Acroloop –– Perfection in Motion he Acroloop Catalog is organized to give T you the information you need quickly and easily. • First, glance through our Acroloop Corporate Profile. The corporate profile outlines the capabilities that are available from Acroloop. • Second, scan the product index. The product index pictorially previews the products available and tells you where to find them. Acroloop’s ACR8010 • Next, take a moment to look over the selection guide. The selection guide provides you with an easy, visual, step-by-step approach to help build the perfect motion control system. Table of Contents • Finally, the product catalog has detailed Corporate Profile . . . . . . . . . . . . . . . . . . . . . . 1-2 outlines of the products and services available from Acroloop. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Applications Assistance. . . . . . . . . . . . . . . . . . . 4 If you don’t see what you need or if you need additional help, contact Acroloop for assistance. Product Index. . . . . . . . . . . . . . . . . . . . . . . . . . . 5 An Acroloop applications engineer will assist you Selection Guide . . . . . . . . . . . . . . . . . . . . . . . 6-11 or redirect you to the local technical office that can help you solve your motion control needs. Product Catalog . . . . . . . . . . . . . . . . . . . . . 12-53 Motion Controllers . . . . . . . . . . . . . . . . . . .12 Development Tools . . . . . . . . . . . . . . . . . . 36 Application Software . . . . . . . . . . . . . . . . . 38 Controller Chassis . . . . . . . . . . . . . . . . . . . 43 Operator Interfaces . . . . . . . . . . . . . . . . . . . 46 Brushed Motors & Amplifiers . . . . . . . . . . 49 Brushless Motors and Amplifiers . . . . . . . 50 ACROLOOP Feedback Devices . . . . . . . . . . . . . . . . . . . 51 MOTION CONTROL SYSTEMS, INC. Turnkey Packages . . . . . . . . . . . . . . . . . . . 52 Networking Products . . . . . . . . . . . . . . . . . 53 3 APPLICATIONS ASSISTANCE Acroloop offers applications engineering assistance. If Distributors you have a motion control application, contact Acroloop Acroloop also maintains a nationwide network of to discuss your needs with one of our engineers. factory trained distributors. Acroloop distributors Acroloop Applications Engineers are technical specialists typically represent a number of complimentary product that work with motion control applications involving lines for a wide variety of applications. Acroloop complex industrial projects or products with exacting distributors function in two main ways: technical specifications on a daily basis. We’ll be glad to put our motion control knowledge to work and help solve • First, to provide local technical support to your problems. Acroloop customers similar to that provided by manufacturers representatives. Applications Acroloop also offers Engineering • Second, to provide ongoing support for territory re- individual, technical brochures Assistance purchase of Acroloop products. Acroloop that describe the intricacies of distributors will maintain an inventory of Acroloop the products available from Individual, Technical products locally when the demand for specific Acroloop. These product Brochures products in the territory exists. brochures complement this Available product catalog. Thus, Acroloop distributors can provide local technical support, inventory management and parts In addition, Acroloop maintains a national and support to help better serve the needs of our customers. international network of factory trained manufacturers representatives, distributors, and value-added resellers. Value-Added Resellers (VAR’s) The main function of these organizations is to help you Acroloop also maintains a network of VARs. In with motion applications while providing local technical general, an Acroloop VAR can provide local support. integration services in the form of engineering, programming, technical support, on-site training, and Manufacturers Representatives (MR’s) start-up assistance. Obviously, Acroloop also provides Acroloop has developed a network of MR’s across the these services, but a VAR is essential when the country. The Acroloop MR’s are factory trained and application requires a local technical integration possess years of industrial motion control specialist. experience. An approved Acroloop VAR Acroloop MR’s are particularly effective in solving has undergone extensive and complex motion control applications, especially where Knowledgeable ongoing training at the hands on intimate knowledge must be maintained Manufacturers factory in order to become Representatives between the customer needs and the Acroloop products familiar with the types of and services required to meet the application. Acroloop Nationwide, Factory engineering issues that arise MR’s have exclusive territories in which they service our Trained Distributors in applying Acroloop customers, support distribution and our VARs. controllers and products. VAR: Contact Acroloop for a list of Local Technical approved Acroloop VAR’s. Integration Specialists 4 ACROLOOP MOTION CONTROL SYSTEMS ACROLOOP PRODUCT INDEX Building the Perfect System here are six main product categories to consider when designing your motion control system. These categories are outlined below. The outline visually shows the products that are available from Acroloop and where to T locate them throughout the Selection Guide and the Product Catalog. MOTION CONTROLLERS ACR Family of Controls Selection Guide: page 6 Product Catalog: pages 24-35 SOFTWARE/DEVELOPMENT TOOLS AcroView, AcroCut, AcroJet, AcroMill, DLL’s, OCX’s Selection Guide: page 7 Product Catalog: pages 36-42 CHASSIS ACH Family of Chassis Selection Guide: page 8 Product Catalog: pages 43-45 OPERATOR INTERFACE OPS Family of Interfaces Selection Guide: page 9 & 10 Product Catalog: Pages 46-48 AMPLIFIERS/MOTORS/ FEEDBACK Selection Guide: Page 11 Product Catalog: pages 49-51 TURNKEY SYSTEM Acroloop or an Acroloop approved Value-Added Reseller (VAR) can package all the components in a panel and provide start-up assistance. Product Catalogs: page 52 5 Selection Guide he selection guide is an easy, visual, step-by-step tour to help you build the perfect motion control system. From components to integrated systems, the Selection Guide is designed to help T you visualize exactly what you need for your motion control application. Step 1 - Selection of Controller The controller is the single most important element in motion control. There are a wide variety of issues to consider. However, the basic requirements consist of: • Number of axes • Communications interface requirement • Type of motion control • Input/Output requirements Model ACR8020 ACR8010 ACR2000 ACR1500 ACR1200 Motion Control 32 Bit Floating Point DSP YES YES YES YES YES CPU Speed 150 MHZ 60 MHZ 50 MHZ 40 MHZ 40 MHZ Axes/Controller 2-8 (Expandable) 2-8 2-4 ` 2-4 1-2 Servos YES YES YES YES YES Steppers YES YES YES YES YES Line/Arc/ Splines/Nurbs, 3D Arc Interpolation YES YES YES YES (except NURBS) YES Memory Size STD (OPT) 512K (2MB) 512K (2MB) 512K 128K 128K (512K) Flash for Saving Programs YES YES YES YES YES PreEmptive Multitasker YES YES YES YES YES Communications Interface Binary, ASCII Binary, ASCII Binary, ASCII Binary, ASCII Binary, ASCII COM1, COM2 Serial YES, Optional YES, Optional YES, Optional NO YES, Standard AcroWire IEEE-1394 Option YES, Optional YES, Optional YES, Optional NO YES, Optional Standalone Option N/A YES YES NO YES PC-Bus Pluggable YES, PCI YES, ISA YES, ISA YES, ISA N/A Parallel (LPT) Option YES YES YES NO YES Dual Port Memory Option YES, Standard YES, Optional NO NO N/A Bus Mastering YES NO NO NO N/A Inputs/Outputs Encoder Inputs 4-10 (Expandable) 4-10 2-4 2-4 3 Encoder fault Detection YES, in hardware YES, in hardware NO NO YES, in hardware Absolute Encoder Option YES YES YES YES YES D/A Outputs 2-8 (Expandable) 2-8 2-4 2-4 2 Uncommitted I/O 64 (Exp. to 320) 64 (Exp. to 320) 32 (Exp. to 288) 48 32 (Exp. to 160) I/O Type 24V Opto Isolated 24V Opto Isolated 24V Opto Isolated TTL 24V Opto Isolated I/O Active Hi/Lo Select YES YES YES YES YES AUX Analog Inputs 8 Single Ended/4 Differential 12 or 16 Bits 12 or 16 Bits 12 Bits 12 or 16 Bits 12 or 16 Bits Additional technical information is available in the Motion Controllers section of this catalog. Additional technical assistance and information can also be obtained from Acroloop or the local representative. 6 ACROLOOP MOTION CONTROL SYSTEMS Step 2 - Selection of Software Tools AcroView This is a diagnostic and programming tool that allows developers to communicate to all Acroloop controllers in PC-Bus, Serial or Acrowire IEEE-1394 applications. This software allows project based program design for motion and graphical ladder logic IEC1131 PLC programming. AcroMill/AcroCut CNC Machine Tool Software program standard RS-274D programming language. This software is offered for DOS as well as Windows. Can cycles, work coordinates, macros, parametric programming, cutter compensation is standard. Customer Written Application using Acroloop SDK The Acroloop Software Development Kit (SDK) allows customers to develop their own application very rapidly. Source code samples are provided in the SDK for visual Basic and Visual C++. Custom Applications Let Acroloop or an Acroloop VAR modify one of your existing application software programs to your specification. 7 Step 3 - Selection of Controller Chassis The third step is to decide how to physically mount the controller within the motion control system. The main factors in selecting a controller chassis are: • Type of chassis required • Interface Connectors • Acroloop controller supported • Physical size considerations Size Standalone Controller Interface (W x H x D) or PC-Bus** Model* Supported Connectors ACH3120 Standalone ACR1200 34 pin/26 pin headers 4.25” x 9.6” x 7.45” ACH3200 Standalone ACR2000 34 pin headers 4.38” x 11” x 6.75” ACH4800 Both ACR8010 Terminals 4.75” x 15” x 11.25” ACH6200 Both ACR1500/ACR2000 D-connectors 9.12” x 5.75” x 9” ACH6800 Both ACR8010 D-connectors 6.38” x 6.75” x 15.5” * = Acroloop Industrial Controller Chassis include +/- 5VDC and +/- 12VDC power supply ** = 65 Watt Power Supply is supplied with Standalone chassis’ ** = 150 Watt Power Supply is supplied with PC-Bus chassis’ or or ACR8010 SPL026 with ACH6800 Breakout Box ACH4800 or or ACH3200 with Breakout Box ACH6200 ACR2000 ACH4800 or ACH6800 ACH6200 ACR1500 ACR1200 ACH3120 8 ACROLOOP MOTION CONTROL SYSTEMS Step 4 - Selection of Operator Interface Acroloop carries four main types of operator interfaces. The main question is to decide what information needs to be displayed and communicated to the operator. When deciding on the operator interface, the main factors are: • Number and Type of Keys • Application, physical constraints, and aesthetics • Interface requirements and operating system • Cost Sensitivity Interface Display Keyboard Size Power Model* Type Type Type (W x H x D) Requirements OPS9200 PC/CNC 14” Color CRT Tactile 19” x 15.75” x 14.5” 120VAC OPS9210 PC/CNC 12.1” Color