ADLINK AMP-204C/AMP-208C Motion Control Card

ADLINK AMP-204C/AMP-208C Motion Control Card

Product positioning

AMP-204C (4-axis)/AMP-208C (8-axis) is a self-developed PCI bus pulse motion control card by Linghua, equipped with TI floating-point DSP and large capacity FPGA, combined with self-developed Softmotion core, outputting differential pulse instructions, adapting to servo/stepper drivers, using PCI Rev2.2 32-bit 33MHz bus and high-speed interaction of motion instructions, encoder feedback, and axis parameters with industrial computer.

Core hardware architecture

Computing core: 375MHz TI floating-point DSP; Storage of 64Mx16bit DDR2 SDRAM+16M bit Flash ROM

FPGA integration: PCI bridge, 4/8 PID, pulse generator, encoder acquisition, high-speed position comparison trigger, universal I/O logic

Separated isolation design: All servo and limit isolation circuits are equipped with external dedicated terminal boards DIN-825-GP4 to prevent wiring short circuits from burning out the main control card

Key hardware specifications

Bus: PCI 32-bit, 3.3V/5V compatible, IRQ automatically allocated by BIOS

sports performance

Pulse output: Differential Line Driver, up to 6.5MHz; Supports two pulse formats: OUT/DIR and CW/CCW

Encoder input: up to 20MHz (4x), differential EA/EB/EZ Z-phase index, supports 1/2/4x decoding

Programmable control cycle: 500 μ s/1ms/2ms; Position/speed/acceleration/deceleration all have 32-bit accuracy

I/O resources

Sports specific I/O: Independent SVON servo enable for each axis, ALM servo alarm, ORG origin, PEL positive limit, MEL negative limit, INP in place, EZ zero phase

High speed trigger: AMP-204C 2-channel and AMP-208C 4-channel hardware position comparison trigger, with a maximum output of 1MHz

PWM laser control: 2/4 channels with 16 bit resolution, three modulation modes (fixed frequency to duty cycle/fixed width frequency conversion/fixed duty cycle frequency conversion)

Universal isolation DI/DO: Single DIN-825-GP4 with 20 inputs and 24 outputs; Dual card supports 8-axis full I/O

Environment and power consumption

Working temperature 0~55 ℃, storage -20~75 ℃, no condensation; Self cooling, resistant to 1500VPP noise

Power supply: 3.3V 0.8A, 5V 0.8A, ± 12V 0.5A

Software support

MotionCreatorPro 2: Windows visual debugging tool, wizard style hardware wiring, axis parameter configuration, real-time collection of motion curves and I/O status, no programming required for single axis/interpolation testing.

APS development library: supports VS C++, VB.net, C #, C++Builder, hundreds of APIs, supporting routines, compatible with WinXP/Win7 32/64 bits.

Development process: Hardware installation and wiring → MotionCreatorPro configuration axis parameters → Software debugging motion → APS library secondary development.

Supporting terminal board DIN-825-GP4

Specially designed for the AMP series, with built-in optocoupler isolation, compatible with mainstream servo cables from Mitsubishi, Yaskawa, Panasonic, and Delta, and supporting dual interfaces of Pulse Mode (CMP) and Analog Torque Mode (CMA); Integrate emergency stop, brake, laser PWM, and expand DI/DO terminals.

Hardware installation and debugging

Packing List

1 main control card, IDE44 to DSUB37 flat cable, warranty card, and this manual; The 8-axis system requires 2 DIN-825-GP4 terminal boards.

Definition of Board Interface

AMP-204C

P1：100Pin SCSI， 4-axis pulse, encoder, servo dedicated I/O

P2：37Pin DSUB， 16 channel universal TTL DI/DO

SW2 4-digit DIP dip code: Board ID (0~15, default 1111), multi card distinguishing device number

AMP-208C

P1: Dual VHDCI 100Pin (P1-A/P1-B), covering all motion signals of axes 1-8

P2 is aligned with 4 axes; The dialing rules for SW2 are consistent

Hardware installation steps

Power off the industrial control computer, wear anti-static clothing, insert the card into the white 32-bit PCI slot and fix it;

The SCSI cable connects the main control P1 to the DIN-825-GP4 main interface;

Connect 24V DC to the terminal board, and sequentially connect the limit, origin, servo pulse, encoder, and emergency stop;

Power on the servo motor without load, first verify the I/O and single axis motion through MotionCreatorPro, and then connect it to the mechanical load;

Mandatory requirement for terminal shielding layer grounding to reduce the risk of electric shock and interference.

