting

5CH Integral Gain 0 Integral gain while in motion

5EH Differential Gain 0 Differential gain

60H Extend Feed Forward 100 Feed-forward drive when extending

62H Retract Feed Forward 100 Feed forward drive when retracting

64H Scale 32768 Measured position conversation number

66H Position Offset 0 Fixed position offset

68H Direction 0 Sign of position units with respect to Transducer Counts

6AH Maximum Position Error 250 Set point for position error indication

6CH At Command Position 50 Window around requested position for status bit

6EH Near Command Position 0 Window around requested position for status bit

70H Extend Limit Position on power-up Maximum length allowed

72H Retract Limit Position on power-up Minimum length allowed

74H Mode 0 Function selection bits

76H Acceleration 1000 Acceleration rate or distance

78H Deceleration 1000 Deceleration rate or distance

7AH Requested Speed 1000 Maximum speed during a move

7CH Requested Position N/A Destination position in position units

7EH Command N/A Command to be executed (F, G, H, P,O, R, S)

VMC 186/40 Motion Control Module Control Parameters

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Motion Control Parameters

The motion control parameters are the means of axis control. A complete understanding of the parameters and

Status Word bits are necessary in order to fully utilize the motion controller's features.

Read Only Parameters

Command Position

The Command Position is the Requested Position with bounds checking applied. If the Requested Position was

outside the Retract or Extend Limit, the Command Position will be truncated to the value of the limit, and the

axis will go only to the limit. The Command Position is updated when a 'G' or GO command is issued using

the Command parameter.

Note: If the requested position is outside the limits, the Parameter Error bit in the Status Word will be set. If

the Halt or Estop masks are enabled for a parameter error, the axis will not move.

Target Position

The Target Position is the calculated position where the axis should be at any moment. When the axis is

moving, the Target Position is updated every millisecond as it moves toward the Command Position. When an

axis is stopped, the Target Position should be the same as the Command Position unless an error has occurred.

Actual Position

The Actual Position is the measured position of the axis at any moment. This position is updated every

millisecond. The Actual Position is obtained from the Transducer Counts with the following formula:

Transducer Counts * Scale

Actual Position =  XOR Direction + Offset

32768

If the quadrature encoder (Q option) is installed, the Actual Position is calculated using a different formula.

Please refer to the quadrature addendum for more information.

Transducer Counts

Transducer Counts is the axis position read directly from the transducer without scaling.

VMC 186/40 Motion Control Module Control Parameters

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Status Word

The Status Word contains 16 bits of information about the axis. Five bits represent some type of motion error

(Lag, Lead, Overdrive, Position Overflow, and Parameter Error) and can be used to trigger a halt or emergency

stop. Seven bits indicate something about the motion profile (At Command Position, Near Command Position,

Halted, Accelerating, At Requested Speed, Decelerating and Stopped) and can be used by the VME Controlled

to monitor the motion profile. Two bits can be used to monitor transducer and drive performance (Transducer

Not Responding, Value Out of Null). One bit (Parameters Initialized) can be used to make sure the VMC

186/40 has accepted control parameters, and another bit (Active) can be used to generate a periodic VME

interrupt.

Status Word Bits

1514131211109876543210

Latched Momentarytoggle

Programmable

axis one

1 Near Command Position

0 At Command Position

2 Halted

3 Accelerating

4 At Requested Speed

5 Decelerating

6 Stopped

7 Active

8 Parameter Error

9 Position Overflow

10 Tranducer Not Responding

11 Valve Out of Null

12 Overdrive

13 Lead Error

14 Lag Error

15 Parameters Initialized

1514131211109876543210

LSBMSB

1514131211109876543210

emergency

If masks

removed,

will cause

a halt or

stop

Always causes

an emergency

stop

Bit Descriptions

The Status Word bits 0, 1, 2, 6, 8, 9 and 11-14 are cleared whenever a 'G' command is given.

Bit 0 = At Command Position

This bit will be set when the difference between the Actual Position and Command Position is less

than the value in the At Command Position field. This bit is latched and is only cleared by a 'G'

command.

Note: This bit will not be set if the axis is halted outside the At Command Position window.

Bit 1 = Near Command Position

This bit is similar to the At Command Position except it is set before or at the same time as the At

Command Position bit - never later (i.e., it has a larger window). The Near Command Position bit is

latched and is only cleared by a 'G' command.

