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Galil presentation advanced motion control techniques for nanopositioning applications 2009
1. Advanced Motion Control Techniques for
Nanopositioning Applications
October 2009
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2. 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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3. 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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4. 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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5. 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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6. 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
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• Customer applications and videos
http://www.galilmc.com/support/smartmoves.php
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8. 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
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• Position, Velocity, Time (PVT)
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9. 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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10. 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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• Arithmetic and trigonometric functions
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12. 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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• Ethernet/RS232: DMC-40x0
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13. 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”
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14. 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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15. RIO Pocket PLC
Smart. Compact. Low-Cost. Packed with I/O
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16. RIO-47xxx Pocket PLC
Analog and Digital I/O with intelligence
in a cost-effective, compact unit
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17. 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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18. 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.
All I/O are self-contained in each RIO unit.
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Network multiple RIO units to add more I/O.
19. 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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20. RIO-47200 PLC with Screw terminals
Pocket PLC with Screw Terminals and DIN Tray
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21. 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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22. System Elements
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23. Position Control Systems
BLOCK DIAGRAM
HOST MOTION MOTOR
DRIVER
COMPUTER CONTROLLER AND LOAD
POSITION
SENSOR
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24. 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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25. System Elements
FILTER
DESIRED R X Y
POSITION
+
Σ G DAC AMP
GENERATOR -
C
POSITION
DECODER
P M
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26. 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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34. 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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35. 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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36. 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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37. WSDK System Analysis
• Provides impulse test to
check for absolute
stability
• Actual response to
impulse is displayed
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38. 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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39. 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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46. RIO-47xxx Networking
Can be networked so all devices can access it
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47. 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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48. Advantages to Remote IO - continued
•Offload processes to RIO
• Free up controller processing time
•Theoretically infinite IO points
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50. 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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51. LabVIEW HTML help
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55. 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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57. 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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