RoboteQ AX2550/2850 manual

AX2550/2850 Dual Chann el High P o w er Digital Motor Contr oller User ’ s Manual v1 .7 , F ebrua r y 1, 2 00 5 visit www . robot eq.com to download the lat est revisio n of thi s manua l ©Cop yright 2003-2005 R oboteq, I nc.[...]

2 AX25 50/2 850 Mo tor Co ntroll er U ser ’ s Ma nual V e rsio n 1 .7 . F ebruar y 1, 20 05 The inf ormation contained in this manua l is beli ev ed to be accurate a nd reliab le. Ho we v er , it ma y contain e rrors tha t were no t noticed a t time of p ublication. User’ s are e xpected to perf orm their o wn pro duct v alidation and not re ly[...]

AX25 50/2 850 Mo tor Co ntro ller U ser ’ s Manua l 3 Revision History[...]

4 AX25 50/2 850 Mo tor Co ntro ller U ser ’ s Manu al V e rsio n 1 .7. Februar y 1, 20 05[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 5 Re vi sion Hist or y 2 SECTION 1 AX250 0/2850 Quic k St art 11 What you will need 11 Locating Switc hes, Wir es and Conn ectors 12 Connecti ng to the B at teri es and Motors 13 Using the P ow er Contro l Wire 14 Conne cting the R/C Radio 14 P o wering On t he Contro ller 15 But ton Oper ation 16 De[...]

6 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Current Li mit Set tings 38 Contin uous and Extended Current Lim ita tion 38 T empe rature-B ase d Current Limit ation 39 Surge Current Protection 40 Regeneration Cu rrent Limiting 40 Programmable Acceleration 40 Comman d Contro l Cur ves 42 Lef t / Right T uning[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 7 Self-T est Displa y 68 SECTION 7 R/C O peratio n 69 Mode Des cription 69 Selecti ng the R /C Input M ode 70 T ypic al W iring 70 Connector I/O Pin Assignmen t (R/C Mode ) 71 R/C Inpu t Circuit Descri ption 72 Suppli ed Cable Descriptio n 73 Cablin g to R/C Receiver using F u ll Opto-Is olation 74 C[...]

8 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Apply Parameter Changes 97 Re set Control ler 97 Optica l Encoder Commands 97 Commands Ac knowledg e and Error Mes sages 97 Characte r Ec ho 97 Comm and A c kno wle dgemen t 98 Command Error 98 W atc hdog time-out 98 RS-232 W atc hdog 98 RS2 32 Ac cessible Pa ram[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 9 Using O ptical Enc oder for Spe ed F eedback (AX2850 on ly) 124 T ac hometer or En coder Moun ting 124 T ac h ometer wirin g 124 Spe ed Sens or and M otor P olar ity 125 Adjust Offset and M ax Spe ed 126 Contro l Loop Descr iption 127 PID tuning in S peed Mode 128 SECTION 12 Inst alling , Conn ecti[...]

10 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Vie wing Encoder Data 152 Upda ting the En coder Sof t w are 152 SECTION 13 Conf iguri ng the Cont roller usin g the S wit c h es 153 Programming Method s 153 Programming usi ng built -in Switc hes and Dis play 153 Entering Programming Mod e 154 Changing pa rame[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 11 SECTION 1 AX250 0/2850 Quic k Star t Thi s sectio n will g ive you t he basic in fo rmation ne eded to qu ic kly in stall, set up a nd r un you r AX2500/2850 co ntroller in a minima l configu ration. T he AX285 0 is a v ersion of the AX25 50 control ler with the a ddition of Optic al Encoder i npu[...]

AX250 0/2850 Quic k Start 12 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Locating S witc hes, Wires and Connector s T ak e a moment to fam iliariz e yours elf with the control ler ’ s wires, sw itc hes and co nnector . The front side (sho wn in Figure 1) contains the bu t tons and dis pla y needed to opera[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 13 Connecting to the Bat teries and Motors Connecting to the Bat teries and Motors Connecti on to the ba t teries and motors i s sho wn in the fig ure belo w and is done b y con- necting the set of wir es coming o ut from the bac k of the control ler. 1 - Connect the t w o thic k blac k wires to the [...]

AX250 0/2850 Quic k Start 14 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Importa nt W arning The contr oller inc ludes lar g e capacit ors. When connecting the Mot or P ow er Cabl es, a spar k will be g enera ted at the connection point. This is a nor mal oc cur r ence and should be expect ed. Using the P o [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 15 P o wering On the Controller Thi s wiring - with the wi re loop un cut - assum es hat the R/C ra dio will be po wered b y the AX2500/2850 c ontroller . Other w iring options are described in “ R/C Operation ” on pa ge 6 9 of th e User ’ s Manual. Importa nt W arning Do not conne ct a bat t e[...]

AX250 0/2850 Quic k Start 16 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 T urn the R/C transmit ter On. T he “ no ctrl ” scrol ling mess age wil l disapp ear and the d ispla y will sh ow stea dy patterns de pendi ng on t he mot ors ’ se lecte d directio n. Mov e the jo ystic k on the transmit ter to ac[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 17 Default Controller Configuration Default Co ntroller Conf iguration V ersion 1 .7 of the AX2500/285 0 sof tware is configure d with the fact or y def aults sho wn in the table bel ow . Althou gh Rob oteq striv es to k eep the s ame paramete rs and v alues f rom one v ersion to th e next, c hanges [...]

AX250 0/2850 Quic k Start 18 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Connecting t he contro ller to y our PC usin g Roborun Connecti ng the con troller to y our PC is not neces sar y fo r basic R/ C operation . How e ver , it is a v er y sim ple procedure that is us eful f or the f ollo wing pu rposes: ?[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 19 Obtaining the Controller ’ s Software Revi sion Nu mber T o connect the contro ller to your PC, use the pr ovided ca ble. Connect the 1 5-pin connecto r to the co ntroller . Connec t the 9-pin connector to your P C ’ s av ail able p ort (t ypi cally COM1) . Apply po w er to the controller to t[...]

AX250 0/2850 Quic k Start 20 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 Eac h sof twa re ve rsion is ide ntified w ith a uniq ue number . Obtaining this numb er can be done us ing the PC c onnection d iscussed p re viously . It is also poss ible to get the controll er to displa y the sof tware version nu mb[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 21 SECTION 2 AX250 0/2850 Motor Contr oller Ov er view Congrat ulati ons! B y selec ting R oboteq ’ s AX2500/2850 y ou ha ve e mpow ered you r- self wi th the indu str y ’ s mo st v ersatile and programmabl e DC Motor Controller f or mobile robots. This ma nual wi ll guide you step b y step th ro[...]

