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Accelera Motion ControllersSizzling 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 Settling2. Coordination – Modes of motion,

Application programs3. Smaller package size and integration with

power drivers

4. Communication

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Structure of Motion Control System

Host

Application Program

Closed Loop

Driver

Motor

I/ODigital/Analog

Modes of MotionProfile Generation

Encoder

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Structure of Motion Control System

Host

Application Program

Closed Loop

Driver

Motor

I/ODigital/Analog

Modes of MotionProfile Generation

Encoder

PerformanceSample TimeEncoder FrequencyDAC ResolutionFilters PID/NotchTuning Program

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Structure of Motion Control System

Host

Application Program

Closed Loop

Driver

Motor

I/ODigital/Analog

Modes of MotionProfile Generation

Encoder

CoordinationModes of MotionApplication Programs

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Structure of Motion Control System

Host

Application Program

Closed Loop

Driver

Motor

I/ODigital/Analog

Modes of MotionProfile Generation

Encoder

Integration with Power Drivers

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Structure of Motion Control System

Host

Application Program

Closed Loop

Driver

Motor

I/ODigital/Analog

Modes of MotionProfile Generation

Encoder

Communication

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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 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 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 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

• Additional communication ports such as RS232

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Accelera PCI Controller

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

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

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Introducing the DMC-40x0 Series

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

Top: DMC-4040 4-axis Ethernet controllerBottom: 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 Speed

40 microseconds 400 microseconds

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 510 254

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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

• 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 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

Box-Level Controller

DMC-21x3 Econo

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

Outputs (.5A, 24V)

8 or 16, standard Optional with ICM-20105

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

up to 115 kBaud

One port only

up to 19.2 kbaud ICM Included Optional

DC-to-DC converter Included

Accepts 20-80 VDC

Optional

Metal enclosure Included Optional

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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 of Axes

Motor Type Specs

AMP-43020 2 Brush or brushless servo

7A cont, 10A peak 20-80 VDC

AMP-43040 4 Brush or brushless servo

7A cont, 10A peak 20-80 VDC

AMP-43140 4 Brush servo 1A

+/-12-30 VDCSDM-44040 4 Full, half, ¼, 1/16

stepper

1.4A/phase

12-60 VDC

SDM-44140 4 Microstep 3A/phase

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

• No external heat sink required

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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

• No external heat sink required

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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

• No external heat sink required

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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 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

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.

Posmotor Posload

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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 PC2. Controller receives Contour mode position data3. Customer has complete control over equations, constants, and

update rates2. On controller, in a software program

1. Encoder positions calculated by Galil in a dmc file2. No host PC necessary3. 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 firmware1. Motor positions calculated within the controller’s servo loop2. Very fast calculations3. Once programmed into firmware, customer cannot change

equations

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Simple 2-D Example

Example of 2 DOF robot arm

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Simple 2-D Example

Given: Xhand, Yhand, L1, L2

Find: θ1, θ2

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Simple 2-D Example

B: Length of imaginary line

Q1: Angle between X axis and imaginary line B

Q2: Interior angle between imaginary line B and link L1

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Simple 2-D example

• Equations:

B2 = Xhand2 + Yhand

2

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

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

AMS

MG"DONE"

EN

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Simple 2-D Example

Resulting trajectory data in Excel:

End-Effector X-axis position vs. time

140

160

180

200

220

240

260

0 50 100 150 200

Time, msec

Xh

and

End-Effector Y-axis Position vs. Time

90

110

130

150

170

190

210

0 50 100 150 200

Time, msecY

han

d

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Simple 2-D Example

#GENR8'L1 = LENGTH OF FIRST LINK'L2 = LENGTH OF SECOND LINK'B= LENGTH OF HYPOTNUSE'Q1 = ANGLE BETWEEN X AXIS AND LINE B'Q2 = INTERIOR ANGLE FROM B TO L1'Theta1 = ABS ANGULAR POS OF FIRST MOTOR'Theta2 = ABS ANGULAR POS OF SECOND MOTORL1=200L2=200DA,Theta1[];DA,Theta2[]NOTE BUILD ARRAYS FOR CONTOUR DATADM Theta1[100],Theta2[100] N=0;'ARRAY INCREMENT#CALC2B=@SQR[(Xpos[N]*Xpos[N])+(Ypos[N]*Ypos[N])]Q1=@ATAN[(Ypos[N])/(Xpos[N])]Q2=@ACOS[((L1*L1)-(L2*L2)+(B*B))/(2*L1*B)]Theta1[N]=Q1+Q2Theta2[N]=@ACOS[((L1*L1)+(L2*L2)-(B*B))/(2*L1*L2)]N=N+1JP#CALC2,N<100MG"DONE GENR8"EN

Theta1 Absolute Angle

70

75

80

85

90

95

100

0 50 100 150 200

Time

An

gle

, Deg

rees

Theta2 Absolute Angle

45

55

65

75

85

95

105

115

0 50 100 150 200

Time

An

gle

, Deg

rees

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Simple 2-D Example

#CONTMOVNOTE Encres = ENCODER COUNTS/DEGREE Encres=4000/360NOTE BUILD ARRAYS FOR ENCODER RELATIVE DATADA,Enc1[];DA,Enc[2]DM Enc1[100],Enc2[100] N=0; 'INCREMENT RESET #CALC3Enc1[N]=Encres*((Theta1[N+1])-(Theta1[N]))Enc2[N]=Encres*((Theta2[N+1])-(Theta2[N]))N=N+1JP#CALC3,N<99MG"DONE CONTCLC"

DP0,0NOTE THIS ROUTINE SENDS ALL 100 CONTOUR MOVESCMXYDT1N=0;'INCREMENT RESET#LOOP3CD Enc1[N],Enc2[N]N=N+1JP#LOOP3,N<100#WAIT;JP#WAIT,_CM<>511CD 0,0=0EN

X Encoder Value

-300

-250

-200

-150

-100

-50

0

0 20 40 60 80 100 120 140 160 180 200

Time(ms)

En

cod

er R

elat

ive

Val

ue

Y Encoder Value

0

100

200

300

400

500

600

0 50 100 150 200

Time(ms)

En

co

de

r R

ela

tiv

e V

alu

e

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Inverse Kinematics

Questions?