AX500 Dual Channel Digital Motor Controller User’s Manual v1.9b, June 1, 2007 visit www.roboteq.com to download the latest revision of this manual ©Copyright 2003-2007 Roboteq, Inc.
AX500 Motor Controller User’s Manual Version 1.9b.
Revision History Revision History Date Version Changes June 1, 2007 1.
AX500 Motor Controller User’s Manual Version 1.9b.
Revision History 3 SECTION 0 Important Safety Warnings 11 This product is intended for use with rechargeable batteries 11 Avoid Shorts when Mounting Board against Chassis 11 Do not Connect to a RC Radio with a Battery Attached 11 Beware of Motor Runaway in Improperly Closed Loop 11 SECTION 1 AX500 Quick Start 13 What you will need 13 Locating the Connectors 13 Connecting to the Batteries and Motors 15 Connecting to the 15-pin Connector Connecting the R/C Radio 16 16 Powering On the Controller 17
SECTION 4 General Operation 35 Basic Operation 35 Input Command Modes 35 Selecting the Motor Control Modes 36 Open Loop, Separate Speed Control 36 Open Loop, Mixed Speed Control 36 Closed Loop Speed Control 37 Close Loop Position Control 37 User Selected Current Limit Settings 38 Temperature-Based Current Limitation Battery Current vs.
Selecting the Position Mode 63 Position Sensor Selection Sensor Mounting 64 64 Feedback Potentiometer wiring 65 Feedback Potentiometer wiring in RC or RS232 Mode 65 Feedback Potentiometer wiring in Analog Mode 65 Analog Feedback on Single Channel Controllers 66 Feedback Wiring in RC or RS232 Mode on Single Channel Controllers 66 Feedback Wiring in Analog Mode on Single Channel Controllers 67 Sensor and Motor Polarity 67 Encoder Error Detection and Protection 68 Adding Safety Limit Switches 69 Using C
Operating the Controller in R/C mode 86 Reception Watchdog 87 R/C Transmitter/Receiver Quality Considerations Joystick Deadband Programming Command Control Curves 88 88 89 Left/Right Tuning Adjustment 90 Joystick Calibration 90 SECTION 10 Data Logging in R/C Mode 91 Analog Control and Operation 93 Mode Description 93 Connector I/O Pin Assignment (Analog Mode) 94 Connecting to a Voltage Source Connecting a Potentiometer 95 95 Selecting the Potentiometer Value 96 Analog Deadband Adjustment
Query Heatsink Temperatures Query Battery Voltages 111 Query Digital Inputs 112 Reset Controller 112 111 Accessing & Changing Configuration Parameter in Flash 113 Apply Parameter Changes 113 Flash Configuration Parameters List 114 Input Control Mode 115 Motor Control Mode 115 Amps Limit 116 Acceleration 116 Input Switches Function 117 RC Joystick or Analog Deadband 118 Exponentiation on Channel 1 and Channel 2 118 Left/Right Adjust 118 Default Encoder Time Base 1 and 2 119 Default Encoder Distance Divider
Logging Data to Disk 141 Connecting a Joystick 142 Using the Console 143 Viewing and Logging Data in Analog and R/C Modes 144 Loading and Saving Profiles to Disk 144 Operating the AX500 over a Wired or Wireless LAN 145 Updating the Controller’s Software 146 Updating the Encoder Software 147 Creating Customized Object Files SECTION 14 Mechanical Specifications Mechanical Dimensions 147 149 149 Mounting Considerations 150 Thermal Considerations 150 Attaching the Controller Directly to a Chassis Preca
SECTION 0 Important Safety Warnings Read this Section First The AX500 is a power electronics device. Serious damage, including fire, may occur to the unit, motors, wiring and batteries as a result of its misuse. Please review the User’s Manual for added precautions prior to applying full battery or full load power. This product is intended for use with rechargeable batteries Unless special precautions are taken, damage to the controller and/or power supply may occur if operated with a power supply alone.
Important Safety Warnings 12 AX500 Motor Controller User’s Manual Version 1.9b.
SECTION 1 AX500 Quick Start This section will give you the basic information needed to quickly install, setup and run your AX500 controller in a minimal configuration.
AX500 Quick Start The front side contains the 15-pin connector to the R/C radio, joystick or microcomputer, as well as connections to optional switches and sensors. Connector to Receiver/ Controls and sensors Status LED FIGURE 1. AX500 Controller Front View At the back of the controller (shown in the figure below) are located all the that must be connected to the batteries and the motors. Note: Both VMot terminals are connected to each other in the board and must be wired to the same voltage.
Connecting to the Batteries and Motors Connecting to the Batteries and Motors Connection to the batteries and motors is shown in the figure below and is done by connecting. Motor2 + Power on/off switch + Fuse VMot M1+ M1VCon GND GND GND M2M2+ VMot Motor1 Controller 12V to 24V Motor Battery Notes: - The Battery Power connection are doubled in order to provide the maximum current to the controller. If only one motor is used, only one set of motor power cables needs to be connected.
AX500 Quick Start Important Warning The controller includes large capacitors. When connecting the Motor Power Cables, a spark will be generated at the connection point. This is a normal occurrence and should be expected. Connecting to the 15-pin Connector The controller’s I/O are located on it’s standard 15-pin D-Sub Connector. The functions of some pins varies depending on controller model and operating mode. Pin assignment is found in the table below.
Powering On the Controller Channel 3 Channel 2 3: 4: 6: 7: 8: Channel 1 Channel 1 Command Pulses Channel 2 Command Pulses Radio battery (-) Ground Radio battery (+) Channel 3 Command Pulses 8 9 Pin 1 Wire loop bringing power from controller to RC radio 15 FIGURE 4. R/C connector wiring for 3 channels and battery elimination (BEC) This wiring - with the wire loop uncut - assumes that the R/C radio will be powered by the AX500 controller.
AX500 Quick Start The status LED will start flashing a pattern to indicate the mode in which the controller is in: RC Mode RS232 Mode No Watchdog RS232 Mode with Watchdog Analog Mode FIGURE 5. Status LED Flashing pattern during normal operation Default Controller Configuration Version 1.9b of the AX500 software is configured with the factory defaults shown in the table below.
Obtaining the Controller’s Software Revision Number • to update the controller’s software FIGURE 6. Roborun Utility screen layout To connect the controller to your PC, use the provided cable. Connect the 15-pin connector to the controller. Connect the 9-pin connector to your PC’s available port (typically COM1) use a USB to serial adapter if needed. Apply power to the controller to turn it on. Load your CD or download the latest revision of Roborun software from www.Roboteq.
AX500 Quick Start Each software version is identified with a unique number. Obtaining this number can be done using the PC connection discussed previously. Now that you know your controller’s software version number, you will be able to see if a new version is available for download and installation from Roboteq’s web site and which features have been added or improved.
