World in motion... Reaching New Heights in Motion Technology Delta Tau (UK) Limited 18 Faraday Close Gorse Lane Industrial Estate Clacton-on-Sea Essex CO15 4TR Tel: +44 (0)1255 221055 Fax: +44 (0)1255 225391 Email: [email protected] www.deltatau.co.uk 02 Precision motion and machine control 03 For more than a quarter of a century Delta Tau has consistently and continually set the global benchmarks for precision motion and machine control. Over a million axes of motion installed worldwide in control equipment as diverse as machine tools and medical device manufacturing, robots and the Hubble telescope, packaging machines and Hollywood movie sets. There are few lives untouched by products made using Delta Tau motion controls. Delta Tau in the UK has forged specialised services to the high technology and scientific communities. Many Synchrotron and high energy laser and neutron facilities depend on Delta Tau technology to control their complex multi axes equipment – Diamond Light Source is the UK’s national synchrotron science facility, located at the Harwell Science and Innovation Campus in Oxfordshire and uses Delta Tau motion Controllers on many of the beamlines there. By accelerating electrons to near light-speed, Diamond generates brilliant beams of light from infra-red to X-rays which are used for academic and industrial research and development across a range of scientific disciplines including structural biology, physics, chemistry, materials science, engineering, earth and environmental sciences. Despite its scientific pedigree, Delta Tau also offers the most versatile and flexible multiple axis motor controllers for general purpose machine control and automation tasks. The ability of the PMAC range of products to control different motor types and technologies from a single motion card offers machine builders many practical advantages. Moreover, all the Delta Tau products are backed by expert technical support right here in the UK . One of the big storage ring sextupole magnets at Diamond Light Source. Image courtesy of Diamond Light Source www.deltatau.co.uk Protein crystallography sample holder on protein crystallography beamline. Image courtesy of Diamond Light Source MATLAB®’s Simulink® with Power PMAC Facilitates user-servo code generation for Power PMAC using Simulink®’s Embedded Coder (previously known as Real-Time Workshop). The objective is to fully automate code generation for Power PMAC’s servo loop closure routines (tasks) utilising Simulink’s® control blocks. Beamline i04.1 experiment end station. 04 Image courtesy of Diamond Light Source Sophisticated Firmware Features Five built-in control algorithms: The New Power Brick LV-IMS Motion Computer Power Brick LV IMS The Power PMAC is a Motion Controller and Linux computer rolled into one. Running an open source public domain operating system with a Xenomai real time kernel The PMAC has come of age. Now with EPICS and TANGO compatibility running onboard or remotely, the new Power Brick LV-IMS offers the scientific communities around the world a powerful integrated package. Using fully programmable four-quadrant four-phase technology in the eight axis amplifier stage, the power PMAC-LV-IMS is capable of running any mix of stepper, AC servo or DC servo motors. Having unique software control of the current in each axis allows the user to fully customise each application. Each block of four axes comes in three different current ratings of: 0.25A continuous 0.75A peak; 1.0A continuous 3.0A peak; and 5.0A continuous 15A peak. All current ranges operate between 12 and 48VDC. As well as standard quadrature encoder inputs, both versions come complete with a range of serial encoder interfaces. These include Endat 2.2, Hiperface, SSI, Yaskawa Sigma II, and Tamagawa. For more recent and future protocols, not included in the DSPgate3, provision has been made to fit a mezzanine board to facilitate the use of these and analogue sin/cos and resolver feedback devices. The Delta Tau MACRO (Machine And Control Ring Optical) interface now comes as standard, enabling the controller to control 32 axes. It also allows any Delta Tau MACRO product such as I/O, analogue interfaces or amplifiers to be added to the systems. • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Standard PID only PID enhanced with notch filters, deadband filters, lowpass/highpass filters, velocity loop filters, and/or trajectory prefilters Standard Gantry Control Cross-Coupled Gantry Control Adaptive Control Programmable input, integrator, and output limits Automatic or manual tuning of all motors’ current loops and servo loops Phasing algorithms for maximizing the torque output of commutated motors Commutation algorithms for commutated motors (e.g. DC Brushless, AC Induction, etc.) Field weakening algorithm for AC induction motor (through the Motor[x].DtOverRotorTc structure) The user can also implement his or her own custom servo and phase algorithms in C Look-ahead for dynamic acceleration adjustment for accurate contouring Jerk limiting for smooth motion and reducing mechanical wear Cutter radius (2D) and shape (3D) compensation for machining Position, torque, and backlash compensation Multi-threaded general purpose background programs that run asynchronous to motion: Up to 32 in PMAC’s Script language, 32 in C 0 to 3 multi-threaded general purpose foreground Script programs , 1 general purpose foreground C program, which run asynchronous to motion The above programs can be used for whatever purpose the user desires (e.g. safety and status monitoring, servo gain scheduling, data reporting functions, etc.) User-programmable, PMAC-Scheduled kinematics subroutines Position following (electronic gearing) Time-base control (automatic feedrate adjustment based on an external input signal) Transformation matrices for coordinate system rotation and translation Direct microstepping or pulse and direction (PFM) control for encoderless, open-loop control of stepper motors Position Compare with Digital Output at User Programmed encoder positions at 10 MHz, accompanied by an optional user-written interrupt service