LCD Tactile 19” x 12.25” x 4” 120VAC OPS9220 PC/CNC 12.1” Color LCD Full 90 Key 19” x 17.5” x 4” 120VAC OPS9000 PC 14” Color CRT Membrane 19” x 15.75” x 14.5” 120VAC OPS8200 PC 10” Flat Panel** Touchscreen 12” x 10.5” x 8.5” 120VAC OPS8220 PC 12.1” Color CRT Full 90 Key 19” x 17.5” x 10.75” 120VAC OPS8100 PC 10” Flat Panel** Tactile 19” x 10.5” x 10.5” 120VAC OPS8000 Smart 4x40 LCD Membrane 10.3” x 6.6” x 3.1” +/-12 & 5VDC OPS1200 Smart 4x40 LCD Membrane 10.3” x 6.6” x 3.1” +/-12 & 5VDC OPS1000 Smart 2x20 LCD Membrane 6.25” x 9.38” x 2” +/-12 & 5VDC KBD 16 Dumb 1x16 LCD Membrane 7.1” x 4.1” x 1.1” 5VDC * = Acroloop Operator Interfaces are all NEMA 12 and can be panel or pendant mounted ** = Flat Panel display can be LCD, EL, Passive Color or Active Color and ACR8010 CPU Card + VGA OPS9220 ACH4800 9 ACH1200 OPS1200 Complete low cost motion box for 1-2 Axis application can reside totally on the ACR1200 controller! Ideal for cut to length, roll feed machines, screw machines and more! Smart Terminals Smart terminals are useful for applications involving standalone controllers. Since the talk terminal is “smart”, it has the capability of being programmed to display messages and request information from the operator. Smart terminals have the ability to update the display, accept OPS8000 keypad input, and communicate with the Acroloop controllers over a serial port. ACH4800 ACR 8010 Dumb Terminals Dumb terminals are useful for standalone applications that can run entirely on the Acroloop controllers and talk require limited information that needs to be displayed. The Acroloop controllers receive and transmit ASCII text by KBD16 polling the serial port with a separate ACH3200 multi-tasked program running on the Acroloop controller. 10 ACR2000 ACROLOOP MOTION CONTROL SYSTEMS Step 5 - Motors, Amplifiers, and Feedback Devices Many motors are available from stock inventory for immediate delivery. The motors can be supplied with integral encoders, matched amplifiers, power supplies, and the appropriate interconnecting motor cables. ACR8010 ACH 4800 Encoders Motor Type Motor Size Range 10 in./oz. - 75 in./lb. Brushed Brushless 15 in./lb. - 950 in./lb. Motors Amplifiers Step 6 - Consider a Turnkey Package Acroloop or a local distributor or VAR can supply a complete turnkey package. Complete turnkey packages include: • Motion Controller(s) • Controller Chassis’ • Operator Interface • Motor(s), Amplifier(s), and Feedback Device(s) • Software • Complete Integration Hardware Acroloop or a local Acroloop approved integration specialist will package all the electronics in an industrial enclosure complete with all interconnecting cables. Since the system is specifically designed for the application, product differentiation is easily achieved. Both single and multi-axis turnkey packages are available. Multi-Axis Turnkey Package 11 MOTION CONTROLLERS Product Catalog ACR8020 (1-8 Axes Controller) - Page 24 ACR8010 (1-8 Axes Controller) - Page 26 ACR2000 (1-4 Axes Controller) - Page 28 ACR1500 (1-4 Axes Controller) - Page 30 ACR1200 (1-2 Axes Controller) - Page 32 Unique Features: • Backlash and Ballscrew Compensation • Hardware & Capture Registers • 32/64 Bit Floating Point DSP • S-Curve Profiling • On-the-Fly High Speed Trajectories • Pre-Emptive Multi-Tasker • String Handling • Service up to 4 Comm. Channels Simultaneously • Time Based Moves • Floating Point Electronic Gearing • Synchronized Master Moves • Automatic Rollover for No Cumulative Error • Segmented Cams • Real Time Phase Advanced on Gears, Cams or Jog • High Speed Triggered Cams • 50 usec Servo Update Time • Dual Feedback Control (Velocity and Position) • 200-500 usec (Addressable) Trajectory Loop Update Time • Feedback can be Analog or Digital • Ladder Logic PLC • Outputs can be Stepper or Servo • Programmable Limit Switch with Multiple Sources for Initiation • On-Board Diagnostics • Hardware Position Registers • On-Board Oscilloscope • On-Board Data Aqusition • Software Limits • Optically Isolated I/O* • Torque Limits • Multi-Threaded Windows 98, NT Drivers • Spline Moves • Unlimited Data Array Size • NURBS • Complete Access to Variables Through Pre-mapped Parameters • 3-D Arcs • Free C++, Visual C & Visual Basic Libraries • Sinusoidal Commutation • Free Active X Controls • AcroWire IEEE-1394 • Free Development Software with Tuning Tool • Automatic Tangential Tool Orientation *Except ACR1500 which are 5 Volt TTL Signals 12 ACROLOOP MOTION CONTROL SYSTEMS Acroloop’s Family of Multi-axes Motion Controllers At Acroloop Motion Control Systems, we have designed a We believe that a high-end motion controller should be as small, flexible, and high-speed as possible, yet, family of motion control cards that incorporate state-of-the remain affordable. art hardware, firmware, and software. Highlighting the Floating Point DSP We have designed our entire family of motion controllers Software calculations, instead of processor-based calculations, are typically updated at a much lower rate. using high-speed Floating-Point Digital Signal Processors (DSP's). Floating-Point DSP's are the fastest, most accurate This is one of the main reasons Acroloop's family of processors available today. controllers can process trajectory calculations so fast, typically in the 200-500 usec range (our Acroloop uses the Texas Instrument TMS3203X DSP in all competitors are typically in the 5000-8000 usec range). of the Acroloop family of Motion Controllers. The TI DSP The ability to perform calculations on-board the floating simply outperforms non-DSP type processors in speed and point DSP frees the controller to service a accuracy. The Acroloop family's DSP's vary from pre-emptive multi-tasker, with up to 24 programs at 40-150MHz, and have the ability to perform floating-point once, and service up to four communication channels calculations on-board. This gives us an advantage over a concurrently. This means you can communicate with an fixed-point DSP, or fixed-point Microprocessor-based Acroloop controller for troubleshooting and still have controls. If a chip cannot perform floating point calculations the HMI on a production machine fully on line and on-board, then floating point calculations must be done in active! software. State of the Art Manufacturing All cards, after passing a test fixture, are burned-in at Our commitment to product also extends to manufacturing. All cards from Acroloop described in this brochure are Acroloop’s test facility. In line with our commitment to manufactured as Dual Sided Surface Mount Technology being flexible, Acroloop controllers can be configured as stepper or servo in pairs. So you could have 2-axis of Cards on Acroloop’s own Surface Mount manufacturing servo, and 2-axis of stepper, with 2 encoder inputs on a line. This keeps the leadtimes short and insures quality. four-axis ACR1500 controller card. The same software applies to stepper or servo. Common Firmware Acroloop has common firmware for all the Acroloop family Any value such as commanded position, jog offset, of controllers. This means if you want to upgrade to a ballscrew compensation, etc., is a parameter. This means faster or larger card later, all of your development work will it can be the result of a parametric equation, or perhaps carry over. Our firmware is infinitely flexible because it is loaded off a spreadsheet or possibly changed on the fly parameter and flag based. as the result of a flag being set. Development Software Documentation such as User Guides, Hardware or At Acroloop we embrace the trend towards Visual Basic, Software Manuals, Technical Brochures and Specification Visual C, or C++ Human Machine Interface. We also support many Soft PLC manufacturers as possible. Sheets are free on CD with any order. Our Development Acroloop offers DLL's, Libraries and OCX's for various Tool, Acroview, is also available free of charge with any order. windows platforms. 13 Pre-Emptive Multi-Tasker The ACR Family of Controllers are true pre-emptive The architecture permits the motion controllers to be able multi-taskers capable of performing multiple to communicate over the PC-Bus, and two serial ports simultaneous tasks. The advantage of a pre-emptive simultaneously. This ability for all communication ports to multi-tasker is in its ability to toggle tasks based on the be active at once means troubleshooting can be performed condition of a bit. When you have a program that need on a machine from one port while the standard not always run, but needs to be readily available to run, a communication port is active with the HMI. This means pre-emptive multi-tasker is the best choice. For example, on-line trouble shooting is standard with Acroloop if you need to dress a wheel on a grinder based on an controllers. input, or parametric equation. In this example, it would Because of the standard on-board operating system in be a waste of valuable time to have this program being Acroloop controllers, time critical events can be off loaded serviced constantly. However, if you did not have a pre- to the controller. This is important, since the loading and emptive multi-tasker, it would be necessary to allocate therefore timing issues of the host PC CPU, are variable time for this little used program. In a pre-emptive and the programmer cannot be sure of real-time execution. situation, the program would be dormant until called for, Therefore, real time application programming can be and only then would it require time to be serviced. off-loaded to the Acroloop controller to insure real time The 32-bit pre-emptive multi-tasker can perform motion execution. programs, PLC programs, and multi-threaded communications simultaneously. Acroloop Controller Family Windows NT Motion Multi-Thread PC/PCI Program Operating PC/ISA System PC/CPCI PC/IEEE-1394* 32 Bit Pre-Emptive Serial * Motion Multi-Tasker Program Multi-Thread Operating System Serial * PLC Program *Options on Parallel * some boards. PLC Program 32 Bit Pre-Emptive Multi-Tasker The ACR Controllers can perform the following with the pre-emptive multi-tasker: · Perform up to 8 motion programs (50 usec/axis servo update rate) · Perform up to an additional 8 programs (non-motion programs) · Perform up to 8 PLC programs (2-5 msec scan time) · Command up to 4 communication ports simultaneously 14 ACROLOOP MOTION CONTROL SYSTEMS Analog Analog/Stepper Flexibility Analog or Stepper or Stepper Analog Inputs The Acroloop Motion Controllers can be set up to accommodate stepper or servo analog outputs. The controllers can be configured in combinations explained in the ordering matrix on pages 34-35 of this brochure. Analog inputs at 12 or 16-bit resolutions are available as options. These may be field configured as single- ended or differential inputs. Acroloop Trajectory Calculation The architecture of the Acroloop controllers permits All of the trajectory calculations are performed not only pre-emptive multi-tasking, but also highly on-board and calculated with a floating point accurate trajectory calculations. The Controllers are processor. Based on a servo loop update time of 50 unique since they calculate a new trajectory point microseconds per axis, the servo update time for 2 axes every interrupt. A new trajectory point is calculated is 100 microseconds. By adding an additional 100 every 200-1000 microseconds, depending on the user microseconds for “overhead” tasks (PLC programs, programmed interrupt period. Comparatively, other communications, etc.), the total interrupt period is “high performance” motion controllers on the 100usec + 100usec = 200usec. The trajectory market calculate trajectories at a 5-10 millisecond rate. calculation is then the inverse of 200 microseconds or Thus, the Acroloop controller is an “order of 5,000 points per second. magnitude” better with floating point calculations. Acroloop Controller Trajectory Calculation-Trajectories calculated every interrupt. Trajectory Calculation Table Number Calculation 40-150 MHz of Axis Bits Points/Second 2 64 5,000 4 64 3,333 6 64 2,500 8 64 2,000 Calculating a new trajectory every interrupt is the method of choice when the process consists of normal motion geometry’s (i.e. lines and arcs). In PC-Bus applications, the controllers perform the trajectory calculations without host intervention. The host simply sends the appropriate coordinate information to the Acroloop controller. 