Delta Computer Systems TMC 188/40 Series Manuel utilisateur

TMC 188/40 Rev 4.1

Motion Control Module

960912

Delta Computer Systems, Inc.

1818 SE 17th Street

Battle Ground, WA 98604

Tel: 360/254-8688

Fax: 360/254-5435

http://www.deltamotion.com

[email protected]

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 displacement transducers, and safety rules is required. Delta Computer Systems,

Inc. cannot accept responsibility for problems resulting from omissions in this document. The

information in this document is subject to change without notice.

Neither Delta Computer Systems, Inc. nor anyone else involved in the creation, production, or

delivery of this product shall be liable for any direct, indirect, consequential injuries and or damages

arising out of the use, the results of use, or the inability to use this product.

All brand names and trademarks referenced in this manual are the property of their respective

holders.

Printed in USA

Contents

Delta Computer Systems, Inc. 360/254-8688 3

OVERVIEW ............................................................................................................................................ 7

HARDWARE SPECIFICATIONS...........................................................................................................8

GETTING STARTED AND TUNING THE AXIS ....................................................................................9

STEP 1-CONFIGURING THE TMC MODULE........................................................................................9

STEP 2-CONFIGURING THE P/C BASE...............................................................................................9

STEP 3-INITIALIZING THE WYREGISTERS .........................................................................................9

STEP 4-SELECTING THE APPROACH ...............................................................................................10

STEP 5-SETTING UP THE INITIALIZATION PARAMETERS....................................................................10

STEP 6-MOVING THE AXIS USING DCSMON..................................................................................12

STEP 7-JOGGING THE AXIS ............................................................................................................13

STEP 8-TUNING THE AXIS ..............................................................................................................14

P/C PROGRAMMING PRECAUTIONS...............................................................................................15

P/C ERROR HANDLING....................................................................................................................15

KEY THINGS TO REMEMBER.............................................................................................................15

WY REGISTER AND V MEMORY IMAGE DESCRIPTIONS..............................................................16

WYREGISTERS ..............................................................................................................................16

AXIS INITIALIZATION PROCESS .........................................................................................................17

VINIT AXIS INITIALIZATION PARAMETERS .........................................................................................18

VREAD -AXIS POSITION AND STATUS PARAMETERS........................................................................19

VWRITE -AXIS DYNAMIC CONTROL PARAMETERS...........................................................................20

VMEMORY EXAMPLE ......................................................................................................................21

MOTION CONTROL PARAMETERS..................................................................................................23

READ ONLY PARAMETERS (VREAD) ...............................................................................................23

INITIALIZATION PARAMETERS (VINIT)...............................................................................................27

DYNAMIC CONTROL COMMANDS (VWRITE).....................................................................................33

HOW IT WORKS..................................................................................................................................43

INITIALIZATION.................................................................................................................................43

PARAMETER USE ............................................................................................................................43

POSITION SENSING .........................................................................................................................43

DRIVE OUTPUT ...............................................................................................................................43

CLOSING THE LOOP.........................................................................................................................44

PROPORTIONAL GAINS ....................................................................................................................44

INTEGRAL AND DIFFERENTIAL GAINS ................................................................................................44

FEED FORWARD..............................................................................................................................45

CONTROL AT REST..........................................................................................................................45

MODULE HARDWARE........................................................................................................................46

FRONT PANEL INDICATORS..............................................................................................................46

MODULE JUMPERS AND EXTERNAL WIRING ......................................................................................47

FAIL-SAFE TIMERS..........................................................................................................................50

SYSTEM RESET...............................................................................................................................51

CABLE &CONNECTOR INFORMATION................................................................................................51

COMMON PROBLEMS AND SOLUTIONS ........................................................................................53

LADDER PROGRAM CANNOT ACCESS PARAMETERS OR OPERATE MODULE...........................................53

DURING A MOVE,THE ACTUAL POSITION IS ERRATIC....................................................................53

TRANSDUCER COUNTS FIELD NOT INDICATING TRANSDUCER LOCATION.......................................53

TRANSDUCER COUNTS FIELD CHANGES BUT OUTPUT DRIVE DOES NOT WORK..............................53

Delta Computer Systems, Inc. 360/254-8688

AXIS INDICATOR IS CONSTANT RED....................................................................................................54

