Galil motion control product workshop january 2012 presentation eis ver

Galil Product Workshop
January 2012

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ELECTROMATE
Toll Free Phone (877) SERVO98
Toll Free Fax (877) SERV099
www.electromate.com
sales@electromate.com

About the Company

Established Reputation and Long History of Success
• Founded in 1983 by Jacob Tal and Wayne Baron
• Introduced 1st microprocessor-based servo controller
• Profitable for over 100 consecutive quarters
• Delivered over 500,000 controllers world-wide

Excellent Technical Support and Service
• World-wide network of factory-trained reps & distributors
• Technical support team with over 100 man-years of motion
control experience
• On-line support tools at www.galilmc.com

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The Galil Support Team

• Live, prompt technical
support

• Over 100 years of combined
motion control experience

• Degreed MEs and EEs

“The mission of Galil’s experienced Applications Department is to provide
prompt and accurate technical assistance to help OEMs successfully deliver
their products to market ”

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We Are Here to Help!

• LIVE Tech Support Provided at Galil headquarters:

Address: 270 Technology Way, Rocklin, CA 95765
Email: support@galilmc.com
Toll Free: 800-377-6329
Phone: 916-626-0101
Fax: 916-626-0102
Hours: 8am to 5pm PST, Monday through Friday

• Please provide:
– Name
– Company
– Address
– Phone/Email
– Galil Products and revisions
– Problem
– Error messages
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Many On-Line Tools at www.galilmc.com

Galil’s free online support tools include:
• White Papers & application notes
http://www.galilmc.com/support/application-notes.php
• On-Line tutorials on motion control
http://www.galilmc.com/learning/tutorials.php
• MotionCodetm Toolkit with downloadable programs and code
http://www.galilmc.com/learning/motioncode.php
• MotorSizertm Software for easy sizing of motion systems
http://www.galilmc.com/learning/motorsizer.php
• HelloGaliltm Quick start for PC programming languages
http://www.galilmc.com/learning/hellogalil.php
• Bulletin Board with subject search
http://www.galilmc.com/forums/ubbthreads.php
• ServoTrends Newsletter Archives
http://www.galilmc.com/support/servotrends.php
• Product catalog with specs and pricing
http://www.galilmc.com/support/catalog.php
• Customer applications and videos
http://www.galilmc.com/support/smartmoves.php
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About the Products

• Leading Edge
– 32 bit microcomputer with high-speed processing
– On-board program memory with multitasking
• Easy to Use
– 2 letter, English-like instructions
– Software tools for servo tuning

• Cost Effective
– 100 qty price guarantee; as low as $100/axis
• Flexible
– Available in 1 through 8-axis configurations
– Configurable for steppers and servos on any axis
– Box-level or card-level; PCI, RS232, and Ethernet
• Easy to Customize
– Firmware & hardware customized to specifications

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Features- Handles any Mode of Motion

• Point-to-Point Positioning
• Position Tracking
• Jogging
• Linear and Circular Interpolation
• Tangential Following
• Helical
• Electronic Gearing
• Electronic Cam
• PVT Mode
• Teach and Playback
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Features – High Speed

• Encoder frequencies up to 22 MHz for servos

• Outputs pulses for steppers up to 6 MHz

• Servo loop updates as low as 31 µsec/axis

• 40 µsec command processing for application programs

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Features – Intelligent Programming

• On-board, non-volatile memory for storing application
programs, variables and arrays frees host

• Programmable event triggers including At time,
At position, At input, At speed

• Multitasking for simultaneous execution of up to eight
application programs

• Conditional JUMPS and IF/THEN/ELSE/Constructs

• Arithmetic and trigonometric functions
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Features – Multiple Inputs/Outputs

• Accepts both main and auxiliary encoders for each axis
• SSI and sinusoidal encoder interface options
• Uncommitted digital inputs and outputs
• Uncommitted analog inputs on most controllers
• Expandable I/O
• Forward and reverse limits and home input for each axis
• High speed position capture
• High speed position compare

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Features – Variety of Formats

• Available in 1-through 8-axis formats
• Box-level or card-level; Bus-based or stand-alone
• Ethernet/RS232 or PCI cards
• “Mix-n-Match” motor types: User-configurable for
steppers, servos and piezo ceramic motors on any
combination of axes
• Variety of plug-in amplifier options
• Custom solutions available

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Latest Generation Galil Controllers

• Multi-axis Ethernet Motion Controllers
– DMC-40x0 Accelera
– DMC-41x3 Econo New!

• Single-Axis Ethernet Motion Controllers
– DMC-300xx Pocket Motion Controller New!

• Ethernet I/O Controllers
– RIO-47xxx Pocket PLC

• Software Tools
– GalilTools Servo Tuning
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– Frequency Analysis Software – New!
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DMC-40x0 and DMC-41x3 Motor Drives

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Servo Drives with Sine Commutation

• AMP-43540 4-axis 600 Watt
• AMP-43640 4-axis 20 Watt
• Sinusoidal commutation minimizes
torque ripple. Ideal for linear motors
• Initialize with halls or encoders
• Available for DMC-40x0, DMC-41x3,and
DMC-30012 (800 Watt)

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Single-Axis Motion Controller & Drive

DMC-300xx Pocket Motion Controller
Smart. Compact. Low Cost.

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Smart

• Uses 32-bit RISC processor for faster processing
• PVT, gearing, eCAM
• 125 microsecond servo update (2x faster)
• 15 MHz encoder, 3 MHz stepper (25% faster)
• Controls servos or steppers
• Daisy-chainable Ethernet

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Key Benefit – Daisy Chain Ethernet

Multiple DMC-300xx can be daisy chained
over Ethernet without the use of a hub

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DMC-30012 Powerful, Efficient Drive

800W Brushless Sine Drive
10A cont, 15A peak, 20-80V
(CDS-3310 is 7A cont, 10A peak, 20-72V. Trap Drive.)

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RIO-47xxx Pocket PLC

Analog and Digital I/O with intelligence
in a cost-effective, compact unit

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Smart. Compact. Low Cost. Lots of I/O.

Smart – RISC processor, memory, counters, timers,
PID process loops, web interface, data logging, email
alerts, Ethernet, Power-over-Ethernet, Modbus
Master/Slave, Ladder Interface Software
Compact – 3.9” x 4.3” x 1.3”
Low Cost – $295 in single quantity; $195 in 100 qty
Lots of I/O – 32 digital I/O & 16 analog I/O

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System Operation

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Position Control Systems

BLOCK DIAGRAM

HOST MOTION MOTOR
DRIVER
COMPUTER CONTROLLER AND LOAD

POSITION
SENSOR

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System Elements

Host Computer

Motion Controller

Amplifier/Motor

Mechanical System

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System Elements Using AMP-19540

COMPUTER

DMC-1846
Controller

Building Earth 100 Pin Cable

AMP-19540 Vs
Brushless PSR-6-48
GND
Amplifier
Hall/Encoder Feedback

Phase C
Phase A
Phase B
Shield

BLM MOTOR

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System Elements with Built-in Amplifiers

COMPUTER

Building Earth 100 Base-T

Vs
DMC-4000 GND
PSR-6-48
Hall/Encoder Feedback

Phase C
Phase A
Phase B
Shield

BLM MOTOR

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Motion Controller Functions

COMMAND R X V
PROFILE
GENERATOR +
Σ FILTER
-
C

POSITION
DECODER

FUNCTIONS
Decode Position Feedback
Generate Desired Position R( t )
Close the Position Loop
P
Stability Compensation

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Filter Operation

Proportional P(k) = KP · X(k)
Derivative D(k) = KD · [X(k) - X(k-1)]
Integral I(k) = KI · X(k) + I(k-1)

Functions:
Proportional For speed of response
Derivative For stability and damping
Integral For accuracy - slow response

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System Elements

FILTER

DESIRED R X Y
POSITION
+
Σ G DAC AMP
GENERATOR -

C

POSITION
DECODER

P M

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Filter

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System Connection and Compensation

Connecting the system elements is done in three steps:
1. Test each function separately.
2. Close the position loop with low gain.
3. Tune the controller for fast and accurate response.

Potential problems and their effects:
1. Ground loops -- instability and noise sensitivity.
2. Connection with wrong polarity (positive feedback) -
- causes motor to run away.
3. Too high gain -- causes instability and oscillations.