15 Acroloop Cubic Splines · Cubic Spline Interpolation with smoothness of continuous first and second derivatives of position. · Can handle uniform and non-uniform data points. · Ability to define initial and final velocity to blend with other motion profiles. · Exactly goes through the data points. · Spline interpolation can be time based or velocity based. 470 SPLINE mode 0 500 KO X0 510 K1 X4 515 K2 X6 518 K2.5 X2 520 K4 X3 525 K5 X3.5 530 K6 X4 Fig 1. Example of how points can be randomly spaced in time greatly reducing program length. Additional Features with NURBS and SPLINES. · Dynamic Feed Rate over-ride. · Feed Hold and Cycle Start facility like normal moves. · Any source with source scaling like normal moves. · Blending with other motion profiles. Allows normal line/arc move at the beginning or end of spline/nurb segment. · Unique mix of modes only offered by Acroloop. Acroloop NURBS · Mathematical method of defining entire curve of up to 8 With these three modes, one can obtain the right Axes. velocity control over the nurb curve. · Free form curves can be accurately defined. · Suitable for high speed machining up to 8 Axes. Acroloop Nurbs interpolation allows variable degree of · Gives better surface finish. RANK (smoothness). · Shorter program and fewer data points. · Nurb Rank 2 results in linear connection of points with · No break between points at high speed. least amount of smoothness. · No need for high speed data transfer from the host. · Nurb Rank 3 results in smooth 1st and 2nd derivatives · No error due to approximating NURB curve by small linear of position. line segments. · Nurb Rank 4 results in smooth 1st through 3rd derivatives of position. Acroloop NURBS interpolation has three MODES. · Nurb Rank 5 results in smooth 1st through 4th · Nurb Mode0. Time based interpolation. derivatives of position. · Nurb Mode1. Linear Interpolation. · Nurb Mode2. Dynamic Interpolation. 490 NURBS mode 0 502 KO X23.4 Y8.2 504 KO X21 Y13.4 506 KO X17.4 Y11.2 VEL 100 208 KO X20.6 Y19.5 510 K2.96 X18.8 Y22.1 VEL 200 512 K5.83 X17.7 Y15.5 VEL 100 514 K7.17 X16.1 Y14.5 516 K9.82 X15.5 Y24.6 518 K10.82 X13.1 Y22.8 Fig2. Example shows few control points needed to draw random shape and accompanying program. 16 ACROLOOP MOTION CONTROL SYSTEMS Floating Point Mathematics Precision As previously discussed, the Acroloop Controllers are Acroloop Controllers. engineered around the Texas Instruments TMS320C3X The superior design of the processor permits the Floating Floating Point CPU. The controllers are also provided with Point Library to be installed on-board. The same Floating 64-bit precision floating point math functions. Compare the Point Library cannot be installed on other motion 32-bit and 64-bit precision floating point variables to other controllers due to their limited design and architectural motion controllers; you won’t get rounding errors with the features. With the Floating Point Library installed on the Acroloop Controllers. For example, a simple Acroloop Controllers, a full complement of parametric electronic gearing ratio can be set to a floating point evaluations is possible. number unlike other controllers with limited gear ratio The built-in floating point evaluator operates on both ranges. global and local variables programmed in the Acroloop The Acroloop controller family is supplied with a 64 bit controller family. Unlike other motion controllers, the Floating Point Math Library. The Texas Instruments intermediate calculations for trajectories, parametric TMS320C3X uses 6 “decimal” digit numbers as standard evaluations, PLC operations, high speed position captures, to provide 32 bit accuracy. The Acroloop Controllers use and many other tasks can all be performed simultaneously 16 “decimal” digit floating point numbers to provide on the Acroloop controller without host intervention. If a greater accuracy. For example, you can represent the PC host is required, it only requires updating the graphical distance between the Earth and the Sun to a precision of display and feeding new operator information to the motion about 20 miles with a 6 “decimal” digit number. The same controller; the Acroloop controllers take care of everything distance can be represented to a precision of 1/1000th of an else. inch with the 16 “decimal” digit number in the Simultaneous Port Access The Acroloop controllers are unique since they can The second door is open for bi-directional communicate both ASCII and Binary simultaneously. The communications to and from the controller to the simultaneous access ports permit unrestricted integration of CPU. front end software designs. Typically, the ASCII scheme is used In typical PC-Bus applications, the high speed data for traditional serial communications in standalone situations. communications use the binary interface. A binary Simple ASCII codes can be transmitted to the board over any of interface allows communications to occur in “coded” the on-board communications ports (COM1,COM2, LPT, and form. By using the “coded” form, communications the PC-BUS). However, the ASCII port on the PC-Bus port is can be increased dramatically to allow increased data critical in PC-Bus applications. The Binary port is used to throughput to and from the controllers. As a handle the coordinate system data while the ASCII port is left standard feature, the Acroloop controller family has open for additional communication that may require bypassing 2 on-board high speed FIFO buffers to form a the Binary interface port. The Acroloop design allows 2 access queuing system for the data from the host processor. doors to the Acroloop Controllers simultaneously. ACR2000 PC-Bus Port Binary ASCII PC-Bus 17 CPU Card Acroloop Controller Firmware Design The Acroloop firmware is structured into specific object The Operating System group is capable of handling up to groups. Each group has a function and consists of similar 8 coordinate systems. commands. The firmware design lets the user tailor the The coordinate systems are referred to as MASTER. board to the application. Consider the operating system Each MASTER is an independent motion profiler. Each group. MASTER can have up to 8 SLAVE’s. A slave is the model for an AXIS. A set of axes is dependent on the MASTER for the profile velocity, acceleration, and deceleration parameters. The declarations for a 3-axis system with dual loop feedback on the X-Y axis are: Command Description ATTACH MASTER0 REM: Setup profiler 0 ATTACH SLAVE0 AXIS0 “X” REM: Setup the X axis ATTACH SLAVE1 AXIS1 “Y” REM: Setup the Y axis ATTACH SLAVE2 AXIS2 “Z” REM: Setup the Z axis ATTACH AXIS0 ENC0 DAC0 ENC1 REM: Setup dual feedback for X axis ATTACH AXIS1 ENC2 DAC1 ENC3 REM: Setup dual feedback for Y axis ATTACH AXIS2 ENC4 DAC2 REM: Setup Z axis In general, any combination of encoder, analog, stepper, Additional firmware commands are available to perform and DAC output/input combinations can be attached to an complex algorithms or dynamic control. axis. The only restrictions are how the board is Almost all motion controllers have some form of configured from a hardware standpoint. camming, gearing, and I/O control, but at Acroloop, even these general commands are taken to another level of performance. The Acroloop firmware commands include: • Local Variables and Arrays - dynamic local program manipulation • Global Variables and Arrays - dynamic global program manipulation • String Variables and Arrays - full complement of string handling commands • Segmented Electronic Cam - position and velocity matching mode • Floating Point Electronic Gearing - velocity matching mode • Programmable Limit Switch - Digital I/O control (200-500 microsecond scan time) • Ladder Logic PLC - Multi-tasked PLC control (2-5 millisecond scan time) • Cubic Splines Interpolation • NURBS Interpolation • 3D Arc Interpolation • Sinusoidal Commutation • Time Based Moves Acroloop firmware is “OBJECT” based. This makes programming and diagnosing very easy to accomplish. As an example, take the COMMUTATION objects CMT0, CMT1...CMT7. These 8 objects are responsible to software commutate motor windings if the user chooses to use them. To set control parameters, the user can simply address the object properties in easy to understand commands. The following properties come up as default with the commutator turned off. 18 ACROLOOP MOTION CONTROL SYSTEMS Firmware Continued.... Command Description CMT0 OFF REM Commutator if Off. CMT0 ENC0 ENC1 REM Encoder Inputs used for commutation. CMT0 MODE 8 REM Mode is Trapezoidal then Sinusoidal. CMT0 ANG 120 REM Angle between windings is 120 degrees. CMT0 DAC0 DAC1 REM Dac outputs used for Phased Sine Outputs. CMT0 ADC0 ADC1 REM Optional ADC inputs used for current loop. CMT0 SHIFT0 REM Shift between marker and winding. CMT0 PPR 1024 REM Pulses per rev of the encoder. CMT0 ERPMR 2 REM Electrical revs per motor shaft revolution. CMT0 MAX RPM 0 REM Max allowable revolutions per minute. CMT0 MAX AMP 0 REM Max allowable AMPS into motor. Object based programming is not only easy to program but it makes a big impact in diagnosing and debugging a program. The Acroloop programming details are unique in their implementation. Compare these details before you buy! For a complete detailed description of the commands and the firmware structure, contact Acroloop or your local sales office for an Acroloop Technical Brochure. Hardware Parameter Access The Acroloop firmware is implemented for Examples of MASTER Parameters infinite flexibility. The structure is a completely open design allowing the designer complete Position Parameters Type MASTER0 access to virtually every possible motion control Vector Position FP32 P8192 parameter and flag. As previously discussed, Vector Velocity