Diamond Motion Control A quick summary Motion Control Team Phase 1 PMAC-UMAC Phase 2 GeoBrick Working Practice Variations Going Forward 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion control Brian Nutter - senior motion system engineer Iain Johnson - senior electrical technician Lee Hudson – senior electronic technician Trevor Bates – contract motion systems engineer Paul Dunne – contract commissioning engineer 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Phase 1 VME based Solution PMAC2 VME 32 axes UMAC Crate (I/O, encoder, limits) 2 x 16 axes + breakout (Amplifier Crate Extra) Optical link 01/05/2018 Diamond Motion Control multiple authors

Delta Tau PMAC – UMAC MACRO Solution A Quick Comparison 32 axis pmac ultralight 16 axes UMAC ( macro expansion card) 4 axis motion cards 24 in 24 out digital 16 (or 8) amplifier crate Discrete specialist amps MX add on amplifier 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors One of the neater installations Note that side mounted PM modules restrict access to rear mounted connectors on amp and control crates 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS What is the Geobrick LV-IMS? A 4U high 19 crate containing DC power supplies, Delta Tau Motion controller/ amplifier module type Geobrick LV All field connections are available on the rear of the enclosure using diamond standard connectors from phase 1. Limits Encoders TLA Alert Pulse Width Modulated TLA Alert Integrated Motion System Motors 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS What is the Geobrick LV-IMS? 16 axis PMAC 8 axis amplifier board Plant Interface Board Dual Power supply Acc910 Options Board 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS What can the geobrick do? Output types: 5A cont current and 15A peak x32 micro-stepping (6400 steps per rev) 2-phase Stepper Motor 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS What can the geobrick do? Output types: DC Servo Motor 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS What can the geobrick do? Output types: 3 Phase Brushless DC Motor 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS 8 Axes quadrature encoder input up to 16Mhz Optional Encoder Support: via Acc 910 board Sinusoidal SSI Endat Yaskawa Sigma Resolver Hiper Face Tamagawa BisC Note: Only one optional encoder module can be installed in each servo IC ( block of 4 axes). However, standard incremental channels are always available. 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS How does it work? Encoder Conversion Table PID Simulated Position H-Bridge Drive PMAC Drive & Motor +  DAC Master Sine Wave Commutation Decoder/ Counter E Encoder Conversion Table EQU output Trajectory Generation The key here is that the encoder channel is un used. This means we can use it for something else. The encoder counts g into the conversion table from a specific hardware channel, or from a software counter, They can be used by any axis of the servo processor. 01/05/2018 Diamond Motion Control multiple authors

Delta Tau Geobrick LV-IMS What’s in the box? Geobrick LV With Additional break out board Fan fail and Watchdog contacts 24V Logic Supply DC Bus power supply 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Working practices 01/05/2018 Diamond Motion Control multiple authors

Initial Commissioning Record MAC address and assign against DLS asset Number Interrogate amplifier firmware and update if required Download and store Basic Configuration file GB_Startup.pmc Test motor outputs limit and encoder inputs Balance Phase Offsets for all axes 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors GB_Startup.pmc Sets brick to be 8 axis of stepper motor control Set default current level to 1 amp (peak) Set axes 1- 8 open loop stepper 9-16 encoder feedback Set PWM frequency to 20Khz Set servo update rate to be 5Khz Set Phase update frequency to 5 Khz Set protection PLC to de-energise axes after 3 seconds Enable hardware limits for all axes 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Balance Phase Offsets By balancing the dc offset between the two independent motor phases we ensure optimum rotation at current levels from 200mA to 5A. 01/05/2018 Diamond Motion Control multiple authors

