^2 PMAC Laser Calibration v2.0

Transcription

1 ^1 SOFTWARE REFERENCE MANUAL ^2 PMAC Laser Calibration v2.0 ^3 Software Reference Manual ^4 3A0-LASERC-xSxx ^5 July 19, 2006 Single Source Machine Control Power // Flexibility // Ease of Use Lassen Street Chatsworth, CA // Tel. (818) Fax. (818) //

2 Copyright Information 2006 Delta Tau Data Systems, Inc. All rights reserved. This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained in this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every respect to former issues. To report errors or inconsistencies, call or Delta Tau Data Systems, Inc. Technical Support Phone: (818) Fax: (818) Website: Operating Conditions All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers contain static sensitive components that can be damaged by incorrect handling. When installing or handling Delta Tau Data Systems, Inc. products, avoid contact with highly insulated materials. Only qualified personnel should be allowed to handle this equipment. In the case of industrial applications, we expect our products to be protected from hazardous or conductive materials and/or environments that could cause harm to the controller by damaging components or causing electrical shorts. When our products are used in an industrial environment, install them into an industrial electrical cabinet or industrial PC to protect them from excessive or corrosive moisture, abnormal ambient temperatures, and conductive materials. If Delta Tau Data Systems, Inc. products are exposed to hazardous or conductive materials and/or environments, we cannot guarantee their operation.

3 REVISION HISTORY REV. DESCRIPTION DATE CHG APPVD 1 PRELIMINARY RELEASE v2.0 07/07/06 CP V.BUROKAS 2 FULL RELEASE 07/19/06 CP V.BUROKAS

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5 Table of Contents INTRODUCTION...1 Hardware Connection Diagram...1 Backing Up PMAC Before Running PMAC Laser Calibration Software...2 PMAC Laser Calibration Installation...2 PMAC Laser Calibration Main Screen Description...3 Title Bar...3 Position Data Box...3 Program Input Box...4 Motor...4 Comp Distance...4 No Of Readings...4 Feed Rate...4 Start Point...4 Move Direction...5 Laser Direction...5 Comp Enable...5 Data Unit...5 In Pos Band...5 In Pos Scan...5 Dwell...5 Data Table...6 Laser Status...6 Strength...6 Air Temp...7 Pressure...7 Humidity...7 ZERO...7 RESET...7 No Of Readings...7 Captured Data...7 Count Per...7 Unit...7 Terminal Window...7 Status Bar...8 File Management...8 File Path...8 Comp Data Folder...8 Graph Area...8 Function Buttons...9 PERMANENTLY SAVING COMPENSATION TABLES...13 PMAC LASER CALIBRATION DATA FILES...14 CompensationInput.PMC...14 LaserComp.pmc...14 LaserCompDef.h...14 Motor[motor number]backlashtable.pmc...14 Motor[motor number]comptable.pmc...14 Motor[motor number]data.txt...15 AXIS CALIBRATION EXAMPLE...16 APPENDIX...20 Troubleshooting the Laser Calibration Process...20 The axis pauses indefinitely during data gathering The axis pauses indefinitely at the extreme end of travel...20 Table of Contents i

6 Repeatability issues and the effects on calibration PMAC Laser Calibration Error Correction Equations...21 Leadscrew Calculation when Backlash Table is not selected...21 Leadscrew Table when backlash table is selected...21 Backlash Calculation (Ixx85)...21 Backlash Calculation...21 CompensationInput.PMC File Example...22 Example Files...23 LaserComp.pmc File Example...23 LaserCompDef.h File Example...25 motor[motor number]backlashtable.pmc File Example...29 motor[motor number]comptable.pmc File Example...30 motor[motor number]data.txt File Example...30 ii Table of Contents

7 INTRODUCTION PMAC Laser Calibration Software was developed to greatly simplify and accelerate the process of implementing both Leadscrew and Backlash Compensation tables in PMAC. The software was designed to connect easily to a host PC and gather information from the laser system via USB connection. The software gathers data by moving in both positive and negative directions, gathering control and laser feedback data at user specified increments. Once the data has been acquired, PMAC Laser Calibration assembles leadscrew and backlash compensation tables automatically. The user can then download these tables and view the correction immediately. Powerful graphing and printing utilities are included so the operator can view, document, and analyze the system. PMAC Laser Calibration Software is very fast, accurate, and will greatly reduce the time required to implement linear and backlash correction data in your application. Note PMAC Laser Cal Software is compatible with any Turbo PMAC or UMAC. Currently the following laser interferometer equipment is required to use PMAC Laser Calibration Software: 1) Renishaw ML10 Gold Standard Laser System 2) Renishaw DX10 USB Interface Hardware Connection Diagram Renishaw ML10 Gold Renishaw USB PC w/pmac Laser Standard DX10 C al Software. Turbo PMAC or UMAC Introduction 1