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System Compensation

Set PID filter to
KI = 0
KP, KD low values
Step I -- KD
Increase the derivative constant, KD, until system
vibrates, then back off.
Step II - KP
Increase the proportional constant, KP, until system
vibrates, then back off.
Step III -- KI
Increase the integral constant, KI, until system vibrates,
then back off.

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Controller Features for High Precision Linear
Motors

• Update Rates as low as 32.25us
• Sine / Cosine encoder
– interpolation from x32 to x1024
• PID with Feed-forward Acceleration and Velocity.
• Dual PID and frictional bias
• Integration Limit
• Pole and Notch Filters to assist with mechanical
vibrations
• Profile filter to eliminate high-frequency, or select low-
frequency resonances
• New PVT mode provides motion profiles that don’t
have velocity discontinuities.

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Amplifier Features for High Precision Linear
Motors

• New AMP-43540 600W Sinusoidal Amplifier
• Current loop update of 33 kHz –
– Capable of providing a closed loop current loop bandwidth
greater than 3 kHz
• 16 bits of current resolution
– Critical for small adjustments and reducing settling times.
– Linear Zero-Crossing, no dead-band or hysteresis around
zero.
• Settable current loop gains allows for support of a
wide variety of motors using standard product
• Enhanced PWM control to deliver space vector PWM
with sine commutation

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GalilTools

Software package that enables easy set-up, tuning and
analysis of Galil’s latest control systems

• Designed for use on Galil’s current generation of products
Ethernet/RS232: DMC-40x0, DMC-21x3 and RIO-47100
PCI: DMC-18x6 and DMC-18x2

• Cross-platform compatible
• Communication drivers new from the ground-up, designed for
quick and efficient controller communication
• GalilTools Lite (no charge) also available
• Details, demos at http://www.galilmc.com

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GalilTools- Scope

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GalilTools- Watch All

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GalilTools- Watch Some

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GalilTools- Tuning

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Programming

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Programming: Two Methods

• Local (Stand-alone) • Host (Communication Bus)

PC PC DMC
TPXr
. dmc bus DMC C
bus
Controller
DMC
file Controller Program
Download File
123rn:

- PC not required at runtime - Bus can be Ethernet, Serial, PCI,
- BP – Burn Program ISA…
- #AUTO – Automatic Start Routine - Host can be Terminal, C, PLC,
LabView, Visual Basic, QNX
Linux, Touch Screen…

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Programming: Sending Commands

• Install terminal emulator software:
• GalilTools
• Just type commands from keyboard
• USE UPPERCASE!

• <enter> key completes command

• Controller returns
: For valid commands
? For invalid commands (TC1 tell error)

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Programming: Instructional Format

• Two-letter commands (mostly). Two kinds:
• Axis arguments: A (X), B (Y), C (Z), D (W), E, F, G, H
‘comment
BGX Begin X axis only
BGXW Begin X and W axes
BG Begin motion on all axes

• Numerical arguments
PR=1000
PRX = 4000 Set distance for X axis
PR 4000,,,4000 Set distance for X and W axes
PR *= 4000 Set distance on all axes
PRX=? Query distance for X axis (MG _PRX)
PR?,,,? Query distance for X and W axes
PR *= ? Query distance on all axes

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Programming: Interrogating Status

TP Tell Position
RP Report commanded position
TE Tell Error
TT Tell Torque
TV Tell Velocity (Average velocity)
TA Tell Amplifier Error

TC1 Tell error code (Reason for ?)
SC Stop Code. Reason for premature stop.

KPX=? Print value of parameter (MG _KPX)
MG _HMX Print state of the X axis HOME switch (“operand”)
var = _HMX Assign state of the X axis HOME switch to variable
MG var Displays value of variable
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Programming: Configuration Commands

CE Configure Encoders (Quadrature vs. Pulse/Direction)
MT Motor Type (Servo vs. Stepper; Motor Polarity)
BR Brushed Motor (for use with internal amplifiers)

KD Derivative Gain
KP Proportional Gain
KI Integral Gain

BN Burn (Store above settings in EEPROM)
BP Burn Program
BV Burn Variables and Arrays

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Programming: Safety Commands

Position Error
OE Turn on Off on Error functionality (can be turned off
due to position error, limit switch, and/or abort input)
ER Position Error Limit TE > ER, turn off motor
#POSERR Automatic subroutine that will run with position error
occurs

Encoder Failure Detection – Standard on Accelera
Will trip when encoder has not registered > 1 count of change for OT
ms and the torque is > OV.
KI should be used when Encoder Failure detection is enabled
OA Turn on Off on Encoder Failure
OT Time for encoder failure
OV Voltage for encoder failure
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Motion Programming

• Many modes of motion including:

Point-to-Point Positioning
Independent
Jogging

Vector Mode
Multi-axis
Linear Interpolation

Gearing
Following
Electronic CAM

Contouring
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Point to Point Positioning

• Motion between specified axes is independent

• PR or PA Relative or Absolute Position [counts]

• Can change SP and AC during motion

• Example:
PR 1000, 4000 Specify relative position
SP 2500, 2500 Specify slew speed
AC 100000, 100000 Specify acceleration
DC 50000, 50000 Specify deceleration
BG XY Begin motion
AM XY Wait until motion complete

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Jogging

• User specifies:
JG Jog speed and direction [counts/sec]
ST Stop motion
• Can change JG, AC, DC during motion
• Example:
JG -1000 Specify jog speed
AC 200000 Specify acceleration rate
DC 200000 Specify deceleration rate
BG X Begin motion

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Vector Mode
• Linear and circular interpolation on two axes
• VM Specify axes
VP Linear segment [counts]
CR Circle arc segment [counts]
VS Vector speed [counts/sec]
VA Vector acceleration [counts/sec2]
VD Vector deceleration [counts/sec2]
VE End sequence
BGS Begin sequence
• Up to 511 segments can be given prior to motion
• Can send additional segments during motion
• Can change VS and VA during motion
• Can specify start and end speed with each segment using
VP <n

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Specifying Linear Segments

6000 C

4000 B

A
2000

• Specify linear segments as destination coordinate with respect to start
of move sequence (absolute coordinate system)
Segment AB VP 2000, 4000
Segment BC VP 2000, 6000

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Specifying Arc Segments

B

90

180 0 A

270
• Specify circular segment as radius, starting angle and travel angle.
Clockwise rotation is negative travel.
Segment AB CR 1000, 0, 90
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Coordinated Motion

C (-4000,3000) D (0,3000)

R = 1500

• Example: B (-4000,0) A (0,0)
#MOVE
VM XY Specify axes
VS 5000 Specify speed
VP - 4000, 0 Linear Segment AB
CR 1500, 270, -180 Circular Segment BC
VP 0, 3000 Linear Segment CD
CR 1500, 90, -180 Circular segment DA
VE End of sequence
BGS Begin sequence
AMS Wait for sequence complete
EN
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Linear Interpolation Mode

• Coordinated motion of up to 8 axes
• VS, VA, VD also apply
• Incremental distances (unlike Vector Mode)

• Example:
#MOVE
LM XYZ Linear Interpolation Mode-use XYZ axes
LI 5000, 2000, 0 Specify incremental moves for each axis
LI 2000, 1000, 2000
LI 0, 1000, 2000
LE End Linear Interpolation Mode
BGS Begin Motion
AMS Wait for profiled motion to complete
EN

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Gearing

• Up to 8 axes electronically geared to master
• Eliminates mechanical gears

GA n n = X main encoder as master
n = CX command position as master
n = DX auxiliary encoder as master
n=S vector path as master

GR Gear Ratio ( + 127.9999 range)
• Can change Gear Ratio during motion
• Optima and Accelera Series support multiple masters

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Gearing (cont.)

