XPS Universal High-Performance Motion Controller/Driver

844 XPS Universal High-Performance Motion Controller/Driver MOTORIZED LINEAR The XPS is an extremely high-performance, easy to use, integrated motion controller/driver offering high-speed communication through 10/100 Base-T Ethernet, outstanding trajectory accuracy and powerful programming functionality. It combines user-friendly web interfaces with advanced trajectory and synchronization features to precisely control the most complex to the most basic motion sequences. Multiple digital and analog I/O's, triggers and supplemental encoder inputs provide users with additional data acquisition, synchronization and control features that can improve the most demanding motion applications. Proprietary universal driver modules allow the XPS to drive 1 to 8 axes of any Newport actuator, linear or rotary stage. By using pass-through drive modules, the XPS is also capable of controlling many other motion devices, whether they use stepper, DC brush, DC brushless rotary or linear, voice coil or piezoelectric actuation. The XPS utilizes a high-performance 10/100 Base-T Ethernet communication link with TCP/IP protocol and uses an integrated web-site interface for all utility software tools, data transfer using FTP and device communication. This enables the XPS to perform complex multi-tasking and execute multi-user applications using virtually any operating system including Win 2000, Win XP, Win NT, etc. When networked, authorized Unix-, Linux-, or Windows users can access the same controller from any place in the world for remote control, code development, data transfer or diagnostics. The object oriented format of the XPS firmware with powerful, yet intuitive, multi-parameter functions (commands) is also more consistent with state-of-the-art programming methods than traditional mnemonic commands. Positioner Grouping and Compensation Features To optimize the performance and ease-of-use of advanced features like line-arc trajectories, splines, contouring, and complex PVT trajectories, the XPS incorporates motion groups which are user defined as single axis positioners, spindles, gantry groups, XY groups, XYZ groups or multiple axis groups. This greatly improves process flow and error handling and provides a uniform structure for easy application development. An extensive set of compensation factors including backlash, linear error and single axis, 2D, and 3D mapping offer a broad selection of options to increase the accuracy and performance of any application, which can transform the most basic positioner into a high performance device. All compensations, including the most sophisticated 3D mapping, are corrected dynamically during each servo cycle, which has an update rate of 10 khz. [For a more detailed description, see the Seminar notes of the XPS web page.] High performance, 1-8 axes motion controller for steppers, DC servos, brushless motors, voice coils and other motors. High-speed 10/100 Base-T Ethernet TCP/IP communication interface (typ. 0.3 ms command execution). Advanced 10KHz servo loop with variable PID s, low-pass and notch filters, linear error compensation and 3D error mapping. Wide variety of motion modes including point-to-point, velocity profiling, line-arc trajectories, splines, PVT trajectories, electronic gearing and analog input tracking. Extensive external device or system functionalities utilizing 4 user-definable analog inputs, 4 user-definable analog outputs and 30 TTL inputs and outputs. Enables hardware position latch input, position compare output and event triggers for process development and synchronization. Advanced Trajectory and Servo Loop Features The advanced trajectory generation and servo loop algorithms of XPS are some of the most powerful developments in the motion control industry. The proprietary motion profiler (trajectory generator) automatically optimizes the S-Gamma trajectory jerk time

845 for each commanded move profile. This drastically reduces the excitation of mechanical resonances and stress in any motion system resulting in faster settling, more accurate trajectory execution and an increased lifetime without sacrificing the move time. A sophisticated PID loop corrects for any variations of the actual motion from the commanded trajectory. In addition to the classical PID gain parameters, customers can optimize their motion system by applying feedforward gains, a deadband threshold, a derivative filter cut-off frequency or apply up to two notch filters. Furthermore, the XPS features variable PID s that automatically adjust their values proportional to the distance from final position. This unique feature can tighten the gain loop when in position or close to final position while loosening the gain during motion to improve stability. Using variable PID s also allows dedicated tuning of the servo behavior for short and long stroke motion resulting in improved motion sensitivity. [For a more detailed description, see the Seminar notes of the XPS web page.] High Speed Execution and Synchronization The XPS is much more than just a motion controller. Based on a real-time multi-tasking functionality, the XPS is capable of executing complex, internally stored, user-defined applications in real time using TCL scripts (for more information about TCL go to www.tcl.tk). The state-of-the-art Pentium P4 2 GHz motion processor has enough bandwidth to support TCL program execution without adversely impacting higher-priority tasks. With this advanced real-time multi-tasking functionality, the XPS can not only manage the most complex motion requirements but also serve as a powerful process controller. 