8 Backing Up PMAC Before Running PMAC Laser Calibration Software It is recommended that users create a backup of any PMAC system before making any changes or modifications including running PMAC Laser Calibration software. This will insure a place of reference in the event the user needs to go back to an original configuration. Please follow the procedure outlined in the PEWIN Pro2 manual or use existing established practices from the facility where the work is being done. PMAC Laser Calibration Installation Installing PMAC Laser Calibration Software is an automated process. Double-click the installation icon and follow the steps when prompted. There are no custom features which need to be configured during this process. 2 Introduction

9 PMAC Laser Calibration Main Screen Description PMAC Laser Calibration Software Reference Manual Program Status Position Data Title bar Prog. Input Box Data Table Graph Area File Management Status Bar Terminal Window Title Bar The title bar will display the type of PMAC and CPU speed when proper communication has been established between the software and PMAC. Position Data Box The position data box will display PMAC s feedback data for the addressed motor in the upper box and laser data in the lower box. The selected motor feedback channel will be displayed to the left of the upper box. In-Position and Laser Read status is displayed via the two oval indicators located to the left of the data boxes. The motor feedback channel is selected using the Motor pull down menu located in the Program Input portion of the application. Introduction 3

10 Program Input Box The move characteristics of the motion program are defined using the Program Input Box. The parameters are described as follows: Motor Select the desired PMAC feedback channel using this pull down selection tool. PMAC Laser Calibration currently supports 8 motor feedback channels. Comp Distance Specifies the total distance of travel beginning at the start point. This value should always be a positive number. Be aware if this distance is greater than the machines allowable travel the program will pause indefinitely on the hardware or software end of travel limit. No Of Readings This input specifies the interval distance at which the laser reading will be taken. The move increment is calculated as: Move Increment = Comp Dis tan ce No Of Re adings Note that the actual number of readings PMAC Laser Calibration uses is No Of Readings + 1. PMAC Laser Calibration takes an extra reading at the start position for instances where the home position does not fall at the extreme end of travel. Feed Rate This input specifies the feed at which the selected motor will move in data units per minute. Start Point This input specifies the absolute position from Home the program will first move to and subsequently begin taking readings. 4 Introduction

11 Move Direction This input specifies the direction of the motion. Normally this is opposite of the Homing direction. Laser Direction This specifies the sign of the laser data being collected allowing flexibility in the physical setup of the laser system. The Laser counting direction and PMAC s feedback direction must match. Comp Enable This input checkbox sets PMAC I-variable I51 for Compensation On/Off. The Comp OFF Lamp indication will turn Green if the compensation is enabled (I51=1) otherwise it will be Red. PMAC s I51 enables both leadscrew and backlash compensation tables simultaneously. Data Unit This input specifies the user units (inch or mm). In Pos Band This input box sets PMAC I-variable Ixx28. The In Pos Band needs to be specified in units of counts. Ixx28 specifies the magnitude of the maximum following error at which Motor xx will be considered In-Position when not performing a move. In general, the tighter this parameter is set, the better the compensation results will be. The In Pos Scan parameter is set in conjunction with the In Pos Band. If the machine is not physically capable of positioning to the requirements set by the user in this parameter, the motion program will pause indefinitely waiting for the In-Position bit to become true. Some users will be required to widen the In Pos Band parameter to allow the motion profile to complete. In Pos Scan This input box sets PMAC I-variable Ixx88. The Ixx88 parameter determines the number of background task cycles Turbo PMAC must scan through before it allows the In-Position status bit to be considered true. This permits the user to ensure the motor is truly settled in position before executing the next operation. The range is 0 to 255 background task cycles. Dwell This input box allows the user to specify a dwell time at each program point for analysis and inspection. PMAC Laser Calibration does not require a dwell period. This has been added as a user tool for machine analysis purposes. The Dwell parameter must be input in units of seconds. Introduction 5

12 Data Table The Data Table will display tabulated move information including commanded position, laser position, and following error. This table is generated automatically on selecting Show Data after running the data collection program. The units displayed are as selected by the user in the Program Input section. The columns may be sized by sliding the upper table lines left or right. Laser Status This box will display various Laser parameters including laser strength, air temperature, pressure, and humidity (a Renishaw EC10 Environmental Unit is required to display air temperature, pressure, and humidity). Strength Represents the Laser signal strength. This is a valuable tool for aligning the laser head and optics. You must insure the laser strength indicator stays green over the entire motor travel distance. Yellow represents a weakening signal whereas Red represents a weak or non-existent signal. 6 Introduction