Software installation process

Run the WDM driver installation program and follow the wizard to complete it;

Restart the industrial computer and confirm hardware recognition in the device manager;

Install MotionCreatorPro 2 (dependent) NET Framework 3.5 and above);

Suggest downloading the latest driver kit from the official website.

Common troubleshooting

Troubleshooting plan for fault phenomena

Device Manager: No hardware. Re insert PCI card, reinstall driver, check motherboard PCI slot

MotionCreatorPro cannot start installation NET3.5

Motor no signal, indicator light alarm terminal board 24V power supply not connected

Servo fault check ALM alarm logic, emergency stop circuit, and axis parameters

The encoder feedback and instruction deviation do not match the encoder multiplier and counting direction parameters

Motor only moves unidirectionally OUT/DIR/CWCCW pulse mode setting error

Terminal board switch and terminal definition

S1/S2 DIP: Switch CMP interface pin 10 to servo reset ALM-RST or universal digital output EDO;

Terminal partition: CMP pulse interface, CMA analog torque interface, J1/J2 limit origin, J5 emergency stop 24V power supply, IOIF expansion 16DI/16DO, CN1 laser PWM;

DI common terminal DICOM connected to 24V+, DO common terminal DOCOM connected to 24V GND.

Hardware installation steps

Power off the industrial control computer, wear anti-static clothing, insert the card into the white 32-bit PCI slot and fix it;

The SCSI cable connects the main control P1 to the DIN-825-GP4 main interface;

Connect 24V DC to the terminal board, and sequentially connect the limit, origin, servo pulse, encoder, and emergency stop;

Power on the servo motor without load, first verify the I/O and single axis motion through MotionCreatorPro, and then connect it to the mechanical load;

Mandatory requirement for terminal shielding layer grounding to reduce the risk of electric shock and interference.

Software installation process

Run the WDM driver installation program and follow the wizard to complete it;

Restart the industrial computer and confirm hardware recognition in the device manager;

Install MotionCreatorPro 2 (dependent) NET Framework 3.5 and above);

Suggest downloading the latest driver kit from the official website.

Common troubleshooting

Troubleshooting plan for fault phenomena

Device Manager: No hardware. Re insert PCI card, reinstall driver, check motherboard PCI slot

MotionCreatorPro cannot start installation NET3.5

Motor no signal, indicator light alarm terminal board 24V power supply not connected

Servo fault check ALM alarm logic, emergency stop circuit, and axis parameters

The encoder feedback and instruction deviation do not match the encoder multiplier and counting direction parameters

Motor only moves unidirectionally OUT/DIR/CWCCW pulse mode setting error

Terminal board switch and terminal definition

S1/S2 DIP: Switch CMP interface pin 10 to servo reset ALM-RST or universal digital output EDO;

Terminal partition: CMP pulse interface, CMA analog torque interface, J1/J2 limit origin, J5 emergency stop 24V power supply, IOIF expansion 16DI/16DO, CN1 laser PWM;

DI common terminal DICOM connected to 24V+, DO common terminal DOCOM connected to 24V GND.

Various signal wiring specifications

All servo and limit signals are isolated by DIN-825-GP4 optocouplers for input and output, and are divided into two types of wiring circuits: differential Line Driver (long-distance, anti-interference) and open collector Open Collector (short distance).

Pulse output (OUT/DIR differential)

CMP terminal OUT+/- pulse, DIR+/- direction; Maximum 6.5MHz;

Do not apply current exceeding 20mA to avoid burning out the 26LS31 driver chip.

Encoder EA/EB/EZ differential input

Support servo differential encoder, with a maximum frequency of 20MHz for 4th harmonic generation; The 26LS32 receiving chip has a current limit of 20mA;

Z-phase EZ is used for precise origin locking and high-speed position triggering.

Safe input signal

EMG emergency stop: Hardware global shutdown, triggering all axis pulses to immediately cut off, synchronously outputting emergency stop signals to all servos;

PEL positive limit/MEL negative limit: After triggering, movement in the corresponding direction is prohibited, and the software can set the signal high and low to be effective;

ORG origin switch: return to zero motion reference, paired with EZ index to achieve precise zeroing.

Servo interactive I/O

SVON servo enable output: high/low effective programmable, automatically disconnected in case of malfunction;

ALM servo alarm input: servo abnormality triggers interruption and stops movement;

IN in place input: feedback on servo positioning completion, used for process triggering.