• Example:
GA Y,,Y Y is master of X and Z
GR 5,, -2.5 X ratio = 5, Z ratio = -2.5

PRY=1000 Master position
BGY Begin motion

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Electronic Cam

• Can be used to simulate the motion of a mechanical cam

• Non-linear, periodic motion

• Up to 7 axes can be synchronized with an independent master

• The master can be either a controlled axis or an outside encoder

• An ECAM table is used to specify the position(s) of the slave(s)
with respect to the master throughout the motion cycle

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ECam Example

EAY Y axis is master
EM 0, 4000 X (slave) change is 0 counts. Y (master) change is 4000
EP 2000 Master interval is 2000 counts between entries

ET[0] = 0 ECAM table defines positions of slaves
ET[1] = 1000 3 points, 2 intervals
ET[2] = 0

EB1 Enable ECam mode
EG -1 Engage slave immediately
JGY = 500 Jog master at 500 counts per second
BGY Begin master motion
X Slave Position (counts)

Cam Table
1000

500

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Contour Mode

• Bypasses the motion profiler
• Allows any time based function
• Incremental distances

• CM Enter contour mode, specify contoured axes
DT Specify time interval for each contour segment
CD Specify incremental distances for each axis
WC Wait for contour move to complete (similar to
AM command) - Not valid for Accelera Controllers

• Record (RA, RD, RC) and playback motion using Contour Mode and
arrays

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Contour Mode (cont.)

Example – Accelera Example – Non Accelera

CM XY; ‘Setup Contour Mode
CM XY; ‘Setup Contour Mode
DT4; ‘Interval Time
DT4; ‘Interval Time CD50,100; ‘Contour Data
CD50,100; ‘Contour Data WC; ‘Wait for Contour
CD10,30; ‘Contour Data CD10,30; ‘Contour Data
CD100,50; ‘Contour Data WC; ‘Wait for Contour
CD 0,0=0; ‘End Segment CD100,50; ‘Contour Data
‘wait for buffer to empty WC; ‘Wait for Contour
MG “MOVE DONE”
#WAIT;JP#WAIT,_CM<511
EN; ‘End Program
MG “MOVE DONE“
EN; ‘End Program

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PVT (Position Velocity Time) Mode

• Standard on Accelera products, available as a standard special for
other products
• Allows arbitrary motion profiles defined by position, velocity and time
• Advantage over Contour mode is there are no velocity discontinuities

• PVa=p,v,t PV command (position, velocity, time)
_PVa Contains number of segments available in buffer
BT Begin PVT Mode
_BTa Contains number of PV segments that have
executed

• Buffer is “per axis” and is 255 segments.

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PVT Mode (Cont.)
• Multi-Axis Coordinated Move Example

Required XY Points

6000
X Axis Y Axis
500 500 5000
1500 5000
Y Axis (Counts)

4000
2500 4000
3300 4200 3000
7300 3300
2000

1000

0
0 1000 2000 3000 4000 5000 6000 7000 8000
X Axis (Counts)

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PVT Mode (Cont.)
X vs Y Commanded Positions
#PVT
6000
PVA = 500,2000,500
PVB = 500,5000,500
5000
PVA = 1000,4000,1200
PVB = 4500,0,1200 4000
PVA = 1000,4000,750

Y Axis (Counts)
PVB = -1000,1000,750 3000
BTAB
PVA = 800,10000,250 2000
PVB = 200,1000,250
PVA = 4000,0,1000 1000

PVB = -900,0,1000
0
PVA = 0,0,0
0 1000 2000 3000 4000 5000 6000 7000 8000
PVB = 0,0,0
-1000
EN X Axis (Counts)

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PVT Mode vs Contour Mode

Contour Mode Solution PVT Mode Solution

Point 3 Point 3
Y-Axis

Y-Axis
Point 1 Point 1
Finish Finish
Point 2 Point 2

Start Start
X-Axis X-Axis

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Application Programming

• A DMC program allows motion commands to be combined with
other commands such as I/O handling to solve a complete
machine application.

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Entering Programs

•Use Editor window for entering programs

•Use Upload and Download on GalilTools, Smart Term or WSDK to
modify existing programs and download changes to the controller

•SmartTerm: Turn on Syntax – Help for ease of programming and
press F1 to see more information

•GalilTools: double tap “Tab” in Terminal to get info on a command

•DMC Code Helper on line
• http://www.galilmc.com/support/code-helper/dmc-code-help.php

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Program Structure

• Programs begin with #Label and end with EN instruction
• Labels designated by # followed by up to 7 characters
First character must be a letter
Other characters can be numbers
Spaces are not permitted

• Examples:
#AUTO Automatically starts on power-up
#BEGIN
#Pos1

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Entering Commands

• Some commands return a value, some do not
• TPX returns a value
• STX does not

• Explicit Notation vs Implicit Notation
• PAX=1000 or PA 1000 either method is okay
• Don’t do: PA=1000 that will set a variable named PA

• XYZW or ABCD
• PAA=1000 or PAX=1000 both formats will move axis 1

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Example Program

#BEGIN; ‘Begin program
PAX= 10000; ‘Position absolute
SPX= 50000; ‘Slew speed
ACX= 500000; ‘Acceleration rate
DCX= 500000; ‘Deceleration rate
BGX; ‘Begin motion
AMX; ‘After motion
EN; ‘End program

XQ #BEGIN Execute program from terminal

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Program Flow

• Galil controllers offer many instructions to control program flow
such as halting until an event occurs, jumping to a location,
looping or executing a subroutine.

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Trippoints

• Special commands that pause execution of a program until a
specified event occurs.

• Only valid inside a .dmc program.
AD After distance (profiled)
AI After input
AM After motion complete (profiled)
MC After motion complete (actual)
WT After time elapsed (wait)

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Conditional Statements

• Special commands that cause program to branch on specified conditions.
• JP is a “blind” jump. JS jumps to a subroutine and then returns.
• Format: JP #LABEL, condition(s)
• Conditions: < less than
> greater than
= equal to
<= less than or equal to
>= greater than or equal to
<> not equal
• Examples:
JP #STOP, (error>100) Jump to #STOP if error is
greater than 100
JS #B, ((v1<0) & (v2>0)) Jump to subroutine #B if v1 is less than
zero and v2 is greater than zero
(JS statements can be nested up to 16 deep)

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Conditional Statements

• IF statements can be nested up to 255 deep
• Use parentheses to surround each statement
• Example:
IF ((_TPX <= 5000) & (_TPX >=4000))
MG “In Position”
ELSE
IF (_TPX < 4000)
MG “UNDERSHOOT”
ELSE
MG “OVERSHOOT”
ENDIF
ENDIF

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Creating Loops

#A Main program
n=5 Loop counter
#LOOP Loop program
PRX= 1000 Move distance 1000
BGX Begin Motion
AMX Wait for motion done
WT 500 Wait 500 msec
PRX=-1000 Move distance-1000
BGX Begin motion
AMX Wait for motion done
WT 500 Wait 500 msec
n=n-1 Decrement loop counter
JP#LOOP, n>0 Repeat 5 cycles
EN End program

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Automatic Subroutines

• Controller can monitor certain conditions in the background
(“Event Driven” programming)
• Automatic monitoring is enabled by using the following
special labels:

#LIMSWI Limit switch active
#ININT Designated input changes state
#POSERR Position error exceeds ER limit
#CMDERR Bad command given
#MCTIME Timeout on motion complete trippoint
#TCPERR Communication error (Ethernet only)
#COMINT Communication interrupt subroutine
(RS-232 only)
#AMPERR Amplifier Error (Galil Amps)
• An application program must be running in Thread 0
for automatic monitoring for Optima/Econo controllers
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Multitasking

• Multiple independent programs called “threads” can run
simultaneously
• All threads have equal priority
• One thread can execute or halt another thread
• All trippoints are available in every thread
• Variables are global - common to all threads
• Useful for background PLC; truly independent motions
• Use semicolons to execute a group of commands together

Commands:
XQ #Label,n Execute Program in thread ‘n’, where n=0
through 7 is thread number. 0 is main thread.
HXn Halt Execution of Thread ‘n’

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Multitasking -- Example

• Example to Download:
#X X-Thread
PR 1000;BGX;AMX Move 1000
PR-1000;BGX;AMX Move-1000
JP #X Repeat Motion
#Y Y-Thread
PR,500;BGY;AMY Move 500
PR,-500;BGY;AMY Move -500
JP#Y Repeat Motion
#TIME I/O Thread
AT-50;SB1;AT-10;CB1 Every 50 msec Set Bit 1
JP#TIME Repeat
#MAIN Main Thread
JP#EXIT,@IN[1]=0 If input 1 low, exit
JP#MAIN Loop if input 1 high
#EXIT
AB Abort Motion and Program
EN End Program
• To execute from host/terminal:
XQ#MAIN,0
XQ#X,1
XQ#Y,2
XQ#TIME,3

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Special Features

• Galil controllers use comments, variables, arrays, and
mathematical functions to make programming easier
and free your host PC for other tasks.

