1. _____________ Status and plans in motion control at SOLEIL
Workshop
Exchange around motion control at radiation facilities
_____________
Status and plans in motion control at SOLEIL
Dominique Corruble
May 11th, 2011

2. Summary .. SOLEIL context and organization 2) Motion control status
Soleil in few figures
Computing division and ECA group
2) Motion control status
Hardware architecture and products
Software architecture and microcodes embedded
Results
Plans
Current developments
New requirements and Revolution

3. .. SOLEIL context and organization 2) Motion control status
Soleil in few figures
Computing division and ECA group
2) Motion control status
Hardware architecture and products
Software architecture and microcodes embedded
Results
Plans
Current developments
New requirements and Revolution

4. Synchrotron SOLEIL in few figures
SOLEIL Context
Synchrotron SOLEIL in few figures
Some dates :
Building Construction began late 2003
First beam in Linac : July 2005
First beam in Storage Ring : June 2006
Fisrt beam in a beamline : September 2006
Located 25km from Paris
357 permanent peoples (trainees, Ph D student , post doctoral , not included)
2800 users in 2010
Some Beamlines (BL) characteristics :
- 43 BL possible, but 26 planned
- 17 BL open to user in 2010 (19 BL in 2011)
- Goal : Commissionning of all BL before the end of 2011,
except the “long” beamline Nanoscopium (new building)
- Proposal submission : 33% from international
Some Machine characteristics :
Linac (110 Mev)
Booster (157m circumference)
Storage ring (circumference : 354 m)
Energy : 2.75GEV
Current : 400mA in top up mode,
soon 500mA
Beam availability : 96.3% (2010)
organized in 5 departments
Machine - Administration
Experimental - Technical supports
Computing

5. Computing Division 14/05/2018 SR group GD group ICA group ECA group
Head : Brigitte GAGEY
Assistant : Deborah IORO
5 engineers 5 technicians
Systems & Communication
Philippe PIERROT
Systems Administration
Micro-computing
Scientific & technical computing facilities
Networks & associated services
Telephony
Data Management
Jean-Marie ROCHAT
Management Information System
Technical Information System
Machine & BeamLines databases
Users’ tools
Control & Data Acquisition Software
Alain BUTEAU
Process management
Supervision
Man-machine Interfaces
System Administration of the Control & Data Acq. Infrastructure
9 engineers 5 technicians
Control & Data Acquisition Hardware
Pascale BETINELLI
CPCI crates
PLCs, FieldBus
Digital Electronics
Analog Electronics
Associated Cabling
5 engineers 4 technicians
The Soleil Computing Division is organized in four teams. People are grouped by field of work and skills, to have coherent tools and developments and to be able to adapt the man power to the workload all along the phases : more on the machine control during the first building phase and progressively transferred to the beamlines and experiments.
First, the System and Communications Group is in charge of all the administration and exploitation of computers, scientific facilities as technical facilities. Micro-computing and networks (it includes site network and also control network or experiments network).
Second, the Data Bases Group is in charge of the administrative Management Information System, a key system for the good working of the company. In charge of the engineering data management : to give access to all the documents of the project, drawings, and so on. And at last, this group is in charge of the management of experiments data to allow storage and retrieving of experimental data and so on.
Third, the software controls and acquisition group is in charge of the software aspects for the control of machine, beamlines and experiments and support experimental data acquisition. It includes softwares to co-ordinate the running of each set of equipments, the man-machine interfaces for the operators, experimentalists and the process to manage the devices.
At last, the electronics group is in charge of the hardware aspects. Control and electronics groups work in a close collaboration
4 engineers 2 technicians
SR group
GD group
ICA group
ECA group

6. ECA Group The ECA team is in charge OEM Electronics
PLC
CPCI
Motion System
Timing System
Specific developments
Timing system
Processing local analog I/O (SPI boards)
Processing encoder signal ….

7. .. SOLEIL context and organization 2) Motion control status
Soleil in few figures
Computing division and ECA group
2) Motion control status
Hardware architecture and products
Software architecture and microcodes embedded
Results
Plans
Current developments
New requirements and Revolution

8. Motion control issues.
Requirements define the objectives of motion control systems
Large number of axes
more than 1200 motors, distributed on the site
Changing Applications
particularly near the sample environment
High availability
in 2010 operating for 6120 hrs, 24 hrs a day for 4 to 9 weeks , overall availability measured: 96.3%
High performance
a high level of requirements for some applications (accuracy, stability, etc.)
 Using standardized products
 Easy to use and easy to maintain
 Reliability, based on industry
 Flexibility, adapting to the best technical solution

9. Standardization: first results ..
Stepper motor
4 phases, bipolar
Encoder
incremental TTL,
or absolute SSI or analog
ControlBox
integration of motion controller
DriverBox
power unit
Standardized Cables
Adapted to main static positioning needs
Open technology
Reliable and easy to configure
Industrial open standard
Stand-alone rack independent from power unit
Multiaxis and easy to use, from a major company
Rack for reliable power board
based on industrial products
Connectors and cables are clearly defined industrial products.