AX250 0/2850 Motor Controlle r Overview 22 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 The motors ar e driv en using high-ef fi ciency P ow er MOSFE T transi stors con trolled us ing Pul se Width Modula tion (PWM) at 1 6kHz . The AX2 500/2850 po we r stages can ope rate from 1 2 to 40VDC and can sustain up t[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 23 T ec hnical features • T ac ho meter input s f or closed lo op speed control • P otentio meter inpu t for po sition (s er vo mode) • Motor tempera ture sensor i nputs • External v oltage s ensors • User defi ned purpose (RS 232 mode o nly) • One S witc h input confi gurable as • Emer[...]

AX250 0/2850 Motor Controlle r Overview 24 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uar y 1, 2005 • 1 00A up to 30 secon ds • 80A e xtended • High cur rent ope ration ma y be e xtende d with f orced cool ing • 250A peak Amps per c hannel • 1 6kHz P ulse Width Modulati on (PWM) outp ut • Au xiliary output f [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 25 Connecting P o wer SECTION 3 Connecting P o w er and Motor s to the Contr oller Thi s sectio n describes the AX2500/2850 Con troller ’ s co nnecti ons to pow er so urces and motors. Importa nt W arning Please f ollo w the ins tr uctions in this section v ery ca refull y . An y pr oblem due to w [...]

Connecting P o wer and Motors to the Controller 26 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Co ntro ll er P ower The AX2500/2850 us es a fle xible po w er supply sc hem e that is best describ ed in Fig ure 9. On this diagram , it can b e seen that the Control Logic requires a stable 1 2V supply , whi le th[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 27 Controller P o wer that conn ecting one wire of a gi ven b at tery potential wi ll elimin ate the need fo r connecting the ot her . Malfunction o r e ven dam age ma y occur if one wire is assum ing the load of all tw o. T ABLE 4. Effect of P ower Control under various voltage c onditions P ow er C[...]

Connecting P o wer and Motors to the Controller 28 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 P o weri ng the Contr oller using the Motor Bat teries The AX2500/2850 included a DC/DC conv erter to generat e the internal 1 2V re quired f or its operatio n. Th e diagram on Figure 1 0 sho w ho w to wi re the con[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 29 Controller P o wer Using a Bac kup Bat ter y T o ensure that the controll er will alwa y s be operationa l, regardless of the c harge lef t in the main ba t tery , it is reco mmended to add a 1 2V bac kup bat tery connecte d as sho wn i n Figur e 1 1. 2 x 1 2V B at teries = 24V 3 x 1 2V B at terie[...]

Connecting P o wer and Motors to the Controller 30 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Mak e sur e that you r mot ors have their wir es isolat ed from th e motor casing. Some mot ors, par ticular ly au tomotiv e par ts, use on ly one wir e, with the other conne cted to th e mo t or ’ s fr ame . If y[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 31 Electrical Noise Reduc tion T e c hn iques has bu ilt-in c apacito rs and vol t age limiter s that wi ll redu ce these ef f ect s. Ho we v er , shoul d the wire ind uctance be incre ased, f or examp le by extendin g the wire lengt h, these ef fect s will be amplified b ey ond the controlle r ’ s[...]

Connecting P o wer and Motors to the Controller 32 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Importa nt W arning A v oid sw itching O ff or c utting o pen the main pow er cable s (thick bl ack and r ed wir es) while the mot ors ar e spinni ng. D amag e to the contr oller ma y occur . Overvoltage P ro tectio[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 33 Using the Controlle r with a P ow er Supply high cur rent surge s during moto r acceleration, making it possible to use a lo w er current po w er supply . B at tery mounted in thi s wa y should be co nnected f or the first time only while ful ly c h arged and sh ould not b e allo w ed to disc harg[...]

Connecting P o wer and Motors to the Controller 34 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 35 Basic Operat ion SECTION 4 General Operation Thi s section dis cusses the co ntroller ’ s normal operation in all i ts sup ported ope rating mode s. Basic Operation The AX25 00 /285 0 ’ s opera tion c an be su mmarized as follows: • Recei ve c ommands fro m a radio receiv er , joy stic k or [...]

General O peration 36 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Selecting the Moto r Control Modes F or eac h motor , the AX2500/2850 support s multiple mo tion control modes. Th e controller ’ s f actor y def aul t mode is Open L oop Spe ed control f or ea c h mot or . The mod e can be c han ged using an[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 37 Selecting the Motor Contr ol Modes Closed Loop Speed Contr ol In this m ode, illu strated in Fi gure 1 5, an analog tac hometer or an optical encoder (AX285 0 only) is used to m easure the ac tua l motor spe ed. If the sp eed c ha nges becau se of c hanges in load, the controller au tomatically co[...]

General O peration 38 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Current Limit Set tings The AX2500/2850 ha s curre nt sensor s at eac h of its two output stages. Every 1 6 ms , this curr ent is meas ured and a cor recti on to the output p ow er le ve l is appl ied if high er than the user pres et v alue. Th[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 39 T emperature-Based Current Limitation Y ou can select one of 7 cu rrent limit se t tings bas ed on yo ur robot ’ s compon ent capabi lities (motors, bat te r y , wiring), up to th e controll er ’ s o wn lim it. Th e av ailabl e curren t limit v alues are sho wn i n the table belo w . The contr[...]

General O peration 40 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Surge Current Pr otection During ex ceptio nally high load con ditions suc h as moto r stalls, the motors ma y make demand s on the c ontroller i n ex cess o f sev eral hundred Am ps. The current l imiting f e a- t ures des cribed abo ve will a[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 41 Pr ogrammable A ccelerati on Numeri cally spe aking, eac h acceleration v alue corres ponds to a fixe d percentage spe ed inc rement , appl ied ever y 1 6 m illis econd s. The value for eac h setting is sh own in th e t able below . When con figurin g the accelera tion para meter using the Rob oru[...]

General O peration 42 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Command Cont rol Cu r v es The AX2500/2850 can also be s et to transla te the jo ysti c k or R S232 m otor command s so that the m otors resp ond dif f erently whether the jo ys tic k is ne ar the cen ter or near the ex tremes. The controlle r [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 43 Lef t / Right T uning Adjustment The AX2500/2850 is deli vered w ith the “ lin ear ” cur v es se lected f or bot h jo ysti c k c hannels. T o select di f f erent cur v es, y ou will ne ed to c hange the v alues of “ E ” (c hann el 1) and “ F ” (c ha nnel 2) ac cording to th e table bel[...]

General O peration 44 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 directio n will ca se the motor to spin 3 to 5.25% faster th an the s ame command applied in the re ver se directi on. Note tha t since th e motors can not be made to spin f aster tha n 1 00%, the rev erse d irection is th e one tha t is act ua[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 45 Emergency Stop using External S witc h Aft er and Emerg enc y Stop c ondition, the c ontroll er must be r eset or po we red Off and On t o r esum e nor mal oper ation. Emer gency Stop using E xternal Switc h An ex ternal swit c h can be ad ded to the AX2500/285 0 to allow the operator to s top the[...]

