1. (1) REconsider Various contrOLlers for yoUr moTION
Motion controller upGRAde IN SOLEIL : REVOLUTION (1) project DominIque Corruble On behalf of Electronic Control and Data Acquisition team
10/29/2017
Hello everybody
I’m Dominique Corruble from Synchrotron SOLEIL
I’m presenting the last talk of the workshop, I hope it will be not the least
This talk concerns the motion controller upgrade in SOLEIL, the REVOLUTION project.
REVOLUTION is the acronym of Reconsider Various Controller for your Motion
I a few time for a lot of content.
I will not read the slide, you can do it better than me,
I will only give a few comments
(1) REconsider Various contrOLlers for yoUr moTION

2. Choices and project progress
Summary
Reminder
Status of motion control and project motivations
Choices and project progress
Change model and architecture
Classic controller upgrade
High performance controller selection process
Conclusion
Goals status and next tasks
Technical and beyond ….
Summary in 3points
First Reminder of the status and motivations of the project
Second point : the content of the project
And last the conclusion

3. Choices and project progress
Reminder
Status of motion control and project motivations
Choices and project progress
Change model and architecture
Classic controller upgrade
High performance controller selection process
Conclusion
Goals status and next tasks
Technical and beyond ….
My colleague Pascale Betinelli presented this morning SOLEIL and motion control in SOLEIL.
It’s just a quick reminder

4. Reminder : status and motivations
Standardized hardware and software architecture
Wide and homogenous installed base of motion controllers
Motivation :
Very low long-term risk of obsolescence of
our standardized motion controller : GALIL DMC-2182 (1)
New motion control applications become more complex and demand
More performance
More advanced functionnalities
Beam
Detector
Sample
More accurate
More stable
Faster
Better coordinated and synchronized
About the Status, two facts
The standardized architecture
And a wide and homogenous installed base
Our motivation
Prevent a very low long-tem risk of obsolescence, there is no emergency
To meet new motion challenges, we need a motion controller
with more performance
And more advanced functionnalities
GALIL company :

5. Choices and project progress
Reminder
Status of motion control and project motivations
Choices and project progress
Change model and architecture
Classic controller upgrade
High performance controller selection process
Conclusion
Goals status and next tasks
Technical and beyond ….
Now the content of the project
The main changes in our model and our architecture
Classic controller upgrade
High performance controller selection

6. faster, higher, stronger
Project stakes
3 goals of REVOLUTION project
Significantly increase performance and advanced functionalities
Ensure the operational continuity of installed base
Keep overall costs under control
faster, higher, stronger
money, money, money
These goals are are more or less compatible with each other.
In order to reconcile and to achieve them, we decided
to change our motion control strategy and use model of motion controller
to modify our hardware architecture
the stakes and the goals of the project
Increase performance, as a sports champion
Ensure operationnal continuity, as caring parents
Keep cost under control, as a rigouros accounting
there is not obvious solution.
So we had to make significant changes,
Change our strategy and model
Change our hardware architecture

7. Pareto principle Change model
Distribution of motion applications and use model of motion controller
Current model :
one standardized controller for any application
suitable for a very small team which has to implement many applications with limited complexity
Next model :
2 controllers selected according to application needs
Tomorrow
Performance/functionality
Axis Number
Distribution of
Motion applications
Pareto principle
Performance/functionality
Axis Number
Today
Use of
«single &
universal»
controller
Distribution of
Motion applications
Use of
«Classic»
controller
Use of
«High Performance»
controller
Border to be defined
Fist
Our current model is based of the model of a single and universal motion controller for any application or almost any application.
the distribution of applications according to performance and functionality is a rule 80% - 20% or a Pareto principle
Many applications with a low level of performance
And few applications with a high level of performance,
We plan for the future a significant increase of high performance applications
So we decide to change our model and to have 2 standardized controller used according to the applications needs.
The main features of the 2 controllers are summarized in this table
Main features 
« Classic»
controller
«High Performance»
Percentage of use
HIGH
LOW
Compatibility with current architecture (Hard & Soft)
FULL
LIMITED
Level of performance and advanced functionalities
Synthesis
table