SECTION 2 AX500 Motor Controller Overview Congratulations! By selecting Roboteq’s AX500 you have empowered yourself with the industry’s most versatile, and programmable DC Motor Controller for mobile robots. This manual will guide you step by step through its many possibilities. Product Description The AX500 is a highly configurable, microcomputer-based, dual-channel digital speed or position controller with built-in high power drivers.
AX500 Motor Controller Overview ate from 12 to 24VDC and can sustain up to 15A of controlled current, delivering up to 360W (approximately 0.5 HP) of useful power to each motor. The many programmable options of the AX500 are easily configured using the supplied PC utility. Once programmed, the configuration data are stored in the controller's non-volatile memory, eliminating the need for cumbersome and unreliable jumpers.
Technical features • • • • • • • User defined purpose (RS232 mode only) One Switch input configurable as Emergency stop command Reversing commands when running vehicle inverted General purpose digital input One general purpose 12V, 100mA output for accessories Up to 2 general purpose digital inputs Internal Sensors • • • • Voltage sensor for monitoring the main 12 to 24V battery system operation Voltage monitoring of internal 12V Temperature sensors on the heat sink of each power output stage Sensor
AX500 Motor Controller Overview • Watchdog for automatic motor shutdown in case of command loss (R/C and RS232 modes) • • • • Diagnostic LED Programmable motor acceleration Built-in controller overheat sensor Emergency Stop input signal and button Data Logging Capabilities 24 • 13 internal parameters, including battery voltage, captured R/C command, temperature and Amps accessible via RS232 port • • • • • Data may be logged in a PC, PDA or microcomputer Efficient heat sinking.
Power Connections SECTION 3 Connecting Power and Motors to the Controller This section describes the AX500 Controller’s connections to power sources and motors. Important Warning Please follow the instructions in this section very carefully. Any problem due to wiring errors may have very serious consequences and will not be covered by the product’s warranty. Power Connections The AX500 has three Ground, two Vmot terminals and a Vcon terminal.
Connecting Power and Motors to the Controller Note: Both VMot terminals are connected to each other in the board and must be wired to the same voltage. VCon VMot M2+ M2- 3 x Gnd M1- Motor 2 M1+ VMot Motor 1 FIGURE 7. AX500 Controller Rear View Controller Power The AX500 uses a flexible power supply scheme that is best described in Figure 8. In this diagram, it can be seen that the power for the Controller’s processor is separate from this of the motor drivers.
Controller Powering Schemes The table below shows the state of the controller depending on the voltage applied to Vcon and Vmot. TABLE 2. Controller status depending on Vcon and Vmot voltage VCon VMot Controller Status Off Off Off Off 5-24V Off 8-24V Off Controller MCU is On.
Connecting Power and Motors to the Controller There is no need to insert a separate switch on Power cables, although for safety reasons, it is highly recommended that a way of quickly disconnecting the Motor Power be provided in the case of loss of control and all of the AX500 safety features fail to activate.
Single Channel Operation In Closed Loop Speed or Position mode, beware that the motor polarity must match this of the feedback. If it does not, the motors will runaway with no possibility to stop other than switching Off the power. The polarity of the Motor or off the feedback device may need to be changed. Important Warning Make sure that your motors have their wires isolated from the motor casing.
Connecting Power and Motors to the Controller • • • • Disconnect the controller from power Open the controller’s case by removing the front bracket and sliding the cover off Place a drop of solder on the PCB jumper pads show in Place the cover and bracket back Before paralleling the outputs, • Place the load on channel 1 and verify that it is activated by commands on channel 1. • Then place the load on channel 2 and verify that is also activated to commands on channel 1.
Wire Length Limits Fuses are typically slow to blow and will thus allow temporary excess current to flow through them for a time (the higher the excess current, the faster the fuse will blow). This characteristic is desirable in most cases, as it will allow motors to draw surges during acceleration and braking. However, it also means that the fuse may not be able to protect the controller.
Connecting Power and Motors to the Controller It is therefore essential that the AX500 be connected to rechargeable batteries. If a power supply is used instead, the current will attempt to flow back in the power supply during regeneration, potentially damaging it and/or the controller. Regeneration can also cause potential problems if the battery is disconnected while the motors are still spinning.
Using the Controller with a Power Supply Using the Controller with a Power Supply Using a transformer or a switching power supply is possible but requires special care, as the current will want to flow back from the motors to the power supply during regeneration. As discussed in “Power Regeneration Considerations” on page 31, if the supply is not able to absorb and dissipate regenerated current, the voltage will increase until the overvoltage protection circuit cuts off the motors.
Connecting Power and Motors to the Controller 34 AX500 Motor Controller User’s Manual Version 1.9b.
Basic Operation General Operation SECTION 4 This section discusses the controller’s normal operation in all its supported operating modes.
General Operation Selecting the Motor Control Modes For each motor, the AX500 supports multiple motion control modes. The controller’s factory default mode is Open Loop Speed control for each motor. The mode can be changed using any of the methods described in “Loading, Changing Controller Parameters” on page 134. Open Loop, Separate Speed Control In this mode, the controller delivers an amount of power proportional to the command information. The actual motor speed is not measured.
Selecting the Motor Control Modes Controller FIGURE 14. Effect of commands to motors examples in mixed mode Closed Loop Speed Control In this mode, illustrated in Figure 16, an analog tachometer is used to measure the actual motor speed. If the speed changes because of changes in load, the controller automatically compensates the power output. This mode is preferred in precision motor control and autonomous robotic applications.
General Operation Position Feedback Position Sensor Gear box FIGURE 16. Motor with potentiometer assembly for Position operation User Selected Current Limit Settings The AX500 has current sensors at each of its two output stages. Every 16 ms, this current is measured and a correction to the output power level is applied if higher than the user preset value. The current limit may be set using the supplied PC utility. Using the PC utility is it possible to set the limit with a 0.125A granularity from 1.
Battery Current vs. Motor Current The numbers in the table are the max Amps allowed by the controller at a given temperature point. If the Amps limit is manually set to a lower value, then the controller will limit the current to the lowest of the manual and temperature-adjusted max values. This capability ensures that the controller will be able to work safely with practically all motor types and will adjust itself automatically for the various load and environmental conditions.
General Operation Vbat Off Motor On FIGURE 17. Current flow during operation On Off I mot Avg I bat Avg FIGURE 18. Instant and average current waveforms The relation between Battery Current and Motor current is given in the formula below: Motor Current = Battery Current / PWM Ratio Example: If the controller reports 10A of battery current while at 10% PWM, the current in the motor is 10 / 0.1 = 100A. Important Warning Do not connect a motor that is rated at a higher current than the controller.