General O peration 46 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Special Use of Accessory Digital Inputs The AX2500/2850 in cludes tw o genera l purpose dig ital inputs id entified as Input E and Input F . O n the AX28 50, input E is disabl ed. Th e location o f these inputs on the DB1 5 con- nect or can be [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 47 Self-T est Mode Af ter a f ew second s, the LEDs will dis pla y a sequen ce of two n umerical digits and an opti onal le t ter se parate d by dashe s as sh own in the examp les be low . Af ter these digits are displa yed , the controll er will at tempt to po wer the m otors. Moto r 1 will be ra mp[...]

General O peration 48 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 49 AX250 0/2850 Connections SECTION 5 Connecting S ensor s and A ctuator s to Input/Outputs Thi s sectio n descri bes the v arious i nputs an d output s and pro vides g uidance on ho w to conne ct senso rs, ac tuators or o ther ac cessor ies to t hem. AX2500/2850 Conn ections The AX2500/2850 us es a [...]

Connecting S ensor s and A ctuators to Input/Outputs 50 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Pr o gram S e t R es e t S e t Re se t 5 6 7 9 8 4 3 1 2 1 - DC Motors 2- Optiona l sensors : - T ac h ometers (Clos ed loop Sp eed mode) - P oten tiometers ( Ser vo mode) - Optica l Encoder (AX2850 only - al l[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 51 AX250 0/2850 ’ s Inputs and Outputs AX2500/2850 ’ s Inputs and Outputs In additio n to the RS23 2 and R/C c ha nnel comm unicatio n lines, the AX2500/2850 includes se vera l inputs and outputs f or v arious sensors an d act uators. D epending o n the sel ected operatin g mode, some of these I/[...]

Connecting S ensor s and A ctuators to Input/Outputs 52 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 I/O List an d Pin Assi gnment The figure and table belo w lists al l the input s and outp uts that are av ailabl e on the AX25 00/ 2850. T ABLE 1 2. DB15 c onnector pin assignment Pin Numbe r Wire Color* Input [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 53 Connecting devic es to Output C *The wir e color s are those used by Robo teq on our p refabric ated c ables. It is recom - mended you use these colors f or con sistency . **T hese con nections should onl y be done in RS 232 mode o r R/C mod e with radio pow- ered from the con troller . Other wise[...]

Connecting S ensor s and A ctuators to Input/Outputs 54 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 When the c ontroller is used i n RS2 32 mode, th is output c an be t urned On and Of f using the !C (On) and !c (Of f) command strings. S ee “ R S232 Comma nds Set ” on page 92 for more inf ormation. Import[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 55 Connecting S witc hes or De vices to Input E This output i s not a v ailable on the AX2850 or on the AX2 550 with the E ncoder Mod- ule in stalled. Connecting S witc h es or Devices to Input E Input E is a genera l purpose, d igital input. T his inp ut is only a ctive w hen in the R S232 a nd Anal[...]

Connecting S ensor s and A ctuators to Input/Outputs 56 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 be activ ated b y a sim ple switc h connected to +5V and no e xternal resistor , as sho w in the Figur e. The status of Input F can b e read i n the R S232 m ode with the ?i com mand string. The co n- troller w[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 57 Connecting P osition P otentiometers to Analog Inputs The status of the EStop/ Inv c an be rea d at all tim es in the R S2 32 mode with the ?i com- mand s tring. The con troller wil l respond w ith three se ts of 2 dig it numbers. T he s t at us of the ES/In v Inpu t is containe d in the last set [...]

Connecting S ensor s and A ctuators to Input/Outputs 58 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Connecti ng the pote ntiometer to the control ler is as s imple as shown in the di agram on Figur e 29. The potentiom eter must be at t ac hed to the mot or frame s o that its bo dy does not mo ve in relation s[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 59 Connecting External Thermistor to Analog Inputs The tac hometers can generate v oltages in e x cess of 2.5 volts at ful l speed. It i s important, theref ore, to s et the pote ntiometer to the minimu m va lue (cur sor all the wa y do wn p er this dra wing) duri ng the first in stallation. Since in[...]

Connecting S ensor s and A ctuators to Input/Outputs 60 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 The rmistor are non-line ar de vices. Us ing the c ircuit descri bed on Fi gure 31, the controller will re ad the f ollo wing v alues ( represented in signe d binary) according to th e temperat u re. T o read t[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 61 Connecting User De vices to Analog Inputs Using these resis tor valu es, it is possibl e to measure a vo ltage ranging from -5V to + 60V with a 0.25 V resolution. The f ormul a for con v erting the A/D reading in to a vol t age v alue is as follows. Meas ure d volts = ((contr oller r eading + 1 28[...]

Connecting S ensor s and A ctuators to Input/Outputs 62 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Internal V oltage Mon itoring Senso rs The AX2500/2850 i ncorporate s v oltage sensors that mon itor the Main B at tery voltage a nd the Internal 1 2V supply . This inf ormation is us ed by the controll er to p[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 63 T emperature Con v er sion C S ource Code T emperature Con v er sion C Source Cod e The code belo w can be us ed to con vert the ana log readi ng into temperat ure . It is provid ed f or ref erence on ly . Interpolation table is f or the intern al thermistor s. int ValToHSTemp(int AnaValue) { // I[...]

Connecting S ensor s and A ctuators to Input/Outputs 64 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 65 Use of the LE D Displa y SECTION 6 Normal and F ault Condition LED Messages Thi s sectio n discus ses the meaning of th e va rious mes sages and codes th at ma y be dis - pla yed on the LED d ispla y during n ormal ope ration and faul t conditions . Use of the LED Display The AX2500/2850 uses a si[...]

Normal and F ault Condition LED Messages 66 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Motor Direction Status When the c ontroller is r unning, two pa irs of LED segm ents are d irectly rela ted to com - mand inf ormatio ns to the P o we r Output stage. Th e position and mea ning of the segme nts is sho wn i[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 67 Fau l t M e ss ag es Fault M essages The AX25 00 /2850 u ses th e LED di splay to r epor t fault co nditio ns. Wh en th ese me ssages are dis play ed, the m otors are normally sto pped. No Contr ol Thi s message is disp lay ed in the R/C mode to i ndicate tha t no v alid radio s ignal has been det[...]

Normal and F ault Condition LED Messages 68 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Emergency St op The “ Emergency Stop ” message is displ ay ed af ter the moto rs hav e stopped f ollo wing an emergenc y stop cond ition trigg ered b y an y of the meth ods desc ribed in Figu re , “ Emer- gency Shut [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 69 Mode Description SECTION 7 R/C Operation Thi s section describes the contr oller ’ s wiring and func tions specif ic to the R/C radio control mode. Mode Des cription The AX2500/2850 c an be direc tly con nected to an R/C receiv er . In thi s mode, the spee d or positio n inf ormatio n is contain[...]

