ADLINK PCI-8154 Four Axis Pulse Motion Control Card

ADLINK PCI-8154 Four Axis Pulse Motion Control Card

Product basic positioning and core highlights

1. Product positioning

32-bit universal plug and play PCI bus 4-axis motion control card, with pure ASIC hardware for trajectory calculation, does not occupy the host CPU; Output high-frequency pulse driven pulse type servo/stepper driver, supporting linear, circular arc, spiral interpolation, continuous contour motion, supporting multi card cascade synchronization, suitable for high-precision multi axis automation equipment.

2. Core upgrade features (compared to the old PCI-8134)

1. The maximum pulse output is 6.55MHz (8134 only 2.4MHz), and the encoder input is up to 6.5MHz;

2. Added * * three-axis spiral interpolation * * and hardware position comparison trigger output (high-speed imaging/marking);

3. 13 types of zero return modes, hardware gap compensation, and vibration suppression algorithms;

4. EEPROM software encryption to prevent program duplication, independent hardware emergency stop input;

5. Support sub card expansion of distributed IO and high-speed trigger module DB-8150;

6. Multi card synchronous daisy chain cascading, with a maximum of 12 cards (48 axes) per system;

7. All digital IO 2500Vrms are optically isolated, providing stronger industrial anti-interference capabilities.

3. Core Function List

-Pulse output: OUT/DIR single pulse, CW/CCW dual pulse, AB phase three modes;

-Speed curve: trapezoidal, pure S-shaped, Bell hybrid S-shaped curve (shock absorption and noise reduction);

-Interpolation: 2-axis straight line/arc, 4-axis straight line, 3-axis spiral continuous interpolation;

-Hardware functions: 28 bit encoder counter, hardware position comparison, external handwheel MPG, multi card synchronous start stop;

-Protection: Positive and negative hard limit, origin switch, servo alarm shutdown, independent emergency stop input;

-Assistance: gap compensation, dynamic speed coverage, real-time position rewriting, 13 sets of return to zero logic.

Complete hardware and electrical specifications

1. Operations and Bus

-Bus: 32-bit PCI PnP, PLX9052 bridge chip, ASIC specific motion core;

-Counter: Each axis has an independent 28 bit bidirectional encoder for counting, with a range of ± 134217728 pulses;

-Clock reference: 19.66MHz internal crystal oscillator.

2. Pulse performance

-Pulse output: 0.1~6553500 PPS, differential/open set hardware jumper switching;

-Encoder input: AB phase 1/2/4 harmonics, CW/CCW single pulse input;

-Handwheel input: up to 3.2MHz, suitable for manual inching of handheld units.

3. I/O isolation and power supply

-All external signals are isolated by 2500V optoelectronics to eliminate interference from industrial circuits;

-Host PCI+5V maximum 900mA, external isolated 24V input maximum 500mA;

-Onboard isolation 5V output 300mA, supplied to limit and encoder sensors.

4. Physical dimensions and environment

-PCB size: 185mm (L) × 100mm (W), standard half length PCI;

-Working temperature: 0~50 ℃, storage -20~80 ℃;

-Humidity range of 5% to 85% without condensation, compatible with fanless industrial control chassis.

5. Matching terminal board (optional)

DIN-100S (universal stepper), DIN-814M (Mitsubishi J2 servo), DIN-814M-J3A (Mitsubishi J3), DIN-814Y (Yaskawa ∑ II), DIN-814P-A4 (Panasonic A4), 100pin one-to-one corresponding simplified wiring.

Definition of onboard connectors, jumpers, and dials

1. Four major connectors

1. CN3 (100 pin SCSI main interface): 4-axis all pulse output, encoder feedback, limit, origin, servo IO, multifunctional DI/DO, whole machine signal core;

2. K1/K2 synchronization terminal: Multi card cascaded STA synchronization start, ST synchronization stop signal, daisy chain interconnection;

3. CN4 handwheel interface: external MPG handheld pulse generator, PA/PB differential input;

4. SW1 4-digit DIP dialing: Set card numbers from 0 to 15, and differentiate device IDs in multi card systems.

2. JP2~JP9 pulse output jumper

Each axis has independent jumper wires, short circuiting 1-2=differential drive (default, long line anti-interference); Short circuit 2-3=open collector output (short distance low-voltage driver), open collector current upper limit 20mA.

3. CN3 core signal grouping (4-axis universal)

(1) Pulse output OUT ±/DIR ±

Differential pair output, supports two types of pulse logic, hardware jumper switches electrical mode.

(2) Encoder EA+/EB+/EZ+

A/B orthogonal counting, Z-index zero position, compatible with differential encoders and open set encoders (with external current limiting resistors).

(3) Mechanical switch input

PEL positive hard limit, MEL negative hard limit, ORG origin switch, software can switch between normally open/normally closed logic.

(4) Servo specific IO

-SVON: Servo Enable Output;

-ALM: Servo fault alarm input (triggering immediate stop pulse);

-INP: servo in place completion signal;

-ERC: Deviation counter reset output (return to zero/alarm/limit triggered automatically).

