Installation guide
Overview 13
4.2 - General Overview
The Programmable Motion Controller is a powerful, DSP-
based machine controller that is capable of far more than
simply moving motors. This section is intended to give the
user an overview of the controller's many capabilities
including all the functions and features users expect for
controlling motion. There are a wide variety of inputs and
outputs and software features that, in many cases, allow the
controller to operate an entire sophisticated machine. Figure
4.1 shows a typical 2-axis application. Section 5 has details
on setting up and wiring the unit.
Of special note is the ease of communication with either
"intelligent" or "dumb" operator interfaces. The controller
does not require the use of any operator interface panel or
host computer to operate as a stand-alone system. Simple
switch interfaces via axis I/O or expansion I/O will often
suffice for controlling a machine that does not need
extensive interaction with the operator for setup information
or message display. BCD switches are often used to enter
numeric data for simple setup. However, using a panel with
a keypad and display gives more flexibility and sometimes
easier and more "user-friendly" machine operation.
4.2.1 - Serial Communications
Communication with the MX2000 controller is via two
serial ports on the DSP Card. These serial ports can be
operated as an RS232 or RS485 device. The Host port is
used for programming and operating the unit. The Auxiliary
Port is used to communicate with an external serial device
during program execution. Use of these ports is covered in
more detail in Sections 5.6.1 and 5.6.2.
4.2.2 - Shutdown Input & Program
Select Inputs
The 32 bit DSP interface has four optically isolated inputs.
One of these inputs is used as a system shutdown or "motion
clear" input. The 3 remaining inputs allow selection of any
one of up to seven user programs that will be executed at
power-up or when a Reset command is issued. These inputs
can be sinking or sourcing. See Section 5.6.3 for more
details.
4.2.3 - Expansion I/O - BCD Port
An expansion I/O port is provided on the MX2 or MX6
Power Supply or optional Expansion I/O board. The I/O is
designed to interface to industry-standard "OPTO-22" style
high-power inputs and outputs.
Alternatively, this port can be used to read BCD switches
(seven digits plus sign per bank). Warner Electric provides
standard switch banks for use with the controller. Users may
also combine BCD's and expansion I/O. See Sections 5.7
and 5.9 for more details.
4.2.4 – Digital I/O
A digital I/O port is provided on the MX2A or MX6A
Power Supply or optional Digital I/O board. The I/O is
designed to operate with switches and relays. These inputs
and outputs can be sinking or sourcing. See Sections 5.8 and
5.10 for more details.
4.2.5 - Stepper Interface
Standard pulse and direction signals are provided on the
Axis Card for controlling most types of stepper drives.
Signals are compatible with drives up to 50,000 pulses per
revolution (1/250 micro-stepping), since the maximum pulse
rate is 1.99 MHz. See Sections 5.5.1 and 5.5.5 for more
details.
It is important to note that the controller can be easily
programmed in user units, such as inches or revolutions,
based on the motor/drive resolution and the machine's
characteristics. This is possible because of the controller's
extensive math functions. See Section 7
Software
Reference
Guide
for more details.
4.2.6 – Analog Drive
The analog outputs can be used as the torque command for
a servo drive. In addition a pair of drive enable output and
drive ready inputs have been provided.
4.2.7 - Encoder Interface
Inputs from two incremental encoders are provided on the
Axis Card. The maximum count rate is 2 MHz. There is
5Vdc power available on this connector to power the
encoders. Wiring to this port is covered in Section 5.5.3.
4.2.8 - Axis I/O and Analog I/O
Inputs are provided on the Axis Card for two axes worth of
limit switches, home switches, and mark registration sensors.
(The latter two are connected to the "Event 1" and "Event
2" pins.) These can be configured for sink or source
operation. Also, there are two sets of analog inputs that can
be read under program control. These inputs may be used
for reading various types of sensors (temperature, pressure,
etc.) and then controlling index distance or motor speed
based on the value read. See section 5.5.4 for more details.