R/C Oper ati on 70 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 S electing the R/C Input Mode The R/C Input Mo de is the f acto r y def ault set tin g . If the con troller ha s been pre viou sly set to a di f f erent I nput Mode, it will b e necessary to reset it to the R/C mode using one o f the f ollow ing m[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 71 Connector I/O Pin Assignment (R/C Mode) • at le ast on e moto r • optional 1 2V bac kup pow er supp ly fo r the contro ller • R/C radio See “ Conn ecting P owe r and Motor s to the Controll er ” on pa ge 25. T he connec tion to the R/C radio is further detailed n this c hapter . The opti[...]

R/C Oper ati on 72 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 R/C Inpu t Circuit Description The AX2500/2850 in cludes a n optical i solation barrie r on the Cha nnel 1 and Ch annel 2 R/C radio in puts. Figure 41 sho ws an electric al representation of the R/C input c ircuit. Th e right side is pow ered from[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 73 Supplied Cable Description Supplie d Cable Descrip tion The AX2500/2850 is deliv ered with a custom cable that can eas ily be ada pted to op erate in an y of the su pported is olated a nd non is olated mo des. T he figure s belo w sho w the ca ble and its wiring di agram Isolator Power 14 3 7 8 6 [...]

R/C Oper ati on 74 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 . The wire loo p is used to bring po wer fro m the cont roller ’ s internal po we r supply to th e optocou plers and to t he R C radio. L ea ving the l oop untouc hed causes the contro ller to operate in non-isola ted mode, with po w er flo wing[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 75 Cabling to R/C Receive r with P artial Opto-Isolation The opto iso lators mus t be po we red with a 5V suppl y for their buil t-in ampli fiers to w ork. Thi s po wer is normally su pplied from the R/C radio ’ s ba t tery as detailed in the diagra m on Figur e 45 . Note tha t if full o ptical iso[...]

R/C Oper ati on 76 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 pow er v oltage are still se parate, some protectio n remains sh ould the c ontroller f ail and accid entally genera te a high voltage on its +5V ou tput. Figure 46 sho ws the ca bling of the R/C rad io to the controller w hen Channel 3 is used an[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 77 P o wering the Radio fr om the controller Importa nt W arning Do not conne ct a bat t ery to the radio w hen in this m ode. The bat te ry volta ge wi ll flow dir ectly into t he con trol ler and c ause pe rm anent d amage i f its voltag e is higher than 5. 5V . Notice that in th is config uration,[...]

R/C Oper ati on 78 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Los ing the o ptical isol ation increa se the risks that damage in the contro ller will reac h the radio, al though thes e risks remain e xtremely low . Without optical is olation, th e radio is less immune to elec trical “ noi se ” and theref[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 79 Reception W atc hdog F or best results, relia bility and saf e t y , the co ntroller will also perf orm a se ries of cor rec- tions, a djustmen ts, and c hec ks to the R/C co mmands, as describe d in the f ollo wing sec- tions. Reception Wa tc hdog Immedia tely af ter it is pow ered on, if in th e[...]

R/C Oper ati on 80 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Another im portant consid eration is th e R/C receiv er ’ s abi lit y to oper ate in a n electr ically noisy e nviro nment: the AX25 00/2850 switc h es high cur rent at v er y high frequencies. Su c h transien ts along long bat ter y and motor w[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 81 Command Control Curves Command Co ntr ol Curves The AX2500/2850 can also be set to tra nslate the j oy stic k motor comman ds so that the motors re spond dif fere ntly whet her the jo ysti c k is ne ar the cen ter or near th e extrem es. Fiv e dif fere nt expon ential or l ogarithmi c transla tion[...]

R/C Oper ati on 82 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 The re are tw o method s for c alibrati ng the jo y stic ks: • The a utomatic method is the simpl est and is b ased on the controller “ learn ing ” the joy stic k ’ s parameters u sing the s imple traini ng seque nce desc ribed bel ow . ?[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 83 Activ ating the Accessory Outputs Notes: If y ou at tempt to calibra te the jo ysti c ks whil e the radio i s of f or no t connecte d to the co n- troller , the calibration data will no t c han ge and the pre viou sly stored i nforma tion wil l con- tinu e to be used. If cali bration i s perf orme[...]

R/C Oper ati on 84 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Data Logg ing in R/C Mode While in R/C Mode, the AX2500/2850 w ill continuo usly se nd a string of c harac ters on th e R S232 outp ut line. T his st ring will contain 1 2 t w o-digits he xad ecimal nu mber repres enting the 1 2 follo wing o perat[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 85 Data Logging in R/C Mode 1 2 3 4 7 8 9 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 RX Data RS232 Data Out GND R/C Ch 1 R/C Ch 2 R/C GND R/C +5V GND DB9 Female T o PC DB15 Male T o AX2550 FIGURE 55 . Modified R/C cable w ith RS2 32 output f or data loggin g to a PC 1 2 3 4 7 8 9 5 1 2 3 4 5 6 7 8 9 10 [...]

R/C Oper ati on 86 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 87 Use and benefits of RS232 SECTION 8 S erial (RS-232) Contr ols and Operation Thi s sectio n descri bes the co mmunicatio n set tings and the c ommands accepte d by the AX2500/2850 i n the R S232 mode of operatio ns. T his inf ormation i s useful if y ou p lan to write y our o wn con trolling s of [...]

Serial (RS-232) Contr ols and Operation 88 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Connector I/O Pin Assi gnment (RS232 Mode) When use d in the R S232 m ode, the pi ns on the controlle r ’ s DB1 5 connector are mapped as des cribed in the t abl e belo w T ABLE 1 7 . D B1 5 Connector pin assignment in RS[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 89 Cable configuration Cabl e conf ig uration The R S232 connec tion requi res the s pecial ca bling as described in the fi gure belo w . T he 9- pin f emale connecto r plugs in to the PC (or other micro controlle r). The 1 5-pin male co nnec- tor plugs into the AX 2500/2850. It is cri tical tha t yo[...]

Serial (RS-232) Contr ols and Operation 90 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Commu nicat ion Set tin gs The AX2500/2850 se rial commun ication port is se t as f ollo ws: 960 0 bits/s, 7 -bit data, 1 Star t bit, 1 St op bit, Ev en P a r ity Communi cation is done wi thout flo w control, meaning t hat[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 91 Establishing Manual Communica tion with a PC and Inst al ling th e Utilit y ” on pa ge 159). The conf igur atio n fil e is set to use the COM 1por t. Y ou can easily c hange this set ting to a dif f erent port from the program ’ s menus. In all c ases, immedi ately af ter reset or po we r up, [...]