DURING A MOVE,THE AXIS COMES TO A HALT FOR NO APPARENT REASON...........................................54

HYDRAULIC SYSTEM PROBLEMS....................................................................................................55

NONLINEAR VALVES.........................................................................................................................55

SLOW-RESPONSE VALVES ...............................................................................................................55

HOSES............................................................................................................................................55

PUMPS AND ACCUMULATORS ...........................................................................................................56

IDENTIFICATION AND CORRECTION....................................................................................................56

REPAIRS AND RETURNS...................................................................................................................59

FIELD REPAIR OF A MODULE ............................................................................................................59

DELTA BULLETIN BOARD SYSTEM.....................................................................................................59

MODULE RETURNS ..........................................................................................................................59

GLOSSARY..........................................................................................................................................60

APPENDIX A: MAPS, TIPS, AND COMMANDS.................................................................................61

STATUS WORD BIT MAP...............................................................................................................61

MODEWORD BIT MAP..................................................................................................................62

EXAMPLE VMEMORY MAP...............................................................................................................63

QUICK-START GUIDE.......................................................................................................................64

AXIS TUNING TIPS ...........................................................................................................................69

DCSMON COMMAND SUMMARY......................................................................................................71

CONTROL EQUATIONS......................................................................................................................73

ASCII CODE CHART........................................................................................................................74

APPENDIX B: ASBX/40 ANALOG MODULE......................................................................................75

DESCRIPTION ..................................................................................................................................75

INSTALLATION..................................................................................................................................75

SPECIFICATIONS..............................................................................................................................75

VREAD VMEMORY ........................................................................................................................75

NEW VREAD PARAMETER DEFINITIONS...........................................................................................77

VINIT VMEMORY............................................................................................................................77

NEW VINIT PARAMETER DEFINITIONS ..............................................................................................78

MODE AND STATUS WORD CHANGES..........................................................................................79

PRESSURE-SPECIFIC COMMANDS.....................................................................................................79

ASBX/40 SETUP...........................................................................................................................80

SETTING THE PRESSURE SCALE AND PRESSURE OFFSET.......................................................81

USING THE TMC 188/40-TA............................................................................................................81

PRESSURE PLOTS ...........................................................................................................................82

CONNECTOR ...................................................................................................................................82

APPENDIX C: QSBX/40 QUADRATURE MODULE ...........................................................................83

INTRODUCTION ................................................................................................................................83

QSBX/40 SPECIFICATIONS..............................................................................................................83

QSBX/40 BLOCK DIAGRAM..............................................................................................................84

IMPORTANT CONSIDERATIONS WHEN USING QUADRATURE ENCODERS..............................................84

QUADRATURE ENCODER POSITION MEASUREMENT...........................................................................86

QUADRATURE ENCODER-SPECIFIC COMMANDS ................................................................................87

TMC 188/40-(T)Q PARAMETER CHANGES .......................................................................................89

READBACK PARAMETERS.................................................................................................................91

LIMIT AND HOME DIGITAL INPUTS......................................................................................................92

QSBX/40 BOARD JUMPERS.............................................................................................................94

QUADRATURE ENCODER INTERFACE EXAMPLES................................................................................95

Delta Computer Systems, Inc. 360/254-8688 5

FRONT PANEL INDICATORS..............................................................................................................96

FRONT PANEL DB 37 FEMALE CONNECTOR .....................................................................................97

SAMPLE LIMIT AND HOME CONFIGURATION.......................................................................................98

APPENDIX D: APPLICATION NOTES................................................................................................99

USING THE OFFSET AND DIRECTION FIELDS................................................................................99

ACCELERATION AND DECELERATION MODES ..................................................................................101

EVEN ENDING...............................................................................................................................102