8. “CLASSIC” CONTROLLER Use of «Classic» controller
Performance/functionality
Axis Number
First part : the classic controller
Main features 
« Classic»
controller
«High Performance»
Percentage of use
HIGH
LOW
Compatibility with current architecture (Hard & Soft)
FULL
LIMITED
Level of performance and advanced functionalities

9. Classic controller upgrade
Use of
«Classic»
controller
Full compatibility with current architecture
Software part :
Current embedded software (microcode) written in a language proprietary to GALIL 
DMC-2182 will be progressively replaced
by DMC-4183, its backward-compatible natural successor
Hardware part :
Using current ControlBox rack (same size, same pinout)
minor changes needed : internal power supply socket, mounting holes, USB socket
development of an interface board (MIG-4121)
in order to adapt the DMC-4183 to internal pinouts of ControlBox rack
Results
Few hardware and software development
Software : Minor changes in microcode
and Tango devices
Already developed and tested
Hardware : interface board MIG-4121
Specification in progress
Technical benefits:
Long term continuity of a last generation product
Stronger TCP-IP stack
Faster user application execution time (divided by 2)
USB port instead of RS232 port
Improvement in some functionalities :
Index homing, deceleration on limit-switch, ….
The main issue of the classic controller is the fully compatibility with our current architecture.
We will replace the current DMC 2182 by its backward compatible successor : the DMC4183, to ensure the software compatibility
The hardware compatibility is ensured by the reuse of the ControlBox rack.
Only few minor changes are need to integrate the new Galil board
In hardware part, we want to make the least possible modifications.
The main change is to add a interface board (MIG-4121) to adapt the pinout,
The specifications of this board are in progress

10. “HIGH PERFORMANCE” CONTROLLER
Use of
«High Performance»
controller
Performance/functionality
Axis Number
Second part : the high performance controller
Main features 
« Classic»
controller
«High Performance»
Percentage of use
HIGH
LOW
Compatibility with current architecture (Hard & Soft)
FULL
LIMITED
Level of performance and advanced functionalities

11. High performance controller requirements
Currently operational
with GALIL DMC-2182
Ethernet 100Mbps
NO (1)
Number of axes per system: at least 8
YES - 8 axis
Stepper Motor technology supported
YES
Servo Motor technology supported
Absolute Encoder supported
Digital Encoder supported - quadrature
Analog Encoder supported
Continuous closed loop for stepper motor NO
Multi axes & multi controller synchronization
Gearing
Piezo Motor technology supported
Double loop feedback, PID regulation, dead band…
Fast processing function (non linear feedback)
Virtual axes
NO (2)
PVT (for Undulator/monochromator scan)
NO (3)
Embedded safety process
User embedded software development capabilities
Collect of user needs
Define requirements
Trading : Select industrial manufacturer well known in scientific facilities, price
Time : Obtain a product ready to use
Organizational : Evaluate impacts for SOLEIL by using the controller
Technical : ….
(1) : 10 Mbps half duplex in DMC-2182.
Use of
«High Performance»
controller
Essential features to
High performance applications
We made the user need collect and define the requirements
Trading, Time, Organizational, and obviously Technical
I let you read the table
A large part of these requirements are already achieved with our current system, but not all.
5 missing requirements are essential for the most demanding applications
- Continuous closed loop for stepper motor (with PID parameter)
Muti axes and muti controller synchronization
Fast processing function
Virtual axes
PVT or synchronized non linear trajectories
(2) : PVT mode available in DMC-2182 but never implemented.
(3) : Only one virtual axis available in DMC but never implemented.