Serial (RS-232) Contr ols and Operation 92 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Thi s inf ormation c an be saf ely ignored a nd the con troller will s till be a ble to switc h to R S232 mode upon rece iving 1 0 con tinuou s Carria ge Re turns as des cribed ab ov e. The format of the data logging s trin[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 93 RS232 Commands Set !B7F c han nel 2, 1 00% forward !a3F c han nel 1, 50% rev erse Notes: The hexadeci mal nu mber must alw ays c ontain tw o digits . F or e xample, !a 5 will not be recogni zed and the contr oller wil l respond with a “ - ” to indicate an error . T he proper c om- mand in this[...]

Serial (RS-232) Contr ols and Operation 94 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 ex er cising the c ontroller m anually , y ou ma y use th e Deci mal to He xadec imal con ve rsion table on page 1 03. Query Amps Consumed by Motors Descrip tion: This quer y will caus e the con trol ler to return the a ctu[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 95 RS232 Commands Set Query Heatsi nk T emperatures Descrip tion: Thi s query will cause the controlle r to ret urn v alues based on the temp eratu re measu red by internal t hermistors located at e ac h he atsink sid e of the co ntroller . Be cause NTC ther- mistors are non-l inear de vices , the co[...]

Serial (RS-232) Contr ols and Operation 96 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 R eply: nn mm oo Where: nn = Inp ut E st atus mm = I nput F stat us oo = E stop/In ver t Swi tc h Input s t at us Exampl es: ?I Re ad Input stat us query 01 Controller r eplies, In put E is On 00 Inpu t F is Off 01 Emergenc[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 97 Optical Encoder Commands Notes: All pa rame ters and valu es are e xp resse d with 2 hexadeci mal di gits No c ha nges will be made and an error will be repo rted ( “ - ” c h aracter) when at tempting to read or write a p arameter that doe s not exist or w hen at tempti ng to store a parame te[...]

Serial (RS-232) Contr ols and Operation 98 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Command Ac knowledgement The AX2500/2850 w ill ac knowle dge comm ands in one of two wa ys: F or comm ands that c ause a reply , suc h as a speed or a mps queries, th e reply to the quer y must be consi dered as the comma n[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 99 RS232 Acc essible P arameter T able RS232 Accessible P arameter T able T able 1 8 below lists the co mplete set of configura tion paramete rs that ma y be acce ssed and c ha nged using R S232 comma nds. T ABLE 18. AX2500/2850 Conf iguration parameters accessible through RS232 Pa r a m nbr Descript[...]

Serial (RS-232) Contr ols and Operation 10 0 AX2500/2850 Motor C ontroller User ’ s Manu al V ersion 1 .7. F ebr uar y 1, 2005 04 Input sw itc h func- tion Bits 0 to 3 contain the ESto p/Inv in put operat ing mode 0 = cau ses emergenc y stop 1 = invert comma nds (2) = no a ction (de fault ) Bits 4,5 a nd 6.7 con t ain the Input E and Input F res [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 101 Automatic S witc hing fr om RS232 to RC Mode Automatic Switc hin g from RS232 to RC Mode In man y com puter contr olled app lication, i t may be usefu l to allo w the controller to s witc h bac k to the RC mode. T his w ould typically us ed to let a us er to take o v er the contro l of a robotic [...]

Serial (RS-232) Contr ols and Operation 10 2 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 to re vert th e controller i n the R C mode (the controller mu st be configu red to def ault to R C mode). Th e swit c hing s equence goes as foll ows : Upon contro ller power on wit h Radio of f: (o r Radi o on wit h R[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 10 3 Data Logging Cables DB1 5 connector is desc ribed on page 85 for the R/C mode , and on page 1 1 3 f or the Analog mode. Thi s string i s composed of a start c haracter delimi ter , follo w ed by 1 2 or 1 3 two-digi t Hexa - decima l numbers represent ing 1 2 o r 1 3 internal p arameter v alues, [...]

Serial (RS-232) Contr ols and Operation 10 4 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 logging purposes . Thi s cable ha s a 1 5 -pin male connector a nd 3 1 5 -pin conn ectors. T he male c onnector plug s into the controlle r . The a pplication cable th at wo uld normall y plug into the c ontroller may n[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 10 5 Decimal to He xadecimal Con v ersion T able 6 0 6 3 82 67 0 4 61 0 2 6 6 7 0 7 3 92 77 1 4 71 0 3 6 7 8 0 8 4 02 87 2 4 81 0 4 6 8 9 0 9 4 12 97 3 4 91 0 5 6 9 1 0 0A 42 2A 7 4 4A 1 06 6A 1 1 0B 43 2B 7 5 4B 1 07 6B 1 2 0C 44 2C 7 6 4C 1 08 6C 1 3 0D 45 2D 7 7 4D 1 09 6D 1 4 0E 46 2E 7 8 4E 1 1 [...]

Serial (RS-232) Contr ols and Operation 10 6 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 -1 20 1 36 88 -88 1 68 A8 -56 200 C8 -24 232 E8 -1 1 9 1 37 89 -87 1 69 A9 -55 20 1 C9 -23 233 E9 -1 18 1 38 8A -86 1 70 AA -54 202 CA - 22 234 EA -1 1 7 1 39 8B -85 1 7 1 AB -53 203 CB - 21 235 EB -1 1 6 1 40 8C -84 1 [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 10 7 Mode Description SECTION 9 Analog Contr ol and Operation Thi s sectio n descri bes ho w the motors may be opera ted using analog voltage c ommands. Mode Desc ription The AX2500/2850 ca n be con figured to u se a 0 to 5V analog v oltage, typic ally prod uced using a potenti ometer , to con trol e[...]

Analog Control and O peration 10 8 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 Connector I/O Pin Assi gnment (Analog Mod e) When use d in the An alog mod e, the pins on the contro ller ’ s DB1 5 con nector are mapped as des cribed in the t abl e belo w T ABLE 21 . DB15 Connector pin assignme nt in Analog [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 10 9 Connecting to a V oltage S ource Connecting to a V oltage S ource The analog inputs e xpec t a DC v oltage of 0 to 5V whic h can be so urced b y an y custom cir- cuitr y (po tent iomete r , Digit al t o Ana log co nv ert er). The controlle r considers 2.5V to be the z ero position (Motor Of f). [...]

Analog Control and O peration 11 0 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 The controlle r include s two 47K ohm resis tors pull ing the in put to a mi d-vo ltage point of 2.5V . When configu red in the An alog Inpu t mode, this w ill cause the motors to b e at the Of f state if t he control ler is po wer[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 111 Analog Deadband A djustment 1 00K or higher pote ntiometer . Figure 66 sho ws ho w the output v oltage va ries at the v ari- ous pote ntiometer pos itions, f or three typical p otentiomete r va lues. Note tha t the ef f ect is an exponen tiatio n that wi ll cau se the mo tors to st art moving slo[...]