FP32 P8193 there are up to 8 MASTER’s and up to 8 axes on Vector Acceleration FP32 P8194 a motion controller. A master controls a group of Vector Jerk FP32 P8195 axes. Thus, each MASTER has a unique group of variables that can be monitored or changed Vector Length FP32 P8196 on-the-fly. Target Velocity FP32 P8196 Target Acceleration FP32 P8197 Examples of AXIS Parameters Analyzing the tables, the vector velocity for MASTERprofiler 0 is stored in hardware Position Parameters Type AXIS0 parameter number P8193. Variable P8193 is a Current Position LONG P12288 32-bit floating point variable. If the programmer Target Position LONG P12289 wanted to display the current position of AXIS0 on the operator display, a request would be made Actual Position LONG P12290 to the Acroloop controller to retrieve the 32-bit Following Error LONG P12291 long integer stored in hardware register P12288. Hardware Capture LONG P12292 There are approximately 15,000 different Software Capture LONG P12293 parameters pre-programmed into the Acroloop Primary Setpoint LONG P12294 controllers. Secondary Setpoint LONG P12295 19 3-D Arc Generation In addition to the Spline and Nurb feature, the Acroloop These points can be specified as incremental or absolute controllers now offer Three Dimensional Arc position. For successive 3-D Arcs, the end point of the Interpolation. arc is used as the start point of the next arc. In 3-D machining, smart CAD systems have the ability to As required, any additional number of axes can be specified output 3-D arc segments to the CNC control. For this to the three-dimensional interpolation axes to perform a specific reason, Version 1.18.05 and above software coordinated move. allows user to specify 3-D Arcs (TARC command) The user simply specifies the start point, intermediate point directly into the controller. This command is used to and the end point. There is no need to specify clockwise or select any three of the axes attached to the master to do counterclockwise direction, since the controller can 3-dimensional circular interpolation. In this mode, the automatically calculate the direction of rotation from user 3-D Arc is defined by a start point, an intermediate point specified intermediate point. and an end point of the arc. EXAMPLE TARC OFF Default is TARC mode off. X1 Y-14 Z1 Position to start point TARC ON X Y Z XYZ-axes are put to 3-D circular interpolation mode X13 Y-6 Z5 1st Arc intermediate point X8 Y2 Z10 1st Arc end point X5 Y6 Z-5 2nd Arc X10 Y2 Z-10 A2 A-axis will do linear coordinated move with XYZ-axes X0 Y0 Z-4.5 3rd Arc intermediate point X-10 Y-2 Z1 3rd Arc end point X1 Y3 Z15 4th Arc X-1 Y-2 Z1 This feature is not only limited to 3-D arcs. In 2-D, this is the simplest method of making an Arc. This command is a superset of the 3 point circle generate function. This has tremendous advantages for digitizing and teaching applications. 20 ACROLOOP MOTION CONTROL SYSTEMS HSINT - High-Speed Interruptible Move The purpose of the HSINT command is to give the With this command one needs to define a target programmer a way to initiate an incremental move based on position, then a window. Once this is done, point to an input. On webs, in particular, it is common to initiate an input and when it goes to the correct state, it will initiate the incremental move. This is all done at high motion on the leading edge of a marker. speed with one line of code. HSINT Target Win Start Window No Interrupt Incremental Move Hardware Capture PLS - Programmable Limit Switch The PLS command allows sequencing an Output Parameter (usually Physical I/O bits) based on the changing values of an PLS SRC Set PLS source Input Parameter (usually an encoder). The simplest form of a PLS PLS BASE Attach array to PLS is what is used in most "drum" sequencers in washing machines to PLS ROTARY Set PLS rotary length control various wash cycles. In the Acroloop PLS, the user can PLS ROTARY Set PLS rotary length select from a host of input and output parameters. Via software, PLS ON Enable PLS update the user can electronically advance and retard the source PLS DST Set PLS destination pointer parameter, mask and scale the output parameter. Typically, PLS RES Reset or pre-load counter Outputs are fired based on the position of a source encoder. This PLS FLZ Set PLS index offset can be done in conjunction with a CAMMING operation. The PLS RATIO Set PLS Scaling ratio MASK feature allows the user to allow the PLS to operate only on PLS OFF Disable PLS update as many I/O bits as required. The firing sequence is programmed into a Local Variable Array. The size of the array can be as long as available memory allows. Automatic Tangential Orientation Tangential Orientation This feature automatically orients a cutting tool to a user set angle along an XY path. Rather then jump at discontinous geometries, the control delays the next move and waits for the tool axes to orient. TANG Z X Y ANG 90 The above command will hold the tool at 90 degrees along the path shown. 21 Cam - Electronic Cam The CAM command is used as a replacement CAM Commands for mechanical cam. The ability to segment the CAM DIM Allocate cam segments CAM gives the programmer flexibility. The CAM SRC Redefine cam source CAM profiler will automatically linearly CAM OFF Disable cam output interpolate between any two points no matter CAM OFFSET Set cam output offset the density of the points. The data for each CAM SHIFT Set incremental cam shift segment of the CAM table resides in separate CAM SEG Define cam segments long integer arrays, possibly of different sizes. CAM ON Enable cam output This allows some parts of the table to be CAM SCALE Set cam output scaling defined coarsely, and others to be defined in CAM FLZ Set cam input offset more detail. CAM RES Transfer cam offset TRG Cam - Triggered Cam The TRG CAM command allows that a cam be started with 60ft/sec x 12in/ft = 720in/sec x .002sec = 1.44 inches almost no following error or time delay. The advantage to of error. this type of move is the ability to negate the hysteresis The TRG CAM command negates this and therefore typically associated with this type of move. For instance, if increases repeatability and accuracy to within one a web line was moving at 60 ft/sec and there is a 2msec microsecond. Barring mechanical limitations, the hysteresis before motion took place you can see by formula electronic accuracy is now reduced by a factor of 2000 that there will be an error of: to 0.0007”! 22 ACROLOOP MOTION CONTROL SYSTEMS TMOV - Time Based Move The TMOV command was implemented to give With a constant time for moves the speed would need to programmers an eloquent means of having moves be be different for every length of move and would have to completed in a specific amount of time. Previous to be recalculated. Now the Acroloop family of TMOV, the programmer would need to program with a controllers solves your equation using TMOV. You need calculator to determine the speed, acceleration and just to decide the length and time of your move! deceleration needed to arrive at a destination in a specific amount of time. Velocity Accel Decel Once Velocity, Accel and Decel are set in the default settings, TMOV will calculate Velocity, Accel and Decel based on length and time of move. SYNC - Master Synchronizing Occasionally it is necessary to run several coordinated Using SYNC moves, instead of coordinated moves, groups of axis’ masters, in synchronization with another gives the flexibility of using different motion master. For instance, in sewing, if a X-Y table is under a profiles for different masters, while still keeping them in needle, the table can only move when the needle is up out sync. of the fabric. In this example the SYNC command can be used to coordinate the movement of the needle to the movement of the table. The figure above shows a velocity vs. time graph for five axes attached to different masters that move with independent accelerations and decelerations yet are synchronized amongst themselves. They all complete their moves within the prescribed time interval of tmsec specified by the user. This mechanism can be useful in coil winding applications when the wire feed moves continuously, yet other axes must come and go at their own pace, but yet be synchronized to the wire feed. 23 MOTION CONTROLLERS Product Catalog ACR8020 Our fastest most featured packed controller ever! (PCI, CPCI PC Bus Operation) The ACR8020 is Acroloop Motion Control Systems’ ACR8020 Exclusives newest and most feature packed controller ever for PCI/ CPCI PC Bus Operation. It has the ability to run 8 Servo • 150 MHz floating Point DSP Loops (16 with expansion board), DAC or Stepper outputs and 10 encoders (20 with expansion board) at 20Mhz • 8 Axes of Servo or Steppers Expandable to 16 counting rate. It can also be equipped with 8 analog (12 or 16 bit resolution) inputs. MultiAxis coordinated motion • 10 Encoder Inputs at 20MHz Expandable to 20 can be performed in multiple groups of axes. Because of our modular design, it is possible to have several axes of servo mixed with stepper outputs on the same controller. • User and System Memory 512Kbytes (Expandable All of the Acroloop Motion Control Systems’ controllers to 2 Mbytes) each are software compatible so the standard features and benefits apply to the ACR8020. • Encoder Loss and Fault Protection As far as speed, the ACR8020 is unmatched in the • 64 Optically Isolated 24VDC I/O Expandable to industry at 150MFLOPS! 