13 Air Temp Displays current Air Temperature (requires a Renishaw EC10 Environmental Unit). Pressure Displays current pressure (requires a Renishaw EC10 Environmental Unit). Humidity Displays current Humidity (requires a Renishaw EC10 Environmental Unit). ZERO This button is used to set the current Laser Position to Zero. You must zero the laser after homing the axis to insure proper calibration data. RESET This will reset the Laser Instrument and force the electronics to re-initialize. No Of Readings This will display the current reading increment while the motion program is being executed. Captured Data This will display the current laser position data corresponding to the current reading increment. Count Per Displays the current axis coordinate system definition in counts per user unit. The PMAC Laser Calibration software uses this definition when generating the motion program. Unit Displays selected user units. Terminal Window The Terminal Window allows direct communication to the PMAC. This tool can be used to query or set PMAC parameters. Introduction 7

14 Status Bar The Status Bar will display communications status, EC10 Environmental Unit status, and download status There are three panels. Panel 1 displays messages related to laser communication. If the Laser is communicating to the software it will display as DX10 connected with the DX10 device serial number. Panel 2 displays EC10 Environmental Unit status. If the EC10 Unit is not present, this panel will be empty. Panel 3 displays all PMAC related messages related to downloading and table clearing. File Management File Path C:\Program Files\Delta Tau\Laser Calibration RunTime\Laser Calibration is the default folder path. The user can change this folder by selecting Browse. This is the location where all compensation tables and information will be stored. Comp Data Folder The default Compensation Data Folder name is Machine1. This folder will be created in the path specified in the previous section. All output files will be stored in this location. The user should enter an appropriate name for their application here. Graph Area A chart displaying actual laser position vs. error will be displayed when the Show Data button is pressed. All graph properties are configurable by double-clicking the right mouse button over any part of the graph window. This utility alows for scaling, printing, annotating, and exporting data. 8 Introduction

15 Function Buttons Six main function buttons control the application This button establishes communication with the Renishaw DX10 USB communication hardware. On connection to the DX10 unit successful communication status will be displayed in the lower left corner of the application and will include the DX10 serial number. When this button is pressed, the software will use the parameters entered in the Program Input section to assemble and download a PMAC motion program which will step the axis through the desired trajectory. The download status will be displayed in the status bar at the lower right corner of the application. Any time the parameters are changed you must re-download the program to PMAC before these changes will take effect. On pressing this button, the downloaded motion program will be executed. The user will see the selected motor move through the programmed intervals stopping momentarily (based on In Pos Band and In Pos Scan settings) to collect data at each point. This captured data will be displayed in Laser status window. The Status bar will display a Program Running message. Introduction 9

16 On completion of the data gathering motion program, the status bar will display Program End. At this point the user can select this button to display the tabulated data and Plot. The data will be stored in text format for future use in the Comp Data Folder. Pressing this button opens the Compensation Table Setup dialog box. Select the type of table to be generated and downloaded to PMAC. The user can select leadscrew, backlash, or both. The Download button will download compensation tables for all axes which have been generated by the PMAC Laser Calibration software during the current session or were previously saved to PMAC memory. PMAC Laser Calibration does this by uploading any leadscrew or backlash compensation tables existing in PMAC memory on startup of the application. These tables will be written to the same Comp Data Folder as the new tables. Any new compensation table generated will overwrite the existing file in the Comp Data Folder. It is important to note even if the original compensation data is overwritten in the Comp Data Folder no permanent changes will be made to PMAC until they are downloaded and written to PMAC s flash memory using the online PMAC SAVE command. Please see the Permanently Saving Compensation Tables section of this manual for more information. Note If a compensation table is downloaded to PMAC, and the result is not acceptable, the user must un-check the Comp Ena ble box and re-run the uncompensated axis to generate new compensation table information. Otherwise the application will generate compensation tables on compensated data, resulting in an inadequate or erroneous correction at each point. 10 Introduction

17 The Clear button will delete the currently addressed motor leadscrew and backlash compensation table from PMAC s memory. The Close button closes this dialog box. The Exit button closes the PMAC Laser Calibration application. Introduction 11

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19 PERMANENTLY SAVING COMPENSATION TABLES It is recommended that the user save the final compensation tables using the PEWIN Pro2 Software. The reason for this is that PMAC Laser Calibration modifies groups of P, Q, and M variables, downloads calibration specific motion programs, and sets various I-variable parameters in order to analyze any given axis. To insure the application is not accidentally modified by any of these temporarily required modifications, use the following procedure once you are satisfied with the calibration results for all axes: 1. Exit the PMAC Laser Calibration Software 2. Start the PEWIN Pro2 application (or whatever version of the PMAC Executive software you currently use). 3. Make sure the machine is in a safe state for re-initialization (i.e., place the machine in an Emergency Stop condition so that no motors or devices could cause potential harm during the re-initialization and download process). 4. Issue a $$$ to re-initialize the PMAC to a pre-pmac Laser Calibration state. Any modifications made to the application during the calibration process you want saved need to be noted and re-input before the final save command is issued. The $$$ command will bring the PMAC back to last saved state. 5. Issue a CTRL^D to stop all foreground and background PLCs. 6. Download the CompensationInput.PMC file which is located in the Comp Data Folder generated in the last applicable session of the PMAC Laser Calibration software. 7. Set I51 = 1 in the terminal window. 8. Once download is complete set I51 =1 in the terminal windows. 9. Issue the online PMAC SAVE command to permanently store the compensation tables to PMAC flash memory. Introduction 13