routine (ISR) that runs at these positions if desired Coordinate systems make grouping motors for synchronous motion and converting motor units to engineering units simple Multiple-motor axis definitions supported (e.g. for Gantries) Synchronous motion move modes: Linear, Circular, Spline, PVT, and Rapid 1/T extension for digital enhancement of standard Digital A Quad B encoder resolution Automatic move-until-trigger functions with hardware capture User-configurable servo clocks (for closing the servo loop at the appropriate sampling frequency), phase clocks (for commutation), PWM clocks (to get the right pulse frequency depending on motor characteristics) and real- time interrupt clocks (for move planning) Safety Features: • • • • • • www.deltatau.co.uk Hardware and software over-travel limits Amplifier enable/fault handshaking Following error limits Integrated current limit Encoder loss detection Watchdog timer and relay for safely stopping the machine if the controller freezes. 05 07 06 Turbo PMAC LV-IMS Motion Controller Geo Brick LV IMS-II Delta Tau sets the global benchmarks for precision motion control, The Turbo PMAC based multiple axis low voltage motion controller/data acquisition system with integral amplifiers is designed specifically for the high energy physics market. Controlling up to 8 axes of mixed servo and stepping motor types, the new Geo Brick LV IMS-II family of products is also a fraction of the size and cost of most conventionally built 8-axis systems. The Geo Brick LV concept was designed to control the combination of motor technologies typically encountered in synchrotron applications. Given the complexity of such systems, this new design has significantly reduced cabling, simplifying installation and reducing costs. the amplifiers, the LV controllers offer the unique power of the Delta Tau position control systems. This concept provides great savings in both panel space and installation costs and whilst the design is optimised for operation using a 48VDC bus - a level that eliminates many regulatory concerns – the amplifiers each have a 250W or 5A capacity. By simply adding the MACRO (Machine And Control Ring Optical) option, the controller can be expanded to 32 axes, also enabling any Delta Tau Macro product such as I/O, analogue interfaces or amplifiers to be added to the system. It is also possible using MACRO to create master/slave configurations linking two Geo Bricks. The Geo Brick LV IMS-II expands the range of Delta Tau’s widely used Geo Brick integrated multi-axis controller/amplifier family of products. As well as integrating Six circle diffractometer. Image courtesy of Diamond Light Source www.deltatau.co.uk Quad PSU 1.6kVA & Quad PSU 500VA Power Supplies 08 09 Quad PSU 1.6kVA NEW Digital Brick Controller IMS-II Delta Tau has two new compact switch mode power supplies, called the Quad PSU, that not only reduces cabling for the new Geo Brick LV IMS-II, but also provides reliable power for up to four separate controller crates in a single rack mounted device. The power supply unit is a low profile 1U configuration with three power supplies plus a Regen unit. It has a universal Input (85 - 265VAC) with built in power factor correction. Brick Controller IMS-II and the Power Brick Controller IMS The PMAC “Brick Controller IMS” now comes in two distinct types. The original Turbo PMAC based Brick Controller IMS and now the NEW Power Brick Controller IMS. Not only has Delta Tau upgraded to the NEW Power PMAC we have created a whole new digital version of both systems. These units do not come with integrated drive amplifiers. To augment the original system concept with analogue outputs Delta Tau now offers a wholly digital version. Designed with stepper motors in mind, the output from this unit is a digital PWM signal that can be configured to be either step and direction to interface with existing external stepper drives or it can be configured to output a PWM signal compatible with Delta Tau’s larger AC servo drives. Quad PSU 500VA Because of the highly efficient nature of the switch mode power supplies used, it runs at a cool 10 degrees above ambient at full load. As well as standard quadrature encoder inputs both versions come complete with a range of serial encoder interfaces. These include Endat 2.2, Hiperface, SSI, Yaskawa Sigma II, and Tamagawa. Both the Quad PSU 1.6kVA and 500VA offer a 48Vdc or 24Vdc motor PSU and two 150W 24Vdc supplies for logic and I/O providing the power to up to four motion controllers. For more recent and future protocols, not included in the DSPgate3, provision has been made to fit a mezzanine board to facilitate the use of these and analogue sin/cos and resolver feedback devices. The Delta Tau MACRO (Machine And Control Ring Optical) interface now comes as standard, enabling the controller to control 32 axes. It also allows any Delta Tau MACRO product such as I/O, analogue interfaces or amplifiers to be added to the systems. Each motor, Logic and I/O output is individually switched and thermally protected. Storage Ring at Diamond Light Source. Image courtesy of Diamond Light Source The Motor power supply is additionally protected from over voltage by motor regeneration with an internal electronic circuit and thermally protected regen resistor. All power supplies are internally protected from over voltage, over current, over temperature and fan failure where fitted. www.deltatau.co.uk 10 Diamond Light Source facility at Rutherford Appleton Laboratory near Oxford UK. Image courtesy of Diamond Light Source Cables & Accessories 11 Delta Tau offers a full range of mating connectors and interconnecting cables. TANGO Software EPICS Technology The addition of TANGO software for the Power PMAC provides another option for synchrotron motion control community. Observatory Sciences has worked with Delta Tau to integrate its GeoBrick LV controller and the Brick Controller IMS with EPICS to provide the Diamond Light Source synchrotron with its next generation motor controller solution. TANGO (TAco Next Generation Object) is a distributed control system, based on object