Galil galil's new accelera controller; sizzling speed, fully loaded 2007 presentation

Accelera Motion Controllers
Sizzling Speed. Fully Loaded.

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Outline

• Advances in Technology
• 5th Generation Accelera Series
• DMC-18x6 PCI Accelera Controller
• DMC-40x0 Ethernet Accelera
Controller
• Inverse Kinematics Example
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A New Generation of Motion Control

Today’s generation of motion controllers
provide more capability than ever before
due to advancements in technology

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Areas of Improvement

1. Performance – Accuracy and Settling
2. Coordination – Modes of motion,
Application programs
3. Smaller package size and integration with
power drivers
4. Communication

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Structure of Motion Control System

Host

Application
Program

Modes of Motion I/O
Profile Generation Digital/Analog

Closed
Loop

Driver
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Encoder Motor
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Host

Application
Program

Modes of Motion I/O

Closed
Loop Performance
Sample Time
Driver Encoder Frequency
Sold & Serviced By: DAC Resolution
Encoder Motor Filters PID/Notch
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Tuning Program


Host

Application
Program

Modes of Motion I/O

Closed
Loop Coordination
Driver
Modes of Motion
Application Programs
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Encoder Motor
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Host

Application
Program

Modes of Motion I/O

Closed
Loop Integration with
Power Drivers
Driver
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Encoder Motor
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Host

Application
Program

Modes of Motion I/O

Closed
Loop
Communication
Driver
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Encoder Motor
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Advancements in Several Areas

• Advancements in Microprocessor faster
motion control
• Advancements in Motor Drives more power
in a small space
• Advancements in Ethernet virtually
deterministic for motion applications
• Advancements in ICs and Circuit Design
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allows more features to be added
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Microprocessor Advancements

• In 1983, Galil introduced the world’s 1st
microprocessor-based servo motion
controller. One axis of motion was
controlled using an 8-bit microprocessor
• In the 1990’s, Galil continued to introduce
new generations of motion controllers
based on 16-bit and 32-bit microprocessors
• Today, Galil offers its 5th generation motion
controllers—the Accelera Series which is
Sold & Serviced By: based on a powerful, RISC/DSP processor.
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Accelera—It’s all about Speed

Fast RISC processing means faster motion control!
• Servo loop update rates 4X faster than prior generation, as
low as 31 microseconds per axis good for high bandwidth
systems such as voice coils or short, fast moves
• Command processing 10X faster than prior generation, as low
as 40 microseconds per command executes entire motion
program quickly and allows more tasks to be completed by
controller
• Accepts encoder inputs 2X faster, up to 22 MHz good for
ultra-high resolution position sensors
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Advancements in the Motor Drives

Improvements in amplifier design using Direct
FETs allows better power density—more power
in less space!
500W drive takes less than 6 square inches
• Direct FETs are smaller in size
• Direct FETs have better thermal characteristics
which gets heat to top of package more
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efficiently
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Advancements in Ethernet

• 100Base-T Ethernet is virtually
deterministic for motion control applications
• Time to send commands across network is
insignificant

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Advancements in Circuit Design

Improvements in circuit design means more
features can be added cost-effectively:
• Optically isolated I/O
• Analog inputs for interface to sensors such as
joysticks
• High powered outputs to drive relays and
brakes
• On-board memory, variables and arrays
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• Additional communication ports such as RS232
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Accelera PCI Controller

In 2005, Galil Introduced the DMC-18x6 Accelera PCI
Controller

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Top: DMC-1886 8-axis PCI controller
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Bottom: DMC-1846 4-axis PCI controller

Introducing the DMC-40x0 Series

In 2006, Galil Introduced the DMC-40x0 Accelera
Ethernet Controller

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Top: DMC-4040 4-axis Ethernet controller
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Bottom: DMC-4080 8-axis Ethernet controller
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Sizzling Specs of Accelera Controllers