20 PMAC LASER CALIBRATION DATA FILES PMAC Laser Calibration Software generates a number of different files. These files are always stored in the Data Comp Folder established by the user. A typical calibration session of axis 1 & 2 would create a group of files such as the following: CompensationInput.PMC LaserComp.pmc LaserCompDef.h motor1backlashtable.pmc motor1comptable.pmc motor1data.txt motor2backlashtable.pmc motor2comptable.pmc motor2data.txt CompensationInput.PMC This is the actual file PMAC Laser Calibration downloads to PMAC when the Download button is pressed from the Comp Table dialog box. This file will include all leadscrew and/or backlash table applicable to the download session. Please see the appendix for an example of this file. LaserComp.pmc The LaserComp.pmc file is the motion program file the application creates to step the axis through a series of incremental moves during the data gathering process. This program contains information directly from the Program Input section of the software. Please see the appendix for an example of this file. LaserCompDef.h This header file contains many temporary parameters necessary to complete the motion and data gathering portion of the calibration process. The parameters include home complete bits, desired velocity zero bits, coordinate system in-position and program running bits, and many other parameters and variables used by the PMAC Laser Calibration software. Please see the appendix for an example of this file. Motor[motor number]backlashtable.pmc This file contains the actual backlash compensation table information. This file name is motor number specific and is of the format motor<motor Number>BacklashTable.PMC where <motor Number> corresponds to the motor addressed at the time of Comp Table download. Please see the appendix for an example of this file. Motor[motor number]comptable.pmc This file contains the actual leadscrew compensation table information. This file name is motor number specific and is of the format motor<motor Number>CompTable.PMC where <motor Number> corresponds to the motor addressed at the time of Comp Table download. Please see the appendix for an example of this file. 14 Introduction

21 Motor[motor number]data.txt This file contains the data from the PMAC and laser during the data gathering cycle. The data includes increment number, commanded position, actual position, and positional error. This file name is motor number specific and is of the format motor<motor Number>DATA.TXT where <motor Number> corresponds to the motor addressed at the time of Comp Table download. Please see the appendix for an example of this file. Introduction 15

22 AXIS CALIBRATION EXAMPLE The following example will demonstrate how to compensate a linear axis using the PMAC Laser Calibration Software along PMAC s second axis (PMAC Hardware Channel 2). Axis 2 was chosen arbitrarily. 1. Setup and configure the Renishaw ML10 Gold Standard and DX10 USB interface unit per the manufacturer instructions. 2. Start the application by clicking the PMAC Laser Calibration Icon from the desktop: 3. The application will immediately prompt you to set the Compensation Data Folder. Enter an appropriate folder name for the machine. All compensation tables and data will be stored in this folder during the active session: Comp Data Folder name used for this example: OZO_Comp 4. Once the Comp Data Folder has been assigned, select the Connect key to establish communications with the Renishaw DX10 USB interface. On successful connection the application will display the current environmental parameters, laser strength, and communication status in the lower left corner of the Status bar. 5. At this point we will adjust the laser to have proper optics alignment. Adjust the laser to get full strength (Green Color) over the full axis stroke. The application will not function properly if either yellow or red strength indication shows at any point on the axis stroke. 6. At this point we are ready to set all the necessary parameters in the Program Input box. Make sure the sign of the motor and laser feedback match. If not, change the sign of the Laser Direction (+VE or VE). This is very important for valid data generation. We will set the parameters for this example as follows: 16 Axis Calibration Example

23 7. Once all Program Input parameters have been entered, select the Program Download button to build and download the PMAC motion program. Verify the program downloaded successfully by checking the Status bar at the lower right corner of the application. The following message should be displayed: Downloading Complete! No Errors 8. Be sure the axis is homed and the laser position is at zero position before attempting to run any calibration programs. Do this by homing the axis as you would normally and subsequently press the ZERO button on the Laser portion of the form. Be sure to allow time for the axis to settle before zeroing the laser. Caution It is critical for successful calibration to home the axis and zero the laser at the home position before attempting to run any calibration motion programs! 9. Next, the data gathering program will be started which will send the axis through the distance entered in the Program Input section of the form. Select the Run button. The axis will start moving and will stop momentarily at each programmed increment to gather both PMAC and laser feedback data. Note The axis may appear to pause indefinitely if the In-Position requirements which have been set in the Program Input section are not met. If this happens, you must increase the In Pos Band, lower the In Pos Scan, or re-tune the axis to get better servo performance. 10. On program completion, select the Show Data button to display the data table and Position vs. Error plot. Our initial plot showed an increasing error from approximately to Axis Calibration Example 17