oriented and service oriented approaches to software architecture. It is being actively developed by the collaborative effort of a group of European scientific institutes, including Alba, Desy, Elettra, ESRF, FRM II, Solaris and Soleil. The first user of Observatory Sciences TANGO software library for the Power PMAC will be the Soleil synchrotron – the French national synchrotron which provides a multi-disciplinary instrument and research laboratory. The synchrotron is currently home to a number of high profile research projects, including looking into the production of graphene semiconductor nano-ribbons. This twodimensional crystal composed of a single layer of carbon atoms has very promising properties that could drive major advances in microelectronics. More recently, Observatory Sciences is continuing its work with Brookhaven National Laboratory’s Synchrotron Light Source II (NSLS-II) with the latest project for Power PMAC EPICS support. The ability to use the Power PMAC with both EPICS and now TANGO will enable adoption of these systems at large scientific facilities such as synchrotrons. Observatory Sciences is a recognised leader in EPICS, developing control systems and delivering EPICS training. The EPICS toolkit has been used on many high energy physics facilities as well as on large astronomical telescopes around the world, and EPICS software now provides the core control system for many synchrotron facilities. www.deltatau.co.uk TANGO software interface EPICS interface screen A highly integrated and compact automation controller 12 13 Safety & Other Features Power Brick AC The Power Brick AC is an integrated fully scalable Machine and Motion Controller combining the brain of the cutting edge Power PMAC processor, the unsurpassed custom-designed Digital Signal Processor Gate3 ASIC and the brawns of the latest IGBT-based amplifier technology into one compact 4, 6, or 8-axis servo package drive. Additional axes are available via MACRO (high speed fibre optic network) and/or EtherCAT for a possible total of 104 (8 local + 32 MACRO + 64 EtherCAT) axes of centralized and coordinated motion control. Motor Control The Power Brick AC performs current loop closure, commutation and servo loop (position) closure to drive directly: • AC/DC Brushless Servo (synchronous) linear / rotary motors • AC Induction (asynchronous) motors • DC Brush and Voicecoil motors • High Voltage Stepper motors See page 30 for a more detailed overview of the Power PMAC capabilities Encoder Support Fieldbus Connectivity The Power Brick AC can interface with one or a combination of the following types of motor feedback devices: Servo • MACRO (Master/Slave) • EtherCAT (Master) • Quadrature • Sinusoidal x 16K/64K • Resolver • Halls (60oe/120oe) • Kawasaki • Analog +/- 10VDC • LVDT / MLDT • Mitsubishi • Panasonic • Yaskawa • Nikon-D • BiSS-B/C • EnDat 2.1/2.2 • Mitutoyo • Tamagawa • SSI • HiperFace • Encoder count error and encoder loss detection • Dedicated brake relays and power input (24V) • Plus/Minus over-travel, home, user inputs • Software over-travel limits • Warning/fatal following error limits • High speed compare outputs • Internal and external shunt resistors • Safe Torque Off (STO) with dynamic braking • Abort Input for safe stop • Watchdog output • Over / Under volta ge faults • Short circuit, overcurrent protection • Hardware /Software thermal I2T protection • Motor thermal inputs (PTC) I/O • EtherNet /IP (Scanner/Adapter) • EtherCAT (Master/Slave) • Profibus-DP (Master/Slave) • DeviceNet (Master/Slave) • CANopen (Master/Slave) • Open Modbus (Master/Slave) • CC-Link (Slave) • PROFINET IO RT (Controller/Device) GP Digital Inputs/Outputs - Relays The Power Brick AC can be equipped with: • 8 x general purpose relays • 32 x digital inputs 12-24VDC • 16 x digital outputs 12-24VDC, 500 mA All protected and optically isolated. Can be either sinking or sourcing. Thousands of additional digital inputs and outputs can be added via various fieldbus options. CONNECTOR LAYOUT 4-Axis Model Shown Top View 24V Logic Motor # 1 Encoders # 1 to 4 7.00” (177.83mm) GP Digital I/0 Shunt Resistor Motor # 2 R232 Limits & Flags MACRO Status Display USB 13.38” (339.73 mm) EtherCAT Ethernet Watchdog & Abort LED Status Bottom View Motor # 3 Encoders # 5 to 8 Fieldbus Motor # 4 Analog I/O GP Analog I/Os Alt. Enc. Pwr GP Analog Inputs/Outputs- PFM The Power Brick AC can carry up to: • 8 x Pulse and Direction / PFM outputs • 8 x 16-bit analog inputs (+/-10V) • 8 x 14-bit analog outputs (+/-10V) STO & Brake 4.50” (114.29mm) www.deltatau.co.uk AC/DC PowerBus Input 15 14 Power Brick Controller A highly integrated and compact automation controller The Power Brick Controller is a packaged, scalable, Machine and Motion Controller combining the brain of the cutting edge Power PMAC processor and the unsurpassed custom-designed Digital Signal Processor Gate3 ASIC in one compact 4 or 8-axis package. Additional axes are available via MACRO (high speed fibre optic network) and/or EtherCat for a possible total of 104 (8 + 32 MACRO + 64 EtherCat) axes of centralised and coordinated motion control. Output Control Encoder Support Fieldbus Connectivity GP Analog Inputs/Outputs- PFM The Power Brick Controller provides servo loop closure (position or torque) ouputs, and current loop closure (PWM option): The Power Brick AC can interface with one or a combination of the following types of motor feedback devices: Servo • MACRO (Master/Slave) • EtherCAT (Master) • Analog +/-10V 13.5 bit Filtered PWM • 16-Bit True DAC (optional) • Pulse and Direction • Sine Wave • Direct digital PWM • Quadrature • Sinusoidal x 16K/64K • Resolver • Halls (60oe/120oe) • Kawasaki • Analog +/- 10VDC • LVDT / MLDT • Mitsubishi • Panasonic • Yaskawa • Nikon-D • BiSS-B/C • EnDat 2.1/2.2 • Mitutoyo • Tamagawa • SSI • HiperFace I/O • EtherNet /IP (Scanner/Adapter) • EtherCAT (Master/Slave) • Profibus-DP (Master/Slave) • DeviceNet (Master/Slave) • CANopen (Master/Slave) • Open Modbus (Master/Slave) • CC-Link (Slave) • PROFINET IO RT (Controller/Device) The Power Brick AC can carry up to: • 8 x Pulse and Direction / PFM