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Commenting Programs

• Code with comments is far easier to understand
• Use NO or ‘ (single quote) to cause the processor to ignore
the following text. Not valid on Legacy controllers.
• Use “REM” to save space by having Galil software strip out
those lines before downloading to the controller
• Example:
REM – JOG motor 5000 cts/sec
JGX= 5000
‘set accel
ACX=100000
NO set decel
DCX= 100000
BGX; ‘ Begin Motion

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Variables

• For inputting or changing parameters in a program
• Each variable is defined by a name, up to 8 characters long.
Variables are case sensitive. Lower case recommended.
• Range: +/- 2,147,483,647.9999 for numeric
variables
Six characters for string variables
• Examples:
posx=500 Assigns 500 to the variable posx
PR posx*2 Multiply variable by 2 and increment X axis
by result
var = “cat” Assign string cat to variable named var

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Axis Designator

• Axis Designator ~a to ~h can be used like a variable axis

• Example
~a=0; ‘Axis A
#L
PR~a=1000;BG~a;AM~a;
~a=~a+1
JP#L,~a<4; ‘move axes 0-3
EN

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Arrays

• For storing and collecting data (ideal for contour mode, teach,
and playback)
• One dimensional
• Each entry has same numerical range as variable
• Arrays defined by a name and number of entries

DM posx[7] Defines an array named posx with
seven entries

• Can automatically capture certain types of data, such as position,
error and commanded torque, into arrays over specified time
intervals

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Record Data Mode

Instruction Interpretation
#RECORD; ‘Label
DM yerr[100]; ‘Dimension array
RA yerr[ ]; ‘Specify record mode
RD _TEY; ‘Data type for record
RC 4, 100; ‘Actual recording
EN; ‘End program

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Mathematical and Functional Expressions

Mathematical Operators Logical Operators
&
+ - * /
|
@SIN[n] @COS[n] @COM[n]
@ABS[n] @FRAC[n]
@INT[n] @RND[n]
@TAN[n] @ATAN[n]
@ASIN[n] @ACOS[n]
@SQR[n]

Note: Math order of operations is left to right. Use
( ) parenthesis for correct order of operations

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Programming with Inputs/Outputs (I/O)

• Galil application programs handle hardware I/O, data
input, and messaging.

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Input of Data

• Input data using variables
#INIT
Speedx=1000
#GO
JGX=Speedx
WT250
JP#GO

• From Host PC or HMI, send Speedx=2000 to double the speed
• Can use arrays instead of variables to enter a lot of data

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Output of Data

• MG command used to send a message or return a value
• MG _KPX to show the value of KPX
• MG posx to display the variable POSX
• Output to specific communication port:

MG "HELLO THERE" Displays message out default port (CF command)

MG {P2} "HELLO THERE" Displays message to auxiliary RS-232 port

LU0; MG {L1} “ERROR” Displays message to Line1 of DMC-40x0 LCD
MG {EA}"POSITION=",_TPX Displays message via Ethernet (Handle A)

MG "Variable=",v1{F6.1} Displays message and value of
variable v1 with format 6
integers and one decimal

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Uncommitted Inputs

• Available commands:
AI +/- n Wait for input n high/low
II n Interrupt if input n occurs
TI n Return state of all inputs in block n
MG@IN[1] Return state of input 1
TZ Returns all status of all i/o points

• After Input Example:
#JOG Jog program
JGX=1000 Jog speed
AI 1 After Input 1 high
BG X Begin motion
AI - 1 After Input 1 low
ST X Stop motion

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Uncommitted Outputs

• Defined by:
SB n Set Bit n
CB n Clear Bit n
OP n Define all 8 bits

• Example:
#POS Label
PRX=1000 Position
BG X Begin motion
AM X After motion
SB1 Set bit 1
WT 1000 Wait
OP 0 Clear all outputs
EN End program

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Analog Inputs

• + 10 Volts with 12 bit resolution (16-bits optional)

• AQ to adjust input range 0-10V, 0-5V, +/-5, differential
(AQ not available on all controllers)

• Available commands:
a1 = @AN[n] set variable a1 to analog input (in volts)

• Analog Input Example
#JOYSTK Joystick
JG0 Jog mode
BGX
#LOOP Loop
a1 = @AN[1] Read analog input
JGX= a1*1000 Change jog speed
JP #LOOP Repeat
EN End program
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Homing

• Special moves to initialize the system:

FE Find Edge - Look for a transition on the home switch input

FI Find index - Look for an index (Z channel) pulse

HM Home - Includes:
High speed FE
Reverse and low speed FE
Low speed FI

HV Home Velocity – Velocity for 2nd stage for Accelera

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Homing Sequence
HOME SENSOR

H O M E S W IT C H
_H M A=1 _H M A=0

P O S IT IO N

V E L O C IT Y

(1 ) M O T IO N B E G IN S
TO W AR D H O M E

D IR E C T IO N

P O S IT IO N

V E L O C IT Y
M O T IO N R E V E R S E
(2 )
TO W AR D H O M E
P O S IT IO N
D IR E C T IO N

V E L O C IT Y
M O T IO N TO W AR D
(3 )
IN D E X
D IR E C T IO N
P O S IT IO N

IN D E X P U L S E S

P O S IT IO N

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Limit Switches

• Define the physical forward and reverse limits of your system.
• When a limit switch is triggered during a commanded move,
motion is stopped and further motion in the direction of the
triggered switch is not possible.
• Use the TS command or the _LF and _LR operands to monitor the
state of the limit switches.
• Use the #LIMSWI subroutine to respond to limit switches.
• SD – Switch Deceleration for new controllers
• Use the FL and BL commands to set travel limits in software.
• #LIMSWI example:
#LIMSWI;
~c=0
#Lim
IF (_LF~c=0);MG ~c," LIMIT HIT";ENDIF
IF (_LR~c=0);MG ~c," LIMIT HIT";ENDIF
~c=~c+1;JP#Lim,~c<4
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Dual Encoders

• Every axis has two encoder ports: Main and Auxiliary.
• The main encoder is used to close the primary control loop.
• The auxiliary encoder can be used to:
• Read the load position (linear encoder) for backlash
compensation. (Dual Loop mode – DVX=1)

• Provide position feedback for external device.
Applications: hand-wheel input, synchronizing with an
open loop motor (ie: a conveyor belt).

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Program Troubleshooting

TC1 Tell Error Code (Why was a command rejected?)

SC Stop Code (Why did the motor stop?)

TI Tell Inputs (Is controller reading inputs correctly?)

TR1 Trace Program (Display each line as it executes)

TS Tell Switches (Home, Limit Switch status)

TA Tell Amplifier Status (Galil Amps)

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More Information

• DMC Code Helper for 40x0 and RIO
• http://www.galilmc.com/support/code-helper/dmc-code-help.php

• Sample DMC Code Programming Library
• http://www.galilmc.com/support/sample-dmc-code.php

• User Manuals and Command References
• http://www.galilmc.com/support/manuals.php

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I/O Hardware

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I/O Hardware Overview

• Home, limit and general
purpose inputs

• Amp Enable Circuit

• Uncommitted outputs

• Analog inputs

• Extended I/O options

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Optically Isolated Inputs

• Two Primary benefits of Opto
• Electrical Isolation between systems
• Voltage level conditioning
• Grounding issues: the ground of an isolated power supply should not be
connected to the controller gnd for true isolation.

• Non-opto inputs: inputs are TTL with pull-up to 5V/3.3v. Close to ground for
activation. Take extra precautions to prevent noise.
(examples DMC-21x3-ICM-20100, DMC-18x2, DMC-40x0 extended I/O)

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Optically Isolated Inputs (Cont)

Bi-directional Optos

External R needed External R needed
LSCOM if V > +28V LSCOM if V < -28V

+ 2.2K
2.2K
Isolated Isolated
I Supply I Supply
+

FLS FLS

Example Hardware:
DMC-40x0-I000
DMC-41x3
DMC-18x6
DMC-18x0
DMC-21x3-ICM-20105
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Encoder Synchronization
• High Speed Latch – Save encoder position when input occurs
• Use inputs 1-4 for latch inputs. IN[1] for X, IN[2] for Y, etc.
• ALx arms latch and _RLx stores the position once the position is captured.
• Captures position on state transition of specified input.
• Latch speed on TTL input is less than 1µs, low-going opto-isolated input is
12µs, 35 µs for high-going.