24 Note If the coordinate system definition is grossly mis-defined, you should redefine the axis definition before proceeding. A grossly mis-defined C.S. definition will appear as a group of data points with a very large linear error (a steep slope in either direction). If the C.S. definition is not reasonably accurate, the axis may exhibit a noticeable growling noise and jumping after compensation is turned on. 11. Select Comp Table if you are satisfied with the data to generate and download leadscrew and/or backlash compensation tables. It is recommended you run several iterations of the program to insure you have consistent data. For this example we will download both leadscrew and backlash tables: 12. Check the download status to be sure the tables downloaded successfully before moving to the next step. The status display should show Downloading Complete! No Errors 13. Make sure to select the Comp Enable checkbox from the Program Input box and Re- Run the program. Follow steps nine and ten (9, 10). Check the plot and determine if you are satisfied with the compensated results. Our compensated example resulted in almost perfect linearity and error perturbations evenly spaced about zero with a range of approximately for the forward run and for the reverse run. 18 Axis Calibration Example

25 Axis Calibration Example 19

26 APPENDIX Troubleshooting the Laser Calibration Process The axis pauses indefinitely during data gathering. The axis may appear to pause indefinitely if the In-Position requirements which have been set in the Program Input section are not met. If this happens you must increase the In Pos Band, lower the In Pos Scan, or re-tune the axis to get better servo performance. Refer to the PMAC Software manual for more information regarding In-Position requirements. The axis pauses indefinitely at the extreme end of travel. The axis may appear to pause indefinitely if one of the axis over travel limits is set. Check to make sure both hardware and software over travel limits are not being violated. In some cases the over travel limits must be disabled during the data gathering process. Care should be taken to make sure the application is safe when this is required. Repeatability issues and the effects on calibration. The repeatability of an axis is a key factor in generating useful compensation tables. Perturbations caused by vibration, dirt, inappropriate mounting of laser optics, and poor mechanical condition can cause erroneous spikes in the collected data. It is critical to verify the data used to generate the actual compensation tables is correct. The best way to do this is to run multiple passes on an axis and visually verify the data being collected is consistent. It may be necessary to manually adjust the data when working with older machines or machines which do not have a highly repeatable mechanical design. You can do this by generating the compensation table, opening the file in a suitable text editor such as Microsoft Notepad, and modify the erroneous entry or entries manually. Once you have done this, you can re-download the file and verify the accuracy. All this can be done without leaving the PMAC Laser Calibration Software. 20 Appendix

27 PMAC Laser Calibration Error Correction Equations PMAC Laser Calibration Software Reference Manual PMAC Laser Calibration Software uses the following equations to generate the actual compensation tables and backlash correction I-variable values. Leadscrew Calculation when Backlash Table is not selected result = (((forwardlaserdata(index) - zerooffsetforward) + reverselaserdata(index)) / 2) - forwardcmddata(index) errorcorrectiondata = axisdef(motornumber) * result * 16 Leadscrew Table when backlash table is selected result = (forwardlaserdata(index) - zerooffsetforward) - forwardcmddata(index) errorcorrectiondata = axisdef(motornumber) * result * 16 Backlash Calculation (Ixx85) backlash = forwardlaserdata(0) - reverselaserdata(0) backlashincounts = backlash * axisdef(motornumber) * tabledirection Backlash Calculation result = (forwardlaserdata(index) - reverselaserdata(index)) errorcorrectiondata = axisdef(motornumber) * result * 16 Appendix 21

28 CompensationInput.PMC File Example A typical calibration session of axis 1 & 2 would create CompensationInput.PMC file such as the following: // // CompensationInput.PMC // Compensation File to Download // I51 = 0 Del Gat Del Trace &1 Del Look &1 Del Rot #1 DEL BLCOMP #2 DEL BLCOMP #3 DEL BLCOMP #4 DEL BLCOMP #5 DEL BLCOMP #6 DEL BLCOMP #7 DEL BLCOMP #8 DEL BLCOMP // #1 DEL COMP #2 DEL COMP #3 DEL COMP #4 DEL COMP #5 DEL COMP #6 DEL COMP #7 DEL COMP #8 DEL COMP // Add LeadScrew Comp table #include "motor2comptable.pmc" #include "motor1comptable.pmc" // Add Backlash Comp table #include "motor2backlashtable.pmc" #include "motor1backlashtable.pmc" // Appendix