Programmable Acceleration Programmable Acceleration When changing speed command, the AX500 will go from the present speed to the desired one at a user selectable acceleration. This feature is necessary in order to minimize the surge current and mechanical stress during abrupt speed changes. This parameter can be changed by using the controller’s front switches or using serial commands.
General Operation TABLE 4. Acceleration setting table Acceleration Setting Using RS232 Acceleration Setting Using Switches %Acceleration per 16ms Time from 0 to max speed 15 Hex - 17.97% 0.089 second 05 Hex 5 18.75% 0.085 second When configuring the acceleration parameter using the Roborun utility, four additional acceleration steps can be selected between the six ones selectable using the switch, extending the slowest acceleration to 2.04 seconds from 0 to max speed.
Left / Right Tuning Adjustment % Forward (Motor Output) 100 80 Logarithmic Strong Logarithmic Weak 60 Linear (default) Exponential Weak Exponential Strong 100 80 60 20 0 40 - 20 - 40 - 60 20 - 80 - 100 40 % Command Input 20 Deadband 40 60 80 100 % Reverse FIGURE 19. Exponentiation curves The AX500 is delivered with the “linear” curves selected for both joystick channels.
General Operation is found on all R/C transmitters, and which is actually an offset correction, the Left/Right Adjustment is a true multiplication factor as shown in Figure 20 100 80 60 60 40 40 20 40 40 60 60 80 5.25% 3% 100 % Reverse 0% % Forward (Motor Output) 100 80 0 20 60 % Command Input - 20 - 40 - 60 20 - 80 - 100 100 80 60 20 0 40 - 20 - 40 - 60 - 80 20 40 80 - 100 % Forward (Motor Output) 0% -3% -5.
Activating Brake Release or Separate Motor Excitation TABLE 6. Left/Right Adjustment Parameter selection Parameter Value Speed Adjustment Parameter Value Speed Adjustment 5 -1.5% 12 4.5% 6 -0.75% 14 5.25% Activating Brake Release or Separate Motor Excitation The controller may be configured so that the Output C will turn On whenever one of the two motors is running. This feature is typically used to activate the mechanical brake release sometimes found on motors for personal mobility systems.
General Operation Special Use of Accessory Digital Inputs The AX500 includes two general purpose digital inputs identified as Input E and Input F. The location of these inputs on the DB15 connector can be found in the section “I/O List and Pin Assignment” on page 50, while the electrical signal needed to activate them is shown on “Connecting Switches or Devices to Input F” on page 52. By default, these inputs are ignored by the controller.
AX500 Connections SECTION 5 Connecting Sensors and Actuators to Input/Outputs This section describes the various inputs and outputs and provides guidance on how to connect sensors, actuators or other accessories to them. AX500 Connections The AX500 uses a set of power wires (located on the back of the unit) and a DB15 connector for all necessary connections. The diagram on the figure below shows a typical wiring diagram of a mobile robot using the AX500 controller.
Connecting Sensors and Actuators to Input/Outputs 2 4 1 3 3 6 5 7 9 8 1- DC Motors 6- 2- Optional sensors: - Tachometers (Closed loop Speed mode) - Potentiometers (Servo mode) R/C Radio Receiver, microcomputer, or wireless modem 7- Command: RS-232, R/C Pulse 8- Miscellaneous I/O 9- Running Inverted, or emergency stop switch 3- Motor Power supply wires 4- Logic Power supply wire (connected optionally)5- Controller FIGURE 21.
AX500’s Inputs and Outputs When the controller operates in modes that do not use these I/O, these signals become available for user application. Below is a summary of the available signals and the modes in which they are used by the controller or available to the user. TABLE 7.
Connecting Sensors and Actuators to Input/Outputs I/O List and Pin Assignment The figure and table below lists all the inputs and outputs that are available on the AX500. 9 15 Pin1 8 FIGURE 22. Controller’s DB15 connector pin numbering TABLE 8.
Connecting devices to Output C TABLE 8.
Connecting Sensors and Actuators to Input/Outputs Important warning: This output is unprotected. If your load draws more than 100mA, permanent damage may occur to the power transistor inside the controller. Overvoltage spikes induced by switching inductive loads, such as solenoids or relays, will destroy the transistor unless a protection diode is used. Connecting Switches or Devices to Input E Input E is a general purpose, digital input. This input is only available when in the RS232 and Analog modes.
Connecting Switches or Devices to EStop/Invert Input +5V Out 14 +5V Out 14 +5V In 7 10kOhm Input F 4 10kOhm 10kOhm Input F 4 +5V In 7 Internal Buffer GND In 6 Internal Buffer 10kOhm GND In 6 GND Out 5 GND Out 5 FIGURE 25. Switch wiring to Input F The status of Input F can be read in the RS232 mode with the ?i command string. The controller will respond with three sets of 2 digit numbers.
Connecting Sensors and Actuators to Input/Outputs +5V 14 AX2500 Internal Buffer and Resistor 10kOhm Input EStop/Inv 15 Ground 5 FIGURE 26. Emergency Stop / Invert switch wiring The status of the EStop/Inv can be read at all times in the RS232 mode with the ?i command string. The controller will respond with three sets of 2 digit numbers. The status of the ES/Inv Input is contained in the last set of numbers and may be 00 to indicate an Off state, or 01 to indicate an On state.
Connecting Tachometer to Analog Inputs Connecting the potentiometer to the controller is as simple as shown in the diagram on Figure 28. +5V 14 Ana 1: Ana 2: Ana 3: Ana 4: 11 10 12 8 Internal Resistors and Converter 47kOhm A/D 10kOhm 10kOhm 47kOhm Ground 5 FIGURE 28. Potentiometer wiring in Position mode The potentiometer must be attached to the motor frame so that its body does not move in relationship with the motor. The potentiometer axle must be firmly connected to the gear box output shaft.
Connecting Sensors and Actuators to Input/Outputs eter is used to scale the tachometer output voltage to -2.5V (max reverse speed) and +2.5V (max forward speed). The two 1kOhm resistors form a voltage divider that sets the idle voltage at mid-point (2.5V), which is interpreted as the zero position by the controller. The voltage divider resistors should be of 1% tolerance or better. To precisely adjust the 2.5V midpoint value it is recommended to add a 100 ohm trimmer on the voltage divider.
Connecting External Thermistor to Analog Inputs Connecting External Thermistor to Analog Inputs Using external thermistors, the AX500 can be made to supervise the motor’s temperature and adjust the power output in case of overheating. Connecting thermistors is done according to the diagram show in Figure 30. The AX500 is calibrated using a 10kOhm Negative Coefficient Thermistor (NTC) with the temperature/resistance characteristics shown in the table below. TABLE 11.