• Output Compare – Pulse output at encoder position
• One-Shot and circular/modular compare possible
• OC command sets up all behavior
• Powerful for position based external hardware synch
(e.g. laser marking, raster scans)

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Input Safety Features

• Abort input configuration and usage:
- Instantly stop motion on all axes (infinite deceleration)
- Opto-isolation provided through INCOM
- Used with OE command will disable amplifier (coast stop)
- CN command configures inputs for axis-specific aborts and code handling
• #ININT subroutine (configure with II command)
- Used to interrupt the controller on a specific input.
- Can be used to interrupt on a high or low going signal
• #LIMSWI subroutine
- Used if a limit switch condition occurs.
• #AMPERR subroutine
- used to interrupt on an amplifier fault (bad hall state, over current, over voltage,
ELO, etc)
• Note for Optima/Econo: Thread 0 must be running for automatic
subroutines to function.
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Amplifier Enable

• The amplifier enable signal
allows the Galil firmware to
control an external amplifier’s
ready state. (SH/MO)
• Third party amps have widely
differing enable signals.
– Active High/Active Low;
Enable/Inhibit;
Sinking/Sourcing; 5v, 12v,
24v
• DMC-40x0-I200, DMC-41x3 &
DMC-21x3-20105 are easily
field upgradeable for 16+
configurations.
• Provisions for other hardware
(ICM-20100, 2900,1900)
through 7406/7407 ICs

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Uncommitted Outputs

• Outputs are single ended and TTL level on the controller board.
• Opto-Isolated Outputs
• DMC-4000, RIO, DMC-21x3-ICM-20105 have high power
opto outputs. 500mA at a max of 3A per byte. 12-24VDC
• RIO also has 8 low power opto at 25mA. 5-24VDC
• DMC-41x3 has 4mA outputs, 5-24VDC. High power, 500mA
outputs available with (HSRC) order option
• PCI based: low power, 24mA opto-isolated outputs are
available through the ICM-1900-Opto and ICM-2900-Opto.
Available sourcing with –HISIDE order option.

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Uncommitted Outputs (cont)

High-power, sourcing, optically-isolated outputs as on the RIO, 4000, 41x3(HSRC),
and ICM-20105

Low power, sinking, optically isolated outputs on the RIO, ICM-1900/2900-OPTO,

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Analog Inputs

• Single ended analog inputs can be used for feedback, joystick
control, pressure or force transducers, etc.
• Controllers equipped with “AQ” command provide +/- 10, 0-10, +/-
5, 0-5 v ranges, and allow differential inputs.

• Standard 12-bit resolution. Optional 16-bit resolution. Increased
resolution does not necessarily yield increased accuracy.

• Noise considerations should be taken into account when using
analog inputs, especially in PC environment.

• DMC-40x0, 41x3 and RIO controllers have a dedicated analog
ground.

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Extended I/O Options (local and remote)
• DMC-4000 has 32 extended I/O 3.3v or 5v. Other boards may add DB
daughterboard.
• Extended I/O available on the controllers is 3.3 or 5v level. Take caution not to
connect 5v circuits to 3.3v extended I/O. Order -5v.
• Remote extended I/O via the RIO. Programmatically, the I/O appears local (SB,
CB, @IN, @OUT).
• Galil Ladder Compatible.

• Modbus TCP/IP and RTU. Motion controllers are ModBus masters.

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Troubleshooting

"There are only 10 types of people in the world:
Those who understand binary, and those who don't."

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Troubleshooting Overview

• Communication problems

• Feedback problems

• Motion problems

• The red LED

• Programming problems

• Noise problems

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Troubleshooting Bus Communication (PCI, ISA)

• Install most current Galil communication drivers/software
• PCI is Plug and Play
• Check for Error LED
• Check for communication conflicts in PC’s Device Manager
- I/O Address conflicts – especially ISA
- IRQ/DMA Conflicts
Software OS PCI Driver
Win7/Vista/XP x86 x64 GALILPCI.INF
GalilTools
Linux, Linux 64 GALILPCI.KO
WSDK, SmartTerm, XP x86 x64, Win2000
GLWDMPCI.INF
Setup32, ActiveX WinNT, Win98SE
DMCTerm, Talk2DMC Win98, Win95, Win3.1
-
Legacy (16 bit), DOS

Choose the right software for your application!
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Troubleshooting Serial Communication
• Check for proper communication settings
A. Baud rate (jumper configurable)
Controller Default Baud
DMC-21x3 19.2k
DMC-4xxx 115.2k
RIO-47xxx 115.2k
B. RS232 Settings (when not using Galil software)
Data Bits 8
Parity None
Stop Bit 1
Flow Control Hardware
• DMC-41x3 behaves like a USB-SERIAL converter. PC’s OS is bundled with
device driver and will connect like a COM port.
http://www.ftdichip.com/Drivers/VCP.htm
• Proper serial cable – straight 9 Pin, CTS/RTS connected. Order from Galil -
CABLE-9-PIND, $10
• Aux RS232 port uses NULL modem cable. CC,CI,#COMINT sets up
operation
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Troubleshooting Unsolicited Messages (CW)

• Data transmitted from the controller asynchronously from embedded
code
– embedded command such as MG “Hello” or TP, or a program bug
• CW1 sets most significant bit for Galil drivers. CW2 doesn’t.

Character from Binary Hyperterm
controller display
“H” with CW2 01001000 H

“H” with CW1 11001000

• CW,1 used to determine what to do when nothing is listening to RS232
traffic. TC1 error: 131 Serial Port Timeout

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Troubleshooting Unsolicited Messages (CF)

Where should the controller send the “Hello” message?

Main CFA / CFB GalilTools
w/ Scope
RS232 Port
CFC
RIO-47100
CFS
CFD
RIO-47120
DMC-40x0
#A CFE
CFB Ethernet DMC-40x0
MG{EH}”Hello”
EN CFF
DMC-41x3

CFT
CFG LCD Screen
Aux
RS232 Port CFH
HMI
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GalilTools 3 Controller Data Streams

• Unsolicited messages transmit in a data stream that go to one
location, set by CF or { }. Other controller data streams are the
Data Record, and UDP interrupts.
• By default GalilTools will redirect messages (CFI), data records
(DR,n) and interrupts (EI,,n).
• To connect without affecting these channels, use optional
connection switches in GalilTools and the GCL.
• -s (totally silent)
• -ei 0 (leave interrupts alone)
• -mg 0 (leave unsolicited messages alone)
• -dr 0 (leave data records alone)
• http://www.galilmc.com/support/manuals/galiltools/connections.html

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Ethernet Communication

Simplified Network Model
• Why Ethernet?
Application
– Proven technology
– Non-proprietary
– High performance Packets
– Low cost
– hardware and software readily
available Physical
– No special kernel drivers
– Can easily be totally Wire
deterministic for real-time apps

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Ethernet Communication Physical Layer

• Correct Ethernet Cable? Auto-
MDIX (DMC-4xxx and many
newer computers) don’t care.
May need a crossover cable.
Check for LINK/ACT led.
• Activity LED will blink
indicating network traffic and
BOOTP/DHCP requests
• RIO can receive power from
cat5 cable via P.O.E
• RIO-47xx0 requires a jumper
for 10BaseT networks
(100BaseT default)

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Ethernet Communication Packets Layer (IP)

• IP address can be assigned
with many methods
– DHCP or BOOTP server
– GalilTools assign IP over
Ethernet (may depend on
Firewall, user permissions,
etc)
COM1, RIO47100 Rev
1.0d, 938
– GalilTools assign IP over :DH0
RS232 with DH, IA, BN :IA 10,0,6,46
commands :BN
:IA?
10, 0, 6, 46

• Most OS default to DHCP. If
there is no DHCP server, set IP
static before assigning the
Galil’s IP. This is set in
Windows Device Manager, not
GalilTools.
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Ethernet Communication Packets Layer (Subnet)

• Devices with IP numbers
matching the subnet pattern can
communicate with each other.
PCs, 4xxx and RIO have subnet
settings (SM command).
• 255.255.0.0
10. 0.6. 27
10. 0.6. 39
10. 1.6.233
• Computers with multiple network
interface cards (NICs) should use IP
numbers that are outside of each
others subnet.
• 4xxx and RIO have subnet disabled
by default, but PCs always use one.
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Ethernet Communication Applications Layer