Accelera Prior Generation

Max encoder rate 22 MHz 12 MHz

Max stepper rate 6 MHz 3 MHz

Command Execution 40 microseconds 400 microseconds
Speed
Minimum Servo Update 31 microseconds 125 microseconds

Program memory 2000 lines x 80 chr 1000 lines x 80 chr

Array Size 16000 elements 8000 elements

Number of variables
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Handles Virtually any Mode of Motion

• Point-to-Point Positioning
• Position Tracking
• Jogging
• Linear and Circular Interpolation
• Tangential Following
• Helical
• Electronic Gearing
• Electronic Cam
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• Contouring

• Teach and Playback
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DMC-4000- Full Featured, High Speed

• DMC-40x0 Accelera Ethernet Controller
combines all the enhanced capabilities of
the processor, drives, Ethernet and features
in a single compact unit

• The DMC-40x0 is ideally suited for OEMs
who need a full-featured, box-level
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controller with enhanced performance
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DMC-40x0 Accelera Controller

• Full-featured, packaged
controller
• Ultra-high speed and precision
• Ethernet 10/100Base-T and
two RS232 ports
• 1 through 8 axes
• Standard features: optically
isolated I/O, high-powered
outputs, analog inputs, metal
enclosure, D-type connectors
• Available packaged with
stepper and servo drives
DMC-4040 4-axis controller
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DMC-40x0 vs DMC-21x3 Features

DMC-40x0 Accelera DMC-21x3 Econo
Box-Level Controller Card-level Controller
Analog Inputs 8, standard 8, optional with DB-28040

Isolated Inputs 8 or 16, standard Optional with ICM-20105

Isolated, high-power 8 or 16, standard Optional with ICM-20105
Outputs (.5A, 24V)
Extended digital I/O 32, Standard 40, Optional with DB-28040

LCD display 2 line x 8chr, included Not available

Ethernet 10/100 Base-T 10 Base-T only

RS232 ports Two ports One port only
up to 115 kBaud up to 19.2 kbaud
ICM Included Optional

DC-to-DC converter
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Included Optional
Toll Free Phone: 877-378-0240 Accepts 20-80 VDC

Metal enclosure
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Drives Save Space, Cost and Wiring

• DMC-40x0 is available with internal, multi-
axis drives for steppers and servos
• Internal drives save space, cost and wiring
• DMC-40x0 can also be connected to
external drives of any size or power

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Drive Options

Drive Model Number Motor Type Specs
of Axes
AMP-43020 2 Brush or 7A cont, 10A peak
brushless servo 20-80 VDC
AMP-43040 4 Brush or 7A cont, 10A peak
brushless servo 20-80 VDC
AMP-43140 4 Brush servo 1A
+/-12-30 VDC
SDM-44040 4 Full, half, ¼, 1/16 1.4A/phase
stepper 12-60 VDC
SDM-44140 4 Microstep 3A/phase
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12-60 VDC
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AMP-430x0 2- and 4-axis 500W Drives

• AMP-43040 contains four PWM amplifiers
for driving brush or brushless servos.
AMP-43020 2-axis version also available.
• 7 Amps cont, 10 Amps peak; 20-80 VDC
• Configurable for inverter or chopper mode
• No external heat sink required
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AMP-430x0 is a “Hybrid” Design

AMP-430x0 has both Digital and Analog circuitry
Hybrid Design
• Analog current loop for highest bandwidth and
response. Analog circuitry is on AMP-430x0
amplifier board
• Digital circuitry for amplifier set-up and status
reporting. Microprocessor is on DMC-40x0
controller board. For example, AG sets AMP gain
and TA reports AMP status

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AMP-43140 Four 20W Servo Drives

• Drives four brush servos
• Linear drives
• Requires +/-12-30 VDC input
• Maximum current for each amplifier is 1A
• Maximum output power: 20 W per amplifier
and 60 W total
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SDM-44040 Four Stepper Drives

• Drives two-phase bipolar steppers
• Requires single 12-30 VDC input
• User configurable for: 1.4A, 1.0A, .75A or .5A
• User configurable for: full-step, half-step,
¼ step or 1/16 step
• Short circuit protection
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SDM-44140 Four Microstep Drives

• Drives two-phase bipolar steppers
• 64 microsteps/full step
• Drives motors up to 3A, 12-60 VDC
• Software Selectable current settings: .5A,
1A, 2A, 3A

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DMC-40x0 Physical Dimensions

DMC-40x0 is extremely compact!