Analog Control and O peration 11 2 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 Importa nt Notice Some analo g joys ticks do not caus e the pot entiomet er t o r eac h either e xtr emes. This ma y caus e the an alog v oltage ran ge t o be abo v e 0V and below 5V when th e stic k is mo ve d to the extr emes, [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 11 3 Data Logging in Analog Mode • Internal Hea t Sink tempera ture s 1 and 2 • Main B at ter y v oltage • Internal 1 2V voltage • Encoder Sp eed or P osition (A X2850) The entire string is repeate d ev ery 21 3 millisecond s with the la test internal parameter v al- ues. This i nfo rmation c[...]

Analog Control and O peration 11 4 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 11 5 Mode Description SECTION 10 Closed Loop P osition Mode Thi s sectio n describes the AX2500/2850 P osition mo de, ho w to wire the motor and posi- tion sen sor ass embly , and ho w to tune and opera te the con troller in t his mode. Mode Desc ription In this mode, the axle o f a geare d do wn mot[...]

Closed Loop P osition Mode 11 6 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 P os ition Se nsor S electi on The AX2500/2850 ma y be used with th e fol lowi ng kind of sensors: • P otentio meters • Hall ef fec t angula r sensors • Opti cal En coders The first two a re used to generate an anal og vo ltag[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 11 7 P otentiometer wiring The mec ha nical coupli ng betwee n the motor and the s ensor must be as tight as possibl e. If the gear b ox is loose, the positioni ng will no t be accurate a nd will b e unstable, pote ntially causing t he motor to o scillate. Some se nsor , suc h as potent iometers, h a[...]

Closed Loop P osition Mode 11 8 AX2500/2850 Motor C ontroller Us er ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 In the P ositi on mode , the co ntroller c ompares the act ual p osition, as measu red b y the sen- sor , to the des ired positio n. If the mo tor is not at that p osition, the c ontroller wil l apply pow er to the motor so th at it t[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 11 9 Adding S afety Limit S witc hes Nev er apply a comman d that is low er than the sensor ’ s minimum output v alue, or higher than the sen sor ’ s maximum output v alue as the motor w ould tur n f orev er try- ing t o reac h a position it can ’ t . For examp le if the max position of a poten[...]

Closed Loop P osition Mode 12 0 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 The second m ethod uses the AX2500/2850 ’ s Emergency Sto p input to sh ut dow n the con- troller if any of the limit s witc hes i s tripped. Figure 72 sh ows the wiring diag ram used in this c ase. Eac h of the lim it switc h es is[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 121 Control Loop Description Figure 7 3 sho ws a repr esentation of t he PID al gorithm. Ev ery 1 6 mill iseconds, the control - ler measure s the act ual mo tor position a nd substracts it from the d esired position to com- pute the p osition er ror . The resulting error v alue is then multi plied b[...]

Closed Loop P osition Mode 12 2 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 PID tuning in P osition Mod e As di scusse d abov e, thre e paramet ers - P roportiona l Gain, Inte gral Gain and Dif fere ntial Gain - ca n be adjus ted to t une the p osition control algorithm. The ultimate goa l in a w ell t uned P[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 123 Mode Description SECTION 1 1 Closed Loop Speed Mode Thi s section dis cusses the AX2500/2850 Clos e Loop Spe ed mode. Mode Desc ription In this mode, an analog or digital sp eed sens or measures the ac tual motor sp eed and com- pares i t to the desi red speed . If the spe ed c ha nges becau se o[...]

Closed Loop Speed Mode 12 4 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Using Optical Encoder for Speed F eedbac k (AX2850 only) Digital Optic al Enco ders ma y be used to capt ure ac curate mo tor speed. This capabili ty is only a v ailable o n the AX2850 or AX2550 fi t ted wi th the optio nal encoder module[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 125 Speed Sens or and Motor P olarity Connecti ng the tac ho meter to the controller is as simp le as sh own in the dia gram in t he figure be low . Speed S ensor and Mot or P olari ty The tac hometer o r encoder polarity (i.e. w hic h rotation d irection produces a positiv e of negativ e speed info [...]

Closed Loop Speed Mode 12 6 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 6. Apply po we r to the Moto r P o wer wires (thic k pow er wires). T he motor w ill be stopped . 7. Mov e the cursor of the desired motor to the right so that the mot or starts rotating, and v erify that a positiv e speed is reported. Mo[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 127 Control Loop Description Control Loop De script ion The AX2500/2850 pe rforms the Closed Loop Sp eed mode using a full f eat ured P ropor- tional, Integral and Dif f eren tial (PID) a lgorithm. This tec hnique h as a long h istor y of usage in control s ys tems and w orks o n perf orming ad justm[...]

Closed Loop Speed Mode 12 8 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 PID tuning in Speed Mo de As di scusse d abov e, thre e paramet ers - P roportiona l Gain Inte gral Gain, and Dif fere ntial Gain - can b e adjusted to tune th e Closed L oop Speed con trol algorith m. The ultimate goal in a w ell t uned [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 129 PID tuning in Speed Mode[...]

Closed Loop Speed Mode 13 0 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 131 Optical Increm ental Encoders Overview SECTION 12 Installing, Connecting and Using the Encoder Module Thi s sectio n describes the Encod er input mo dule that is f actory installed ins ide the AX2850, o r that ma y be a dded onto the AX2550. Optical Incremental Encoder s Overview Optica l increme[...]

Installing, Connecting and Using the E ncoder Mod- 13 2 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 The figure bel ow s hows the typical co nstr uction of a quadrat ure enc oder . As the disk rotates in front o f the stationar y mask , it shut te rs light from the LED . T he light th at passes through th e ma[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 133 Installing the Encoder Module Specifi cally , the en coder mod ule can p rocess 250, 00 0 co unts per sec onds. A s discu ssed in the pre vio us section, a count i s generated f or eac h transition o n the Chan nel A and Channel B . Ther efore the module will w ork with encoders out put tin g up [...]

Installing, Connecting and Using the E ncoder Mod- 13 4 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 When ins talling y ourself , fol low the se simpl e steps 1 - With the pow er rem ov ed, remo ve controll er ’ s face plate and sli de off the cover 2- Car efully insert the encod er module on top of the two [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 135 Connecting the Encoder 4- Slide the co ve r bac k on. Install the ne w f ace plate 5- P owe r on the con troller and install v ersion 1 .6 or ne wer of the controll er firmw are and P C utility . Update the encoder fi rmwa re if a ne w v ersion e xists . Connecting t he Encoder The Encoder module[...]