High speed position comparison triggers TRG

Hardware real-time position matching output pulse, up to 1MHz, supports linear continuous triggering, FIFO buffer (single channel 255 points), suitable for laser marking and visual synchronization.

Universal isolation DI/DO

DI supports NPN/PNP sensors; DO single channel maximum 250mA, with an additional 16 in and 16 out IOIF terminal for fixture, indicator light, and auxiliary control.

Core Motion Control Theory

Basic Control Architecture

Coordinate system: Cartesian Cartesian coordinate system, supports unit factor conversion, customizable mechanical units (mm/μ m/°), distinguishes between user coordinates (floating point) and motor pulse coordinates (32-bit integer).

Unit coefficient calculation formula:

(Unit Factor= frac {Encoder Resolution} {Screw Pitch (User Units)} × frac {Number of Driven Gear Teeth} {Number of Active Gear Teeth} )

Suitable for three typical mechanisms: ball screw, conveyor belt, and linear grating.

Three level control cycle

Servo loop: minimum 50 μ s (20kHz), PID, encoder acquisition;

Motion trajectory loop: default 1ms (1kHz), interpolation, speed planning;

Host communication loop: default 2ms, upper computer interaction, status sampling;

The priority of the motion cycle is higher than that of the host, and it is recommended to keep the load below 70% to avoid overclocking errors.

speed curve

T-trapezoid curve: constant acceleration and deceleration, simple calculation, large start stop jitter;

S-curve: Gradual acceleration and deceleration (S factor 0~1), reducing impact, suitable for high-precision precision equipment.

Basic motor functions

Home: 3 mainstream modes for returning to zero

Mode 0: Only ORG origin; ORG+EZ index accurately returns to zero;

Mode 1: Positive and negative limit EL find the origin;

Mode 2: Only encoder EZ index returns to zero;

Support software configuration of zeroing speed, offset, and deceleration parameters.

Continuous velocity/Jog jog: continuous constant speed operation, supporting real-time online speed modification; Jogging supports step size and continuous jogging mode.

Point to point PTP positioning

Synchronized multi axis startup; Real time modification of position/speed during exercise; Continuous multi-point buffering motion;

50 point position table per axis, supporting delay, DO output, pause and resume.

Multi axis interpolation

Linear interpolation: 2-6 axis synchronous lines;

Arc interpolation: 3D spatial arc, spiral/helix interpolation;

Continuous interpolation speed fusion: Smooth transition between segments without pause, supporting 7 fusion algorithms.

Advanced featured features

Electronic gear: master-slave axis synchronization, suitable for winding and cutting equipment, automatic meshing speed adjustable;

High speed position comparison trigger: hardware level no delay output, FIFO batch point trigger;

PWM laser modulation: dynamically adjust laser power with interpolation speed to achieve uniform engraving;

Sports data sampling: real-time collection of speed, position, and I/O status for data analysis;

Hardware security protection: emergency stop, limit hardware locking; Software overtravel, overspeed, overload protection;

Host interrupt: In place, alarm, limit, and trigger signals can all generate interrupts to the upper computer.

Axis parameters and API

All pulse modes, encoder harmonics, I/O effective levels, acceleration/deceleration, and unit coefficients can be read and written through APS_det_axis_param/APS_get_axis_param, with parameters permanently stored in the board's Flash and automatically loaded upon power up.

Pulse format, encoder decoding, limit logic, and origin logic can all be reversed by software without the need to modify external wiring.

Safety, maintenance, and additional instructions

Mandatory requirements for safe operation

Disconnect the motor load during the first debugging, confirm that the shaft parameters are correct, and then connect the machinery;

The emergency stop circuit is normally closed in series, and the terminal board is independently powered by a 24V power supply;

Shielded cable grounding to prevent electrostatic breakdown of optocouplers and main control cards.

Service channel: Troubleshooting manual, fault table. If unable to solve the problem, please contact the agent/Linghua technical support;

Document supporting resources: system installation flowchart, complete wiring schematic, complete pin definitions for each connector, dialing comparison table, motion curve timing diagram.

Overall application scenario

This control card is designed for semiconductor equipment, laser processing, automated dispensing, AOI visual inspection, and multi axis gantry equipment. It relies on differential pulses, 3D interpolation, laser PWM, high-speed hardware triggering, and separated isolation terminal boards to achieve high-precision and high stability pulse type servo/stepper motion control.