Box Dimensions:
1-4 axes: 8.1” x 7.25” x 1.72”
5-8 axes: 11.5” x 7.25” x 1.72”

package includes the multi-axis drives
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DMC-4080 Controller/Drive Package

The DMC-4080 8-axis controller and drive unit
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connects to 8 servo motors
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DMC-40x0 Options

New options for the DMC-40x0:

-DIN Din rail mounting clips
-16-BIT 16-bit ADC (12-BIT is standard)
-5V 5V for extended I/O (3.3V is standard)
-SSI SSI interface
-DIFF Differential outputs for analog motor command
-STEP Differential outputs for step/direction command
-I100 Sinusiodal encoder interpolation
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Part Number Generator for DMC-40x0

• New web tool helps generate part number with
all the options for the DMC-40x0
• Also calculates pricing
• Part Number Generator Tool is on DMC-40x0
webpage:
http://www.galilmc.com/products/accelera/dmc40x0.html

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For More Info

• See website for complete specs and pricing
information

http://www.galilmc.com/products/accelera/dmc40x0.html

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Galil Material is protected by copyright and must not be
reproduced or disassembled in any form without prior written
consent of Galil Motion Control, Inc.

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Inverse Kinematics

Inverse Kinematics Applications

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Inverse Kinematics - Agenda

• What is Inverse Kinematics and why is it used?
• Simple 2-D example
• Solution Methods

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Inverse Kinematics

Inverse Kinematics equations allow an Engineer to compute angular
(rotary encoder) positions knowing the end-effector location and
robot geometry.

Forward Kinematics
Posmotor Posload

Inverse Kinematics

Increase in complexity with additional DOF
Min/max angular positions, boundary conditions, and ‘keep-out’ zones
are critical in providing a complete solution.
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Inverse Kinematics

Why use inverse kinematics?

To allow an operator to move a machine to a
real, known location in Cartesian space
without intimate knowledge of the machine
mechanics

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Solution Options

Three general options:
1. Host PC
1. All motor positions are calculated by a host PC
2. Controller receives Contour mode position data
3. Customer has complete control over equations, constants, and
update rates
2. On controller, in a software program
1. Encoder positions calculated by Galil in a dmc file
2. No host PC necessary
3. Accelera series can generate profiles at up to a 2 msec update
(depends on equation complexity)
4. Customer can change equations or constants at will
3. On controller, in firmware
1. Motor positions calculated within the controller’s servo loop
2. Very fast calculations
3. Once programmed into firmware, customer cannot change
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equations
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Simple 2-D Example

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Example of 2 DOF robot arm

Simple 2-D Example

Ø2

Ø1

Sold & Serviced By: Given: Xhand, Yhand, L1, L2
Find: θ1, θ2
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Simple 2-D Example

Ø2

Ø1

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B: Length of imaginary line
Q1: Angle between X axis and imaginary line B
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Q2: Interior angle between imaginary line B and link L1
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Simple 2-D example

• Equations:
B2 = Xhand2 + Yhand2
Q1 = atan(Yhand/Xhand)
Q2 = acos[(L12 - L22 + B2)/(2 * L1 * B)]
θ1 = Q1+Q2
θ2 = acos[(L12 + L22 - B2)/(2 * L1 * L2)]

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Simple 2-D Example

Sold & Serviced By: Calculate points along trajectory (150,100)-(250,200)
Use Galil motion profiler
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Simple 2-D Example

Use the Galil motion profiler to define a end-effector acceleration, speed
and deceleration.