320 I/O • Dual Port Memory Standard • Master PCI and CPCI DMA Interface • Full size PCI and 6U CPCI Size • Optional Parallel Port and 2-Serial RS232/RS422/ RS485 or AcroWire (IEEE1394) Interface 24 ACROLOOP MOTION CONTROL SYSTEMS ACR8020 SPECIFICATIONS Hardware Performance Axes/controller 1-8 Axes (Expandable to 16) Multi-tasker 16 Coordinate Systems, Communications PCI, CPCI Bus Motion/PLC programs Processor 32/64 bit Floating Point Trajectory Update Every 100-500 usec DSP @150MHz Servo Update 25usec/axis Trajectory Calc. 64-bit Precision Ladder Logic PLC 100-500usec scan User Memory 512KB (expandable to 2 MB) Interpolation Linear, Circular, Sinusoidal, System Memory 512KB (expandable to 2 MB) Helical and Elliptical, Firmware Flash Based Splines, Nurbs, 3-D Arcs Flash Memory 512KB (expandable to 2 MB) Servo Loop PID, Velocity Feedforward, Size Full size PCI, 6U CPCI Acceleration Feedforward Operating System Multitasking RTOS Notch, LoPass filtering Position Reg. Hardware, < 1usec Communications Simultaneous PCI, Serial and Communications LPT ports, AcroWire IEEE-1394 PC Interface Bus Mastering PCI, CPCI with Dual Port Memory Software Support Standard Lang. Visual Basic,C++, Inputs/Outputs Program Tools AcroVIEW Motion/PLC Encoder Inputs 10 (expandable to 20) at Program 20MHz Dev. Tools ActiveX Controls Analog Outputs Up to 16 16-bit Precision Operating System Windows NT, 98, 2000 Stepper Outputs Up to 16 @ 4 MHz Digital I/O 64, 24V-DC Additional Firmware Highlights: Optically-Isolated · Triggered Floating Point Electronic GEARING (expandable to 320) · Triggered Segmented Electronic CAM Auxiliary Analog · On-the-fly Position and Velocity Matching Inputs Up to 8 (12 or 16 bit) · Ladder Logic PLC · Interruptible Moves · Either Analog or Digital Feedback for Position or Velocity Loops · Dual Encoder Feedback · Teach and Learn Functions · Parameter Based with over 15,000 addressable Predefined Hardware Registers · Sinusoidal Commutation · NURBS and Splines · 3-D Arcs · Automatic Tangential Tool Orientation 25 ACR8010 Our fastest most featured packed controller ever! (Standalone or ISA PC Bus Operation) ACR8010 Exclusives The ACR8010 is Acroloop Motion Control Systems’ newest and most featured packed controller for ISA • 8 axis of Servo or Stepper Control PCBus Operation. The ACR8010 is capable of Standalone or PC-Bus operation. It has the ability to run • 60 MHz Floating Point DSP up to eight servo loops, with up to 10 encoders at 20MHz. It can optionally be equipped with 8 analog inputs through • Up to 10 Encoder Inputs at 20MHz a 12 or 16 bit analog/digital converter and introduce these • User and System Memory 512KBytes inputs into servo loops. It is possible to have a Virtual Standard (Each Expandable to 2 Mbytes) Axis be the Master to multi-axis coordinated motion. Because of our modular design to our outputs, it is • Encoder Loss and Encoder Fault possible to have several axis of servo with several axis of Protection stepper on the same controller. Of course all of Acroloop Motion Control Systems’ controllers run on the same • 64 Optically Isolated 24 VDC software and firmware, so the standard features and Inputs and Outputs (Expandable to 320 benefits apply to the ACR8010 as well. Optically Isolated 24 VDC Inputs and Outputs) The ACR8010 is Acroloop Motion Control Systems’ answer to affordable high performance control when flexibility, real-time speed, and ease of programming are • Up to Four Communication Channels most needed. (PC Bus, 2 Serial RS-232/RS-422, 1Parallel Port) This product is the successor to the very popular • Calendar Clock Option ACR8000 and offers plug compatibility with the older product. • Dual Port Memory Option • Single Slot Plug & Play Controller 26 ACROLOOP MOTION CONTROL SYSTEMS ACR8010 SPECIFICATIONS Hardware Performance Axes/controller 1-8 axes Multi-tasker 8 coordinate systems, Communications PC-Bus or Standalone Motion/PLC programs Processor 32/64 bit Floating Point Trajectory Update Every 200-500 micro DSP @ 60MHz seconds Trajectory Calc. 64-bit precision Servo Update 50 microseconds/axis User Memory 512KBytes (expandable Ladder Logic PLC 200-500 microsecond scan to 2 MB) time System Memory 512K bytes (expandable Interpolation Linear, Circular, Sinusoidal, to 2 MB) Helical and Elliptical, Firmware Two 128K x 16 EPROM's Splines, Nurbs, 3-D Arcs Flash Memory 512K bytes (expandable Servo Loop PID, Velocity Feedforward, to 2 MB) Acceleration Feedforward Size Full size ISA board with Notch, LoPass and Operating System Real time system programmable filtering independent of PC Position Capture Hardware, < 1 microsecond Communications Simultaneous PC, Serial and LPT Ports, AcroWire IEEE-1394 Software Support Communications Standard Lang. Visual Basic,Visual C++, PC Interface Two 512 x 8 hardware C++ FIFO's, Optional Dual Port Program Tools AcroVIEW Motion/PLC RAM Program Standalone Two Serial Ports (RS-232 Dev. Tools ActiveX/OCX controls and/or RS-422) Operating System Windows NT, Windows One Parallel Port (8-bits) 95/98, DOS Protocols Binary (PC), String, & ASCII Additional Firmware Highlights: · Triggered Floating Point Electronic GEARING · Triggered Segmented Electronic CAM · On-the-fly position and velocity matching Inputs/Outputs · Ladder Logic PLC Encoder Inputs 10 (32-bit registers), up to 20 · Programmable Limit Switch MHz · Interruptible moves Analog Outputs up to 8, 16-bit precision · Either analog or digital feedback for position or Stepper Outputs up to 8, 4 MHz velocity loops Digital I/O 64, 24VDC · Dual encoder feedback optically-isolated · Teach and Learn functions (expandable to 320) · Parameter based with over 15,000 Auxiliary Analog addressable pre-defined hardware registers Inputs up to 8 (12 or 16 bit) · Sinusoidal commutation · NURBS and Splines · 3-D Arcs · Automatic Targential Tool Operation 27 ACR2000 Full featured 1 - 4 axis PC or standalone controller! The ACR2000 is capable of Standalone or PC-bus ACR2000 Exclusives operation. It has the ability to run up to four servo loops, with up to 4 encoders at 20MHz. It can optionally be • 4 axis of Servo or Stepper Control equipped with 8 analog inputs through a 12-bit analog/digital converter and introduce these inputs into • 50 MHz Floating Point DSP servo loops. Because of our modular design to our outputs, it is possible to have four axis of servo or four axis of • Up to 4 Encoder Inputs at 20MHz stepper on the same controller. The ACR2000 controller, like the ACR8010, uses a SIMM card for analog outputs • User and System Memory 128 x 8 bytes or stepper outputs and can be purchased as 2 or 4 axis. Of Standard (Each Expandable to .5 Mbytes) course, all of Acroloop’s systems run on the same software and firmware, so the standard features and benefits apply to the ACR2000 as well. • 32 Optically Isolated 24 VDC Inputs and Outputs (Expandable to 288 Optically The ACR2000 is Acroloop Motion Control Systems’ Isolated 24 VDC Inputs and Outputs answer to four axis or less affordable high performance control, when flexibility in the field, real-time speed, and • Up to Four Communication Channels ease of programming are most needed. (PC Bus, 2 Serial RS-232/RS-422, 1Parallel Port) 28 ACROLOOP MOTION CONTROL SYSTEMS ACR2000 SPECIFICATIONS Hardware Performance Axes/controller 1-4 axes Multi-tasker 8 coordinate systems, Communications PC-Bus or Standalone Motion/PLC programs Processor 32/64 bit Floating Point Trajectory Update Every 200-500 micro DSP @50MHz seconds Trajectory Calc. 64-bit precision Servo Update 50 microseconds/axis User Memory 512KBytes Ladder Logic PLC 200-500 microsecond scan System Memory 512KBytes time Firmware Two 128K x 16 EPROM's Interpolation Linear, Circular, Sinusoidal, Flash Memory 512KBytes Helical and Elliptical Size Half- size ISA board Splines, Nurbs, 3-D Arcs Operating System Real time system Servo Loop PID, Velocity Feedforward, independent of PC Acceleration Feedforward with Notch, LoPass and programmable filtering Position Reg. Hardware, < 1 microsecond Communications Simultaneous PC, Serial and Communications LPT ports, AcroWire IEEE-1394 PC Interface Two 512 x 8 hardware FIFO's Standalone Two Serial Ports (RS-232 Software Support and/or RS-422) Standard Lang. Visual Basic,Visual C++, One Parallel Port (8-bits) C++ Protocols Binary, String, & ASCII Program Tools AcroVIEW Motion/PLC Program Dev. Tools ActiveX/OCX controls Operating System Windows NT, Windows 95/98, DOS Inputs/Outputs Encoder Inputs 4 (32-bit registers), 8 MHz Additional Firmware Highlights: Analog Outputs up to 4, 16-bit precision Stepper Outputs up to 4, 4 MHz · Triggered Floating Point Electronic GEARING Digital I/O 32, 24VDC · Triggered Segmented Electronic CAM optically-isolated · On-the-fly position and velocity matching (expandable to 320) · Ladder Logic PLC Auxiliary Analog · Programmable Limit Switch Inputs up to 8 (12- bit) · Interruptible moves · Either analog or digital feedback for position or velocity loops · Dual encoder feedback · Mixing of Axes and interpolation · Teach and Learn functions · Parameter based with over 15,000 addressable pre-defined hardware registers · NURBS and Splines · Spherical Commands · Automatic Targential Tool Operation 29 ACR1500 OEM priced PC based ACR controller! The ACR1500 is Acroloop Motion Control Systems’ new ACR1500 Exclusives OEM 4-axis PC-Bus based controller. The ACR1500 is a PC-bus based card only and offers no serial or LPT ports as an option. It has the ability to run up to four servo loops • 4 Axis of Servo or Stepper Control with up to 4 encoders at 20MHz. It can optionally be equipped with 8 analog inputs through a 12 or 16 bit • 40 MHz Floating Point DSP analog/digital converter, and introduce these inputs into the servoloop. Because of our modular design to our outputs, • 4 Encoder Inputs at 20MHz it is possible to have two axis of servo with two axis of stepper on the same controller or all of one type. Unlike • User and System Memory 128KBytes Standard the Acroloop family of controllers the ACR1500 utilizes a 16-bit bus, therefore, reducing cost dramatically. Until the • 48 TTL I/O with an Industry Standard Opto 22, ACR1500, this level of control had been typically double 50 Pin Connector the price! Of course, all of Acroloop’s systems run on the same software and firmware, so the standard features and benefits apply to the ACR1500 as well. • Low Cost 16-bit Bus The ACR1500 is Acroloop Motion Control Systems’ • High Performance at a Low Cost answer to affordable high performance control when low cost, real-time speed, and ease of programming are most needed. 30 ACROLOOP MOTION CONTROL SYSTEMS ACR1500 SPECIFICATIONS Hardware Performance Axes/controller 1-4 axes Multi-tasker 8 coordinate systems, Communications PC-Bus Motion/PLC programs Processor 32/64 bit Floating Point Trajectory Update Every 200-750 micro DSP @40MHz seconds Trajectory Calc. 64-bit precision Servo Update 75 microseconds/axis User Memory 128KBytes Ladder Logic PLC 200-750 microsecond scan System Memory 128KBytes time Firmware One 256K x 16 EPROM Interpolation Linear, Circular, Sinusoidal, Flash Memory 128KBytes Helical and Elliptical Size Half- size ISA board Splines, 3-D Arcs Operating System Real time system Servo Loop PID, Velocity Feedforward, independent of PC Acceleration Feedforward with Notch, LoPass and programmable filtering Position Reg. Hardware, < 1 microsecond Communications PC,Bus Communications PC Interface Two 512 x 8 hardware FIFO's Software Support Standalone N/A Standard Lang. Visual Basic,Visual C++, Protocols Binary, String, & ASCII C++ Program Tools AcroVIEW Motion/PLC Program Dev. Tools ActiveX/OCX controls Operating System Windows NT, Windows Inputs/Outputs 95/98 Encoder Inputs 4 (32-bit registers), up to 20 MHz Additional Firmware Highlights: Analog Outputs up to 4, 16-bit precision · Triggered Floating Point Electronic GEARING Stepper Outputs up to 4, 4 MHz · Triggered Segmented Electronic CAM Digital I/O 48 Opto-22 compatible, · On-the-fly position and velocity matching programmable as inputs or · Ladder Logic PLC outputs in groups of 8 · Programmable Limit Switch Auxiliary Analog · Interruptible moves Inputs up to 8 (12 or 16 bit) · Either analog or digital feedback for position or velocity loops · Dual encoder feedback · Mixing of Axes and interpolation · Teach and Learn functions · Parameter based with over 15,000 addressable pre-defined hardware registers · Sinusoidal Commutation · Automatic Targential Tool Operation 31 ACR1200 OEM priced Full Featured Standalone Controller! The ACR1200 is Acroloop Motion Control Systems’ new ACR1200 Exclusives OEM 2-axis standalone controller. The ACR1200 is a standalone controller card only and offers no PC port as an option. The ACR1200 comes standard with two serial • 2 Axis of Servo or Stepper Control ports, either RS-232 or RS-422. It has the ability to run up to two servo loops with up to 3 encoders at 20MHz. It can • 40 MHz Floating Point DSP optionally be equipped with 8 analog inputs through a 12 or 16 bit analog/digital converter and introduce these inputs • Up to 3 Encoder Inputs at 20MHz into the servoloop. Because of our modular design to our outputs, it is possible to have one axis of servo with one • User and System Memory 128KBytes, each, Standard axis of stepper on the same controller, or all of one type. Until the ACR1200, this level of control at our price had not • Encoder Loss and Encoder Fault Protection been available. Of course, all of Acroloop’s systems run on the same software and firmware, so the standard features and benefits apply to the ACR1200 as well. • High Performance, at a Low Cost The ACR1200 is Acroloop Motion Control Systems’ • 32 Opto Isolated, 24 VDC, I/O Standard answer to affordable high performance standalone control, (Expandable to 160 Opto Isolated 24 VDC, I/O) when low cost, real-time speed, and ease of programming are most needed. 