• Useful tools for Ethernet diagnostics
– ipconfig – network status of PC, IP &
subnet
– ping – Checks route to controller. Reply
indicates link, IP assigned, and subnet
ok
– telnet – Simple connection indicating
controller is available for
communication
– GalilTools – Galil development
<ctrl>R<ctrl>V
environment, assigns IP to controller
– Wireshark – Free network analysis tool
http://www.wireshark.org

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Encoder Problems

• No encoder counts
– Check wiring
– For single ended encoder, CHA- and CHB- must be left unconnected
– Encoder configuration set with CE command
– If position increments by only one count, one channel is either missing or
damaged.
– PCI - Auxiliary encoder requires separate cable attached to ICM-1900 or
ICM-2908
• Motor Position Drifts
– Compare TP to actual, independently observed motor position
– Check for loose connections or coupling
– Avoid noise:
» Use differential encoders
» Add termination resistors (-TRES)
» Shield encoder wires from motor wires
» Use 12V encoders
» Add ferrite
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Troubleshooting “Runaway” Motors

• Positive Feedback
A. Reverse motor or encoder wiring to reverse feedback
B. Use MT or CE commands to reverse feedback (non-defaults lost
after master reset)
C. See Application Note #1418 – “Motor and Encoder Configuration”

• Broken Encoder wire
A. Motor movement without change in TP
B. Accelera – Encoder Failure detection feature (OT,OV,OA)
C. Application Program can monitor for broken wires
D. See Application Note #1417 – “Encoder Failure Circuitry”

• Motor Moves in opposite direction than desired
A. Hardware or software swap of encoder AND motor leads
B. Use MT & CE command to reverse direction

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Amplifier Fault LEDs

• Over Current/ Short Circuit LED
A. Check for short between phases or between phase and ground
B. Fix problem before re-enabling
C. Clear with MO/SH commands (latching)
• Over/Under Voltage LED
A. Unregulated power supply may overcharge during forced
deceleration
B. Use regulated power supply or add Galil shunt regulator
C. LED turns off when voltage drops to acceptable level
D. Ensure integrated amplifier is powered, even when unused
• Over Temperature LED
A. Turns on if heatsink temp rises above 80 c
B. May require MO/SH

Use TA and #AMPERR to monitor the status of integrated Galil Amps.

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Motors Not Moving
• 3rd party Amplifiers
- Check amplifier docs for enable/disable requirements
- Check for MO due to Abort, _AB, _TS, _MO
- Is motor command output driving correct voltage?
1. Disconnect motor command signal from amplifier
2. Set KI,KP,KD to 0
3. Use OF command to set output, e.g. OFX=7
4. Check value of TT (If not correct, check TL)
5. Use voltmeter to measure MCMA
6. If output is 0, TT is not zero, may have blown analog switch on ICM unit
• Integrated Amplifiers
- Check for MO condition BR1, TA, _AB, _TS, _MO
- TL or filter set to 0? If TT shows 0, no motion expected
- Proper commutation? QH, 6 combos

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Troubleshooting Poor Performance

• Motion is uneven or oscillations occur
A. Use GalilTools for tuning assistance
B. Commutation of brushless motor. QH, 6 combos.
C. Commutation track of motor
D. Sine Amp configuration (BA,BM,BZ)

• Motion stops before target position
A. Use KI and IL to compensate for deadband
B. Encoder failure detection misconfigured
C. Stop Code, “SC”, command to check for unexpected stops
A. Soft Limits
B. Noise on limit switches or abort
C. Error limit

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Stepper Motors

• Verify SM jumpers are installed. Issue MT2; if the controller returns
“Stepper motor jumpers must be installed”, check the physical jumper
placement. NO JUMPERS ON 4xxx,18x6.

• Check connections to ICM module; STEP, DIR, AEN

• Use correct motor type command (MT2, MT-2, MT2.5, MT-2.5)

• Verify commanded motion gives change to both RP and TD. In stepper
mode, TD is a “loop-back counter” of the commanded steps, RP.

• Motor Stalling?
• KS for stepper smoothing
• Reduce AC/DC & SP/JG
• Change gain AG on integrated amps
• Check TA for amp problems
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Command/Program Execution Problems
Command Description
TR1 Trace. Prints each command as it's executed.
Print message strings, variables, and controller
MG parameters.
Print current line number that is executing in
MG _XQn thread n (or -1 if thread is not running)
LV List all declared user variables and their values
LS List the controller program
LS first line, last line List a program section
LS_XQn,_XQn List current running line of code
QU array[] Print the contents of a given array

SC Stop code for axis

Tell error code and brief description (reason for
TC1 controller returning a "?")
#CMDERR Automatic sub, runs on crashed thread
XQ Begin Program
ST Stop Program
BK line Set breakpoint at line
BK Resume from breakpoint
SL Single Step
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Troubleshooting Errors

Three Reasons for the Red LED

• Position error exceeds error limit
A. Check TE value vs. ER limit
• Use SH to clear error
• #POSERR subroutine can be used for error handling

• Watchdog timer is activated due to microprocessor lock up
A. Check the voltages on the power supply
• +5V supply must be at least 4.75V for proper operation
B. Verify communication with controller
• A master reset may clear the watchdog error
• Re-installation of the firmware may clear error

• Controller is in the reset state.
A. Check for reset line shorted or pulled to ground
B. Protect against noise on reset line and ground loops
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Software

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Galil CD-Rom

Free Software Password Required
• GalilTools Lite (includes GCL) • GalilTools Full
• DMC Smart Terminal • Ladder
• DMC Setup • Galil PVT
• DMC .NET API • CAD-to-DMC
• DMC Win32 • ECAM Setup
• WSDK
• User manuals and examples included • Active X Toolkit
• Latest versions of software and manuals are on
website
Items in grey are not recommended for new applications
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GalilTools Lite

Provides direct interface between controller and computer:

1. Can send commands directly and see response
2. Function to upgrade controller firmware
3. Editor for creating, editing, uploading, downloading programs
4. Watch Window for real-time controller status
5. Function for download, upload arrays
6. Dynamic syntax help
7. Includes GalilTools Communication Library (GCL)

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GCL Introduction

• Use GCL to interface high level programs with the controller

• Abstract away communication protocols (Ethernet, RS-232,
USB, PCI)

• Works with any development environment that supports COM
objects including Visual Basic, Visual C++, C#, Labview, and
Matlab

• Also includes Visual C++ DLL

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Visual Basic (VB)

• Majority of customers prefer VB because of ease of use and
ability to program quickly

• All versions of VB are supported from VB6 up to Visual Studio
2010

• Express version of VB is free

• Visual Basic is a simple programming tool created by Microsoft.
It uses the BASIC language and a graphical interface to allow a
developer to write powerful programs quickly and easily.

• Object oriented and event driven

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Visual Basic Overview

The VB environment has three basic parts:
• The tool bar on the left
• The program form in the middle
• The property list on the right

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VB Example

• This program will print “Hello” inside a textbox when the
command button is pressed.

• Step 1. Draw a command button on the form:
a. Click on the rectangle shaped tool called the
Button. To locate this tool hold the mouse
pointer over each tool until the help tag appears
as “Button”
b. Click on the tool.
c. In the form area draw the button by holding down
the mouse button and dragging within the form
area. Release the mouse button.

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VB Example Create Command Button

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VB Example (cont.)

• Step 2. Draw a textbox on the form:
a. Find the tool with the help tag ‘TextBox’ and draw it on
the form above the command button. The textbox tool is a
white rectangle with the letters ‘ab’ inside.
• The form should now look like this:

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VB Example (cont.)

• VB is event driven and
VB code has to be
entered to make
something happen when
the button is pressed.
• Step 3. Double click on
the command button.
Enter the code:
TextBox1.Text = “Hello”
• The line of code tells VB
display “Hello” inside the
textbox control.

• “TextBox1” is the default name of the textbox. “Text” is a property of the
textbox, in this case the text that will be shown inside the textbox control.
By making the text property equal to a string, VB is instructed to display
136 it in the textbox.
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VB Example – Changing Properties

• Properties define how any object looks
or operates. To see a list of properties
select an object on the form and look
at the property list on the right of the
VB screen.

