Galil presentation advanced motion control techniques for nanopositioning applications 2009

Advanced Motion Control Techniques for
Nanopositioning Applications

October 2009

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Agenda

• Company and Product Overview

• System Elements

• Galil Control Filter

• Advanced Control Features

• Tuning – GalilTools and WSDK

• Adding IO to Motion Control Systems

• GalilTools API and LabView

• Medical/Biotech Sample Applications
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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 90 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!

• 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
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– Problem
– Error messages
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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
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http://www.galilmc.com/support/smartmoves.php
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Galil Motion Controllers

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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
• Contouring
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• Teach and Playback
8
• Position, Velocity, Time (PVT)
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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

• Ethernet available for 10Base-T and 100Base-T
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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

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Galil Product Line

• ACCELERA Controllers & Drives
– DMC-40x0 Ethernet/RS232
– DMC-18x6 PCI
• ECONO Controllers & Drives
– DMC-18x2 PCI
• Single-Axis Controllers & Drives
– CDS-3310 Ethernet/RS232
• Pocket PLC I/O Controllers
– RIO-47xxx Ethernet/RS232
• Software Tools
– GalilTools Servo Tuning and Analysis software
– Ladder Interface Converts ladder program into RIO code

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ACCELERA – Sizzling Speed. Fully Loaded.

• Galil’s latest generation motion controller family
• RISC processor for high-speed performance and
processing power
• Accepts encoder inputs up to 22 MHz for servos
• Servo updates as fast as 31 µsec/axis
• Command processing time as low as 40 µsec
• 2000 lines x 80 chr program memory
• 16,000 array elements; 510 user defined variables
• Enhanced instruction set
• Available in 1- through 8-axis formats
• PCI: DMC-18x6
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DMC-40x0 Accelera Ethernet Controller

• Accelera, Ethernet/RS232 controller
• Full-featured, packaged controller
• Ultra-high speed and precision
• Ethernet 10/100Base-T, RS232
• 1 through 8 axes
• Optically isolated I/O, high-powered
outputs, analog inputs, expanded
3.3V I/O, metal enclosure, d-type
connectors
• Available packaged with multi-axis
servo and stepper drives DMC-4040 4-axis controller
• Compact-Box Dimensions:
1-4 axes: 8.1” x 7.25” x 1.72”
5-8 axes: 11.5” x 7.25” x 1.72”
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DMC-40x0 Drive Options from Galil

Model Description

SDM-44040 Four 1.4 A drives for step motors (Full, Half, ¼, 1/16)

SDM-44140 Four 3.0 A drives for microstepping

AMP-43140 Four 20W Linear amps for brush servos

AMP-43040 Four 500W PWM amps for brush/brushless servos
AMP-43020 Two 500W PWM amps for brush/brushless servos

The DMC-40x0 can also connect to external drives
of any size or power range.

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RIO Pocket PLC

Smart. Compact. Low-Cost. Packed with I/O

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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 – just 3.88” x 4.26” x 1.30”
• Low Cost – only $295 in single quantity $195 in 100
quantity
• Lots of I/O – 32 digital I/O & 16 analog I/O

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RIO-471xx Provides Numerous I/O

• 16 isolated inputs, 5-24 VDC
• 8 isolated, sourcing outputs, 12-24 VDC, 500mA
• 8 isolated, sinking outputs, 5-24 VDC, 25mA
• 8 analog inputs, 0-5V
– 47120: Selectable +/-10V, +/-5V, 0-5V, 0-10V 12-
bit std, 16-bit opt. Differential or Single-ended.
• 8 analog outputs, 0-5V
– 47120: Selectable +/-10V, +/-5V, 0-5V, 0-10V 12-
bit std, 16-bit opt.

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All I/O are self-contained in each RIO unit.
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Network multiple RIO units to add more I/O.

