1. Diamond Motion Control
A quick summary
Motion Control Team
Phase 1 PMAC-UMAC
Phase 2 GeoBrick
Working Practice
Variations
Going Forward
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2. 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
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3. 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
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4. 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
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5. 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
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6. 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
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7. 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
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8. 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
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9. Delta Tau Geobrick LV-IMS
What can the geobrick do?
Output types:
DC Servo Motor
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10. Delta Tau Geobrick LV-IMS
What can the geobrick do?
Output types:
3 Phase Brushless DC Motor
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11. 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.
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12. 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.
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13. 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
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14. Diamond Motion Control multiple authors
Working practices
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15. 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
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16. 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
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17. 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.
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18. 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.
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19. 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
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20. 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
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21. 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 …
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22. 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
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23. 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)
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24. 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.
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25. 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.
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26. 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
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27. Diamond Motion Control multiple authors
QUESTIONS
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28. Diamond Motion Control multiple authors
Thank You
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29. 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
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