• Step 4. To change the caption of the
command button:

a. Select the Button1 button on the form
b. Scroll down the property list to the ‘Text’ property
c. Enter the text “Say hello” in the box directly to the right of the
property name.
d. The caption of the command button should now be changed
• Step 5. To run the program, hit F5.
• The textbox should be blank by default.
To change it press the command button.
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Example #1 – Query Position

Purpose: Allow the user to query the controller’s position by
pressing a button

Procedure
1. Add a reference to the Galil Communications Library (GCL)
2. Add a button and a text box
3. Program the Form Load event to open a connection to the
controller
4. Program the Button Click event to send the command and display
the response in the text box

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Using the GCL in VB

• Using the COM object from GCL
allows us to communicate to the
controller

• To add a reference click
Project->Add Reference->COM

• Select the Galil COM object

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Opening Communication

• Create a Galil object
called g

• Set the address
property in the Form
Load event
– Setting address to
double quotes opens
connections dialog box

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Add Visual Objects

• Create a command button and a textbox
control on the form

• Select the command button. Find the
property list on the right and change the
‘Text’ property to “TPX”.

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Sending Command

• Double click the TPX button and add this code to the Button
Click event
• TextBox1.Text = g.command(“TPX”)

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Run The Program

• Run the program by pressing F5

• Notice the connections dialog box appears

• Select the controller then press the TPX button

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Example #2 – Continuous Update

Purpose: Learn to use the data record to automatically display X and Y
position data from the controller

Procedure
1. Establish Communication

2. Add textboxes and labels

3. Program the On_Record event to display positions

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Data Record

• A packet that contains all the information on
the controller

• Accelera controller’s can automatically send
DR packet every other servo sample
– As fast as every 125us on the DMC-40x0!
– No polling by host PC
– Econo/Optima support DR but slower

• Used by GalilTools for the scope

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Example #2 – Set Up

• Add a reference to the
GCL
• Create a Galil object
• Set address property
• Add 2 textbox’s and 2
labels
– Change the Text
property of the labels

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Example #2 – OnRecord

• Select the
object g and
choose the
event onRecord

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Example #2 – OnRecord (cont.)

• Add g.recordsStart(-1) to the Form_Load
– Tell the controller to send DR packets as fast as
possible
• Use g.sourceValue() to parse the datarecord
– Record object contains DR information

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Example #3 – User Interface

Purpose: Create a project that allows the user to write a DMC program
and download it to the controller while also sending commands and
displaying user selectable data

Procedure
1. Add a GCL reference and establish communication
2. Add textboxes and labels for a program editor, terminal, and display areas
3. Add combo boxes for selecting data to be displayed
4. Write code to populate combo boxes
5. Write code to use datarecord
6. Write code to send commands and display response
7. Write code to download DMC programs

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Example #3 – Establishing Communication

• Add a reference to Galil
• Dimension Galil object
• Include g.address
– Add Try Catch statement

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Example #3 – Add Design Elements

• Add Program Editor text
box
– Set multiline true and
scrollbars to vertical
• Add boxes for sending
commands, receiving
responses, and displaying
values
• Add 2 combo boxes
• Add labels and buttons to
describe all

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Example #3 – Add Code For Combo Boxes

• Create source strings
• Fill combo boxes with DR
sources
• Combo box event

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Example #3 – Add Code For Datarecord

• Use source1 and source2 strings from combo box
• User g.sourcevalue() to get the user selected data

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Example #3 – Commands and Program

• Use g.command to send commands
• Use g.programdownload() to download
programs

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Example #3 – Complete Program

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Example #3 - Working

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Application Examples

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Drive X-Y with Velocity Proportional to Joystick Position

Task: Drive a motor at a speed proportional to the input
voltage of a joystick. Note; An X-Y joystick 2 signals in the
range between +/- 10V

• Assume that a full voltage of 10 Volts must produce a motor
speed of 3000 rpm with an encoder resolution of 1000 lines or
4000 count/rev. This speed equals:
3000 rpm = 50 rev/sec = 200,000 count/sec

• The program reads the input voltage periodically and assigns its
value to the variable VIN. To get a speed of 200,000 ct/sec for
10 volts, we select the speed as
Speed = 20,000 x VIN

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Drive X-Y with Velocity (cont.)

#JOYS Label
AC 100000 Set Acceleration
DC 100000 Set Deceleration
JG 0,0 Set in Jog Mode
BG XY Start Motion
#LOOP Label
VX=@AN[1]*20000 Read joystick & compute speed X
VY=@AN[2]*20000 Read joystick and compute speed Y
JG VX, VY Change speeds
JP #LOOP Repeat
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EN End program
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Point to Point Motion with 2 Velocity Levels

Task: Move a distance of 10,000 counts at a speed of 20,000.
Acceleration and deceleration should be 100,000. For last 100
msec of move, approach target at speed of 2000 cts / sec.

VELOCITY
200

20000

2000

0 2000 7800 10000
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POSITION
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Point to Point Motion with 2 Velocity Levels (cont.)

Calculate distance to change speed
A = Distance moved during acceleration
A = V2 / (2*AC)
A = 20,000*20,000 / (2* 100,000)
A = 2000
B = Distance moved while approaching target at 2000
B = 2000 cts / sec * .100 sec
B = 200 cts
C = Total Distance for dec and approaching target
C=A+B
C = 2200
D = Distance at which speed must be changed to 2000
D = 10,000 - C
D = 7800
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Point to Point Motion with 2 Velocity Levels

#A Label
DP 0 Define Position of X axis 0
PA 10000 Move to position 100000
SP 20000 Set Speed to 50000
AC 100000 Set Acceleration to 120000
DC 100000 Set Deceleration to 120000
BGX Begin Motion on X axis
D = 7800 Define D (position of new speed)
AD D
SP 2000 Set new speed
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EN End of Program
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Controlling Motion with Digital Input

Task: After start pulse, move forward a distance of 4000
counts at an initial speed of 4000 ct/s. After a distance of 2000,
lower the speed to 2000. After the completion of the forward
motion, wait for 100 ms and move backwards at a speed of
4000 ct/s.
INPUT 1

4000
VELOCITY

2000

TIME

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-4000
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Controlling Motion with Digital Input (cont.)

#A Label
PR 4000 Distance
SP 4000 Speed
AC 10000 Acceleration
DC 10000 Deceleration
AI1 Wait for Input 1
BGX Start X motion
AD 2000 Wait until distance = 2000
SP 2000 New Speed
AMX Wait until move is complete
WT 100 Wait 100 ms
PR -4000 Distance
SP 4000 New speed
BGX Start motion
AMX Wait for motion completion
JP #A Start the cycle again
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EN End
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Stop Motion at N Counts After Input

Task: Jog Motor at 5000. Capture the encoder position of the
motor when the input is detected, using the Latch Function.
Stop the motor at 1000 counts after detecting input.
• Define the following variables:
N = The target distance, 1000
D = The distance required for the motor to decelerate to a stop
= (1/2 * SP2 / DC)

• The latch is armed with command, ALX. When latch occurs, _ALX changes
from 1 to 0 and _RLX = captured position.

• Desired target position is _RLX+N

• Initiate deceleration (ST command) at position _RLX+N-D

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VELOCITY Stop Motion at N Counts After Input (cont.)

_RLX N D

TIME
INPUT 1
STATE OF
LATCH

_ALX=1 _ALX=0

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Stop Motion at N Counts After Input (cont.)

DP 0 Define X Position 0
N = 1000 Stopping Distance
ALX Arm X axis Latch
JGX = 10000 Set Jog Speed
ACX = 50000 Set Acceleration Rate
DCX = 50000 Set Deceleration Rate
BGX Begin Jog Motion
#WAIT Wait for latch
JP#WAIT, _ALX=1
D= (.5*_JGX*_JGX)/_DCX Calculate Deceleration Distance
T = _RLX + N - D Calculate stopping point
AP T Wait until distance achieved
STX Decelerate to a stop
EN End Program
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Using Vector Mode

Task: Command X and Y axes to trace out the following motion

6000
E F
5000 G
D

1000 C H
B A I
0

-5000 -4000 0 4000 5000

A to B B to C C to D
XB = -4000, YB = 0 R = 1000 XD = -5000
VP -4000,0 q = 270O YD= 5000
D = -90O VP -5000,5000
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168 CR 1000,270,-90
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Using Vector Mode

VP -4000,0 Segment A to B
CR 1000,270,-90 Segment B to C
VP -5000,5000 Segment C to D
CR 1000,180,-90 Segment D to E
VP 4000,6000 Segment E to F
CR 1000,90,-90 Segment F to G
VP 5000,1000 Segment G to H
CR 1000,0,-90 Segment H to I
VP 0,0 Segment I to J
VE End of Vector Sequence
VS 40000 Set Vector Speed
VA 1000000 Set Vector Acceleration
VD 1000000 Set Vector Deceleration
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BGS Begin Sequence
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Maximize Performance of Vector Motion

Task: Vary the speed of the vector motion on difficult segments
(such as corners). Use vector speed operators, < and >.
• Monitor Vector Motion with SDK to determine system
performance

• Use ‘<’ and ‘>’ operators to adjust speed for critical segments

• From Previous Example:
• Maximum speed for circular motion: 40000
• Maximum speed for straight line segments: 80000

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Maximize Performance of Vector Motion (cont.)