Galil Code to generate XY coordinates along motion path

#CALC
TL 0,0; ER -1,-1; 'FOR PURE CALCULATION
VMXY
VS 1000;VA 20000;VD 20000
DP 150,100; 'DEFINE STARTING POSITION
DA,*[]; 'DEALOCATE ARRAYS
DM XPOS[100],YPOS[100]; 'ARRAYS FOR TRAJECTORY DATA
RA XPOS[],YPOS[]; 'SET UP RECORD ARRAY
RD _RPX,_RPY; 'RECORD REFERENCE POSITION
VP 100,100; 'MOVE TO POSITION 250,200
VE
RC1
BGS
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AMS
MG"DONE"
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EN

Simple 2-D Example

Resulting trajectory data in Excel:

End-Effector X-axis position vs. time End-Effector Y-axis Position vs. Time

260 210
240 190
220 170
Xhand

Yhand
200 150
180 130
160 110
140 90
0 50 100 150 200 0 50 100 150 200
Time, msec Time, msec

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Simple 2-D Example

Theta1 Absolute Angle

#GENR8 100

'L1 = LENGTH OF FIRST LINK
95
'L2 = LENGTH OF SECOND LINK
'B= LENGTH OF HYPOTNUSE 90

Angle, Degrees
'Q1 = ANGLE BETWEEN X AXIS AND LINE B
85
'Q2 = INTERIOR ANGLE FROM B TO L1
'Theta1 = ABS ANGULAR POS OF FIRST MOTOR 80
'Theta2 = ABS ANGULAR POS OF SECOND MOTOR
75
L1=200
L2=200 70
DA,Theta1[];DA,Theta2[] 0 50 100 150 200
Tim e
NOTE BUILD ARRAYS FOR CONTOUR DATA
DM Theta1[100],Theta2[100]
Theta2 Absolute Angle
N=0;'ARRAY INCREMENT
#CALC2 115
B=@SQR[(Xpos[N]*Xpos[N])+(Ypos[N]*Ypos[N])]
105
Q1=@ATAN[(Ypos[N])/(Xpos[N])]
Q2=@ACOS[((L1*L1)-(L2*L2)+(B*B))/(2*L1*B)] 95
Angle, Degrees
Theta1[N]=Q1+Q2 85
Theta2[N]=@ACOS[((L1*L1)+(L2*L2)-(B*B))/(2*L1*L2)]
75
N=N+1
65
JP#CALC2,N<100
MG"DONE GENR8"
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55

EN 45
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Tim e

Simple 2-D Example

#CONTMOV X Encoder Value
NOTE Encres = ENCODER COUNTS/DEGREE
0
Encres=4000/360 0 20 40 60 80 100 120 140 160 180 200
NOTE BUILD ARRAYS FOR ENCODER RELATIVE DATA
-50
DA,Enc1[];DA,Enc[2]

Encoder Relative Value
DM Enc1[100],Enc2[100] -100
N=0; 'INCREMENT RESET
#CALC3 -150

Enc1[N]=Encres*((Theta1[N+1])-(Theta1[N]))
-200
Enc2[N]=Encres*((Theta2[N+1])-(Theta2[N]))
N=N+1 -250
JP#CALC3,N<99
MG"DONE CONTCLC" -300
Tim e(m s)

DP0,0
NOTE THIS ROUTINE SENDS ALL 100 CONTOUR MOVES
Y Encoder Value
CMXY
DT1 600
N=0;'INCREMENT RESET
#LOOP3 500

Encoder Relative Value
CD Enc1[N],Enc2[N]
400
N=N+1
JP#LOOP3,N<100
300
#WAIT;JP#WAIT,_CM<>511
CD 0,0=0 200
EN
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100

Toll Free Phone: 877-378-0240 0
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Time(ms)

Inverse Kinematics

Questions?

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Galil galil's new accelera controller; sizzling speed, fully loaded 2007 presentation