outputs • 8 x 16-bit analog inputs (+/-10V) • 8 x 14-bit analog outputs (+/-10V) See page 30 for a more detailed overview of the Power PMAC capabilities GP Digital Inputs/Outputs - Relays The Power Brick AC can be equipped with: • 8 x general purpose relays • 32 x digital inputs 12-24VDC • 16 x digital outputs 12-24VDC, 500 mA All protected and optically isolated. Can be either sinking or sourcing. Thousands of additional digital inputs and outputs can be added via various fieldbus options. CONNECTOR LAYOUT 8-Axis Model Shown 4” 10.16cm Limits & Flags DAC-Sine Output/ Direct PWM AMP1 Encoders # 1 to 4 (PFM Ouput) DAC-Sine Output/ Direct PWM AMP2 SD Card RS232 MACRO Safety & Other Features • Safe Torque Off (STO) with dynamic braking • Abort Input for safe stop • Watchdog output • Over / Under voltage faults • Short circuit, overcurrent protection • Hardware / Software thermal I2T protection • Motor thermal inputs (PTC) • Encoder count error and encoder loss detection • Dedicated brake relays and power input (24V) • Plus/Minus over-travel, home, user inputs • Software over-travel limits • Warning/fatal following error limits • High speed compare outputs • Internal and external shunt resistors 7.75” 19.685cm GP I/O DAC-Sine Output/ Direct PWM AMP3 USB 13.5” 34.29cm Ethernet Watchdog & Abort DAC-Sine Output/ Direct PWM AMP4 Fieldbus Diagnostics Encoders # 5 to 8 (PFM Ouput) DAC-Sine Output/ Direct PWM AMP5 Fieldbus DAC-Sine Output/ Direct PWM AMP6 Analog I/O Relays DAC-Sine Output/Direct PWM AMP7&8 www.deltatau.co.uk 17 16 See page 30 for a more detailed overview of the Power PMAC capabilities GP Analog Inputs/Outputs- PFM Safety & Other Features The Power Brick LV can carry up to: • 8 x Pulse and Direction / PFM outputs • 8 x 16-bit analog inputs (+/-10V) • 8 x 14-bit analog outputs (+/-10V) • Safe Torque Off (STO) with dynamic braking • Abort Input for safe stop • Watchdog output • Over / Under voltage faults • Short circuit, overcurrent protection • Hardware / Software thermal I2T protection • Motor thermal inputs (PTC) • Encoder count error and encoder loss detection Power Brick LV The Power Brick LV is an integrated fully scalable Machine and Motion Controller combining the brains of the cutting edge Power PMAC processor, the unsurpassed custom-designed Digital Signal Processor Gate3 and the low voltage brawns of the latest high performance MOSFET-based drives technology into one compact 4 or 8-axis servo package drive. Additional axes are available via MACRO (high speed fibre optic network) and/or EtherCat for a possible total of 104 (8 + 32 MACRO + 64 EtherCat) axes of centralized and coordinated motion control. Motor Control The Power Brick LV performs current loop closure, commutation and servo loop closure to drive directly: • AC/DC Brushless servo (synchronous) linear / rotary motors • DC Brush and Voicecoil motors • Low Voltage Stepper motors CONNECTOR LAYOUT 8-Axis Model Shown Encoder Support Fieldbus Connectivity The Power Brick LV can interface with one or a combination of the following types of feedback devices: Servo • MACRO (Master/Slave) • EtherCAT (Master) • Quadrature • Sinusoidal x 16K/64K • Resolver • Halls (60oe/120oe) • Kawasaki • Analog +/- 10VDC • LVDT / MLDT • Mitsubishi • Panasonic • Yaskawa • Nikon-D • BiSS-B/C • EnDat 2.1/2.2 • Mitutoyo • Tamagawa • SSI • HiperFace I/O • EtherNet/IP (Scanner/Adapter) • EtherCAT (Master/Slave) • Profibus-DP (Master/Slave) • DeviceNet (Master/Slave) • CANopen (Master/Slave) • Open Modbus (Master/Slave) • CC-Link (Slave) • Profinet IO RT (Controller/Device) GP Digital Inputs/Outputs - Relays The Power Brick LV can be equipped with: • 8 x general purpose relays • 32 x digital inputs 12-24VDC • 16 x digital outputs 12-24VDC 500 mA All protected and optically isolated. Can be either sinking or sourcing. Thousands of additional digital inputs and outputs can be added via various fieldbus options. • Dedicated brake relays and power input (24V) • Plus/Minus over-travel, home, user inputs • Software over-travel limits • Warning/fatal following error limits • High speed capture outputs • Internal and external shunt resistors Top View 24V Logic Motor # 1 STO Encoders # 1 to 4 7.750” 19.685cm Motor # 2 GP Digital I/O AMP Status MACRO R232 USB Motor # 3 Motor # 4 EtherCAT Ethernet Watchdog & Abort Limits & Flags 13.396” (34 cm) Motor # 5 Bottom View Motor # 6 Encoders # 5 to 8 Motor # 7 Fieldbus Motor # 8 Analog I/O DC Bus Input Analog I/O www.deltatau.co.uk 4.750” 12cm Control Through Industrial Network/Fieldbus Connectivity 18 Hardware / OS Power PMAC EtherLite The Power PMAC EtherLite is a compact and cost-effective product designed for control through industrial networks and fieldbuses. The network interface can be configured with Delta Tau’s MACRO fibre optic or electrical network and/or EtherCAT electrical network, as well as with one of various fieldbus options. The Power PMAC EtherLite is a dedicated controller for driving real-time motion (servo) and I/O networks. The controller communicates to a host PC via Ethernet, or operates standalone, while providing a singlewire connection to any MACRO and/ or EtherCAT drives, I/O or other peripheral devices. The Power PMAC EtherLite utilizes the intelligence and capabilities of Delta Tau’s 7th and latest generation controller, the Power PMAC, a general-purpose embedded computer running under a hard real-time Linux OS with a sophisticated motion and machine control application built in. The software PLCs, programmable in C and/or • Up to 1.2 GHz Single/Dual Core • Full real-time Operating System (Linux OS w/ real-time kernel) • Full file management system (programs, data, files, etc.) • Dedicated controller runs in the RT Linux environment • Full 32/64-bit architecture PMAC script, and built-in motion programs allow for complete machine logic control. Capable of controlling up to 128 axes and thousands of I/O points, the Power PMAC EtherLite employs the motion and software features of the Power PMAC Family in systems with highly distributed network hardware from vendors of your choosing, resulting in a ”Motion Solution” with