Connecting Sensors and Actuators to Input/Outputs 100 Analog Input Reading 50 0 -50 -100 11 0 10 0 90 80 70 60 50 40 30 20 10 0 -1 0 -2 0 -150 Temperature in Degrees C FIGURE 31. Signed binary reading by controller vs. NTC temperature To read the temperature, use the ?p command to have the controller return the A/D converter’s value. The value is a signed 8-bit hexadecimal value. Use the chart data to convert the raw reading into a temperature value.
Connecting User Devices to Analog Inputs Measured volts = ((controller reading + 128) * 0.255) -5 Note: The A/D converter’s reading is returned by the ?p command and is a signed 8-bit hexadecimal value. You must add 128 to bring its range from -127/+127 to 0/255. Connecting User Devices to Analog Inputs The two analog inputs can be used for any other purpose. The equivalent circuit for each input is shown in Figure 33.
Connecting Sensors and Actuators to Input/Outputs using the ?m query, or during data logging (see “Analog and R/C Modes Data Logging String Format” on page 126) The analog value that is reported will range from 0 (warmest) to 255 (coldest). Because of the non-linear characteristics of NTC thermistors, the conversion from measured value to temperature must be done using the correction curve below.
Internal Heatsink Temperature Sensors HiTemp = LoTemp + 5; lobound = TempTable[i]; hibound = TempTable[i+1]; temp = LoTemp + (5 * ((AnaValue - lobound)*100/ (hibound - lobound)))/100; return temp; } } AX500 Motor Controller User’s Manual 61
Connecting Sensors and Actuators to Input/Outputs 62 AX500 Motor Controller User’s Manual Version 1.9b.
Mode Description Closed Loop Position Mode SECTION 6 This section describes the AX500 Position mode, how to wire the motor and position sensor assembly and how to tune and operate the controller in this mode. Mode Description In this mode, the axle of a geared-down motor is coupled to a position sensor that is used to compare the angular position of the axle versus a desired position. The controller will move the motor so that it reaches this position.
Closed Loop Position Mode Position Sensor Selection The AX500 may be used with the following kind of sensors: • • Potentiometers Hall effect angular sensors The first two are used to generate an analog voltage ranging from 0V to 5V depending on their position. They will report an absolute position information at all times. Sensor Mounting Proper mounting of the sensor is critical for an effective and accurate position mode operation. Figure 35 shows a typical motor, gear box, and sensor assembly.
Feedback Potentiometer wiring manner that will allow it to turn throughout much of its range, when the mechanical assembly travels from the minimum to maximum position. Important Notice: Potentiometers are mechanical devices subject to wear. Use better quality potentiometers and make sure that they are protected from the elements. Consider using a solid state hall position sensor in the most critical applications.
Closed Loop Position Mode Roborun will detect the new hardware revision and display Rev B on the screen. 14 2k 2k 2k - 10k +5V 2k - 10k Command 1 Command 2 Feedback 1 Feedback 2 5 Ground 11 Ana1 10 Ana2 12 Ana3* 8 Ana4* FIGURE 37. Pot wiring for Analog Command and Analog Feedback Analog inputs 3 and 4 have different characteristics than inputs 1 and 2, and so require a lower resistance potentiometer in order to guarantee accuracy.
Sensor and Motor Polarity Feedback Wiring in Analog Mode on Single Channel Controllers When the controller is configured in Analog mode, the analog input 1 is used for commands while the analog input 4 is used for feedback. Roborun will detect the new hardware revision and display Rev B on the screen. 14 2k 2k - 10k Command Feedback +5V 5 Ground 11 Ana1 10 Ana2 12 Ana3* 8 Ana4* FIGURE 39.
Closed Loop Position Mode 2. Configure the controller in Position Mode using the PC utility. 3. Loosen the sensor’s axle from the motor assembly. 4. Launch the Roborun utility and click on the Run tab. Click the “Start” button to begin communication with the controller. The sensor values will be displayed in the Ana1 and Ana2 boxes. 5. Move the sensor manually to the middle position until a value of “0” is measured using Roborun utility 6. Verify that the motor sliders are in the “0” (Stop) position.
Adding Safety Limit Switches Adding Safety Limit Switches The Position mode depends on the position sensor providing accurate position information. If the potentiometer is damaged or one of its wire is cut, the motors may spin continuously in an attempt to reach a fictitious position. In many applications, this may lead to serious mechanical damage.
Closed Loop Position Mode required for each motor. Additional switches may be added as needed for the second motor and/or for a manual Emergency Stop. Since very low current flows through the switches, these can be small, low cost switches. The principal restriction of this technique is that it depends on the controller to be fully functioning, and that once a switch is activated, the controller will remain inactive until the switch is released. In most situations, this will require manual intervention.
PID tuning in Position Mode The resulting error value is then multiplied by a user selectable Proportional Gain. The resulting value becomes one of the components used to command the motor. The effect of this part of the algorithm is to apply power to the motor that is proportional with the distance between the current and desired positions: when far apart, high power is applied, with the power being gradually reduced and stopped as the motor moves to the final position.
Closed Loop Position Mode tuned PID is a motor that reaches the desired position quickly without overshoot or oscillation. Because many mechanical parameters such as motor power, gear ratio, load and inertia are difficult to model, tuning the PID is essentially a manual process that takes experimentation. The Roborun PC utility makes this experimentation easy by providing one screen for changing the Proportional, Integral and Differential gains and another screen for running and monitoring the motors.
Mode Description Closed Loop Speed Mode SECTION 7 This section discusses the AX500 Close Loop Speed mode. Mode Description In this mode, an analog speed sensor measures the actual motor speed and compares it to the desired speed. If the speed changes because of changes in load, the controller automatically compensates the power output. This mode is preferred in precision motor control and autonomous robotic applications.
Closed Loop Speed Mode Tachometer or Encoder Mounting Proper mounting of the speed sensor is critical for an effective and accurate speed mode operation. Figure 62 shows a typical motor and tachometer or encoder assembly. Analog Tachometer Speed feedback FIGURE 43.
Adjust Offset and Max Speed Important Warning: If there is a polarity mismatch, the motor will turn in the wrong direction and the speed will never be reached. The motor will turn continuously at full speed with no way of stopping it other than cutting the power or hitting the Emergency Stop buttons. Determining the right polarity is best done experimentally using the Roborun utility (see “Using the Roborun Configuration Utility” on page 131) and following these steps: 1.
Closed Loop Speed Mode To set the potentiometer, use the Roborun utility to run the motors at the desired maximum speed while in Open Loop mode (no speed feedback). While the tachometer is spinning, adjust the potentiometer until the analog speed value read is reaching 126. Note: The maximum desired speed should be lower than the maximum speed that the motors can spin at maximum power and no load.