30 digital inputs and 30 outputs (TTL, open collector) are available to read external switches or to control valves, switches or other digital devices. When used within a TCL script these I/O's can provide the same functionality as a separate PLC device, all within the XPS. 4 channels of 16 bit uncommitted analog outputs increase flexibility to allow users to precisely monitor position, velocity or acceleration of any motion axis. The XPS also offers a very convenient and powerful way to synchronize the triggering of I/O s during a motion process using dedicated event and action" API's. With a single function, users can direct the XPS to trigger an action upon the occurance of an event. Typical examples include setting a digital output when the constant velocity is reached or initiating a TCL script when the motion is done. Once defined, the XPS autonomously monitors the status of the event to trigger the action with a latency of less than 100 µs! This powerful feature does not require any complex programming and does not consume any time of the host PC or the communication link since all the processing is done internally by the XPS. [For a more detailed description, see the Seminar notes of the XPS web page.] High Speed Data Integration and Acquisition Another significant benefit provided by the XPS controller is its high-performance data acquisition capability: The XPS features 4 channels of instrument-grade 14 Bit analog-todigital converters that can, for example, be integrated with a motion process using a TCL script. This provides significant advantages in applications such as precision alignment or auto-focusing routines that require real-time feedback from other devices including power meters, vision systems, or other sensors. Besides the obvious communication speed advantages, since the A-to-D conversion is internal to the XPS there is no added processing burden to the host PC or the communication link, which can improve process development and throughput. Alternatively, the analog inputs can be also configured to directly control the position or speed of a motion axis. For applications that require the capture and analysis of analog data in real-time relation to the position, the XPS offers the gathering mode. In gathering, the XPS captures all important axis information and all I/O s with a time jitter of less than 50 ns and stores the data in a custom configured table. Ideal for high speed, high data rate applications, gathering can be accomplished at a rate of up to 10 khz and with up to 1,000,000 entries to the data table. Dedicated hardware on the XPS processor can also capture the axis positions and the I/O information based on an externally triggered TTL input with latency between the trigger input and the position acquisitions of less than 50 ns. This is equivalent to less than 10 nm of uncertainty when moving at 200 mm/s. All connectors are easily accessible at the back of the controller. Handles and rack mounting brackets are included and mount on both sides of the box. Driver cards are inserted into the slots and can be added in the future. The XPS-RC remote control plugs into the front panel of the XPS controller to enable computerindependent motion and basic system diagnostic. Advanced system diagnostics, incremental stepping, absolute positioning, or jogging of individual axes can be performed from different sub-screens. The integrated 3.8 touch-screen allows simultaneous position and error display of up to eight axes. The amber-colored screen is readable from farther distances and with most laser goggles. The XPS-RC remote control is supplied with a 2 m cable. MOTORIZED LINEAR Email: sales@newport.com Web: newport.com

846 MOTORIZED LINEAR External data acquisition tools or other devices can be synchronized to the motion as well. For this purpose, the XPS features one dedicated TTL trigger output per axis that can be either configured to output a single pulse when crossing a specified position or output continuous pulses at specified distance intervals. Also, output pulses at constant time or constant trajectory length are supported. Powerful, Yet Easy To Use While the XPS is a very powerful motion controller and processor, it is still very easy to use. The on-board web based software supports system and driver configuration. When used with Newport stages and drivers, all settings can be done with just a few clicks or almost automatically using the auto-configuration function. Once the system is defined, the XPS will check with every re-boot, whether the configuration is compatible with the connected hardware components including Newport ESP compatible motor drives and stages. This minimizes the risk of damage due to wrong settings or incompatible hardware. The XPS even has the ability to recognize unwanted hardware changes. For example, consider an xz system based on a Newport IMS500 series and an ILS200 series stage. If a user inadvertently swaps the connections for the IMS and the ILS stage, the XPS controller will notice the change when rebooting the system and will not start the application to avoid possible damage to expense devices. This can be a valuable feature for applications and users of sensitive and expensive devices and can only be found on the XPS motion controller. Other software tools include a manual mode screen with options to initiate simple motions, and a monitor for axis position and group status information. Detailed system diagnostics are supported by numerous, well organized subscreens. A user-friendly motion tuning utility helps optimizing all servo PID settings and allows simultaneous display of analog control signal, position error, integral error, target position, velocity, acceleration and more. The XPS provides also auto-tuning and auto-scaling. The command screen is a very convenient way to learn all XPS functions and allows for simple programming and code testing. All functions are listed by groups including all required or available parameters and short descriptions. Exectuable TCL scripts can be generated from the command history. For LabView users we have developed an extensive library of LabView drivers, which includes VI s for each individual API command. For maximum backward compatibility, these drivers have been developed under LabView version 6.0. XPS also comes with a DLL for Windows and MatLab, as well as sample programs for Visual Basic program development in Windows. I/O Board Motor PSU 500W Configuring the XPS controller is facilitated by a convenient software tool. When used with Newport ESP-compatible stages, all motion settings are loaded with just a few mouse clicks. The command screen lists all XPS functions including the necessary or available parameters. Once familiar with the XPS syntax, iit is a convenient tool which allows for simple programming, code testing and debugging. Interconnect Driver Pentium4 CPU 2 Axes Control Card ATX-12V 300W X8 X X44 Hardware overview of the XPS controller.