29 Example Files PMAC Laser Calibration Software Reference Manual LaserComp.pmc File Example A typical calibration session of axis 2 would create the following LaserComp.pmc file: // // LaserComp.PMC // This Program is designed to work with PMAC - ReniShaw Laser // for leadscrew compensation // #include "LaserCompDef.H" OPEN PROGRAM 100 CLEAR noofpoints = 0 noofrepeats = 0 noofrepeats = 0 programend = 0 movedirection = negativedirection ABS lin I5120 = 0 // disable lookahead. F(100) // value comes from User input DATA_READY_2_UPLOAD = 0 // read data variable for host. IF (HOME_COMPLETE_2_M = 0) ERROR_NUMBER = 1 GOTO1 // Exit not homed. ENDIF Y( 0) // Initial Move as StartPoint WHILE (IN_POSITION_M = 0 OR DES_VEL_ZERO_2_M = 0) ENDWHILE INC WHILE (noofrepeats!=1) WHILE (noofpoints!=17) // Direction 1 - Forward Y( 1 * movedirection) DATA_READY_2_UPLOAD = 0 DWELL 1 DWELL0 WHILE (IN_POSITION_M = 0 OR DES_VEL_ZERO_2_M = 0) ENDWHILE DATA_READY_2_UPLOAD = 1 WHILE (DATA_READY_2_UPLOAD = 1) ENDWHILE noofpoints = noofpoints + 1 ENDWHILE noofpoints = 0 DATA_READY_2_UPLOAD = 1 WHILE (DATA_READY_2_UPLOAD = 1) ENDWHILE WHILE (noofpoints!=17) // Direction 2 - Reverse Y( 1 * movedirection * -1) DATA_READY_2_UPLOAD = 0 DWELL 1 DWELL0 Appendix 23

30 WHILE (IN_POSITION_M = 0 OR DES_VEL_ZERO_2_M = 0) ENDWHILE DATA_READY_2_UPLOAD = 1 WHILE (DATA_READY_2_UPLOAD = 1) ENDWHILE noofpoints = noofpoints + 1 ENDWHILE noofpoints = 0 noofrepeats = noofrepeats + 1 ENDWHILE N1 programend = 1 Close 24 Appendix

31 LaserCompDef.h File Example A typical calibration session would create the following LaserCompDef.h file: // // This file is #define file for Position Compare test. // Creatd : 03/21/2006 // #define HOME_COMPLETE_1_M M764 #define HOME_COMPLETE_2_M M765 #define HOME_COMPLETE_3_M M766 #define HOME_COMPLETE_4_M M767 #define HOME_COMPLETE_5_M M768 #define HOME_COMPLETE_6_M M769 #define HOME_COMPLETE_7_M M770 #define HOME_COMPLETE_8_M M771 #define DES_VEL_ZERO_1_M M772 #define DES_VEL_ZERO_2_M M773 #define DES_VEL_ZERO_3_M M774 #define DES_VEL_ZERO_4_M M775 #define DES_VEL_ZERO_5_M M776 #define DES_VEL_ZERO_6_M M777 #define DES_VEL_ZERO_7_M M778 #define DES_VEL_ZERO_8_M M779 #define IN_POSITION_M M780 #define PROG_RUNNING_M M781 #ifdef _TURBO_ #ifdef _UMAC_ #define HOME_COMPLETE_1_ADR Y:$0000C0,10,1 #define HOME_COMPLETE_2_ADR Y:$000140,10,1 #define HOME_COMPLETE_3_ADR Y:$0001C0,10,1 #define HOME_COMPLETE_4_ADR Y:$000240,10,1 #define HOME_COMPLETE_5_ADR Y:$0002C0,10,1 #define HOME_COMPLETE_6_ADR Y:$000340,10,1 #define HOME_COMPLETE_7_ADR Y:$0003C0,10,1 #define HOME_COMPLETE_8_ADR Y:$000440,10,1 #define DES_VEL_ZERO_1_ADR X:$0000B0,13 #define DES_VEL_ZERO_2_ADR X:$000130,13 #define DES_VEL_ZERO_3_ADR X:$0001B0,13 #define DES_VEL_ZERO_4_ADR X:$000230,13 #define DES_VEL_ZERO_5_ADR X:$0002B0,13 #define DES_VEL_ZERO_6_ADR X:$000330,13 #define DES_VEL_ZERO_7_ADR X:$0003B0,13 #define DES_VEL_ZERO_8_ADR X:$000430,13 #define IN_POSITION_ADR Y:$00203F,17,1 #define PROG_RUNNING_ADR #else #ifdef _PMAC2_ #define HOME_COMPLETE_1_ADR #define HOME_COMPLETE_2_ADR #define HOME_COMPLETE_3_ADR #define HOME_COMPLETE_4_ADR #define HOME_COMPLETE_5_ADR #define HOME_COMPLETE_6_ADR #define HOME_COMPLETE_7_ADR #define HOME_COMPLETE_8_ADR #define DES_VEL_ZERO_1_ADR X:$002040,0,1 Y:$0000C0,10,1 Y:$000140,10,1 Y:$0001C0,10,1 Y:$000240,10,1 Y:$0002C0,10,1 Y:$000340,10,1 Y:$0003C0,10,1 Y:$000440,10,1 X:$0000B0,13 Appendix 25