Installing, Connecting and Using the E ncoder Mod- 13 6 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Moto r - Enco der P olarit y Matc hing When usi ng the Enc oder modu le for closed l oop spee d control, it is imperat ive t hat when the motor is t urning in the f or ward direction, the counter increments its[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 137 Wiring Optional Limit S witc hes In Figure 84, the encoder and switc hes are wir ed to the en coder mod ule using a set of resisto rs desig ned to c reate a multi-le v el sig nal combi ning bot h inf ormati on. Details o n the nece ssary wiring is prov ided in t he ne xt sect ion. Since th e enco[...]

Installing, Connecting and Using the E ncoder Mod- 13 8 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Usin g this circu it, whe n the s witc h is open, a 0V (l ow -level) outp ut fro m the e ncode r goes through a 1k an d 4.7k v oltage divi der , thus cr eating a v oltage th at will nev er be belo w 0.8V at the[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 139 Using the Encoder to Measure Speed Using the Encoder to Measure Speed The encoder module w ill autom atically c ompute rotation speed f or eac h encoder . T he resultin g measur ed speed is a v alue rang ing from 0 t o + 1 27 and 0 to - 1 27 , where 1 2 7 rep- resent a relativ e ratio of a m axim[...]

Installing, Connecting and Using the E ncoder Mod- 14 0 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Using the En coder to T rac k Po sition The encoder module c an be u sed to report the distance between the act ual moto r position and a des ired desti nation. T he resul ting meas ured “ distan ce ” can t[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 141 RS232 Communication with the Encoder Mo dule Encoders do not r epor t an absol ute pos ition v alue but a c ount that is r el ative t o the point wher e the m otor shaf t was at po w er up. It is typically necessary t o ha ve the moto rs m ov e d to a “ home ” position and r eset the count er[...]

Installing, Connecting and Using the E ncoder Mod- 14 2 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Details on sof twa re updatin g is giv en in section Figure , “ Upd ating the Encode r Sof tware , ” on page 1 52. RS232 Encoder Co mmand Set The Encoder m odule res ponds to a d edicated set of com mands a[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 143 RS232 Encoder Command S et S et/Reset Encoder Counter s and Destination Registers Descrip tion: Set one o r both coun ters to z ero or a us er -defin ed v alue. T he va lue is a s igned 32 b it num- ber that m ay range from - 2,1 47 ,836,648 to +2,1 47 ,836,647 ( Hexad ecimal f ormat of valu e 80[...]

Installing, Connecting and Using the E ncoder Mod- 14 4 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Notes: The comman d ret urns a s igned he xade cimal n umber whe re 0 to +1 27 is repre sented b y 00 to 7F , and -1 to -1 27 is rep resented b y FF to 80 resp ectivel y . The he xadec imal f ormat is intended [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 145 RS232 Encoder Command S et Note that f or this function to work, limit switc hes must be c onnected to the encode r mod- ule usi ng the sp ecial wi ring diag ram sho w in “ Wiring Optional L imit S witc hes ” on pag e 1 37. If no limi t swit c hes a re pres ent, this q uer y will return th e [...]

Installing, Connecting and Using the E ncoder Mod- 14 6 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Read par amet er Syn t a x: * mm R eply: DD Where mm = address lo cati on of p aramet er DD = parameter v alu e Exampl e: *84 Read v alue of parameter a t address he x 84 01 Controller r eplies, v alu e is 0 1 [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 147 Reg ister Descr ipt ion Importa nt W arning Do not alt er an y o ther ar ea locations a s this ma y cause pr ogr am ex ecution f ailure inside the encoder mod ule. Regist er Descri ption Encoder Hardw are ID code R eturn s a 4-bi t number i dentifying the enco der modul e hardw are v ersion and t[...]

Installing, Connecting and Using the E ncoder Mod- 14 8 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 S witc h St atus R eturn s a 4 bi t number (4 least signi ficant bit s of the b yte), eac h representi ng the state of one of the limi t switc h when installe d. The ?W comm and desc ribed at “ R ead Encode r[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 149 Counter Read Data Format Speed 1 and 2 The se regist ers contain a s igned 8-bi t value (-1 27 to +1 27) that repres ents the moto r speed relativ e to a maxim um speed, whic h in turn depends on th e number of enco der counts and time bas e set tings as descri bed in “ Using t he En coder t o [...]

Installing, Connecting and Using the E ncoder Mod- 15 0 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 When rea ding the c ounter v alue into a microc omputer , the re ve rse opera tion must tak e place: any output that i s less than 8 digit long must be c ompleted w ith a string of 0 ’ s if the first digit i [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 151 Encoder T esting and Set ting Using the PC Utility • Set and pro gram the Enco der module ’ s parameters in EEPR OM • Activ ate th e motors in e ac h direc tion at v ariable speed • Vie w the m easured enc oder counts • Vie w the m easured enc oder spee d • Vie w the s t at us of the [...]

Installing, Connecting and Using the E ncoder Mod- 15 2 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Ex ercising the Motors A set of b ut tons a nd slide rs are pro vider to starting/stoppin g commun ication with the con- troller a nd encoder . When com municat ion is ac tive , the screen will be u pdated with[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 153 SECTION 13 Conf iguring the Contr oller using the S witc hes The AX2500/2850 Speed Con troller can be pro grammed to operate in many modes using a simple se t-up proced ure. T wo but tons and a 7 -segmen t LED displ ay l et the user e xamin e and c ha nge thes e set tin gs. Alterna tivel y , the [...]

Configuring the Controller using the Switc hes 15 4 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Entering Pr ogramming Mode P rogrammi ng mode is entere d by pressing a nd holdin g the Program but ton for 1 0 sec onds af ter reset ting the control ler . The c ontroller c an be reset b y po we ring it do wn an [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 155 Pr ogramming using built-in S witc hes and Display Be car eful not t o c onfuse the Set and Pr ogra m butt on when ent er ing the Pr ogr am- ming Mode . Pr essing an d holdin g the Set but to n alone f or 1 0 seconds af ter r eset will cause the c ontrolle r to ent er in sel f-test mod e. This wi[...]

Configuring the Controller using the Switc hes 15 6 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 reset ti ng the con troller . All parame ters, includi ng J oy stic k limits will be reset to the ir defa ult v alues sho wn in th e “ Pro grammable P arame ters List ” on page 1 56 Exit ing t he Parame ter Set[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 157 Pr ogrammable P arameters List This ta ble sho ws only the par amet ers that can b e prog ram med using the switc hes and displ ay . Other le ss comm only use d para meters e xist and are only ac cessib le and pr o- gramm abl e usin g the Co nfig urati on Uti lit y (pa ge 1 59) or the RS2 32 c om[...]