847 Specifications Number of Axes Communication Interfaces Firmware Features Motion Compensation Servo Rate Control Loop I/O Trigger In Trigger Out Dedicated Inputs Per Axis Dedicated outputs per axis (when using external drives) Drive capability Dimensions (W x D x H) Weight 1 to 8 axes of stepper, DC brush or DC brushless motors using internal drives. Other devices using external third-party drives Internet protocol TCP/IP Two Ethernet 10/100 Base-T (RJ45 connector). One with fixed IP address for local communication and one for networking, dynamic addressing with DHCP and DNS Typically 0.3 ms from sending a tell position command to receive the answer Optional XPS-RC remote control Powerful and intuitive, object-oriented command language Natural user defined units (no need to program in encoder counts) Real time execution of custom tasks using TCL scripts Multi-user capability using the concept of sockets Distance spaced trigger output pulses, less than 50 ns latency between position crossing and trigger pulse; max. 2.5 MHz rate Time spaced trigger output pulses, 0.02 to 2.5 MHz rate, 50 ns accuracy Trigger output on trajectories with 100 µs resolution Data gathering at up to 10 khz rate and up to 1,000,000 data entries User-defined actions at events monitored by the controller independently at a rate of 10 khz User-definable system referencing with hardware position latch of reference signal transition and set current position to value capability Axis position or speed controlled by analog input Axis position, speed or acceleration copied to analog output Trajectory pre-check function that returns travel requirement and max. possible speed Auto-tuning and auto-scaling Jogging mode including on-the fly changes of speed and acceleration Synchronized point-to-point motion Spindle motion (continuous motion with periodic position reset) Gantry mode including XY gantries with variable load ratio Line-arc mode (linear and circular interpolation incl. continuous path contouring) Splines (Catmull-Rom type) PVT (complex trajectories based on position, velocity and time coordinates) Analog tracking (using analog input as position or velocity command) Master-slave incl. single master-multiple slaves and custom gear ratio Linear error, Backlash, 1D positioner error mapping 2D and 3D error mapping All corrections are taken into account on the servo loop 10 khz Open loop, PI position, PIDFF velocity, PIDFF acceleration, PIDDualFF voltage Variable PID s (PID values depending on distance to target position) Deadband threshold; Integration limit and integration time Derivative cut-off filter; 2 user-defined notch filters 30 TTL inputs and 30 TTL outputs (open-collector) 4 synch. analog inputs +/- 10 V, 14 Bit, prog. gains x1, x2, x4, x8 (prog. gains not with all units. Call Newport for details.) 4 synch. uncommitted analog outputs, 16 Bit Watchdog timer and remote interlock Hardware latch of all positions and all I/O s; 10 khz max. frequency < 50 ns latency on positions < 100 µs latency of analog input data One high-speed position compare output per axes that can be either configured for position synchronized pulses or for time synchronized pulses : <50 ns accuracy/latency, 2.5 MHz max. rate RS-422 differential inputs for A, B and I, Max. 25 MHz, over-velocity and quadrature error detection 1 Vpp analog encoder input up to x32768 interpolation used for servo; amplitude, phase and offset correction; additional 2nd hardware interpolator used for synchronization; up to x200 interpolation Forward and reverse limit, home, error input 2 channel 16-bit, +/- 10 V D/A Drive enable, error output Analog voltage, analog velocity, and analog acceleration (used with XPS-DRV01 and XPS-DRV03 for DC brush motor control) Analog position (used with XPS-DRV01 for stepper motor control) Analog position (used with external drives for example for piezo control) Analog acceleration, sine acceleration and dual sine acceleration (used with XPS-DRV02 for brushless motor control) Step and direction and +/- pulse mode for stepper motors (requires special XPS-DRV00 and external stepper motor driver. Call Newport for details) 500 W total available drive power 19" - 4U, L: 508mm 15 kg max MOTORIZED LINEAR Email: sales@newport.com Web: newport.com