Use ICS boards for Prototyping

Converts D-type to screw terminals

ICS-48026 for analog I/O
ICS-48044 for digital I/O

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RIO-47200 PLC with Screw terminals

Pocket PLC with Screw Terminals and DIN Tray

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RIO Options

• RIO-47100 PLC with 0-5V analog; 12-bit
• RIO-47120 PLC with +/10V analog; 12-bit
• RIO-47120-16 16-bit ADC/DAC
• RIO-47102 -47100 with expanded memory
• RIO-47122 -47120 with expanded memory
• RIO-47200 PLC with screw terminals, DIN,
0-5V analog inputs, 16 high power outputs

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System Elements

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Position Control Systems

BLOCK DIAGRAM

HOST MOTION MOTOR
DRIVER
COMPUTER CONTROLLER AND LOAD

POSITION
SENSOR

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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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System Elements

FILTER

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

C

POSITION
DECODER

P M
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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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Galil Control Filter

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Advanced Filter Features

•Proportional, Integral and Derivate gains
•DAC Offset
•Torque limiting (continuous and peak)
•Integral limiting (including integrator “freeze”)
•Feedforward terms (acceleration and velocity)
•Notch filter
•Pole filter
•Servo sample period

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Dual Loop block diagram

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Piezo Ceramic firmware

•Available as option for increasing performance of
piezo ceramic motors
•Helps deal with static and dynamic characteristics of
piezo ceramic motors
•Features
• Positive and negative anti-friction bias
• Deadband with hysteresis and shutoff
• Dual PID gainsets for static/dynamic operation
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Custom Firmware Options

Galil offers many custom firmware modifications to
achieve ultimate system performance:

•Feedback options: BiSS, SSI, Sine/Cosine
•Linear and 2D error mapping
•Kinematic transformations
•Advanced control algorithms
•Other customizations – FD, input notch, etc.
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System Tuning

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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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WSDK Auto Tuning

• The autotuning feature
allows quick and easy
tuning

• Adjusts PID parameters
for optimum performance

• Several autotuning
methods available

• Step response is
displayed showing
risetime, overshoot and
settling

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WSDK System Analysis

• Provides impulse test to
check for absolute
stability

• Actual response to
impulse is displayed

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WSDK System Analysis

• Provides open and closed-
loop frequency response
test

• Useful for determining
system bandwidth and
resonances

• Frequency range for test is
selectable

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GalilTools- The Next Generation

A new 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-47xxx
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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Adding IO To A System

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RIO-47xxx Networking

Seamlessly interface to Galil motion controllers

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RIO-47xxx Networking

Can be networked so all devices can access it

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Advantages to Remote IO

•Place controller closer to IO points
• Noise immunity

•Cat 5 cabling is cheaper and more readily available
then shielded cables

•Open protocols
• ASCII strings via TCP or UDP
• Modbus TCP/IP

•Interface to many other Ethernet enabled devices
• PC’s, HMI’s, PLC’s…
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Advantages to Remote IO - continued

•Offload processes to RIO
• Free up controller processing time

•Theoretically infinite IO points

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Software

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Software

In addition to the GalilTools GUI, an api and COM
interface have been developed for Galil integration in
the following programming languages:

•C++/CLI
•C#
•Visual Basic
•Visual C++
•G++ (Linux)
•LabView

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LabVIEW HTML help

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LabView Example

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Application Examples

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Application Examples

Galil has been involved in a number of
medical/biotechnology applications including:

XYZ Labs – Ceramic fast step settle:
1 mm @ 60msec, 1µm @ 20msec
XYZ Bio – Linear motor fast short move:
80 µm move @ 1msec
XYZ Micro - FDA and ceramic motors
Documentation
Static configuration
Verification procedure

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Application Examples/Links

Links for high speed/high accuracy systems:

http://www.galilmc.com/support/appnotes/miscellaneous/note5465.pdf



http://www.galilmc.com/support/servotrends/st_10_08.pdf

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Galil Product Training Seminar 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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Galil presentation advanced motion control techniques for nanopositioning applications 2009

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