VMC 186/40 Motion Control Module Control Parameters





Bit 2 = Halted

This bit is set when the axis has been given a Halt ('H') command or an error has caused a halt and the

axis has come to a stop. While the axis is halted, the Null Update timer will not run. The Halted bit is

cleared when a new command is issued to the axis.

Note: If the VMC 186/40 is left on while the axis power is off or the drive output is disconnected, a

Halt command should be issued to keep the null value from drifting.

Bit 3 = Accelerating

This bit equals one (TRUE) while the axis target is accelerating. It is not latched.

Bit 4 = At Maximum Speed

This bit equals one (TRUE) while the axis target is moving at the speed specified by the Requested

Speed parameter. It is not latched.

Bit 5 = Decelerating

This bit equals one (TRUE) while the axis target is decelerating. It is not latched.

Bit 6 = Stopped

This bit equals one (TRUE) when the average speed of the axis is less than 2000 Transducer Counts

per second. This bit is intended for use as an axis obstruction indication. It is not latched.

Bit 7 = Active

This bit will toggle while the motion controller module is running (axis one only). The interval the bit

toggles is programmable using axis's two Clock Word. The Active bit can be used for a module

watchdog or provide a programmable VME interrupt.

Bit 8 = Parameter Error

This bit will be set when an initialization parameter or control parameter is out of bounds. In some

cases one parameter's limit will depend on the value of another parameter so hard and fast limits may

not always be available. However, the motion controller does try to replace the offending value with

another that is within range. By comparing the values written with the values after the error bit was

set, the offending parameter can be determined. This bit is cleared when a new command is issued.

Bit 9 = Position Overflow

This bit is set when the 16 bit Actual Position is about to overflow. This occurs when the Actual

Position tries to go beyond 65500. The Position Overflow bit is latched and is cleared when a new

command is issued.

VMC 186/40 Motion Control Module Control Parameters





Bit 10 = Transducer Not Responding

This bit will indicate when the transducer does not respond with valid data at least once every 10

milliseconds. The transducer data received is compared with previous data. If the two readings differ

by more than 500 counts, the new reading is assumed to be an error. When an error is detected an

emergency stop is made and the corresponding front panel axis indicator will glow red

CAUTION: The Transducer Not Responding bit is not latched. Transducer errors will always cause

emergency stops, but with intermittent errors, the bit may be cleared before the VME Controller sees it. In

this case, the axis will remain stopped with the Halted bit set. It is possible to consistently detect this error

by enabling the Interrupt Mask and responding to a VME interrupt.

Bit 11 = Valve Out Of Null

Normally, when the drive output is zero volts or milliamps, the axis will not move. In hydraulic

applications valves sometimes get dirty and the axis will tend to move even when the drive output is

zero. The motion controller module will try to compensate for this problem, but if more than 10

percent of minimum or maximum drive output is required to hold a static position this error bit will be

set. It will be cleared when a 'G' Go command is used.

Bit 12 = Overdrive

This bit is set when the calculated drive output would exceed the 12 bit range of the A/D converter.

Usually this error is an indication the system does not have enough power to drive the axis at the

requested speed. The computer will truncate the drive to 12 bits. The Overdrive bit is latched and is

cleared when a new command is issued.

Bit 13 = Lead Error

Lead is a condition where the actual position gets ahead of the target position. This bit will be set

when the actual position leads the target position by more than the amount specified by the Maximum

Error parameter. Lead errors can occur if the feed forward is too high or the axis response is too slow

to respond to the output while ramping down. In the first case, the feed forward should be decreased.

In the second case, the Feed Forward Advance should be increased or the deceleration ramp should be

lengthened. The Lead error bit is latched and is cleared when a new command is issued.

Bit 14 = Lag Error

Lag is a condition where the actual position falls behind the target position. This bit will be set when

the actual position lags the target position by more than the amount specified by the Maximum Error

parameter. Lag errors can occur if the Feed Forward is too low or the Feed Forward Advance is set

too high. In the first case, the Feed Forward should be increased. In the second case, the Feed

Forward Advance should be decreased. The Lag error bit is latched and is cleared when a new

command is issued.

Bit 15 = Parameters Initialized

This bit is set after a parameter or 'P' command. Until this bit is set, the axis will not respond to any go

'G' commands. This bit is reset whenever the module is reset.

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