Configuring the Controller using the Switc hes 15 8 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 *The coas t fun ction is not im pleme nted in thi s revisio n of the sof twa re. The con troll er wil l only op erate in b rake mode. ** V alue s are i n hexade cimal numbe rs whe re the d ecima l values 1 0, 1 1 ,[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 159 SECTION 14 Using the Roborun Conf iguration Utility A PC bas ed Configura tion Uti lity is av ailabl e, free of c harge, from Robo teq. T his pro- gram makes configuri ng and op erating the AX2500/2850 muc h more int uitiv e b y using p ull-do wn menu s, but tons and sli ders. T he utility can a [...]

Using the Roborun Configuration Utility 16 0 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 • af ter the in stallation is comple te, you will be able to r un the prog ram from y our Start Menu > Programs > Robo teq Y ou do not need to h av e the con troller connec ted to y our PC to start the Utility . C[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 161 Roborun Frame, T ab and Menu Descriptions Roborun F rame, T ab and Menu Descripti ons The Ro boru n screen contains the fou r main set of comma nds and in fo rmation fra mes des cribe d below: 1 - Progr am Revision Number Thi s is the revisio n and da te of the R obor un utili ty . It i s recomme[...]

Using the Roborun Configuration Utility 16 2 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 With the port op en, R obor un will tr y to establish communi cation with the controlle r . If suc- cessful, thi s windo w will displa y the sof t w are revis ion, the re vision date and a set of digits identify ing hardw[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 163 Loading, Changing Controller P arameter s Control s Set tings The scre en shown in Figure 94 i s used t o view and c hange th e cont roll er ’ s main contro l modes. Belo w is the list of the param eters acces sible from thi s screen 1 - Contr oller Inp ut: Thi s pull d own menu allo ws y ou to[...]

Using the Roborun Configuration Utility 16 4 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Thi s pull do wn men u will le t you s elect the con troller ’ s respons e to c h anges on the opti onal sw itc h in put: Emerge ncy St op, I nv ert C omman ds, or no act ion. Se e “ Emergenc y Stop using Extern al Sw[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 165 Loading, Changing Controller P arameter s Analog or R/C Specif ic S et tings The screen sho wn i n Figure 96 is slightly d if f erent w hether the Anal og Input mo de is selec ted or not. If th e Anal og Inpu t mode is sele cted on t he main scre en, the n this p age is used to set the Analog D e[...]

Using the Roborun Configuration Utility 16 6 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Closed Loop P arameter s Thi s screen shown in Figure 97 is us ed to set the P rop ortional, Inte gral and Di f f erential gains needed f or the PID a lgorithm. Thes e parameters are used in the P osition mode (s ee page [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 167 Optical Encod er Operation Optical Encoder Operati on The Ro boru n utility pro vides many fac ilities f or conf iguring a nd testing the Optic al Encoder module contained in the AX2850. Thes e are des cribed in detail in “ Encoder T es ting and Set ting Using the PC Utility ” on page 1 50 Ru[...]

Using the Roborun Configuration Utility 16 8 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 1 - Run/Stop But t on Thi s but ton will cause th e PC to s end the r un comm ands to th e controller a nd will update the scre en with measure ments receiv ed from th e controll er . When the program is runni ng, the but[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 169 Running the Motors The Po we r field disp lay s the po w er le vel that is act uall y being applied to the motor . T his va lue is d irectly relate d to the mo tor command e x cept du ring cur rent limitati on, in wh ic h case the p ow er le vel w ill be the o ne needed to keep the Amps w ithin t[...]

Using the Roborun Configuration Utility 17 0 AX2500/2850 Motor C ontroller Us er ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 three dig ital inputs prese nt on the contro ller . Blac k rep resents a “ 0 ” lev el. Gr een repre - sent s a “ 1 ” level. 7 - Data Logg ing and Timer A timer is prov ided to keep trac k of time while r unning th[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 17 1 Running the Motors line of th e sa ve file contains the Header n ames. Eac h follo win g line co ntains a com plete set of pa rameters. Th e Header name , order and pa rameter de finition is s hown i n T able 28 Connecting a Jo ystic k Exe rcising the motors can eas ily be do ne using a Jo ys ti[...]

Using the Roborun Configuration Utility 17 2 AX2500/2850 Motor C ontroller Us er ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Vi ew ing and Logging D ata in Analog and R/C Modes When the c ontroller is config ured in R/C o r Analog m ode, it will automatic ally an d continu- ously s end a string of A SCII c hara cters on the R S232 outpu t. “ [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 17 3 Operating the AX250 0/2850 o ver a Wi red or Wireless LAN T o operate o ver t he netw ork two comp uters are required, a s show in Figure 1 0 0 belo w . The top com puter is connecte d to the con troller vi a its COM port. B oth co mputers are con- nected to a TCP/IP n et w ork. The computer con[...]

Using the Roborun Configuration Utility 17 4 AX2500/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005 Updating th e Contr oller ’ s S of tw are The AX25 00 /285 0 ’ s ope rating so f tware c an be easi ly upgrad ed af ter it has lef t the fa ctory . Thi s f eat ure makes it poss ible to a dd ne w f eat ures and enha [...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 17 5 Creating Cust omized Object Files Creating a custom object file c an easily be done u sing the Ob jectmak er utility . T his short program is automa tically installed in the Start menu w hen installin g the R obor un uti lity . 1 - Use the R obor un utili ty to create an d sa ve t o disk a pro f[...]

Using the Roborun Configuration Utility 176 AX2500/2850 Mo tor Controlle r User ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 17 7 Mec hanical D imensions SECTION 15 Mec h anical Specif ications Th is sect ion details the mec hanical c haracte ristics o f the AX2 500/2850 co ntrolle r . Mec h anical Dimensions The AX2500/2850 is built int o a e xtru ded alumi num case w hic h also serves as a heat s ink f or its ele ctronic[...]

Mec hanical Speci fications 17 8 AX2500/2850 Motor C ontroller Us er ’ s Ma nual V ersion 1 .7. F ebr uary 1, 2005 Mounting Co nsideratio ns Mounting brac k ets o n eac h en d are pro vided for du rable asse mbly of the controlle r onto any c hassis. The AX2500/2850 us es no ju mpers and include s no loose p arts or wi res. Conse quently , it wil[...]

AX2500/2850 Mo tor Controlle r User ’ s Manual 17 9 Wire Dimensions F or high current app lications, it is possi ble that the c ontroller ma y hea t-up fa ster and to a highe r tem perature than c an be di ssipa ted by th e heatsi nk en closu re usi ng natural convec- tion alon e. In these applicatio ns, you should ens ure that air flo w e xists [...]

Mec hanical Speci fications 180 AX250 0/285 0 Motor Contro ller User ’ s Manual V ersion 1 .7. F eb rua r y 1, 2005[...]