12. Selection methodology
Methodology in 4 steps
Market analysis
According to commercial documentation
Advanced technical analysis
According to technical documentation
Tests stand
Test of fonctionalities, measure of performance,
setting in operational situation
Initial inventory of controller
Produced by main manufacturers
Selection
Out
FINAL CHOICE TO BE VALIDATED
Not selected candidates
GALIL DMC-4183 Too slow .It’s the «CLASSIC» controller
Result of an previous evaluation
NEWPORT(1) XPS Low reliability from SOLEIL and others facilities feedback
Suitable for Newport mechanisms but low openness
AEROTECH(2) EnsembleMP10 No ceramic control, Form factor not convenient
Suitable for Aerotech mechanisms but low openness
TRIO MOTION(3) EURO2009 Can not control 8 stepper motors with 8 encoders
Not suitable for a typical synchrotron facility
PRO-DEX(4) MAXNet Slow Ethernet 10 Mbps and aging product.
Next generation planned soon (too late)
ESRF(5) IcePAP Not an industrial manufacturer.
Some advanced functionnalities not available or planned
SHORT LIST
Selected candidates
GALIL DMC GALIL’s highest performance controller from last generation
DELTA TAU(6) Power PMAC DELTA TAU latest motion ‘computer’
We define a methodology to select our controller in for step
- Inventory of controller and manufacturer
- A market analysis
- Advanced technical analysis
- Test stand
Make a selection is make choices :
we did not selected six controllers for different reasons
We got a short list for the test stand
Galil DMC-4080 and DELTA TAU Power PMAC
I write here the marketing words from the both companies
Newport company : (3) Trio motion company :
Aerotech company : (4) Pro-dex company :
(5) ESRF Faciltiy :
(6) Delta Tau company :

13. Test stand : comparison elements
Test stand to compare technical features of DMC-4080 and Power PMAC
Measure of performance
Calculation loop, response time to a logic trigger,…
Implementation of advanced functionalities
Multi-axes hardware synchronization, non linear trajectories in PVT mode , virtual axes…
Two tests made in an operational situation
Non linear rotation of a monochromator : Sine arm mechanism with disturbances (spring effect)
Control of an hexapod – 6 jacks of a Stewart platform : Implementation of forward and reverse kinematic equations
Technical results(*)
Advantage to Power PMAC
Faster
All required functionalities are operational
Reasons of Power PMAC advantage
Continuous closed loop (PID) on stepper
Faster as discontinuous closed loop
(stop, correction, restart)
Ability to program directly and run compiled code
Faster as interpreted code
Organizational results (*)
Advantage to DMC-4080
Easier and faster to configure, to use
and to program
Reasons of DMC-4080 advantage
User-friendly tools : you don’t need to be an expert
Language, IDE.
Versatility limited to essential
Few parameters necessary to set an axis
3 steps in test stand in 3 step
- Time measurement
- Implementation of advanced functionalities
- Test in operational situations
First one with a rotation of an old monochromator, which has many defects
Second one with a Stewart platform by implementing the kinematics equations
Power PMAC has a technical advantage
It’s faster and have all required functionnalities
Its main advantages are firstly the continuous closed loop with PID that it’s faster as discontinuous closed loop : that means stop, correct and restart
The second advantage is the ability to directly program and execute compiled code that it’s faster than interpreted code
GALIL controller has organizational advantage
With GALIL controller , you don’t need to be an expert to configure, to use and to program it.
The tools are user-friendly and the versatility is limited to essential, so only few parameters are necessary to set an axis.
November 15th; 2012
(*) SOLEIL opinion