unparalled performance capabilities. • Built in USB2.0 Interface • Optional 4x PCI Express (PCIe) port • Optional Direct Video Interface (DVI Output) • DVI output, 2 extra USB ports input (24V) • Plus/Minus over-travel, home, user inputs • Software over-travel limits • Warning/fatal following error limits • High speed capture outputs • Internal and external shunt resistors Fieldbus Connectivity Servo • MACRO (Master/Slave) • EtherCAT (Master) For large systems where networked connections are important to simplify wiring: Power PMAC EtherLite. I/O • Eth erNe t/IP (Scanner/Adapter) • EtherCAT (Master/Slave) • Profibus-DP (Master/Slave) • DeviceNet (Master/Slave) • CANopen (Master/Slave) • Open Modbus (Master/Slave) • CC-Link (Slave) • PROFINET IO RT (Controller/Device) CONTROL EVERYTHING Programming Languages Delta Tau’s Open Architechture Platform provides complete flexibility to choose multiple types of fieldbuses, enabling you to create a system perfect for your application. PMAC Script • ANSI C • G-Code See page 30 for a more detailed overview of the Power PMAC capabilities • Hardware 64-bit double precision floating point math • Support for large memory - Up to 16 GB Flash - Up to 4GB DDR3 active memory with error correction - 8MB NOR flash for Kernel & Bootloader - Interface for SD Card - Interface for USB 2.0 Devices (Hard drive, USB Stick, Keyboard, Mouse, etc.) • 2 ethernet 1Gbps ports 19 Programming Tools • MATLAB®/Simulink® Embedded Coder® generated code • Epics • CC-Link (Slave) • Profinet IO RT (Controller/Device) CONNECTOR LAYOUT Fibre optic MACRO Version Top View +24VDC Logic Power Connector 7.44” (188.90 mm) Ethernet 0 Ethernet 2 or EtherCAT 1 6.05” (153.67 mm) DVI Ethernet 3 or EtherCAT 2 Ethernet 1 or EtherCAT0 USB 1 Keyboard USB 2 Fibre optic OUT Fibre optic IN 3.90” (99.06 mm) SDCard & Mouse RS232 Watchdog Terminal Bottom View www.deltatau.co.uk Control Through Industrial Network/Fieldbus Connectivity 20 Power UMAC CONTROL EVERYTHING: Power UMAC 465 CPU Power UMAC The Power UMAC a motion computer with the latest hardware and software technology, providing the most highperformance, flexible machine controller in the world. The Power PMAC is a generalpurpose embedded computer. It runs under a hard real-time Linux OS with a sophisticated motion and machine control application built in. With the capability for a full operator interface, the Power PMAC eliminates the need for a separate PC. Users can also program in the easy-to-use Script language or the standard C language, leveraging its sophistication and flexibility. Dynamic Multi-Block Lookahead • Evaluates planned trajectory against motor limits • Slows just enough to stay within position, velocity, acceleration limits • Executes fastest possible traversal within machine constraints Forward and Inverse Kinematics Gantry Control with Skew Correction • Simplifies programming for non- Cartesian mechanisms • User routines convert between tool tip and actuator mechanisms • Permits direct specification of tool tip path • Multiple motors automatically slave commanded trajectory • Automatic removal of power-on skew in homing search sequence • Optional cross-coupling servo correction S-curve Acceleration • Automatically limits rate of change of acceleration (jerk) • Specified by jerk magnitude or S-curve time • Provides smooth profiles with reduced high-frequency content Position Capture and Compare • Specialised circuitry tying encoder counts to I/O • I/O on exact count (w/sub-count interpolation) at any speed • For probing, registration, measurement trigger, laser firing Delta Tau’s Open Architecture Platform provides complete flexibility to choose multiple types of motors, feedback devices, encoders and fieldbuses so you can create a system perfect for your application. Additional axes, feedback, I/O and/or fieldbus interfacing is obtained by sliding accessory cards into the 3U rack system, available in 3 choices of rack widths (largest 21-slot version pictured on the left). Power UMAC 465 CPU Single/Dual Core, Multiple Speeds, Linux RTOS with optional Video output Power Compact UMAC CPU Linux RTOS Custom Designs Power Compact UMAC CPU Multiple Types of Communication Simultaneously Electronic Gearing and Cams • Powerful master/slave techniques • Position following (gearing) requires no program for motion • External time base (cam) keeps full trajectory flexibility Multiple Coordinate Systems • Axes acting together should be in same Coordinate System • Axes acting independently should be in separate Coordinate Systems • Separate Coordinate Systems act as independent machines 1Gb Ethernet to host computer Master Single-port 2nd Ethernet host port, or EthernetIP and/or Modbus Communications USB port for mass storage (i.e.-hard drive, expanded memory, program backup) Dual-port option/ redundancy SD card for additional storage Blended and Splined Moves • Automatic on-the-fly transition for multiple programmed moves • Controlled, specified, acceleration of transitions • For single-axis profiles or multi-axis paths 21 R232 Serial Communications Fibre optic ring Power PMAC CPU Capabilities • Up to 1.2 GHz Single/Dual Core • Full real-time Operating System (Linux OS w/ real-time kernel) • Full file management system (programs, data, files, etc.) • Dedicated controller runs in the RT Linux environment • Full 32/64-bit architecture • Hardware 64-bit double precision floating point math • Support for large memory - 1GB or 2GB DDRAM active memory with error correction - 64MB NOR flash for Kernel and Bootloader - 512MB or 1/4/8 GB built-in NAND flash for user project (built-in) - Interface for SD Card (SDHC, 32GB support - Interface for USB 2.0 Devices (Hard drive, USB Stick, Keyboard, Mouse, etc.) • 2 ethernet 1Gbps ports • Built in USB2.0 Interface • Optional 4x PCI Express (PCIe) port • Optional Direct Video Interface (DVI Output) • DVI output, 2 extra USB ports DVI Video Output See page 30 for a more detailed overview of the Power PMAC capabilities www.deltatau.co.uk 23 22 A powerful and compact integrated controller and drive solution for cost sensitive applications The