32 ACROLOOP MOTION CONTROL SYSTEMS ACR1200 SPECIFICATIONS Hardware Performance Axes/controller 1-2 axes Multi-tasker 8 coordinate systems, Communications Standalone Motion/PLC programs Processor 32/64 bit Floating Point Trajectory Update Every 200-750 micro DSP @40MHz seconds Trajectory Calc. 64-bit precision Servo Update 75 microseconds/axis User Memory 128K bytes (expandable Ladder Logic PLC 200-750 microsecond scan to 512K) time System Memory 128K bytes (expandable Interpolation Linear, Circular, Sinusoidal, to 512K) Helical and Elliptical Firmware Two 128K x 16 EPROM's Splines, Nurbs, 3-D Arcs Flash Memory 128K bytes (expandable Servo Loop PID, Velocity Feedforward, to 512K) Acceleration Feedforward Size 8” W x 5” H with Notch, LoPass and Operating System Real time system programmable filtering independent of PC Position Reg. Hardware, < 1 microsecond Communications Simultaneous, Serial and LPT ports Communications Software Support Interface N/A Standard Lang. Visual Basic,Visual C++, Standalone Two Serial Ports (RS-232 C++ and/or RS-422) Program Tools AcroVIEW Motion/PLC Protocols Binary, String, & ASCII Program Dev. Tools ActiveX/OCX controls Operating System Windows NT, Windows 95/98, DOS Inputs/Outputs Additional Firmware Highlights: Encoder Inputs 3 (32-bit registers), up to · Floating Point Electronic GEARING 20 MHz · Segmented Electronic CAM Analog Outputs up to 2, 16-bit precision · On-the-fly position and velocity matching Stepper Outputs up to 2, 4 MHz · Ladder Logic PLC Digital I/O 32, 24VDC; expandable to 160, · Programmable Limit Switch opto-isolated 24 VDC I/O · Interruptible moves · Either analog or digital feedback for position or Auxiliary Analog velocity loops Inputs up to 8 (12 or 16 bit) · Dual encoder feedback · Mixing of Axes and interpolation · Teach and Learn functions · Parameter based with over 15,000 addressable pre-defined hardware registers · Sinusoidal Commutation · NURBS and Splines · Spherical Commands · Automatic Targential Tool Operation 33 ACR8020 ORDERING MATRIX EXAMPLE: 8 Axis PCI-Bus Controller 1-8 AXIS PCI-BUS CONTROLLER EXAMPLE: ACR8020 / PS / E8 / D4 / D4 / A0 / 0 / 0 0 = No I/O Expansion PC = PCI Bus Card 1 = Add 64 Digital I/O PS = PCI Bus Card w/ 2 Serial 2 = Add 128 Digital I/O and 1 Parallel Port 3 = Add 196 Digital I/O CP = CPCI Bus Card 4 = Add 256 Digital I/O CS = CPCI Bus Card w/ 2 Serial and 1 Parallel Port 0 = 64 Optically-Isolated, 24VDC, Sinking 1 = 64 Optically-Isolated, 24VDC, Sourcing E0 = 0 Encoder Inputs A0 = No Analog Inputs E2 = 2 Encoder Inputs A8 = 12-bit Analog-Digital Inputs E4 = 4 Encoder Inputs AA = 16-bit Analog-Digital Inputs E5 = 5 Encoder Inputs Note: Maximum of 8 S ingle-Ended or E6 = 6 Encoder Inputs 4 Differential A nalog-Digital Inputs. E8 = 8 Encoder Inputs E10 = 10 Encoder Inputs Y5 = 5 Absolute Encoder Inputs (Yaskawa) Y10 = 10 Absolute Encoder Inputs (Yaskawa) D2/00 = 2 Digital-Analog Outputs D4/00 = 4 Digital-Analog Outputs D4/D2 = 6 Digital-Analog Outputs D4/D4 = 8 Digital-Analog Outputs S2/00 = 2 Stepper Outputs S4/00 = 4 Stepper Outputs S4/S2 = 6 Stepper Outputs S4/S4 = 8 Stepper Outputs D2/S2 = 2 Analog and 2 Steppers D4/S2 = 4 Analog and 2 Steppers D2/S4 = 2 Analog and 4 Steppers D4/S4 = 4 Analog and 4 Steppers ACR8010 ORDERING MATRIX EXAMPLE: 8-Axis PC-Bus Servo Controller with serial ports 1-8 AXIS PC-BUS CO NTRO LLER PS EXAM PLE: ACR8010 E8 D4 D4 A0 0 0 PC=PC/ISA B usCard SA=Standalone C ard PS=PC & Standalone 0 - No I/O Expansion Note: SA and PS options include 1 - Add 64 I/O 2 serial and 1 parallel port. 2 - Add 128 I/O Serial ports are program m able for 3 - Add 196 I/O RS-232 or RS-422 com m unications. 4 - Add 256 Digi tal I/O E0 = 0 Encoder Inputs E4 = 4 Encoder Inputs 0 - 64 optically i solated, 24VDC, SINKING E5 = 5 Encoder Inputs 1 - 64 optically i solated, 24VDC, SO URCING E8 = 8 Encoder Inputs E10 = 10 Encoder Inputs Y5 = 5 Absolute Encoder Inputs (Yaskaw a) Y10 = 10 Absolute Encoder Inputs (Yaskaw a) D2/00 = 2 Digi tal-Analog Outputs A0 = No Analog Inputs D4/00 = 4 Digi tal-Analog Outputs A8 = 12-bit Analog-Digital Inputs D4/D2 = 6 Digi tal-Analog Outputs AA = 16-bit Analog-Digital Inputs D4/D4 = 8 Digi tal-Analog Outputs Note: Maximum of 8 Single-Ended or S2/00 = 2 Stepper Outputs 4 Differential Analog-Digital Inputs. S4/00 = 4 Stepper Outputs S4/S2 = 6 Stepper Outputs S4/S4 = 8 Stepper Outputs D2/S2 = 2 Analog and 2 Stepper D4/S2 = 4 Analog and 2 Stepper D2/S4 = 2 Analog and 4 Stepper D4/S4 = 4 Analog and 4 Stepper 34 ACR2000 ORDERING MATRIX EXAMPLE: 4-Axis PC-Bus Servo Controller 1-4 AXIS MOTION CONTROLLER EXAM PLE: ACR2000 A0 0 0 PC E4 D4 00 0 - No I/O Expansion 1 - Add 64 Digital I/O PC=PC/ISA BusCard 2 - Add 128 Digital I/O 3 - Add 192 Digital I/O SA -Standalone Card 4 - Add 256 Digital I/O PS =PC-Bus and Standalone Note: SA and PS options include 0 - 32 Optically I solated 24VDC, Sinking com m unications daughterboard 1 - 32 Optically I solated 24VDC, Sourcing with 2 serial and 1 parallel port. Serial ports are program m able for RS-232 or RS-422 com m unications. E0 = 0 Encoder Inputs E2 = 2 Encoder Inputs A0 =NONE N/C A8 =12 bitA nalog-DigitalI nputs E4 = 4 Encoder Inputs Note: Max of 8 Single-Ended or 4 Differential Analog-Digital Inputs D2/00 = 2 Digital-Analog Outputs D4/00 = 4 Digital-Analog Outputs S2/00 = 2 Stepper Outputs S4/00 = 4 Stepper Outputs ACR1500 ORDERING MATRIX EXAMPLE: 4-Axis PC-Bus Servo Controller 1-4 AXIS M OTION CONTROLLER EXAM PLE: ACR1500 A0 0 0 PC E4 D4 00 0 - No I/O Expansion PC=PC/ISA Bus Card 0 - 48 TTL Digital I/O E0 = 0 Encoder Inputs Note: Programm able as inputs E4 = 4 Encoder Inputs or outputs in groups of eight (8). A0 = NONE A8 = 12-bit Analog-Digital Inputs D4/00 = 4 Digi tal-Analog Outputs AA = 16-bit Analog-Digital Inputs S4/00 = 4 Stepper Outputs Note: Max of 8 Single-Ended or D2/S2 = 2 Digital-Analog Outputs/ 2 Stepper Outputs 4 Differential Analog-Digital Inputs ACR1200 ORDERING MATRIX EXAMPLE: 2-Axis Standalone Servo Controller 1-2 AXIS MOTION CO NTRO LLER SA E3 D2 00 A0 0 0 EXAM PLE: ACR1200 0 - No I/O Expansion 1 - Add 64 Digital I/O SA - Standalone Card 2 - Add 128 Digital I/O 3 - Add 192 Digital I/O 4 - Add 256 Digital I/O 0 - 32 Optically I solated, 24VDC, Sinking 1 - 32 Optically I solated, 24VDC, Sourcing E3 = 3 Encoder Inputs A0 = NONE N/C A8 = 12-bit Analog-Digital Inputs AA = 16-bit Analog-Digital Inputs Note: Max of 8 Single-Ended or D2/00 = 2 Digi tal-Analog Outputs 4 Differential Analog-Digital Inputs S2/00 = 2 Stepper Outputs 35 D1/S1 = 1 Digital-Analog Output / 1 Stepper Output SOFTWARE Product Catalog DEVELOPMENT TOOLS There are several development tools that are provided with the Acroloop controller family. The controllers can be provided with C++ libraries, Visual C libraries, or Visual Basic libraries. Since the libraries are generically designed, the libraries can be used for additional programming languages such as Delphi. The development tools can be provided with drivers for Windows 98, Windows 2000 and Windows NT operating systems. With the development tools, the controllers can be integrated into customized application software. Acroloop Libraries With the Acroloop Library, commands available on the Acroloop motion controller have a corresponding function call. Applications that are programmed on the PC simply use the function call provided in the library when the program needs to use the controller’s motion control capabilities. The Acroloop controller family can be supplied with the following libraries: • Visual C /C++ Dynamic Link Library (Windows98, 32-bit) • Visual C/C++ Libraries (Windows NT, 32-Bit multi-threaded) • Visual Basic Dynamic Link Library (Windows98, 32-bit) • Visual Basic Dynamic Link Libraries (Windows NT, 32-bit multi-threaded) Since the libraries are generically designed, the libraries can be used for additional programming languages such as Borland’s Delphi. With Delphi, the proper arguments must be programmed for the function call. Visual C/C++ and Visual Basic DLL’s allow the programmer to easily customize a graphically orientated operator interface to work in conjunction with the Acroloop controllers. The Acroloop controllers support simultaneous binary and ASCII interface schemes. The “double door” design allows complete access without worrying about congesting the port. Acroloop also supports Windows NT,Windows 2000 and Windows 98 environments. The Windows NT DLL’s can support multi-threaded applications running under Windows NT or Windows 98 and Windows 2000. 36 ACROLOOP MOTION CONTROL SYSTEMS AcroVIEW AcroVIEW is a development tool used to communicate to the motion controllers. AcroVIEW can talk to the controllers either over the PC-BUS or RS-232 communications ports. AcroVIEW is provided at no charge to help integrate, diagnose, and graphically tune the Acroloop motion controllers. AcroVIEW can also be used to debug customized PC applications. Since the Acroloop controllers can communicate simultaneously, the API can be operating on the PC while AcroVIEW tool can dynamically diagnose the Acroloop controller with AcroVIEW on the serial port. This saves valuable development time. AcroVIEW-Diagnostics The AcroVIEW supplied software can also act as a valuable diagnostic tool. AcroVIEW can be used to enter in customized software programs and test the controllers on a bench before implementing the controller into a real world application. AcroVIEW permits the user to send and receive files to and from the controllers. In addition, AcroVIEW provides an on-screen real time display of the input and outputs status while the desired program is being executed. AcroVIEW-Graphical Tuning Possibly the most important aspect of AcroVIEW is to allow the user to graphically tune the servo system. AcroVIEW provides a built-in oscilloscope so that the servo system can be tuned on the computer screen. This could either be accomplished through the parallel port or via a laptop computer at the installation site. Even if other development tools are being used (i.e. C++ Libraries or DLL’s), AcroVIEW can be run separately to insure that the system is tuned properly. 