10. Hardware architecture ..
Standard power unit
incremental TTL
or absolute SSI
Control Unit
Generic Products
Standard
Motor
Mechanism
DriverBox
Midi ingenierie boards
Stepper
4 phases bipolar
Encoder
Ethernet
Tango
Device Server
Standard Signals x8
maximum
Local
applications
ControlBox
User I/O
specific
power unit
Specific Encoder
Specific Products
Example: servo motor, 3 or 5 phase stepper, ceramic motor, sine/cosine encoder, etc.
Converter
Specific
Galil DMC2182
microcode
Flexible architecture :
standard and specific products (standard signals used: pulse & direction, +/-10V)
local applications (microcodes) included in the ControlBox
A set of Tango Device has been developed and standard connectors are defined

11. Motion controller .
Criteria: flexible, easy to use, reliable and cost-effective
Our choice: multipurpose stand-alone 8-axis controller
Galil DMC2182 and extended I/O board DB28040
with Specific Firmware (option: encoder SSI, extended memory, ceramic motor)
Mains features:
Motorola 32-bit microcomputer
24 KB non-volatile memory (microcode and variables)
Ethernet 10Mbps Port and RS232 port
8 individually configurable axes
stepper, servo, ceramic
Encoder: incremental, absolute SSI or analog, or none
Dual loop for servo motor (2 encoders)
I/O auxiliary by axis:1 logic input, 2 logic outputs, 1 analog input
Up to 8 low-level programs running simultaneously (microcode)
Generic and specific Microcode developed by Soleil
Advanced functions
Master-slave mode
Complex Trajectory with several motors, etc.

12. Hardware development : ControlBox .
Standard motion control rack: ControlBox
Integration of Galil Controller board and standard connectors
Objective: easy to use, easy to maintain, cost-effective
key features
Format 19’’ – 3U
2 power supply on rails: 24VDC and 5 VDC
By axis
1 Sub-D 15 male connector: Motor
1 Sub-D 15 female connector: Encoder
1 Sub-D 9 female connector: Auxiliary

13. Hardware development: Power Boxes .
The power units: Integration of manufacturer driver boards in a rack with standard connectors
Objective: easy to use, easy to maintain, cost-effective
DriverBox: Power unit for stepper motors (Midi Ingenierie board)
VacuumBox: Power unit for stepper motors in vacuum (Phytron board)
higher motor temperature could stop current

14. Software Architecture .
Generic Microcode:
Embedded low level software developed by Soleil.
Microcode key features
Data exchange with Tango Device
Motion process
For each axis
Software security,
e.g. : enable or disable movement, motor on, etc..
Complex strategy for ‘Homing’ (limit-switch, encoder index, etc.)
Soleil Remote Control management
Master/slave axis management
For stepper:
Discontinuous closed loop
Backlash and progressive approach
Static and dynamic error compensation
Static loop to compensate slow drift

15. Specific microcodes . Some specific microcode developed by Soleil
Embedded software dedicated to security and low-level processes
Motion in RF Cavity: Phase loop control
using RF Low-Level Electronics
Security for Infra-Red mirror motion in storage ring
links with machine interlock system
Security for MRSV Diagnostic motion
using heat sensors
Security for tilt and roll of tripod mirror
using inclinometer
Security for 2 linked motors used to lift a table
control parallel translation and limit inclination
Security for bending mirror (stepper motor without encoder)
calculation and limit of max bending value
Security for ceramic motor in vacuum (Nanomotion products)
computation and limit Duty Cycle (MotorOn/MotorOFF) to avoid motor overheating
Collision avoidance : calculation and limitation of range of motion

16. Some devices and pannels

17. Standard equipment park .
In May 2011:
1183 stepper motors
and 443 standard Motion Boxes
are operational
Machine
Beamlines
Total
ControlBox 38
182
220
Driverbox 36
118
154
VacuumBox 2 57 59
Stepper axis
140
1043
1183
SpietBox 8

18. Other equipment . In May 2011:
107 non-standard motors and 35 non-standard power supply racks
but controlled by ControlBox
Motor technology
Power unit (crate)
Axis
Equipment concerned
Stepper 5 phases 8 36
monochromator sample support
Servo (DC, brushless) 11 20
Monochromator, Diffractometer heavy grider
Ceramic piezzo 16 51
mirror and sample support
total 35
107 /
And 244 motors on 37 equipments
for specific applications not controlled by our standard controller
=5 different types of controller
Number
Equipement
Motor technology
Motion controller
Axis 21
Motorized Magnetic Insertions
stepper 3 phases
PLC berger Lahar
107 6
Diffractometer
Servo and stepper
Microcontrole XPS 82 8
Hexapod
stepper 4 phases
Delta tau PMAC 48 1
micro hexapod
Servo
PI-E712
Main axis monochromator
Torque motor 37
Total /
244