Power Clipper Drive is an integrated Machine and Motion Controller combining the brain of the cutting edge Power PMAC processor, the unsurpassed customdesigned Digital Signal Processor Gate3 ASIC and the low voltage brawn of high performance MOSFET amplifier technology into a compact solution for more cost sensitive and OEM applications. Motor Control The Power Clipper Drive provides servo loop closure (position or torque) ouputs: • AC/DC Brushless servo (synchronous) linear/rotary motors • DC Brush (Piezo, Voicecoil) motors • Stepper motors See page 30 for a more detailed overview of the Power PMAC capabilities Encoder Support GP Inputs/Outputs The Power Clipper Drive can interface with one or a combination of the following types of motor feedback devices: • 32 general-purpose TTL I/O points, direction selectable by byte: -16-point mux port, Delta Tau I/O accessory compatible -16-point “opto” port, Opto-22 style optically isolated modules compatible • Supports thousands of I/O points • “Handwheel” port with 2 each: - Quadrature encoder inputs - Pulse (PWM or PFM) output pairs • 4 12-Bit Analog Inputs and 1 Filtered PWM DAC Output (optional) • PWM laser control option (controllable TTL signals include PWM width, PWM frequency, laser on/off, and first pulse suppression, typically with CO2 and YAG lasers) • Quadrature • Halls (60oe/120oe) • Kawasaki • Analog +/- 10VDC • LVDT / MLDT • EnDat 2.1/2.2 • Mitsubishi • Panasonic • Yaskawa • Nikon-D • BiSS-B/C • Mitutoyo • Tamagawa • SSI • HiperFace • Sinusoidal (with ACC-51S) • Resolver (with ACC-8D Opt7) Safety & Other Features • Hardware/Software E-STOP and Reset • Watchdog output • I2T protection • Encoder count error and encoder loss detection • Plus/Minus over-travel, home, and user inputs • Software over-travel limits • Warning/fatal following error limits • High speed compare outputs • Automatic brake control • High speed capture outputs • Video Output Plug-In Stack Accessories • Up to 64 Axes (& I/O) Via EtherCat • 32 In / 32 Out 12-24V Digital I/O, Optically Isolated (ACC-34AA) • 32 In / 32 Out Digital I/O for Opto-22 Style Racks (ACC-34B) • Up to 32 daisy-chained ACC-34 boards for up to 1024 inputs / 1024 Outputs • ModBus , 24 In / 24 Out 12-24V Digital I/O, Optically Isolated with optional 2x 12-Bit DAC & 2x 12-Bit ADC & 2 Relays (ACC-65ETH) • Additional 4 Axes (ACC-24ES3) with optional 4 12-Bit Analog Inputs and 1 Filtered PWM DAC Output (ACC-24ES3) • 4 Channels Dual 18-Bit True DAC (ACC-8ES) • 4 Channel Direct PWM Output (ACC-8FS) • 2 or 4 Channel 16-bit Encoder Interpolator (ACC-51S) • 2 or 4 Channel Resolver (ACC-8D, OPT 7) CONNECTOR LAYOUT 8-Axis Model Shown Quadrature Feedback The Power Clipper Drive is a 3-board stack consisting of an amplifier section and the Power Clipper controller conncected by an interface board ”sandwiched” in the middle. The interface board provides connections that are common to the Power Clipper controller, but are more conveniently divided into individualised connectors. I/O GP Sinusoidal Feedback Power Inputs DC Bus Power Status Display 24V Logic Power 4.520” Motor Power Outputs E-Stop Ext. Power watchdog Analog I/0 Flag Power EQII Out User Flags Power Clipper Drive Cabled Accessories Limits/ Home Inputs Prog. Pul/Dir Out 9.475” www.deltatau.co.uk IIW Enc. GP Inputs 25 24 Standard On-Board • Analog +/-10V 13.5 bit Filtered PWM • Pulse and Direction With Accessory Stack Board • 18-Bit True DAC • Sine Wave • PWM The Power Clipper can interface with one or a combination of the following types of motor feedback devices: • 32 general-purpose TTL I/O points, direction selectable by byte: - 16-point mux port, Delta Tau I/O accessory compatible - 16-point “opto” port, Opto-22 style optically isolated modules compatible • Supports thousands of I/O points • “Handwheel” port with 2 each: - Quadrature encoder inputs - Pulse (PWM or PFM) output pairs • 4 12-Bit Analog Inputs and 1 Filtered PWM DAC Output (optional) • PWM Laser • Quadrature • Halls (60o e/120o e) • Kawasaki • Analog +/- 10VDC • LVDT / MLDT • EnDat 2.1/2.2 • Mitsubishi • Panasonic • Yaskawa • Nikon-D • BiSS-B/C • Mitutoyo • Tamagawa • SSI • HiperFace • Sinusoidal (with ACC-51S) • Resolver (with ACC-8D Opt7) CONNECTOR LAYOUT Encoders Amp Fault/ Enable Anlog In See page 30 for a more detailed overview of the Power PMAC capabilities Serial Encoders / Halls GP I/O Battery Safety & Other Features • Watchdog output • I2T protection • Encoder count error and encoder loss detection • Plus/Minus over-travel, home, and user inputs • Software over-travel limits • Warning/fatal following error limits • High speed compare outputs • Automatic brake control A powerful and compact embedded solution for cost sensitive applications EthaCAT The Power Clipper provides servo loop closure (position or torque) ouputs: GP Inputs/Outputs • Additional 4 Axes (ACC-24ES3) with optional 4 12-Bit Analog Inputs and 1 Filtered PWM DAC Output (ACC-24ES3) • 4 Channels Dual 18-Bit True DAC (ACC-8ES) • 4 Channel Direct PWM Output (ACC-8FS) • 2 or 4 Channel 16-bit Encoder Interpolator (ACC-51S) • 2 or 4 channel Resolver (ACC-8D, Opt 7) USB Output Control Encoder Support • Up to 64 Axes (& I/O) Via EtherCat • 32 In / 32 Out 12-24V Digital I/O, Optically Isolated (ACC-34AA) • 32 In / 32 Out Digital I/O for Opto-22 Style Racks (ACC-34B) • Up to 32 daisy-chained ACC-34 boards for up to 1024 inputs / 1024 Outputs • ModBus , 24 In / 24 Out 12-24V Digital I/O, Optically Isolated with optional 2x 12-Bit DAC & 2x 12-Bit ADC & 2 Relays (ACC-65ETH) 4.520” PCle Slot 5V Logic Power Serial RS232 Limits Flags EQU Expansion Connectors 9.475” www.deltatau.co.uk Micro USB The Power Clipper is a compact embedded solution for more cost sensitive and OEM applications, but packed with the power of the cutting edge Power PMAC processor and the unsurpassed custom-designed Digital Signal Processor Gate3 ASIC bundled into one compact panel-mount board. Plug-In Stack Accessories HandWheel/ PFM Power Clipper Cabled Accessories Thumbwheel GP I/O Ethernet 27 26 MIP-22 - Machine Interface Panel with 22” Touch Monitor The MIP-22 interface panel includes