PID tuning in Speed Mode Proportional Gain x E= Error Desired Speed Tachometer dE dt x Σ Output A/D Measured Speed or Integral Gain Optical Encoder dE dt x Differential Gain FIGURE 45. PID algorithm used in Speed mode PID tuning in Speed Mode As discussed above, three parameters - Proportional Gain, Integral Gain, and Differential Gain - can be adjusted to tune the Closed Loop Speed control algorithm.
Closed Loop Speed Mode 78 AX500 Motor Controller User’s Manual Version 1.9b.
Diagnostic LED Normal and Fault Condition LED Messages SECTION 8 This section discusses the meaning of the various messages and codes that may be displayed on the LED display during normal operation and fault conditions. Diagnostic LED The AX500 features a single diagnostic LED which helps determine the controller’s operating mode and signal a few fault conditions. The LED is located near the edge of the board, next to he 15-pin connector.
Normal and Fault Condition LED Messages Output Off / Fault Condition The controller LED will tun On solid to signal that the output stage is off as a result of a any of the recoverable conditions listed below. Temporary Fault Permanent Error FIGURE 47. Status LED Flashing pattern during faults or other exceptions • • • • Over temperature Over Voltage Under Voltage “Dead man” switch activation (See “Using the Inputs to turn Off/On the Power MOSFET transistors” on page 46.
Mode Description SECTION 9 R/C Operation This section describes the controller’s wiring and functions specific to the R/C radio control mode. Mode Description The AX500 can be directly connected to an R/C receiver. In this mode, the speed or position information is contained in pulses whose width varies proportionally with the joysticks’ positions. The AX500 mode is compatible with all popular brands of R/C transmitters.
R/C Operation Selecting the R/C Input Mode The R/C Input Mode is the factory default setting. If the controller has been previously set to a different Input Mode, it will be necessary to reset it to the R/C mode using the serial port and the PC utility. See “Using the Roborun Configuration Utility” on page 131, and “Accessing & Changing Configuration Parameter in Flash” on page 113 Connector I/O Pin Assignment (R/C Mode) 9 15 Pin1 8 FIGURE 49.
R/C Input Circuit Description R/C Input Circuit Description The AX500 R/C inputs are directly connected to the MCU logic. Figure 50 shows an electrical representation of the R/C input circuit. +5V Output R/C Channel 1 R/C Channel 2 R/C Channel 3 14 Controller Power 3 4 MCU 8 5-13 Controller Ground FIGURE 50. AX500 R/C Input equivalent circuit Supplied Cable Description The AX500 is delivered with a custom cable with the following wiring diagram: 1 2 3 1 8 9 15 FIGURE 51.
R/C Operation 3 2 1 . FIGURE 52. RC connection cable Powering the Radio from the controller The 5V power and ground signals that are available on the controller’s connector may be used to power the R/C radio. The wire loop is used to bring the controller’s power to the the radio as well as for powering the optocoupler stage. Figure 53 below shows the connector wiring necessary to do this. Figure 54 shows the equivalent electrical diagram.
Connecting to a Separately Powered Radio 14 Controller Power R/C Radio Power 7 R/C Radio R/C Channel 1 3 R/C Channel 2 4 R/C Channel 3 8 R/C Radio Ground 6 5-13 MCU Controller Ground FIGURE 54. R/C Radio powered by controller electrical diagram Important Warning Do not connect a battery to the radio when in this mode. The battery voltage will flow directly into the controller and cause permanent damage if its voltage is higher than 5.5V.
R/C Operation to the controller does not inject power into the controller. The figure below show the cable with the loop cut. Figure 56 shows the equivalent electrical diagram. Channel 3: Channel 2 3: 4: 6: 7: 8: Channel 1 Channel 1 Command Pulses Channel 2 Command Pulses Radio battery (-) Ground Radio battery (+) Channel 3 Command Pulses 8 9 Pin 1 Cut red loop 15 FIGURE 55.
Reception Watchdog the controller captures the full joystick movement, the AX500 defaults to the timing values shown in Figure 57. These vales can be changed and stored as new defaults. joystick position: min center max 1.05ms 0.45ms R/C pulse timing: 0.9ms FIGURE 57. Joystick position vs. pulse duration default values The AX500 has a very accurate pulse capture input and is capable of detecting changes in joystick position (and therefore pulse width) as small as 0.4%.
R/C Operation Note: the Accessory Outputs C will be turned Off when radio is lost. Important Notice about PCM Radios PCM radios have their own watchdog circuitry and will output a signal (normally a “safe condition” value) when radio communication is lost. This signal will be interpreted by the AX500 as a valid command and the controller will remain active. To benefit from the AX500’s radio detection function, you will need to disable the PCM radio watchdog.
Command Control Curves The deadband is measured as a percentage of total normal joystick travel. For example, a 16% deadband means that the first 16% of joystick motion in either direction will have no effect on the motors. TABLE 13.
R/C Operation Left/Right Tuning Adjustment When operating in mixed mode with one motor on each side of the robot, it may happen that one motor is spinning faster than the other one at identically applied power, causing the vehicle to pull to the left or to the right. To compensate for this, the AX500 can be made to give one side up to 10% more power than the other at the same settings.
Data Logging in R/C Mode Data Logging in R/C Mode Output C OFF Output C OFF Output C ON FIGURE 60. Using Channel 3 to activate accessory outputs While in R/C Mode, the AX500 will continuously send a string of characters on the RS232 output line. This string will contain 12 two-digit hexadecimal numbers representing the following operating parameters.
R/C Operation DB9 Female To PC DB15 Male To Controller 1 1 RX Data 6 9 7 10 8 11 9 12 2 2 RS232 Data Out 3 R/C Ch 1 3 4 R/C Ch 2 4 GND 5 5 13 14 15 GND 6 7 R/C GND R/C +5V 8 FIGURE 61. Modified R/C cable with RS232 output for data logging to a PC 92 AX500 Motor Controller User’s Manual Version 1.9b.
Mode Description Analog Control and Operation SECTION 10 This section describes how the motors may be operated using analog voltage commands. Mode Description The AX500 can be configured to use a 0 to 5V analog voltage, typically produced using a potentiometer, to control each of its two motor channels. The voltage is converted into a digital value of -127 at 0V, 0 at 2.5V and +127 at 5V. This value, in turn, becomes the command input used by the controller.
Analog Control and Operation Connector I/O Pin Assignment (Analog Mode) 9 15 Pin1 8 When used in the Analog mode, the pins on the controller’s DB15 connector are mapped as described in the table below TABLE 14.