EXAMPLE USING 20MASERVO VALVES WITH 100MAOUTPUT.........................................................103

APPENDIX E: SAMPLE LADDER LOGIC.......................................................................................104

TMC 188/40 WIRING DIAGRAMS.....................................................................................................108

INDEX.................................................................................................................................................109

Delta Computer Systems, Inc. 360/254-8688

TMC 188/40 Motion Control Module Overview

Delta Computer Systems, Inc. 360/254-8688 7

Overview

The TMC 188/40 family of Motion Control Modules provides a complete four-axis position control

subsystem for the Siemens SIMATIC TI505 system. The module controls the axes by providing a

complete PID loop plus many additional functions, such as on-the-fly coordinated moves and position

changes. In its standard configuration the module provides four optically isolated magnetostrictive

interfaces and four optically isolated outputs, each individually configurable for voltage or current

mode. A variety of output configurations work with electric servo motors and hydraulic valves. With

the Quadrature and Analog options installed, you can control position using either quadrature

encoders, analog slide potentiometers, or pressure.

The TMC 188/40 Motion Control Module (MCM) occupies one slot of the SIMATIC TI505 rack (two

slots if the Analog or Quadrature options are installed). A Special Function Interface Chip (SFIC)

communicates between the SIMATIC TI505 programmable controller (P/C) and the TMC 188/40. The

TMC 188/40 is programmed using V Memory and eight SFIC WY registers. The on-board 80C188

processor relieves the P/C of the overhead usually associated with servo control. The MCM updates

the actual position and drive output every two milliseconds, assuring accurate positioning even at

high speed.

If you need more than four axes of control you can install additional TMC 188/40 modules.

TMC 188/40 System Block Diagram

NOTE: Increase in P/C scan times (per module installed) when using the TMC 188/40 are:

525 10 ms per module (not including P/C or remote overhead)

535 1.6 ms

545 0.8 ms

If the TMC 188/40 is used on a remote base, the P/C scan time will degrade considerably.

Overview TMC 188/40 Motion Control Module

Delta Computer Systems, Inc. 360/254-8688

Hardware Specifications

TMC 188/40

One slot of SIMATIC TI505 chassis (two slots when ASBX or QSBX options are installed)

13.875MHz 80188 processor

SFIC Interface

2 millisecond control loop time.

Linear resolution to 0.001 inches

Maximum velocity - 60,000 position units per second

Maximum position counts - 65535

Three hardware fail-safe timers

Standard Position Inputs

Four optically isolated magnetostrictive transducer interfaces

Field-replaceable transducer protection resistors for Temposonics® I and

Temposonics® II neuter transducers

1.5V return pulse sensitivity

27.75MHz counters

1, 2, or 4 recirculations

Positive or negative interrogation pulse

Maximum update rate - 2 milliseconds

Drive Four optically isolated, individually configurable servo drive outputs

Current mode: ±100mA, ±50mA, or ±25mA

Voltage mode: ±10 volts, ±5 volts, or ±2.5 volts

12 bit digital to analog converters

Power Requirements

@ 1.0 amps

TI System Bus

@ 0.5 amps

External Sensor

15V

@ 0.5 amps

External Sensor

If transducers are connected to the

-15V

@ 0.5 amps

External Sensor

module; 0.1A for module only.

15V

@ 0.5 amps

External Drive

0.1A for module + max current

-15V

@ 0.5 amps

External Drive

for axes used. Voltage mode uses

zero added current per axis.

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

Sensor power supplies should be independent of drive power supplies.

TMC 188/40 Motion Control Module Getting Started

Delta Computer Systems, Inc. 360/254-8688 9

Getting Started and Tuning the Axis

CAUTION: When starting the Motion Control Module for the first time, great care must be taken to avoid

accidents. The most common accident is a runaway. This is where the MCM tries to move the

axis to a position beyond it's physical limits.

MAKE SURE THE POWER TO THE DRIVE IS TURNED OFF

BEFORE STARTING THIS PROCEDURE!

Step 1 - Configuring The TMC Module

To configure the TMC module so it will work with your system, the following five steps must be taken.