37 Application Software AcroMILL PC Software AcroMILL is a 1-8 axis machine tool software package and is designed to work with the motion controller. AcroMILL software is specifically designed to handle machine tool applications. Acroloop has extensive CNC machine tool experience and we have put our CNC experience to work to create an off-the-shelf software package that can easily be integrated into CNC’s. AcroMILL FEATURES G Codes - AcroMILL works with standard Handwheel - External handwheel Displays - AcroMILL can display the user EIA RS-274 G codes. The basic G codes operation. Handwheel can be programmed programmable information including designed around the GE Fanuc OM to any encoder input with the particular axis current position, program status information Controller works directly with AcroMILL. selected through AcroMILL. and a graphical display of the part being AcroMILL is also directly compatible with processed. Library Parts - Built-in user definable standard CAM packages and appropriate library parts. Library parts are parametric Diagnostics - Use AcroMILL to diagnose post files for machine execution. G and M code files that can be electrical input/output conditions or to M Codes - AcroMILL also uses standard customized(sized) by the user on the screen. dynamically tune the servo system with M codes. The M codes in AcroMILL are AcroMILL’s built-in 4 channel File Transfer- Transfer files to completely programmable. M codes simply oscilloscope. AcroMILL via RS-232 communications, send customized files to the controller. The from the hard disk drive, from a floppy disk Error Correction - Implement files could be PLC files or another complete drive, or automatically convert DXF posts AcroMILL’s programmable ballscrew multi-tasked motion program. into the appropriate G and M codes compensation, backlash compensation, tool PC-Based - Implement an open automatically with AcroMILL. radius compensation, and tool offset architecture solution with the latest PC- registers. Run/Dry Run - Ability to run or dry run Based CNC motion controllers and a program. Programs can also be started Block Processing Speed - AcroMILL incorporating standard off-the-shelf from a user programmable block number. PC software package has a 2-4 millisecond industrial PC Components available from block processing speed depending on the Feedrate Override - Built-in feed- Acroloop. number of axis being controlled. rate override function. The feedrate PLC - Use the on-board PLC to create override can be executed through software Customized - Don’t see what you need? customized automatic tool changer(ATC) or from an external BCD input. Have Acroloop customize the PC software operations. The AcroMILL software uses specifically to meet your application Spindle Override - Built-in spindle the built-in PLC supplied with the motion requirements. override function. The spindle override can controller complete with optical-isolation be executed through software or from an operating at 24VDC. external BCD input. Home - Built-in homing routine for all MDI - Manual data input operation for axes (programmable). immediate execution of blocks. Jog - Continuous or Incremental jog modes (programmable). 38 ACROLOOP MOTION CONTROL SYSTEMS AcroCUT/AcroJET PC Software AcroCUT software is specifically designed to handle PLASMA, OXY-FUEL, LASER, and WATERJET machine tool cutting applications. Acroloop has worked extensively with manufacturers and machine tool operators to create a state-of-the-art PC cutting control software package. The PC software can be customized for the OEM or used to retrofit old cutting machines. AcroJet is identical to AcroCut with the exception of special M-Codes added to AcroJet to handle WaterJet control. AcroCut & AcroJet FEATURES Retrace - Retrace of the cut path to back up diagnose electrical input/output conditions Turnkey Solution - Implement all the way to the beginning. or to dynamically tune the servo AcroCUT with the Acroloop motion system with AcroCUT’s built-in 4 controllers, chassis, operator interfaces, Kerf Compensation - Automatic kerf channel oscilloscope. enclosures, and customized front panels compensation. for a complete OEM solution for PC Customized - Don’t see what you need? Cornering - Automatic corner slowdown based Plasma, Oxy-Fuel, Laser, and Have Acroloop customize the based on acute angle threshold. WaterJet machine tool control. PC software specifically to meet your PC-Based - Implement an open architecture Dripfeed Function - Allows large part files application requirements. solution with the latest PC-Based CNC to be executed on-the-fly from an off-line motion controllers and incorporating PC using the serial link minimizing standard off-the-shelf industrial PC download time and maximizing machine cut components available from Acroloop. time. G Codes - AcroCUT works with standard Pause and Resume - On and Off path pause EIA RS-274 G codes. AcroCUT is also and resume feature. Machine can retrace, directly compatible with standard CAM skip, resume, jog, or home after the pause. packages. Plate Alignment - Automatic plate M Codes - AcroCUT also uses standard M alignment feature for sheet placement. codes. The M codes in AcroCUT are Feedrate Override - Built-in feedrate completely programmable. M codes simply override function. The feedrate override send customized files to the controller. The can be executed through software or from files could be PLC files or another complete BCD input. multi-tasked motion program. Mechanical Compensation - Use Gantry Control - Built-In gantry control (2 AcroCUT’s built-in ballscrew or backlash servos on a single axis). compensation. Home - Built-in homing routine for all axes (programmable). Displays - AcroCUT can display the user Jog - Continuous or Incremental jog modes programmable information including with optional joystick control. current position, program status information and a graphical display of the part being Library Parts - Built-in user definable processed. All of the displays are library parts. 30 shapes provided free of programmable(size, color, location) by the charge. Additional library parts can be user. created by the user. Diagnostics - Use AcroCUT to 39 AcroMill NT AcroMill and AcroCut are also offered in a Windows Probing cycle as well as NURBS, Splines and three NT based version. The main features are very similar to dimensional 3 point arc generation is offered. the DOS versions of these programs but because of the multitasking ability of the operating system, many OEM users can access and pass variables in the SYSVAR enhancements are offered. The following screens show storage area in the CNC from their own independent some of the features. AcroMill for Windows NT is software application in case a custom installation is required. designed to work with a touch screen or a mouse. Therefore, all the menu selections are large enough to This means that the OEM can externally affect machine allow easy finger control and selection. New programs operation from their own piece of software on the fly. This can be created while the machine is running a program. can be very handy in applications like vision, grinding, Full compliments of Can Cycles and Macro and Modal welding….etc. Macro ability is offered. Main screen while running program. Entering M.D.I. commands. 40 ACROLOOP MOTION CONTROL SYSTEMS Jogging Screen. Setting up system parameters. Edit a program even while running a different program. 41 Selecting library parts. Monitoring I/O status while running a part. Tuning axis servos using built-in 4 channel oscilloscope. 42 ACROLOOP MOTION CONTROL SYSTEMS CONTROLLER CHASSIS Product Catalog The main factors in selecting a controller chassis are: • Type of controller used (ACR1200, ACR1500, ACR2000, ACR8010 or ACR8020) • Number of chassis slots required • Interface requirements • Physical considerations SPL026 Standalone Bracket The SPL026 is a standalone mounting bracket for the ACR8010. The SPL026 is designed for integration of the motion controller into an industrial enclosure. Typically, the standalone bracket is ordered with a breakout box. SPL026 Features • Use with Standalone ACR8010 controller SPL026 Standalone Bracket • Industrial Metal Bracket (14”W x 5.38”H x 1.63”D) with Breakout Box • Mounts to Industrial Panel RBD Breakout Box The RBD breakout box is designed to allow integration of the ACR2000, ACR8010, or ACR8020 motion controllers. The breakout box can be used in either standalone or PC-Bus applications. It is typically mounted to an industrial panel next to the motion controller. RBD Breakout Box Feature • Use with either the ACR2000, ACR8010 or ACR8020 controllers • Industrial Breakout Box (4.75”W x 14.75”H x 1.25”D) • Screw terminations for encoder feedback • Screw terminations for digital I/O connections • 2 Serial and 1 Parallel Port DB Connectors RBD Breakout Box • Status LED’s for encoder, digital I/O, and communication diagnostics ACH3120 Controller Chassis The ACH3120 controller chassis is a standard chassis. It is designed to accommodate a standalone ACR1200 controller. The ACH3120 is designed to support the standard digital I/O and 1 expansion ACH3120 Features digital I/O board. • Use with ACR1200 Controller • Industrial Standalone Chassis • Encoder Feedback Connector • Digital I/O Connector • 2-Sided and 1 Parallel Port Connector • Heavy Duty Power Connector, 120 VAC • Integral Power Supply (5VDC, +/- 12VDC) • Cooling Fan Included 43 ACH3120 ACH3200 Controller Chassis The ACH3200 controller chassis is a standalone chassis. It is designed to accommodate a Standalone ACR2000 controller. The ACH3200 is designed to support the standard digital I/O and up to 2 expansion digital I/O boards. ACH3200 Features • Use with Standalone ACR2000 controller • Industrial Standalone chassis (4.38”W x 11”H x 6.75”D) • Encoder Feedback Connector (34 pin) • Digital I/O Connector (34 pin) • 2 Serial and 1 Parallel Port Connector (34 pin) • Digital I/O Power Supply Connector (4 pin) ACH3200 • Heavy Duty Power Connector (120VAC Standard) • Integral Power Supply ( 5VDC, +/- 12VDC) • Cooling Fan Included ACH4800 Controller Chassis The ACH4800 chassis is a multi-purpose 4 slot chassis. The ACH4800 is designed for both Standalone and PC-Bus motion control for the ACR2000 or ACR8010 controllers. The chassis features industrial screw terminals and status LED’s for the encoder and digital I/O connections. ACH4800 Features • Use with either the ACR2000 or ACR8010 controllers • Industrial 4 slot chassis (4.75”W x 15”H x 11.25”D) • Screw Terminations for encoder feedback • Screw terminations for digital I/O connections • Status LED’s for encoder and digital I/O diagnostics • On/Off Power Switch with Fused Protection • Heavy Duty Power Connector (120VAC