32 #define DES_VEL_ZERO_2_ADR #define DES_VEL_ZERO_3_ADR #define DES_VEL_ZERO_4_ADR #define DES_VEL_ZERO_5_ADR #define DES_VEL_ZERO_6_ADR #define DES_VEL_ZERO_7_ADR #define DES_VEL_ZERO_8_ADR #define IN_POSITION_ADR #define PROG_RUNNING_ADR #else // PMAC1 TURBO #define HOME_COMPLETE_1_ADR #define HOME_COMPLETE_2_ADR #define HOME_COMPLETE_3_ADR #define HOME_COMPLETE_4_ADR #define HOME_COMPLETE_5_ADR #define HOME_COMPLETE_6_ADR #define HOME_COMPLETE_7_ADR #define HOME_COMPLETE_8_ADR #define DES_VEL_ZERO_1_ADR #define DES_VEL_ZERO_2_ADR #define DES_VEL_ZERO_3_ADR #define DES_VEL_ZERO_4_ADR #define DES_VEL_ZERO_5_ADR #define DES_VEL_ZERO_6_ADR #define DES_VEL_ZERO_7_ADR #define DES_VEL_ZERO_8_ADR #define IN_POSITION_ADR #define PROG_RUNNING_ADR #endif #endif #else #ifdef _PMAC2_ // #define HOME_COMPLETE_1_ADR #define HOME_COMPLETE_2_ADR #define HOME_COMPLETE_3_ADR #define HOME_COMPLETE_4_ADR #define HOME_COMPLETE_5_ADR #define HOME_COMPLETE_6_ADR #define HOME_COMPLETE_7_ADR #define HOME_COMPLETE_8_ADR #define DES_VEL_ZERO_1_ADR #define DES_VEL_ZERO_2_ADR #define DES_VEL_ZERO_3_ADR #define DES_VEL_ZERO_4_ADR #define DES_VEL_ZERO_5_ADR #define DES_VEL_ZERO_6_ADR #define DES_VEL_ZERO_7_ADR #define DES_VEL_ZERO_8_ADR #define IN_POSITION_ADR #define PROG_RUNNING_ADR #else // PMAC1 // #define HOME_COMPLETE_1_ADR #define HOME_COMPLETE_2_ADR X:$000130,13 X:$0001B0,13 X:$000230,13 X:$0002B0,13 X:$000330,13 X:$0003B0,13 X:$000430,13 Y:$00203F,17,1 X:$002040,0,1 Y:$0000C0,10,1 Y:$000140,10,1 Y:$0001C0,10,1 Y:$000240,10,1 Y:$0002C0,10,1 Y:$000340,10,1 Y:$0003C0,10,1 Y:$000440,10,1 X:$0000B0,13 X:$000130,13 X:$0001B0,13 X:$000230,13 X:$0002B0,13 X:$000330,13 X:$0003B0,13 X:$000430,13 Y:$00203F,17,1 X:$002040,0,1 Y:$814,10,1 Y:$8D4,10,1 Y:$994,10,1 Y:$A54,10,1 Y:$B14,10,1 Y:$BD4,10,1 Y:$C94,10,1 Y:$D54,10,1 X:$3D,13 X:$79,13 X:$B5,13 X:$F1,13 X:$12D,13 X:$169,13 X:$1A5,13 X:$1E1,13 Y:$817,17,1 X:$818,0,1 Y:$814,10,1 Y:$8D4,10,1 26 Appendix