Vector Speed
Vector Speed
Begins Accelerating
is 40000
to 80000

Vector Speed
Vector Speed
Begins Accelerating
is 40000
E F to 80000

D

G

Vector Speed
Vector Speed
Beings Accelerating H
is 40000
to 80000

C
B A I

At this Point, Vector Speed
Beginning of
Vector Speed Begins Accelerating
Motion Path
is 40000 to 80000

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#A
VP -4000,0 <80000>40000 Decrease speed at end of segment
CR 1000,270,-90
VP -5000,5000 < 80000>40000 Increase to 80000; End at 40000
CR 1000,180,-90
VP 4000,6000 < 80000>40000
CR 1000,90,-90
VP 5000,1000 < 80000>40000
CR 1000,0,-90
VP 0,0 < 80000 Increase speed at beginning of segment
VE End of Vector Sequence
VA 1000000 Set Vector Acceleration
VD 1000000 Set Vector Deceleration
BGS Begin Sequence
AMS
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80000
VECTOR SPEED

40000

A B C D E F G H I A

VECTOR SEGMENT

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Maintain Knife Tangent to X-Y Motion

Task: Use Vector Motion on X-Y axes for vector and circular
motion. Use Z axis to control knife position.
• The Z axis has 4000 counts / rev
The resolution is 4000 counts / 360
• Determine the relationship between Knife position and angle
For example: At Position 1000, Z axis points in direction of 00
• Z axis resolution and starting position is specified by TN
command 90

Direction of knife at
position 1000

180 0

270
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Maintain Knife Tangent to X-Y Motion(cont.)

• Use the value _TN to set the correct knife position before
executing the vector motion.
-4000,3000 0,3000

Point Knife in
-4000,0 0,0 Starting Direction
Knife Path PA ,,_TN

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Maintain Knife Tangent to X-Y Motion(cont.)

VMXYZ Motion on XY plane and Z tangent
TN 4000/360,1000 Specify resolution and offset of Z axis
VP -4000,0
CR 1500,270,-180 Specify vector moves
VP 0,3000
CR 1500,90,-180
VE End of vector move
PA 0,0,_TN Move X, Y & Z into starting position
BG XYZ Start the move to get into position
AM XYZ Wait for move completion
SB 1 Move Knife into material (with output bit)
WT 100 Wait for Knife to be in position
BGS Begin vector motion
AMS After the coordinated move is complete
CB 1 Remove Knife from material
EN End program
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Glue Dispensing

Task: Move a dispensing head in the XY plane and dispense
glue at uniform rate per length

• Method - Drive XY in the vector mode, VM, generating linear and
circular segments.

• To achieve uniform glue flow per length, there are two choices:
1. Run VM at constant rate, VS. Turn dispenser on and off when
motors are at full speed. This requires that trajectory must
overlap.
2. Run VM at variable VS rate, allowing slowdown on corners.
Drive pump motor in proportion to vector speed. GAZ=S, GR,,1.

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Using a Gantry System

Task: Maintain equal load sharing between motors on a gantry

X-axis Y-axis

Position Error (TEX) Position Error (TEY)
Commanded Position (RPX, RPY)

Actual Position (TPX)

Actual Position (TPY)

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Using a Gantry System (cont.)

Task: Configure X and Y motors of a gantry to be geared
together. Maintain equal load sharing between the motors.

• To specify the master axis, use the command, GA
Example: GAX=Y specifies Y as the master of X axis

Choices for master:
- Motor position or encoder - XYZW or ABCDEFGH
- Commanded motor position - CX,CY,CZ etc
- Auxiliary encoder - DX,DY,DZ etc
- Vector speed of S or T plane - S,T
- Virtual axis -N
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• To specify gear ratio, use the command, GR
GRX=2 specifies X to follow master with a ratio 2:1
• To maintain gearing, use the Gantry mode, GM. With GM,
gearing will not be disabled by ST command, Limit Switches or
Abort Input.
GM 1 enables Gantry Mode for the X axis.
• For a gantry system:
- Set KI=0 for both master and slave. This eliminates excessive
torque on the system
- Use commanded position (CX) as the gearing master. This
avoids load coupling.
- Enable Gantry Mode for the slave axis
• Use a program to maintain load sharing;
- When positional error exceeds threshold, make a
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correction on the slave axis (on top of gearing).
180
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#GANTRY Label
GA ,CX Define X axis as master, Y as slave
GR ,1 Set Slave Gear Ratio
GM ,1 Enable gantry mode for slave axis
#LOOP
E=_TEX-_TEY Torque difference of master and slave
JP#LOOP, E*E < 400 Do nothing if error is small
IPY=E Make Correction
AMY Wait for Motion to Complete
JP#LOOP Repeat
EN End of Program

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Web Cutting with Fixed Cut Length

Task: As web moves continuously, cut web with a rotary knife at constant
length segments.

Roller w/
Encoder
• Synchronize knife to web in electronic gearing.
• Similar Applications -Applying labels to bottles
• Example
Circumference of knife: 20”
Encoder Resolution of knife axis: 4000 cts / rev
Circumference of Roller: 10”
Encoder Resolution of Roller Axis: 8000 cts
Need to set Web Speed = Knife Speed
Web Line Speed is 30” / sec
Speed of Knife: 1.5 Revs / Sec = 6000 cts /sec
Speed of Roller: 3 Revs / Sec = 24000 cts / sec
Ratio of Knife / Roller = 6000 / 24000
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GA ,X Define X axis as master for Y
ELECTROMATE 1/4
GR, Set Gear Ratio to be 1/4
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Web Cutting With Variable Cut Length

Task: As web moves continuously, cut web with a rotary knife at
constant length segments.
Advancing Knife

Correction
VELOCITY

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ELECTROMATE KNIFE SPEED
TIME
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Web Cutting with Fixed Cut Length

• To cut at a given length, add PR command on top of gearing.
Knife circumference = 20”
Desired cut length = 16”
Knife encoder resolution = 4000 counts
Knife must be advanced
4000/5 = 800 counts
• Position of knife to clear contact: 2500 counts
#A Label
DP0,0 Define X and Y position 0
GA,X Define X axis as master*
GR,.25 Set Slave Gear Ratio 1
V=2500 Position of Knife to advance
#LOOP
MF,V Wait for knife to reach pos.
PR, 800 Advance knife position
BGY Begin advancing movement
AMY Wait for move to complete
V=V+4000 Add 1 Rev to next position
JP#LOOP Repeat
EN

For DMC-1000, DMC-1500 the gear command should be: GAX
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Pause Motion

Task: When input is triggered, decelerate vector motion to a stop,
when input is de-activated, resume motion
• Create #ININT subroutine in Program
• Use General Use Input to generate interrupt
• Set Vector Speed, VS, to zero
• Pause while interrupt remains active

II1 Set X axis only for vector motion
#LOOP Vector motion path
VP -4000,0
CR 1500,270,-180
VP 0,3000
CR 1500,90,-180
VE
BGS;AMS
JP#LOOP Repeat motion when done
EN
#ININT Input Interrupt routine
N= _VS Save Current Vector Speed
VS 0 Set Speed to 0
#PAUSE Wait while input is active
JP#PAUSE,@IN[1]=0
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185 VSN Resume
ELECTROMATE RI1 Return from interrupt
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Backlash Compensation

Task: Eliminate servo instability and / or poor accuracy due to
mechanical backlash

• Install an encoder on the load with resolution <= motor
resolution

• Place motor encoder into auxiliary encoder input. Place load
encoder into main encoder input

• Issue DV1 command

• Tune System Using SDK

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

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