19. Results .
At the present time, the initial objectives have been achieved and the motion systems work
Costs are controlled and no delay in providing working systems
Reliable hardware: Few items of equipment returned to supplier
Galil auxiliary I/O board and Power 5VDC of ControlBox are more sensitive but rate is tolerable (5%)
Efficient and reliable software: very few interventions during operation
2 completely different versions for satisfactory results. Ethernet communication stability problem resolved
Performances are sufficient today for almost all applications

20. .. SOLEIL context and organization 2) Motion control status
Soleil in few figures
Computing division and ECA group
2) Motion control status
Hardware architecture and products
Software architecture and microcodes embedded
Results
Plans
Current developments
New requirements and Revolution

21. microcode developments
Low level Software
Specific Microcode: Biaxial tensile machine Axis management to control mechanical force and deformation
Specific Microcode: collision avoidance 2 axis
Calculation and limitation of range of motion
for simple applications, we can develop and implement a specific firmware very shortly.

22. ServoBox ServoBox: New power unit for servo motors
Rack very similar to DriverBox
Directly compatible with ControlBox
ServoBox contains
Standardized connectors
Power supply: 24VDC (logic) et 48VDC (1KW to motor)
Fans and back plane board
4 slots for 4 power board
Preliminary study and specification written by Soleil
5 rack manufactured and available
Power Board SDB10
based on an Elmo Whistle OEM component
Numeric amplifier for DC or brushless motor
Rated output current: 10A (Voltage 48V)
Feed back by resolver or incremental encoder
Signals managed: limit switch, thermal sensor, brake
Entire design by Soleil (electronics and mechanics)
Prototype debugging in progress

23. SPI Board Package What is the SPI* board package? Objective
This is a set of electronic boards developed by the ECA group. These boards can be connected together in a daisy-chain manner and communicate with the controller via SPI Bus.
Objective
To obtain a platform allowing us to build the specific solution with simple and open tools.
To provide solutions for applications with synchronization requirements (continuous scan).
To implement the process at a low level, that is advantageous for us to obtain the best performance.
To connect easily to the Soleil control network.
This platform enables us to deliver solutions for applications with an analog interface or motion interface (encoder side).
* Serial Peripheral Interface

24. SPIETBOX . SPIETBOX: Encoder Tool BOX (SPI board)
A SOLEIL product that adds new features to motion systems
2 Encoder inputs
2 Encoder outputs,
4 TTL Outputs, 1 TTL out put, 1 aux Port (4 TTL outputs, 4 TTL inputs)
Reprogrammable FPGA  Flexible use
Example:
Copy encoder signals
Protocol transfer
12-bit SSI  25-bit SSI
Quadrature Incremental signals  Pulse & DIR
Adder encoder signals
Trigger generation from encoder signals
Etc.
Works in standalone or connected to a controller board (SPIController)

25. New requirements Control HEXAPOD - Stewart Platform 6 axis
Generate and control complex trajectories
Integration of direct and reverse kinematic equations into standard motion controller and devices.
To be able to replace controller being used with a standard solution
Nanopositioning
Be able to position an axis at few nanometers and keep this position by compensating externals disturbances. A new loop with external sensor (eg interferometer)
Synchronization
Be able to synchronize several axis and several sensors to make continous scan over comples trajectories.

26. What is our future? .
In the future, to retain the use of standardized products, we need to improve our products
Open our standard to other technologies
E.g. ServoBox for brushless motor, or SPIETBOX for protocol transfer
Increase features and performances available for new applications
E.g. Hexapod, nanopositionning
We must consider the next standard controller
Because Galil has a new generation controller (Accelera products)
Our standard Galil DMC 2182 is used for 8 year and comes from the previous generation
and it will be discontinued in few time (but when ?)
We need a new motion controller to maintain SOLEIL
at a high level of performance
the new controller must be
 faster
 more powerful in calculation ?
Tomorrow
Today

27. REconsider Various contrOLler for yoUr moTION
Revolution
SOLEIL starts an upgrade of its motion controller
MAX IV needs to define an up-to-date motion system architecture and to select a controller.
SOLEIL and MAX IV have
similar requirements - reliable,
- performing
- flexible
& similar guidelines the main idea is “costs & time effective “
that means - no or few in-house development
- standardization of hardware
- modular solution
- ready to use and complete solution
So we start a technical collaboration to work together on this
REVOLUTION
REconsider Various contrOLler for yoUr moTION

28. Questions . ?