On A Beamline – low level Physically configure hardware for installed device. E.g. for servo motor or step/direction output rewire the axis connector to suit. Install Limit conversion and In-Line fuse protection hardware if required. Test hardware for motion limit to limit, and quality of encoder signal if fitted. Determine homing method and repeatability. Record results to pass to controls engineer for EPICS setup. Change seriou pin out for different motor types – eg servo or brush dc. Change connector insert for use with step and direction output. Newport ..Micos In Vacuum Bender modules. DLS standard limit reqires dry contact NC switches at 24V dc levels. PNP electronic switches are OK . However some suppliers insist on giving TTL / open collector 5v switching, and in some in vac cases simply switching the limit signal to the machine body / ground…shocking Drive is capable of delivering 15A per phase ( 5A continuous) . Software setting current to 200mA is no protection. 01/05/2018 Diamond Motion Control multiple authors

On A Beamline – low level Geobrick i-values uploaded to a pmc file and then compared with the spreadsheet values. Significant differences recorded in spreadsheet. pmc files exported from spreadsheet Control.pmc and Axis.pmc and any special requirements e.g. ECT.pmc created and stored in Linux area PLC6_Initialise_and_Reset.pmc placed in Linux area Master.pmc modified to include all pmc files mentioned above Motion report generated and controls engineer notified 01/05/2018 Diamond Motion Control multiple authors

On a beamline – controls commissioning Create <AREA>/Settings/analyse.cfg and confirm that the hardware matches the pmc files in the motion area by using dls-pmac-analyse.py Create standard PLCs by creating psub files containing the substitutions needed to turn the generic PLCs in pmacUtil into beamline specific PLCs Create homing PLCs for each axis if required. This may require modifying some I-variables for the relevant axis Create co-ordinate systems to enable complex motion from EPICS Diamond Motion Control multiple authors

On a beamline – controls commissioning Create entries in Master.pmc for all of the above Load onto the Geobrick and test Run dls-pmac-analyse.py once more to verify Commit the pmc files to svn with a suitable commit message Do the higher level EPICS commissioning Handover to beamline scientist as specified in … 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Variants GeoBrick- Junior 24V DC rail GeoBrick –Turbo 240MHz processor GeoBrick-Macro F/O interface to high power amplifiers and +/- 10V interfaces BrickController No amplifiers 16bit true DAC output 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors What Else Other Motion Suppliers NEWPORT XPS – diffractomters monochromators ( now some migration to delta tau) OMS58 / MAX V – machine based motion front ends / Insertion devices some PGM ( OMS58 obsolete, MAX V fuse issues ) P I - mainly Piezo Stack control ( RS232 via Asyn or analogue output from the IOC crate) AEROTECH – 1 or 2 end station devices. Epics support provided ( Annual maintenance fee requested) 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors What Else Turn Key Systems MONOCHROMATORS – subcontracted EPICS front end software on several phase 1 beamlines. ALL now migrated to DLS written code. OD, ACCEL, IDT SAMPLE PLATFORM – 2 Tonne sample stage from Max Voggenriter using Siemens S7 and Profibus. EPICS code written to DLS specification with consultative input from DLS MIRRORS – Some mirror suppliers use proprietary benders which can only be set up by their specialist subcontractor. 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Keeping the lid on At Design Reviews. BJN attends design reviews for all systems involving motion control At Purchasing NPR / BJN have sign off of all purchase orders involving ‘Motion Control System’. May need to be extended to ‘small and precision motors’ and … Guidance document Issued a document guidelines for design and specification of motion control equipment to assist engineers and scientists at the beginning of their projects. 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors In Future AttoCube – piezo stack stages SmarAct – closed loop piezo S/D input PI – resonant piezo devices +/- 10V input Aerotech – 1nm linear servo 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors QUESTIONS 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Thank You 01/05/2018 Diamond Motion Control multiple authors

Diamond Motion Control multiple authors Multi-person effort: Coordinate systems – Tom / Ulrik Asyn driver / device support – Peter D / Matt / Nick Motor record – Matt / Nick / APS Motor GUIs – Tom / Matt / Ronaldo Python apps – Ulrik / Martin / Matt Drivers: VME PMAC driver – Andy / Argonne Lab IP Geobrick PMAC driver – Matt / Pete / Nick PMAC driver – Peter D / Matt / Nick XPS driver – Matt / Jon / APS Other drivers (Aerotech, OMS, PI) - Many 01/05/2018 Diamond Motion Control multiple authors