Connecting to a Voltage Source Connecting to a Voltage Source The analog inputs expect a DC voltage of 0 to 5V which can be sourced by any custom circuitry (potentiometer, Digital to Analog converter). The controller considers 2.5V to be the zero position (Motor Off). 0V is the maximum reverse command and +5V is the maximum forward command. The inputs’ equivalent circuit is show in Figure 62 below. +5V 14 Internal Resistors and Converter Analog In1: pin 11 In2: pin 10 47kOhm A/D 0V = Min 2.
Analog Control and Operation +5V 14 Internal Resistors and Converter Analog Input 1 2 3 or 4 10kOhm 10 11 12 8 47kOhm A/D 10kOhm 47kOhm 13 Ground FIGURE 63. Potentiometer connection wiring diagram The controller includes two 47K ohm resistors pulling the input to a mid-voltage point of 2.5V. When configured in the Analog Input mode, this will cause the motors to be at the Off state if the controller is powered with nothing connected to its analog inputs.
Analog Deadband Adjustment Voltage at Input 5V 1K Pot 4V 3V 10K Pot 100K Pot 2V 1V 0V Min Center Max Potentiometer Position FIGURE 64. Effect of the controller’s internal resistors on various potentiometers Analog Deadband Adjustment The controller may be configured so that some amount of potentiometer or joystick travel off its center position is required before the motors activate. The deadband parameter can be one of 8 values, ranging from 0 to 7, which translate into a deadband of 0% to 16%.
Analog Control and Operation TABLE 15. Analog deadband parameters and their effects Parameter Value Pot. Position resulting in Motor Power at 0% Pot. Position resulting in Motor Power at -/+100% 3 (default) 0% to 7.1% 2.32V to 2.68V 95% 4 0% to 9.4% 2.27V to 2.74 93% 0.18V and 4.83V 5 0% to 11.8% 2.21V to 2.80V 95% 0.13V to 4.88V 6 0% to 14.2% 2.15V to 2.86V 94% 0.15V and 4.85V 7 0% to 16.5% 2.09V to 2.91V 96% 0.10V and 4.90V 0.13V to 4.
Data Logging in Analog Mode Data in Analog and R/C Modes” on page 144). It may also be stored in a PDA that can be placed in the mobile robot. The string and data format is described in “Analog and R/C Modes Data Logging String Format” on page 126. The serial port’s output can be safely ignored if it is not required in the application.
Analog Control and Operation 100 AX500 Motor Controller User’s Manual Version 1.9b.
Use and benefits of RS232 Serial (RS-232) Controls and Operation SECTION 11 This section describes the communication settings and the commands accepted by the AX500 in the RS232 mode of operations. This information is useful if you plan to write your own controlling software on a PC or microcomputer. These commands will also allow you to send commands manually using a terminal emulation program.
Serial (RS-232) Controls and Operation Connector I/O Pin Assignment (RS232 Mode) 9 15 Pin1 8 FIGURE 1. Pin locations on the controller’s 15-pin connector When used in the RS232 mode, the pins on the controller’s DB15 connector are mapped as described in the table below TABLE 16.
Cable configuration Cable configuration The RS232 connection requires the special cabling as described in the figure below. The 9pin female connector plugs into the PC (or other microcontroller). The 15-pin male connector plugs into the AX500. It is critical that you do not confuse the connector’s pin numbering. The pin numbers on the drawing are based on viewing the connectors from the front (facing the sockets or pins). Most connectors have pin numbers molded on the plastic.
Serial (RS-232) Controls and Operation DB9 Female DB9 Male 1 1 RX Data TX Data 6 6 7 7 8 8 9 9 2 3 Data Out 3 Data In 4 4 GND 2 5 5 GND FIGURE 68. RS232 extension cable/connector wiring diagram Communication Settings The AX500 serial communication port is set as follows: 9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity Communication is done without flow control, meaning that the controller is always ready to receive data and can send data at any time.
Establishing Manual Communication with a PC COM1port. You can easily change this setting to a different port from the program’s menus. Note that starting with version 1.9, the Roborun PC utility also includes a Terminal Emulation Console for communicating with the controller using raw data. See “Using the Console” on page 143.
Serial (RS-232) Controls and Operation Power up prompt from main MCU Hardware Code of main board Power up prompt from encoder MCU Hardware Code of Encoder Module FIGURE 70. Hyperterm session showing power up messages from both MCUs After this information is sent, the Encoder’s MCU will “listen” for approximately 100ms and will enter the In System Programming mode (ISP) if the letter “Z” is sent to it.
Commands Acknowledge and Error Messages RS232 Mode if default If the controller is configured in RS232 mode, it will automatically be in the RS232 mode upon reset or power up. In this case, the “OK” message is sent automatically, indicating that the controller is ready to accept commands through its serial port. Commands Acknowledge and Error Messages The AX500 will output characters in various situations to report acknowledgements or error conditions as listed below.
Serial (RS-232) Controls and Operation RS-232 Watchdog For applications demanding the highest operating safety, the controller may be configured to automatically stop the motors (but otherwise remain fully active) if it fails to receive a character on its RS232 port for more than 1 seconds. The controller will also send a “W” character every second to indicate to the microcomputer that such a time-out condition has occurred.
Controller Commands and Queries TABLE 17. Command Type Description ?p or ?P Query Read Analog Inputs 1 and 2 ?r or ?R Query Read Analog Inputs 3 and 4 ?m or ?M Query Read Heatsink Temperature ?e or ?E Query Read Battery and Internal Voltage ?i or ?I Query Read Digital Inputs Set Motor Command Value Description: Send a speed of position value from 0 to 127 in the forward or reverse direction for a given channel.
Serial (RS-232) Controls and Operation Query Power Applied to Motors Description: This query will cause the controller to return the actual amount of power that is being applied to the motors at that time. The number is a hexadecimal number ranging from 0 to +127 (0 to 7F in Hexadecimal). In most cases, this value is directly related to the command value, except in the conditions described in the notes below.
Controller Commands and Queries Query Analog Inputs Description: This query will cause the controller to return the values of the signals present at its two analog inputs. If the controller is used in close-loop speed mode with analog feedback, the values represent the actual speed measured by the tachometer. When used in position mode, the values represent the actual motor position measured by a potentiometer.
Serial (RS-232) Controls and Operation ond is the internal 12V supply needed for the controller’s microcomputer and MOSFET drivers. The values are unsigned Hexadecimal numbers ranging from 0 to 255. To convert these numbers into a voltage figure, use the formulas described in “Internal Voltage Monitoring Sensors” on page 59.
Accessing & Changing Configuration Parameter in Flash Accessing & Changing Configuration Parameter in Flash It is possible to use RS232 commands to examine and change the controller’s parameters stored in Flash. These commands will appear cryptic and difficult to use for manual parameter setting. It is recommended to use the Graphical configuration utility described in “Using the Roborun Configuration Utility” on page 131.