an industrial motherboard, 22” LCD Touch Monitor, keyboard, pointing device, top and bottom mounting locations, 4 USB2.0 ports (2 front / 2 bottom) and Ethernet connectivity, emergency stop and power buttons, and Microsoft Windows 7 Professional 64-Bit Operating System. Description Power PMAC NC 14 Software + Machine Interface Panel 22” Includes one Power PMAC NC 14 Runtime License plus the MIP-22 - Machine Interface Panel with 22” Touch Monitor Power PMAC CNC MIP22 (Machine Interface Panel 22”) The MIP22 is an industrial Machine Interface Panel with a 22” LED Touch Screen and feature rich handheld control pendant. The MIP22 features an industrial long life motherboard with all solid state media and low power consumption components. The MIP22 front panel can be customised to add application specific buttons, switches, or other devices. The MIP22 comes pre-loaded with Microsoft Windows 7 Professional. There are four externally accessible USB ports (2 front/2 bottom). Internally a Gigabit LAN port connects to PMAC devices. The Pendant communicates via Ethernet directly to the Power PMAC or through a user supplied Ethernet switch. The MIP22 was specifically designed to leverage the latest Power PMAC NC 14 Software Suite. See page 30 for a more detailed overview of the Power PMAC capabilities HARDWARE HIGHLIGHTS POWER PMAC PENDANT Industrial Motherboard Specifications: BUTTONS: • Auto Mode • MDI Mode • Reset • Single Block • Block Delete • Option Stop • Continuous Jog • Incremental/Handwheel Jog • Home • Emergency Stop (Dual Contact) • 6 User Definable Buttons • Cycle Start • Feed Hold • Jog + / Jog • ATC + / ATC • Spindle CW / CCW • Long-Life Embedded Industrial Platform through 2020 • Intel Baytrail Celeron N2930, Quad-Core, 1.83Ghz CPU • 4GB Ram (Supports DDR3L-1333 SODIMM up to 8GB) • 60GB SSD mSATA Hard Disk • Operating Temperature 0~60˚C • Mini-ITX Form Factor • 4 USB2.0 Ports (2 front / 2 bottom) • Gigabit LAN Port (Qty. 1 – Second Optional) 22“ LCD Touch Monitor Specifications: • 22“ Diagonal Elo Intellitouch LCD Touch Panel • 16:9 Active matrix TFT LCD with LED backlighting Input Voltage: • 12VDC, 100-240VAC Input Power Supply Included Front Panel: • Emergency Stop (Dual Contact) & Power Button ANALOG OVERRIDE KNOBS: • Feedrate • Rapid • Spindle Power PMAC NC 14 Software + Power PMAC Pendant Includes one Power PMAC NC 14 Runtime License plus the Power PMAC Pendant Power PMAC NC 14 Software + Machine Interface Panel 22” + Power PMAC Pendant Includes one Power PMAC NC 14 Runtime License, the MIP-22 - Machine Interface Panel with 22” Touch Monitor and the Power PMAC Pendant. OVERALL DIMENSIONS E-Stop Power PMAC CNC 14 Software Power PMAC NC 14 is a robust CNC HMI software package specifically designed to leverage the capabilities of the Power PMAC motion controller. Power PMAC 14 is available in a configurable runtime package with an optional SDK package which allows customisation via Microsoft’s Visual C# development environment. POWER PMAC NC 14 FEATURES Pendant mount (can be shown on either side) Start/Stop button (Keyboard tray can be flipped to extend other side) Mounting Brackets SELECT SWITCHES: • Axis Select (XYZABC) • Speed Select (Lo-mLo-Med-mHi-Hi) MANUAL PULSE GENERATOR: • 100 PPR Manual Pulse Feedrate Power PMAC Pendant The Power PMAC Pendant includes mode, jog, speed, reset, spindle, tool changer, and home function buttons. Analog override knobs for feed, speed, and rapid. Six user definable and legendable keys are included. All mode and user function buttons are LED illuminated. The unit communicates to the control via Ethernet. 8 foot cable. Pattern on top & bottom For wires www.deltatau.co.uk • Up to 10 axes, INCH or MM • Multiple Machine Types • Coloured NC File Editor • Mid-Program Start • Execution Monitor • Active G/M code Display • NC File Queue (Automation Enabled) • Jogging, Homing and MDI • User Login System • Foreign Language Translation • Logging and Plotting Tools • Companion Power PMAC Project • Multiple Messaging Levels • Compatible with Windows 7 or newer (64-bit or 32-bit) • Simply copy files to install (approx 5 MB total file size) • Companion PMAC projects for both Power • Choice of Rotary or Fixed Buffer • Secure SSH/SFTP communications with Power PMAC • Includes command terminals, logging and plotting tools • Utilises Block Queries for efficient communications • Coloured NC file editor handles files up to 100 MB 29 28 G3 Drive Motion Machine PC The Motion Machine PC is an industrial PC with the new Soft Power PMAC, a kernel with all the intelligence and capabilities of Delta Tau’s 7th and latest generation controller, the Power PMAC. Software PLCs, programmable in PMAC script or C, and built-in motion programs provide for complete machine logic control through a network of EtherCAT and/or MACRO drives, I/O and peripherals. Software projects migrate seamlessly from any of the Power PMAC controllers. Significant cost savings are achieved because a personal computer (already present) need not be purchased and there is none of the hardware used in traditional PMAC controllers. Protocol Support CoE • Basic I/O • DS402 Drives Hardware Features • 3x Display Ports (DVI-I,Display Port,HDMI) • 120G Solid State Drive • 4x 100/1000 Base T Ethernet Ports • 2 Ports Dedicated to Windows/Linux LAN • 2 Ports Dedicated to Motion Core (ie. 1 EtherCAT, 1 Modbus) • 6x USB ports (w/ i7 two of the ports will be USB 3.0 capable) • 2x RS232/422/485 Ports • No Fan or internal cabling • Industrial Aluminium Casing • Small Formfactor 10” x 6” x 2.7” , DIN-rail Wall mount • 9 – 36vdc (+24V @3A) (Min 72W) AT/ATX • CE, UL, CCC, FCC, C-TICK, BSMI certified • 2 Mini PCIe Slots A PC with all the intelligence and capabilities of the Power PMAC See page 30 for a more detailed overview of the Power PMAC capabilities Description G3 Direct G3 Ultra • Modular Design • Single Axis Design • Brake Control • Ease of Use • Ease of Manufacturing • Ease of Service • Robust Design • Universal Controller – 14 bit ADC Resolution – I2T Protection – Over/Under Frequency Protection – PWM Over Time Protection – IGBT Thermal Dynamic