14. Synthesis table of SOLEIL’s comparison
Ultimate choice
Synthesis table of SOLEIL’s comparison
DELTA TAU
Power PMAC
GALIL
DMC-4080
Plus
Highest performance
More advanced functionalities available
Full versatility
Hardware rack with amplifiers available
(Power Brick LV by DELTA TAU UK)
Embedded and Tango software available and tested
Skills and expertise present at SOLEIL
Continuity of current system, no risk
Easy to configure, to use and to program
Less
More complex to use
Skills and expertise to be developed
Embedded software to be developed
Tango software to be tested
(by OBSERVATORY SCIENCE(1))
No continuous closed loop for stepper motor
Limited versatility
No direct access to user compiled code
Need to develop a dedicated rack included amplifiers
SOLEIL choose DELTA TAU Power PMAC in Power Brick LV format
Reasons :
Technical advantages of Power PMAC and Power Brick rack
Hardware rack (Power Brick LV ) available
Large user community of DELTA TAU products
New hardware architecture :
controller and amplifiers in a single rack
You can read the SOLEIL’s point of view in the synthesis table
Each one has advantages and disadvantages, but a choice had to be made
SOLEIL choose Power PMAC in Power Brick LV format.
The rack Power Brick LV is developed by Delta Tau UK,
It’s the successor of Geobrick LV used in other facilities like DIAMOND or NSLS 2,
It includes Power PMAC CPU and amplifiers in a single rack.
This new hardware architecture is cheaper than two racks,
We hope to collaborate with the user community of Delta Tau products to not reinvent the wheel,
However This choice requires new tasks
The management of a technical transition.
we learned from the DIAMOND feedback what remains to do
November 15th; 2012
Necessary tasks in progress :
Management of a technical transition :
New internal organization, training sessions, generic implementation process,
According to the feedback of DIAMOND(2) which uses widely DELTA TAU products
Inventory of motion control applications which could use Power Brick
OBERVATORY SCIENCE company :
(2) DIAMOND Facility :

15. Choices and project progress
Reminder
Status of motion control and project motivations
Choices and project progress
Change model and architecture
Classic controller upgrade
High performance controller selection process
Conclusion
Goals status and next tasks
Technical and beyond ….

16. Conclusion : Goals status & next tasks
Significantly increase performance and advanced functionalities
Implementation of a very high performance product
Ensure the operational continuity of installed base
Hardware and software compatibility of the CLASSIC controller
Keep overall costs under control
Few development for the CLASSIC controller
Reasonable cost of the HIGH PERFORMANCE controller and amplifier rack (new hardware architecture)
Hidden costs : workload to develop DELTA TAU expertise, training sessions, reorganization of the electronic team
Left to be done in SOLEIL :
Classic Controller :
Develop interface board (MIG-4121) for DMC-4183 into the ControBox planned late 2013
High Performance controller
Reorganize the electronic team, Define generic implementation process, planned late 2013
Deploy the first operating application planned early 2014
Validate Power Brick choice after the first feedbacks from deployed applications planned in 2014
Mainly the goals will be reached
Increase performance by implement a very high performance product
Ensure the operationnal continuity by the compatibility of the classic controller
Keep cost under control by only few development for classic controller and reasonnable cost of high performance controller.
But there is some hidden cost : workload to develop Delta Tau expertise, the trainig session, the reorganization of the team
What is left to be donne
The development of the interface baord
reoganization team
The implementation of the first application
The validation of this choice after the first feedback
All these tasks are planned for the next months
November 15th; 2012

17. Conclusion: Technical and beyond …
Reconciling the three objectives (performance, operational continuity and cost control) of the project required
A change of strategy and model
A change of hardware architecture only for “high performance” controller
A new organization in the electronic team and new working methods
These structural and organizational changes were not initially planned in a project
that seemed to be very technical.
REVOLUTION is well under way, but it might bring new surprises
Now
I talked about technical topics but beyond…
I can say that [lecture slide]
November 15th; 2012

18. Thank you for your attention it’s not my favorite topic
29/10/2017
Thank you for your attention
Ultimate wink
By looking information on DELTA TAU and GALIL,
I found a link to the DeltaGalil website
What is it ?
A merger between the two companies
A new competitor with an ambigous name
Very disappointed
it’s not my favorite topic
Ultimate wink in the last slide :
By looking information on the both companies
I found the DeltaGalil website
What is it ?
A merger between the two companies
A new competitor with an ambigous name
I clicked on the DELTAGALIL link I discovered this page
Oh my god, I was very dissapointed.
Underwear is not my favorite topic
As personnal conclusion I can say
Our job is based on Motion Control
However our job has to integrate Emotion Control