Serial (RS-232) Controls and Operation Reply: + Success, changed parameters are now active - if error Table 18 below lists the complete set of configuration parameters that may be accessed and changed using RS232 commands. Flash Configuration Parameters List TABLE 18.
Accessing & Changing Configuration Parameter in Flash TABLE 18. Configuration parameters in Flash Param Address Description Active after 1D Joystick Max 2 LS Instant F0 Amps Calibration Parameter 1 Reset F1 Amps Calibration Parameter 2 Reset These parameters are stored in the controller’s Flash memory and are not intended to be changed at runtime. Important Notice The above parameters are stored in the MCU’s configuration flash.
Serial (RS-232) Controls and Operation This parameters selects the various open loop and closed loop operating modes as well as the feedback method.
Accessing & Changing Configuration Parameter in Flash Bit 7:0 Definition See pages 0 = very slow See “Programmable Acceleration” on page 41 for complete list of acceptable values 1 = slow (2) = medium-slow (default) 3 = medium 4 = fast 5 = fastest Input Switches Function Address: Access: Effective: ^04 Read/Write After Reset or ^FF This parameter enables and configures the effect of the controller’s Digital Inputs and other settings.
Serial (RS-232) Controls and Operation RC Joystick or Analog Deadband Address: Access: Effective: ^06 Read/Write After Reset or ^FF This parameter configures the amount of joystick or potentiometer motion can take place around the center position without power being applied to the motors.
Accessing & Changing Configuration Parameter in Flash This parameter configures the compensation curve when motors are spinning in one direction vs. the other. Bit 7:0 Definition See pages 0, 1, ..., 6 = -5.25%, -4.5%, ...,-0.75% page 43 (7) = no adjustment (default) 8, ..., D, E** = +0.75, ..., +4.5%, +5.
Serial (RS-232) Controls and Operation Default PID Gains Address: Access: Effective: ^0F - Proportional Gain ^10 - Integral Gain ^11 - Derivative Gain Read/Write After Reset or ^FF These parameters are the Gains values that are loaded after the controller is reset or powered on. These Gains apply to both channels. Gains can be changed at Runtime, and values can be different for each channel using separate commands (see page 122). Gains values are integer number from 0 to 63.
Reading & Changing Operating Parameters at Runtime Gains values are integer number from 0 to 63. This number is divided by 8 internal so that each increment equals 0.125. Bit 7:0 Definition See pages 8 bit value. Two registers used to form one 16 bit number for each Joystick parameter.
Serial (RS-232) Controls and Operation TABLE 19. Runtime R/W Parameters list Location Function R/W 8B Current Amps limit 1 R Only 8C Current Amps limit 2 R Only Important Notice: Do not write in the locations marked as Read Only. Doing so my cause Controller malfunction. Operating Modes Registers Address: Access: Effective: ^80 - Channel 1 ^81 - Channel 2 Read/Write Instantly Modifying the bits in the Operating Mode registers will change the controller’s operating modes on-the fly.
Reading & Changing Operating Parameters at Runtime Actual Gain value is the value contained in the register divided by 8. Changes take effect at the controller’s next 16ms iteration loop. After reset, these bits get initialized according to the configuration contained in Flash. PWM Frequency Register Address: Access: Effective: ^88 Read/Write Instantly The controller’s default 16kHz PWM Frequency can be changed to a higher value in fine increments.
Serial (RS-232) Controls and Operation Controller Identification Register Address: Access: Effective: ^8A Read Only Instantly This register may be used to query the Controller’s model and some of its optional hardware configurations. TABLE 22.
Automatic Switching from RS232 to RC Mode Automatic Switching from RS232 to RC Mode In many computer controlled applications, it may be useful to allow the controller to switch back to the RC mode. This would typically allow a user to take over the control of a robotic vehicle upon computer problem. While the AX500 can operate in either RC Radio or RS232 mode, the RS232 Data Input and RC Pulse Input 1 share the same pin on the connector.
Controller is on, Radio is turned Off (or Radio On with RC ch3 Off) • • • Relay deactivates. RS232 is now connected to shared input. String of Carriage Returns now received by controller. Computer looks for OK prompt to detect that the RS232 mode is now active. Note: Wait 5 seconds for the capacitor to discharge before attempting to switch to RC mode if doing this repeatedly. Controller will not reset otherwise.
Decimal to Hexadecimal Conversion Table logging purposes. This cable has a 15-pin male connector and 3 15-pin connectors. The Front View Rear View Female to PC with RxData Only 4 1 3 2 Cut Wire Female to PC with Rx and Tx Data 1 Female to Application 1 Male to controller 1 1 FIGURE 73. ASCII string sent by the controller while in R/C or Analog mode male connector plugs into the controller.
TABLE 23.
Decimal to Hexadecimal Conversion Table TABLE 24.
AX500 Motor Controller User’s Manual Version 1.9b.
SECTION 13 Using the Roborun Configuration Utility A PC-based Configuration Utility is available, free of charge, from Roboteq. This program makes configuring and operating the AX500 much more intuitive by using pulldown menus, buttons and sliders. The utility can also be used to update the controller’s software in the field as described in “Updating the Controller’s Software” on page 146.
Using the Roborun Configuration Utility • after the installation is complete, run the program from your Start Menu > Programs > Roboteq The controller does not need to be connected to the PC to start the Utility.
Roborun Frame, Tab and Menu Descriptions Roborun Frame, Tab and Menu Descriptions 2 1 5 4 3 FIGURE 75. Roborun screen layout The Roborun screen contains the four main set of commands and information frames described below: 1- Program Revision Number This is the revision and date of the Roborun utility. It is recommended that you always verify that you have the latest revision of the utility from Roboteq’s web site at www.roboteq.
Using the Roborun Configuration Utility This is the program’s main frame and includes several types of tabs, each of which has several buttons, menus and other User Interface objects. These tabs and the functions they contain are described in detail in the following sections. Navigate from one set of commands to another by clicking on the desired tab. 4- File and Program Management Commands This frame contains a variety of buttons needed to load and save the parameters from and to the controller or disk.
Loading, Changing Controller Parameters When starting Roborun, this screen is filled with the default values. If the controller is connected to your PC, Roborun will automatically detect it and ask you if you wish to read its settings. The controller’s setting in the PC at can be read any other time by pressing the “Load from Controller” button. After changing a parameter, you must save it to the controller manually by pressing the “Save to Controller” button. Control Settings 1 2 3 4 5 6 FIGURE 77.
Using the Roborun Configuration Utility 4- Emergency Stop or Invert Switch Select This pull down menu allows the selection of the controller’s response to changes on the optional switch input: Emergency Stop, Invert Commands, or no action. See “Emergency Stop using External Switch” on page 45 and “Inverted Operation” on page 45. 5- Effect of Digital Inputs This pull down menu allows the selection of the controller’s response to changes on either of the two digital inputs.