(5) Multi functional reuse DI/DO

-GDI: Single channel multiplexed emergency stop EMG, deceleration SD, position latch LTC, counter reset CLR, position triggered PCS;

-DO/CMP: Universal digital output/hardware position comparison trigger output (automatically outputs pulses upon reaching the set pulse, used for visual photography and laser marking).

Hardware installation process

1. Jumper pre configuration: Set JP2~JP9 differential/open set mode according to servo type; Set multiple card numbers with SW1 card number;

2. Anti static operation: Touch the chassis to release static electricity, only hold the edge of the board;

3. PCI slot installation: Insert into a 32-bit PCI slot and secure with screws;

4. External wiring sequence: First connect 24V isolated power supply → connect 100pin SCSI cable to terminal board → servo/limit/handwheel peripherals;

5. Troubleshooting: BIOS cannot recognize card replacement PCI slot, interrupt conflict occurs when BIOS shuts down redundant ISA devices.

Full motion control mode (ASIC hardware execution, zero CPU usage)

1. Type of speed curve

1. Trapezoidal curve: constant acceleration and deceleration, universal point position scene;

2. Pure S-curve: Smooth second-order acceleration and deceleration sections, significantly reducing mechanical impact;

3. Bell shaped curve: S-curve+linear acceleration segment, balancing speed and shock absorption.

2. Basic exercise mode

1. Single axis point position (absolute/relative): Set the target pulse to automatically accelerate and decelerate and stop;

2. Continuous constant speed mode: continuous output pulses, supporting dynamic speed modification during operation (speed coverage);

3.13 types of origin zeroing Home: supports only ORG, ORG+Z phase, limit reverse zeroing, multi-stage deceleration zeroing, etc., automatically clearing servo deviation;

4. Handwheel Follow Mode: External MPG pulse real-time synchronous motor motion, adjustable magnification software.

3. Multi axis interpolation (Cartesian Cartesian coordinate system)

1. Two axis linear interpolation: X/Y synchronous start stop, endpoint synchronous arrival, linear trajectory, error ± 0.5 pulse;

2. Two axis arc interpolation: Given the center, starting point, and endpoint, the tangent velocity of the arc is constant;

3. Four axis linear interpolation: any 4-axis synchronous linear motion;

4. Three axis spiral interpolation: XY arc+Z-axis feed, used for milling and thread machining;

5. Continuous contour motion: Hardware three-level motion buffer, seamless connection of multiple trajectories without pause, supporting continuous cutting paths.

4. Featured hardware sports functions

1. Hardware location comparison CMP: preset target pulse, automatically output trigger pulse upon arrival, no software polling required;

2. Gap compensation: Automatic compensation for screw backlash in reverse motion;

3. Vibration suppression: S-curve algorithm reduces start stop impact;

4. Multi card synchronous start stop: K1/K2 terminal daisy chain, all cards start/stop movement simultaneously.

Interrupt system

Enrich hardware interrupt sources, Windows processes through events, DOS processes through ISR:

-Movement completion, limit triggering, servo alarm, origin in place, position comparison triggering, encoder disconnection, emergency stop input;

-Support separate activation/deactivation of any interrupt, accompanied by waiting interrupt API functions.

MotionCreatorPro Debugging Software (Comes with Windows Tools)

Visual programming free debugging tool, core steps of the development process:

1. Hardware recognition: Automatically scan all PCI-8154 and read the SW1 card number;

2. Parameter configuration: pulse mode, encoder multiplier, limit logic, zero return mode, speed curve parameters;

3. Single axis debugging panel: manual jog, absolute/relative motion, real-time display of command/feedback position, IO status indicator light;

4.2D interpolation simulation: Preview of straight/circular trajectory graphics to verify machining paths;

5. Parameter saving: Export the configuration file and load it directly into the user program;

6. Fault diagnosis: Real time monitoring of alarm, limit, and emergency stop signals, quickly troubleshooting wiring errors.

Windows Development Library (C/C++/VB)

1. System initialization: card scanning, hardware reset, loading configuration;

2. Pulse and encoder configuration: pulse mode, AB doubling, count reset;

3. Single axis motion: point position, constant speed, dynamic variable speed, return to zero;

4. Multi axis interpolation: lines, arcs, spirals, continuous contours;

5. Handwheel control: Handwheel magnification, enable switch;

6. IO and servo control: SVON output, ALM/INP read, ERC reset;

7. Position comparison and locking: hardware triggered parameter settings;

8. Interrupt management: Enable interrupts, wait for interrupts, read interrupt status;

9. Gap compensation, soft limit, and speed curve setting;

10. Error code definition: Hardware failure, illegal parameters, motion conflict return value.

Signal wiring specifications

1. Complete wiring of differential servo drive;

2. Selection of external current limiting resistors for open-loop encoders (corresponding resistance values for 5V/12V/24V encoders);

3. Limit/origin switch circuit (24V contact input);

4. Multi card synchronous chrysanthemum link line scheme;

5. External emergency stop button wiring;

6. Handwheel MPG differential input circuit.