33 #define HOME_COMPLETE_3_ADR #define HOME_COMPLETE_4_ADR #define HOME_COMPLETE_5_ADR #define HOME_COMPLETE_6_ADR #define HOME_COMPLETE_7_ADR #define HOME_COMPLETE_8_ADR #define DES_VEL_ZERO_1_ADR #define DES_VEL_ZERO_2_ADR #define DES_VEL_ZERO_3_ADR #define DES_VEL_ZERO_4_ADR #define DES_VEL_ZERO_5_ADR #define DES_VEL_ZERO_6_ADR #define DES_VEL_ZERO_7_ADR #define DES_VEL_ZERO_8_ADR #define IN_POSITION_ADR #define PROG_RUNNING_ADR #endif #endif HOME_COMPLETE_1_M->HOME_COMPLETE_1_ADR HOME_COMPLETE_2_M->HOME_COMPLETE_2_ADR HOME_COMPLETE_3_M->HOME_COMPLETE_3_ADR HOME_COMPLETE_4_M->HOME_COMPLETE_4_ADR HOME_COMPLETE_5_M->HOME_COMPLETE_5_ADR HOME_COMPLETE_6_M->HOME_COMPLETE_6_ADR HOME_COMPLETE_7_M->HOME_COMPLETE_7_ADR HOME_COMPLETE_8_M->HOME_COMPLETE_8_ADR DES_VEL_ZERO_1_M->DES_VEL_ZERO_1_ADR DES_VEL_ZERO_2_M->DES_VEL_ZERO_2_ADR DES_VEL_ZERO_3_M->DES_VEL_ZERO_3_ADR DES_VEL_ZERO_4_M->DES_VEL_ZERO_4_ADR DES_VEL_ZERO_5_M->DES_VEL_ZERO_5_ADR DES_VEL_ZERO_6_M->DES_VEL_ZERO_6_ADR DES_VEL_ZERO_7_M->DES_VEL_ZERO_7_ADR DES_VEL_ZERO_8_M->DES_VEL_ZERO_8_ADR IN_POSITION_M->IN_POSITION_ADR PROG_RUNNING_M->PROG_RUNNING_ADR // // General purpose variable used in program. #define movedistance Q900 #define BACKLASH_DISTANCE Q901 #define Incremental_counter Q902 #define START_L_SCREW_COMP Q903 #define PMAC1_COMPARE_COUNT Q904 #define P_WIDTH Q905 #define INCREMENT Q906 #define ERROR_NUMBER Q907 #define COMP_DISTANCE Q908 #define noofpoints Q909 #define initialmove Q910 #define movedirection Q911 #define CAPTURE_AT_HOME Q912 #define First_Data_POINT Q913 #define Direction1 Q914 #define Direction2 Q915 #define noofrepeats Q916 PMAC Laser Calibration Software Reference Manual Y:$994,10,1 Y:$A54,10,1 Y:$B14,10,1 Y:$BD4,10,1 Y:$C94,10,1 Y:$D54,10,1 X:$3D,13,1 X:$79,13,1 X:$B5,13,1 X:$F1,13,1 X:$12D,13,1 X:$169,13,1 X:$1A5,13,1 X:$1E1,13,1 Y:$817,17,1 X:$818,0,1 Appendix 27

34 #define DATA_READY_2_UPLOAD Q917 #define InposBandTurbo Q920 #define InposBandPmac Q921 #define InPosDebounceTurbo Q922 #define InPosDebouncePmac Q923 #define TEMP5 Q924 #define SPEND_TIME Q925 #define FEED_RATE Q926 #define TEMP8 Q927 #define Feed_Equ_Distance Q928 #define Acceleration Q929 #define Min_Feed_Rate Q930 #define TEMP11 Q931 #define Min_Feed_Constant Q932 #define programend Q933 #define Feed1 Q934 // Used in velocity profile #define Feed2 Q935 // Used in velocity profile #define Feed3 Q936 // Used in velocity profile #define TA_TIME Q937 #define TS_TIME Q938 #define Pos_Reading_Counter Q940 #define CALC_TEMP9 Q941 // USED IN CALC PLC. #define CALC_TEMP10 Q942 // USED IN CALC PLC. #define CALC_TEMP11 Q943 // USED IN CALC PLC. #define CALC_TEMP12 Q944 // USED IN CALC PLC. #define Current_Capture_Pos Q945 // //# PMAC specific defines used. //# Generaldefines used. #define positivedirection 1 #define negativedirection -1 #ifdef _TURBO_ #define ACC_TIME_TS I5188 #define LKHD_MODE I5120 #define Ix86_constant Q3000 #define ACC_TIME_TA I5187 #else // Non Turbo #define ACC_TIME_TS I188 #define LKHD_MODE #define Ix86_constant I5120 Q810 #define ACC_TIME_TA I187 #endif // M definition specific to Program Appendix

35 motor[motor number]backlashtable.pmc File Example A typical calibration session would create the following motor2backlashtable.pmc File: // // Backlash Compensation Table // // No Of Readings = 34 // Start Data collection Point = 0 // Compensation Distance from Start Point = 17 // Extra Point for Table Symmetry=36...n oofpoints+1+zeropadding // // BackLash Table Definition #2 DEF BLCOMP 36, // Backlash Table //--Motor BackLash Size Ixx86 Variable and Take Up Rate Ixx85 -- I286 = 4 I285 = // Backlash Table Ends Appendix 29

36 motor[motor number]comptable.pmc File Example A typical calibration session would create the following motor2comptable.pmc File: // // LeadScrew Compensation Table // // No Of Readings = 34 // Start Data collection Point = 0 // Compensation Distance from Start Point = 17 // Extra Point for Table Symmetry=36...noOfPoints+1+zeroPadding // // Leadscrew Table Definition #2 DEF COMP 36,#2D, // Leadscrew Table // Leadscrew Table Ends motor[motor number]data.txt File Example 30 Appendix

37 A typical calibration session would create the following motor2data.txt File: // // Motor Data - commanded,actual and Error // // No Of Readings = 17 // Start Point = 0 // Compensation Distance from Start Point = 17 // Laser Increment (Comp Distance/No Of Reading) = 1 // First Data Point = Start Point + Increment = 1 // No CMD ACT Error(ACT - CMD) Appendix 31