848 MOTORIZED LINEAR Drive Options The XPS controller is capable of driving up to 8 axes of most Newport positioners with internal drives that slide into the back of the mainframe. These factory-tested modules are powered by an internal 500 W power supply that is independent of the controller power supply. The XPS-DRV01 is a software configurable PWM amplifier that is compatible with most of Newport s and other companies DC brush and 2-phase stepper motor positioners. When used with Newport stages, the configuration of the amplifier is easily completed using the auto-configuration utility software, or advanced users can manually develop their own configuration files specifically optimized for each application. The XPS-DRV01 motor driver supplies a maximum current of 3 Amps and 48 Volts. It can drive unipolar and bipolar 2-phase stepper motors in microstep mode (sine/cosine commutation) and DC brush motors in velocity mode, for motors with a tachometer, or in voltage mode, for motors without a tachometer. Programmable gains and a programmable PWM switching frequency up to 300 khz allow a very fine adjustment of the driver to the motor. For added safety, a programmable overcurrent protection setting can be used. The XPS-DRV02 is a software configurable PWM amplifier for 3-phase brushless motors. This driver has been optimized to perform with the XM and IMS-LM linear motor stages. The XPS-DRV02 supplies a 100 khz PWM output with a maximum output current of 5 Amps per phase and 44 Vpp. The XPS-DRV02 requires 1 Vpp encoder input signals which is also used for motor commutation. Motor initialization is accomplished through a proprietary and patented method that results in insignificant stage motion, without the need for hall effect or other sensors. The XPS-DRV03 is a fully numerical, programmable PWM- Amplifier that has been optimized for the use with highperformance DC motors. The 100kHz high switching frequency and appropriate filter technologies minimize noise, enabling ultra-precision positioning in the nm-range. The XPS-DRV03 supplies a maximum current of 5 Amps and 48 Volts. It can drive DC motors in velocity mode, for motors with a tachometer, in voltage mode, for motors without a tachometer, and in current mode, for torque motors. All parameters are free programmable in physical units, for instance the bandwidth of the velocity loop. Furthermore, the XPS-DRV03 features separate limits for the rms current and peak current. when used with a scale with 4 µm signal period, the resolution can be as fine as 0.122 nm. This interpolator can be used for accurate position feedback on the servo corrector of the system. An additional hardware interpolator with 40 MHz clock frequency and programmable signal subdivision up to 200-fold is used for synchronization. This fast interpolator directly latches the position with less than 50 ns latency and provides a much higher level of precision for synchronization than alternative time based systems. Unlike most high-resolution multiplication devices, the XPS interpolators do not compromise positioning speed. With a maximum input frequency ranging from 180 khz to 400 khz, depending on the interpolation factor, the maximum speed of a stage with a 20 µm signal period scale can be up to 3.6 m/s. Ordering Information Model XPS-C2 XPS-C4 XPS-C6 XPS-C8 XPS-DRV01 XPS-DRV02 XPS-DRV03 XPS-DRV00 XPS-CONKIT XPS-TG5 XPS-RC Description 2-axis XPS controller 4-axis XPS controller 6-axis XPS controller 8-axis XPS controller PWM drive module for DC brush and stepper motors, 3A/48V max. PWM drive module for brushless motors, 5A/44Vpp max. High performance PWM drive module for DC motors, 5A/48V max. Pass-through module Connector kit with 6 GPIO connectors Trigger output cable, LEMO/flying leads, 5m Remote control Refer to the Stage and Controller Compatibility Table (page 842) for a complete list of compatible Newport stages. 1) To order an XPS controller, specify the controller and the drive modules by separate part numbers. For example, for an 8-axis XPS controller with 3 drive modules for ILS stages, one drive module for an IMS300CCHA stage and one passthrough module, the correct part numbers are: 1 x XPS-C8 3 x XPS-DRV01 1 x XPS-DRV03 1 x XPS-DRV00 The XPS-DRV00 pass-through module can be used to pass control signals to other external third-party amplifiers or drivers. By setting the controller s dual DAC output to either analog position, analog stepper position, analog velocity, analog voltage or analog acceleration, including sine commutation, the XPS can control almost any motion device - including brushless motors, voice coils and piezoelectric stages. In addition to conventional digital AquadB feedback encoder interface, the XPS controller also features a high-performance analog encoder input (1 Vpp Heidenhain standard) on each axis. An ultra-high resolution, very low noise, encoder signal interpolator converts the sine-wave input to an exact position value with a signal subdivision up to 32,768-fold. For example, The XPS controller in the above example can still drive 3 more stages. Additional drive modules can be ordered under the same part numbers. An upgrade from a 4-axis controller to a 6-axis controller requires a factory return. 2) Customized training programs are available upon request.