Loading, Changing Controller Parameters accelerate a motor from idle to maximum speed. See “Programmable Acceleration” on page 41. Analog or R/C Specific Settings 1 2 FIGURE 79. Power settings screen The screen shown in Figure 79 slightly changes in function of whether or not the Analog Input mode is selected. If the Analog Input mode is selected on the main screen, then this page is used to set the Analog Deadband value.
Using the Roborun Configuration Utility Closed Loop Parameters FIGURE 80. Closed Loop parameter setting screen The screen shown in Figure 80 is used to set the Proportional, Integral and Differential gains needed for the PID algorithm. These PID gains are loaded after reset and apply to both channels. Gains can be changed individually for each channels and on-the-fly using RS232 commands. These parameters are used in the Position mode (see page 63) and the Closed Loop speed mode (see page page 73).
Running the Motors Running the Motors The Roborun utility will let you exercise and monitor the motors, sensors and actuators using a computer. This feature is particularly useful during development as you will be able to visualize, in real-time, the robot’s Amps consumption and other vital statistics during actual operating conditions. Figure 81 shows the Run Screen and its numerous buttons and dials. 1 7 4 3 2 6 8 5 FIGURE 81.
Using the Roborun Configuration Utility The Amps field reports the current measured at each channel. The Peak Amps field will store the highest measured Amp value from the moment the program began or from the time at which the peak was reset using the Clr Peak button. Motor Amps is a calculated estimated value based on the batter amps and the current power level. See “Battery Current vs. Motor Current” on page 39. The Power field displays the power level that is actually being applied to the motor.
Running the Motors 6- Input Status and Output Setting This section includes two check boxes and three color squares. The check marks are used to activate either of the controller’s two outputs. The color blocks reflect the status of the three digital inputs present on the controller. Black represents a “0”level. Green represents a “1” level. 7- Data Logging and Timer A timer is provided to keep track of time while running the motors.
Using the Roborun Configuration Utility line of the save file contains the Header names. Each following line contains a complete set of parameters. The Header name, order and parameter definition is shown in Table 25: TABLE 25.
Using the Console A joystick test program name “Joytest” is automatically installed in the Start menu when installing the Roborun utility. This program may be used to further verify that the joystick is properly installed in the PC and is fully operational. Using the Console The console screen allows you to communicate with the controller using raw ASCII data. This function is very useful for troubleshooting when normal communication with Roborun cannot be established (e.g.
Using the Roborun Configuration Utility troller Commands and Queries” on page 108 for the complete list of commands and queries.3- Keep Watchdog Alive If the controller is in the RS232 mode with the watchdog enabled, then after 1 second of inactivity motors will be stopped if they were one and a “W” character will be sent to the terminal. When this checkbox is checked, Roborun will send a Null character to the controller on a regular basis so that the watchdog time-out is never reached.
Operating the AX500 over a Wired or Wireless LAN Operating the AX500 over a Wired or Wireless LAN The Roborun utility supports connection and operation of the AX500 controller over a Wired or Wireless TCP/IP network. This feature makes it easy to tele-operate and monitor the controller across a lab or across the globe via Internet. To operate over the network, two computers are required, as show in Figure 83 below. The top computer is connected to the controller via its COM port.
Using the Roborun Configuration Utility FIGURE 84. Roboserver screenshot when idle Note that it is not possible to use this configuration to change the controller’s parameters or update the controller’s software. Updating the Controller’s Software The AX500’s operating software can be easily upgraded after it has left the factory. This feature makes it possible to add new features and enhance existing ones from time to time.
Creating Customized Object Files Notes: The Updating utility will automatically detect whether the new software is intended for the main or encoder’s MCU and program one or the other accordingly. It is a good idea to load the controller’s parameters into the PC and save them to disk prior to updating the software. After the new software in transferred to the controller, you can use the “Load Parameters from Disk” function and transfer them to the controller using the “Save to Controller” button.
Using the Roborun Configuration Utility FIGURE 85. Objectmaker creates controller firmware with custom defaults Creating a custom object file can easily be done using the Objectmaker utility. This short program is automatically installed in the Start menu when installing the Roborun utility. 148 1- Use the Roborun utility to create and save to disk a profile with all the desired parameter value. 2- Launch Objectmaker from the Start menu.
Mechanical Dimensions SECTION 14 Mechanical Specifications This section details the mechanical characteristics of the AX500 controller. Mechanical Dimensions The AX500 is delivered as an assembled and tested Printed Circuit Board. The board includes connectors for direct connection to the Optical Encoders and to the Radio, Joystick or microcomputer on one side. On the other side can be found Fast-on tabs for highcurrent connection to the batteries and motors.
Mechanical Specifications 4.20" (106.7mm) 0.15" (3.8mm) 0.15" (3.8mm) 0.15" (3.8mm) 0.15" (3.8mm) 1.25" (31.75mm) 4.20" (106.7mm) 2.00" (50.8mm) 1.10" (74.0mm) 0.15" (3.8mm) 0.15" (3.8mm) 1.875" (47.6mm) 0.15" (3.8mm) 2.90" (73.7mm) FIGURE 87. AX500 top view and dimensions Mounting Considerations The AX500’s heatsink is located at the bottom of the board. This requires therefore that the board be mounted with spacers that are at minimum 0.6” (15mm). 0.6" (15mm) or longer spacer FIGURE 88.
Attaching the Controller Directly to a Chassis board against a vertical surface as shown in the figure below will ensure a better natural convection flow and is, therefore, recommended. FIGURE 89. Mount the controller against a vertical surface to maximize convection flow For high current applications, it is possible that the controller may heat up faster and to a higher temperature than can be dissipated by the using natural convection alone.
Mechanical Specifications Note that the back of the PCB has large copper areas exposed just under the power MOS Board Thermal Pad Metal Interposer Metal Chassis Spacer FIGURE 90. Mount the controller without heatsink against a chassis area. It is critical that the interposer either is insulated (example: anodized aluminum) or a layer of thermal conducting - but electrically insulating - pad is used. Failure to do so will cause a short among the drains of the power MOS and the board will fail.
Wire Dimensions Wire Dimensions The AX500 uses screw terminals for the power connections to the batteries and motors. These connectors are rated to support the controller’s maximum specified current. It is recommended that you use AWG 14 wire for all power connections to ground, batteries and motors. VCon wire and its return Ground may be much thinner as they will never carry current in excess of a couple of milliamperes. Weight Controller weight is 3.
Mechanical Specifications 154 AX500 Motor Controller User’s Manual Version 1.9b.