See Module Jumpers and External Wiring (on page 47) and TMC Wiring Diagrams (on page 107)

for details about these steps.

1. Select voltage or current mode for the drive output of each axis (Default: current mode).

2. Select the drive level for each axis (Default: 50mA; range: 25, 50, 100mA or 2.5, 5, 10 volts)

3. Individually select each transducer interrogation pulse polarity (Default: Positive; Negative is

for short Temposonics® I rods only).

4. Individually select the number of recirculations used on each axis (Default: 4; Range: 1, 2, 4).

5. Wire the transducer and drive cables to your system.

Step 2 - Configuring the P/C Base

To configure the P/C so it will communicate with the TMC 188/40, the appropriate slot in the Base

must be initialized. To configure the P/C Base:

1. Run TISOFT software.

2. Put it in the ONLINE mode.

3. Enter the CONFIO menu.

4. Verify the appropriate slot is configured for eight WY registers with SPECIAL FUNCTION

capability. This can be done manually or by doing a READBS.

5. Set the I/O address so it will not conflict with other I/O in the system. (The programs supplied

with DCSMON use WY201 through WY208. DCSMON is a monitor program included with

each Motion Control Module. See the DCSMON manual for more information.)

6. Update the information in the P/C by doing a WRITPC.

7. Initialize the WY registers as described in the next section.

Step 3 - Initializing the WY Registers

The eight WY registers must be initialized before the TMC 188/40 will begin normal operation. The

WY registers define the P/C's V Memory locations where the TMC 188/40 reads and writes

information. The initialization can be done either with the CHART utility of TISOFT or with a ladder

logic routine (see filelist.txt on the DCSMON disk for example ladder programs).

Getting Started TMC 188/40 Motion Control Module

Delta Computer Systems, Inc. 360/254-8688

The following example shows you how to initialize the WY registers. The values are the same as

those in the demo program.

WY Register

Value

(V Memory Address)

Definition

WY201

201

VINIT Axis 1

WY202

251

VINIT Axis 2

WY203

301

VINIT Axis 3

WY204

351

VINIT Axis 4

WY205

401

VREAD

WY206

451

VWRITE

WY207

Reserved

WY208

1956

Checksum

(201+251+301+...)

To set up the WY registers:

1. Run TISOFT.

2. Put it in the ON-LINE mode.

3. Select CHART; select BLDCHT.

4. Enter WY201 - WY208 (or whatever WY registers you are going to use).

5. Select CHGVAL to set the values for the eight WY registers. The values you enter are the

addresses of the V Memory locations which the TMC 188/40 talks to (201, 251, etc. in the

demo program).

6. When you have entered all eight values (including the checksum), verify the P/C LED on the

TMC 188/40 panel is green.

NOTE: Once the TMC 188/40 finds a correct set of WY registers (including a valid checksum), it will not

read them again unless reset. Changes in the WY registers will not take effect until the TMC

188/40 is reset or the power is cycled.

Step 4 - Selecting the Approach

Once the WY registers are initialized, there are two methodss to get the TMC 188/40 running. The

first is to use DELTA's PC-based program called DCSMON. DCSMON provides a simple way for you

to get on-line without using a P/C ladder logic program. DCSMON talks directly to the TMC 188/40

by using the P/C's store and forward commands. Please refer to the DCSMON manual for help using

it.

The second method is for you to follow the steps outlined below. To help you start, an example

program is provided with DCSMON. The latest versions of this demo program are listed in filelist.txt

on the DCSMON disk. You can use it with the 525, 535, 545, and 555 controllers after the controller

type is specified using TISOFT.

TIP: Use Delta's DCSMON to help determine initialization parameters and operation. Also, Delta's

SSS/10 Servo System Simulator provides a simple way to test your program before connecting

the Motion Control Module to your system.

Step 5 - Setting Up the Initialization Parameters

When the TMC 188/40 Motion Control Module is first turned on, default values are used for the

initialization parameters. These values are there only to give the MCM so the present position can be

maintained. The parameters need to be changed to work optimally in your system. The P/C is

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