Protection (TDP®) – Over Voltage Protection – Regeneration Over Load Protection – Soft Start Over Load Protection • Short Circuit Total Protection • Short Circuit Inrush Current Limiter • Output EMI CM filter • STO Circuit • Static Brake Circuit • Shunt Resistor Output • Thermal Management – Heat Sink Design – Forced Air Cooling – Using CFD Analysis • Direct PWM Control Three Level Amplifier Power Stage • Reduced Current Ripple – Reduced power dissipation – Reduced position jitter • Distribution of switching losses on more components – Reduction of losses on each component – Allows higher PWM frequencies • Each power transistor only has half the voltage across it compared to a 2 level amplifier – Permits use of MOSFETs for over 100V bus levels – IGBT amplifiers could be used at over 1000V bus levels • Lower switching losses due to lower voltage across each power transistor • Switching during half of the commutation cycle for each power transistor – fully on or fully off during the other half • Reduction in electromagnetic interference generated due to reduced voltage swing G3 ECAT • EtherCAT Interface • Synchronous Cyclic Torque Mode • Synchronous Cyclic Position Mode G3 MACRO • MACRO Interface • Direct PWM Over MACRO • Torque Mode Over MACRO G3 SMART • Standalone Single Axis Controller/ Amplifier • Expandable over Fieldbus www.deltatau.co.uk 31 30 UMAC Accessory Cards Acc36UK Power PMAC Overview The power and flexibility of the Power PMAC allows the integration of the Power PMAC Features into virtually any kind of industrial motion control application. Motor Servo Control • Extremely fast update rates (Phase and Servo) • Standard PID with full feedforward model • Powerful automatic tuning and analyser tools • Analog, Pulse Width Modulated (PWM), Pulse Frequency Modulated (PFM), MACRO or EtherCAT Outputs • Vibration suppression filters • Multiple 7th order notch and low pass filters • Adaptive control for varying loads • Cascaded loops (force, height, camera auto-focus control) • Support for custom-written commutation routines • Support for custom-written servo routines • Custom routines directly in C or from MATLAB®/Simulink® Coordinate Systems / Forward and Inverse Kinematics • Up to 256 axes of coordinated or independent motion • Up to 128 independent coordinate systems • Up to 32 independent axes per coordinate system • Dynamic axes transformations (e.g. offsets, rotations, mirroring) • Forward/Inverse kinematics for non- linear mechanisms -User defined routines convert between tool tip coordinates and actuator positions -Permits direct specification of tool tip path Trajectory Generation - Motion Programs • Auto-coordination of multiple sets of axes • Linear, circular, rapid, position-velocity- time (PVT), LIN to PVT (curve fit), Spline move modes • Seamless blending between linear, circular and PVT modes • Automatic move until trigger (hardware input) • True S-Curve accel / decel • All move modes supported with user kinematics • Dynamic multi-block lookahead with velocity/acceleration control and jerk limit • Sub-millisecond segmentation time • Negative feedrate for true motion reversal in lookahead • Move block execution rate up to 10,000 blocks/sec • G-code, M-code, and T-code ready • Calculations and I/O synchronous to motion • Tool radius compensation, 2D or 3D Programmable Logic Control (PLCs) • Access to all registers • Trigonometric, transcendental, vector and matrix functions • 64-bit floating-point architecture optimized math • Executive functions for standalone operation • Data gathering of up to 128 hardware/ software registers per servo cycle • Program in PMAC Script • Program in ANSI C: - Real time with pre-emptive kernel routines - General purpose routines - MATLAB®/Simulink® Embedded Coder® generated code Compensation Tables • Position/torque compensation tables in 1D, 2D, or 3D with rollover and mirroring options • 1st/3rd order interpolation between points every servo cycle • Up to 256 compensation tables (64K each) • Support for superimposed compensation table results • Backlash compensation, fixed or in tables Hardware Position Capture and Compare • Specialised circuitry tying encoder counts to digital I/O • I/O on exact count (w/sub-count interpolation) at any speed (within 10 nanoseconds) • For probing, registration, measurement trigger, laser firing Gantry Control • Follower motor(s) executes leader’s trajectory • Automatic skew removal on homing • Automatic gantry cross-coupling servo correction Electronic Gearing and Cams • Powerful master/slave techniques • Position following (gearing) requires no program for motion • External time base (cam) keeps full trajectory flexibility (non-returning, limited reversal, e.g. moving web application) • Up to 256 cam tables (16k points each) - Position/torque profile(s) - Returning, forward/reverse travel - Extremely precise synchronized outputs • Requires a Single Slot • 16 Bit Resolution • 16 Channels • 16 Bit Dual Port Ram with Switch Selectable Addressing • Isolated from +5V Digital Supply • 1KHz Update Rate(All Channels) • 16KHz Single Channel Rate • Low Power consumption • +/- 10V Input • High CMR Instrumentation Amplifier I/P with protection to +-40V • 500K Input Impedance • Pin compatible with Acc36E • Optional Low Pass Filter Version • Optional daughter boards - 2 Channel Isolated CAN Interface - Isolated 16 Input 8 Output Digital I/O Interface For special versions contact us. Acc72UK • Single Slot PMAC UBus compatible. • Switch selectable addressing • Selectable Baud Rates of 1M/bit/s, 500K, 250K via Dual Port Ram • Data Transmission and Reception via Dual Port Ram • Isolated from +5V Logic Supply • Hardware: CAN bus drivers compatible with ISO 11898 standard • Software: Supports CAN specification 2.0 Part B • Supports 16 Message Slots with 11 and 29 bit I.D • Auto selects 11 bit I.D. and 29 Bit I.D. • Link selectable Termination Resistors • Front Plate connection via standard 9 way ‘D’ Plug • LED output indication for data transmission and error For special versions contact us. www.deltatau.co.uk
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