Standard) • Integral Power Supply (+/- 5VDC, +/- 12VDC) • Integral Line Filter • Built-in Cabinet Fan Optional Accessories • CPU and VGA Cards ACH4800 • Hard Disk Drive • 3.5” Floppy Drive • Serial and Parallel Communications Ports 44 ACROLOOP MOTION CONTROL SYSTEMS ACH6200 Controller Chassis The ACH6200 chassis is also a multi-purpose 4 slot chassis. The main difference is the ACH6200 is designed for half-size PC boards. Therefore, it is ideal for applications where space is critical. The chassis is used with the ACR2000 controller. ACH6200 Features • Use with the ACR2000 controller • Industrial 4 slot chassis (9.12”W x 5.75H x 9”D) • D-plug connectors for encoder feedback • D-plug connectors for digital I/O connections • On/Off Power Switch • Heavy Duty Power Connector (120VAC Standard) • Integral Power Supply (+/- 5VDC, +/- 12VDC) • Built-in Cabinet Fan • CE Certified Optional Accessories ACH6200 • CPU and VGA Cards • Hard Disk Drive • 3.5” Floppy Drive • Serial and Parallel Communications Ports ACH6800 Controller Chassis The ACH6800 chassis is a 6-slot multi-purpose chassis. The main difference is it is a full size chassis and the connections are made using D-plug connectors. The ACH6800 is used for either standalone or PC-Bus applications. ACH6800 Features • Use with either ACR2000 or ACR8010 • Industrial 6-slot chassis (6.38”W x 6.75”H x 15.5”D) • D-plug connectors for encoder feedback • D-plug connectors for digital I/O connections • On/Off Power Switch • Heavy Duty Power Connector (120VAC Standard) ACH6800 • Integral Power Supply (+/- 5VDC, +/- 12VDC) • Integral Line Filter • Built-in Cabinet Fan Optional Accessories • CPU and VGA Cards • Hard Disk Drive • 3.5” Floppy Drive • Serial and Parallel Communications Ports 45 OPERATOR INTERFACES Product Catalog OPS9220 & OPS8220 The OPS9220 is designed specifically for PC-Based CNC Machine Tool applications. It is typically integrated with an Acroloop controller and controller PC chassis. The OPS9220 integrates the PC monitor and keyboard with CNC spindle, feedrate, handwheel, and emergency stop controls. OPS9220 • Industrial CNC NEMA 12 Interface Including: • Spindle CCW, CW, OFF, and OVERRIDE Controls • Feedrate HOLD, START Controls • Feedrate Override Control • Rapid Override Control • E-STOP and RESET Pushbuttons • One AUXILIARY Pushbutton • Use with Acroloop PC Chassis • 12.1" Active Matrix Color LCD Screen • NEMA 4 Full-size Keyboard • 19"W x 17.5"H x 4"D • Interfaces to Standard CPU and VGA Cards • Optional Pendant Enclosure • Optional Manual Pulse Generator Handwheel • Optional Touchscreen • Industrial Design for “One Step” Panel Mounting OPS 9220 • Integrated Mouse Pad • Operates in Windows, DOS Environment OPS8220 All features of the OPS9220 plus: • Full 6-Slot PC Chassis Mounted Behind Keyboard • On/Off switch with Integrated Power, HDD and Reset LED • 2 RS-232 Serial Ports, 1 Parallel Port • 32 MEG RAM Standard, Expandable to 128 MEG • 19"W x 17.5"H x 10.75"D • Optional CPU and Video Types • Optional Floppy Disk and Hard Disc Drives OPS8220 46 ACROLOOP MOTION CONTROL SYSTEMS OPS9000 The OPS9000 is another option for an industrial PC operator interface. The only difference is the size of the monitor and the keyboard configuration. Again, the OPS9000 is integrated with an Acroloop controller and PC controller chassis. OPS9000 Features • Use with Acroloop PC Chassis • Industrial NEMA 12 Design • 14” Color CRT VGA Monitor OPS9000 • 84 Key Membrane Keyboard • 19”W x 15.75”H x 14.5”D • Panel or Pendant Mounted • Interfaces to standard CPU and VGA cards • Optional Pendant Enclosure OPS8200 The OPS8200 is a complete PC-Based system. The design features flat panel technology with an integral PC chassis. It is also compact since it is designed for 1/2 size PC cards. The OPS8200 is ideal for applications requiring up to 4 axis of motion control and a compact design. OPS8200 Features • Use with ACR2000 Controller • Industrial NEMA 12 Design • 10” Flat Panel LCD Screen • Touchscreen Interface • Integral 4 slot chassis includes: • Industrial CPU Card with RAM • Industrial 64-bit VGA Driver • 3.5” Industrial Floppy Drive • 1 Gigabyte Industrial Hard Drive OPS8200 • 150 Watt Power Supply • Compact Design (12”W x 10.5”H x 8.5”D) • Optional EL, Passive or Active Color Displays OPS8100 Features • Use with ACR2000 or ACR8010 Controller • Industrial NEMA 12 Design • 10” Flat Panel LCD Screen • 83 or 43 Key Keyboard • Integral 6 slot chassis includes: OPS8100 • Industrial CPU Card with RAM OPS8100 • Industrial 64-bit VGA Driver The OPS8100 is similar to the OPS8200 • 3.5” Industrial Floppy Drive except that it includes a PC keyboard and a • 1 Gigabyte Industrial Hard Drive full size PC chassis. The OPS8100 is ideal • 150 Watt Power Supply for applications requiring up to 8 axis of PC- • Compact Design (19”W x 10.5”H x 10.5”D) Based motion control all in a compact • Optional EL, Passive or Active Color Displays package. 47 • Optional Touchscreen Interface Smart Terminals OPS8000 The OPS8000 is a functional smart terminal with a built-in interpreter. The interpreter allows easy customizing of applications requiring 1 to 16 axes of motion control. The OPS8000 smart terminal talks to the Acroloop motion controllers via one of its RS-232 ports. A second RS-232 port can be used to automatically request files from a host computer if a host is used in the application. • NEMA 12 Design • 4 x 40 Supertwist LCD Display OPS8000 • 43 membrane keys • 9 programmable function keys • 2 RS-232 ports • 10.3”W x 6.6”H x 3.1”D • Optional custom overlay COMPLETE MOTION BOX OPS1200 • Offers a LED backlit 4 line x 40 character display. (used on the OPS8000) • Offers 40 key, Motion Control Sealed keyboard with 3 hidden keys. 9 Programmable function keys. • Tactile feel on the keys. • Panel Mounting. • Nema 12 Design • 2-Axis of Stepper or Servo DAC outputs. • 3 Feedback Encoder input with 20MHz counting rate. • Built in hardware Encoder fault detection. • 16 Inputs, 16 Output. All 24 Volts Optically Isolated. • Expandable to 48 Inputs and 48 Outputs. • PRINT, INKEY$ functions in ACR1200 firmware to interface to KBD/Display. • All the features of the ACR1200 and the OPS8000 combined into cost effective package. • Complete "Motion Box" for 1 or 2 Axes of Motion with ACR1200 as the main engine. • Canned Software for various applications. • Power requirements +5V , +12V, -12V • Small package. 10.3"W x 6.6"H x 3.1" D • Optional Custom Overlay. • 1 Parallel port, 2 Serial Ports RS232/RS422 OPS1200 48 ACROLOOP MOTION CONTROL SYSTEMS BRUSHED MOTORS & Product Catalog AMPLIFIERS Acroloop carries a wide variety of brushed type motors. Brushed type DC motors are the oldest type of technology used in industrial feedback servos. The advantages of brushed type motors are time proven technology, construction, and low cost. The main disadvantage is brush wear, although in many applications, this is not a consideration. BRUSHED MOTORS Part Number Continuous Stall Torque Peak Torque Maximum Speed Face Size Length MT2230 10 in./oz. 65 in./oz. 5000 2.25” sq. 4.6” MT30F4-25 13 in./lb. 66 in./lb. 4000 5.0” sq. 8.65” MT30M4-38 26 in./lb. 124 in./lb. 3700 5.0” sq. 10.2” MT30U4-36 40 in./lb. 195 in./lb. 4000 5.0” sq. 11.95” MT30U4-57 40 in./lb. 195 in./lb. 2500 5.0” sq. 11.95” MT40W4-68 75 in./lb. 440 in./lb. 4000 5.9” sq. 17.9” BRUSHED MOTOR AMPLIFIER CHASSIS PART NUMBER #AXIS VOLTAGE TYPE CONT AMPS PEAK AMPS SA412 1. 2. or 3 40VDC Linear 4 12 SA1020 1, 2, or 3 100VDC PWM 10 20 SA1525 1, 2, or 3 100VDC PWM 15 25 SAFP1525 1, 2, or 3 160VDC PWM 15 25 SA3060 1 160VDC PWM 30 60 Brushed Motor Servo Amplifier Chassis are supplied with: • Servo Amplifier • Inductors • Noise Suppressors • Buss/Bias Power Supply • Terminal Blocks • Main Buss Relay • 115 VAC Transformer 49 BRUSHLESS MOTORS & Product Catalog AMPLIFIERS Acroloop also carries a wide variety of brushless motors. Typically, lower rotor inertia and efficient thermal dissipation result in faster acceleration and better volumetric efficiency. Part Number Stall Torque Peak Rating Max Speed Volts/KRPM KT SMR104 13 in./lb. 27 in./lb. 5400 RPM 31 4.67 SMR202 22 in./lb. 62 in./lb. 2500 RPM 79.5 11.64 SMR204 42 in./lb. 90 in./lb. 3600 RPM 51.2 7.50 SMR402 58 in./lb. 118 in./lb. 3000 RPM 67.2 9.84 SMR404 112 in./lb. 238 in./lb. 2500 RPM 81.2 11.88 SMR602 151 in./lb. 306 in./lb. 2000 RPM 104.5 15.29 SMR604 278 in./lb. 560 in./lb. 1500 RPM 95.8 14.02 BRUSHLESS MOTOR AMPLIFIERS Part Number Amps Peak Amps Cont. KVA Peak KVA AM203 3 6 1.2 2.4 AM206 6 12 2.4 4.8 AM210 10 20 4.0 8.0 AM220 20 40 8.0 16.0 Brushless Amplifiers include amplifier, industrial enclosure, 1024 PPR encoder output, resolver input, 230VAC PWM output to motor, and all connectors. Completely wired and tested at the factory. BRUSHED MOTOR AMPLIFIER POWER SUPPLIES Part Number Cont. Amps Peak Amps Cont.Power Peak Power PS212 12 24 40 Watts 5.6 KW PS220 20 40 40 Watts 11.2 KW 160 to 250 VAC single or three phase 50/60 Hz input. 325 VAC nominal buss @230 VAC input voltage. Transformer is not required. 50 ACROLOOP MOTION CONTROL SYSTEMS FEEDBACK DEVICES Product Catalog All closed loop motion requires feedback devices to inform the control of the axis position. Acroloop carries an extensive line of motor shaft or remote mounted encoders. These encoders can be mounted right on the motor shaft (rotary encoders) or on another part of the machine (rotary or linear encoder). Acroloop Rotary Encoders Model PPR Mounting Type Connections Output Type EC500 500 Motor Shaft Pigtails Open collector EC1000 1000 Motor Shaft Pigtails Open collector EC1024R 1024 Remote MS-connector Line driver EC012 100 Remote or panel Screw terminals Line driver Consult Acroloop for other configurations. Acroloop can also supply linear encoders, resolvers, interferometers, and analog feedback devices. 51 TURNKEY PACKAGES Product Catalog Put the Acroloop production team to work for you by letting Acroloop create a turnkey package specific to your application. You supply the requirements and we’ll supply everything else. Acroloop can supply any or all of the following: • Motion Controller(s) • Operator Interface • Controller Chassis • Motor(s), Amplifier(s), and Feedback Device(s) • Software Tools • Complete integration hardware including: enclosure, cables, and supporting hardware. We’ll package all the electronics in an industrial enclosure complete with all interconnecting cables. Because this The fully-automated 3-axis mill cuts polypropylene orthotic supports. The system is a “bolt-on” package, you can integrate them supports are used to correct pediatric problems within the easily into your motion control application. Both single medical industry. Acroloop’s multi-axis turnkey package provides and multi-axis turnkey packages are available. the control, speed and precision needed to meet the most demanding requirements. Want to automate a single axis? Acroloop can provide you a single axis turnkey package. 52 ACROLOOP MOTION CONTROL SYSTEMS Networking Products - AcroWire IEEE-1394 AcroWire (based on IEEE-1394) high speed serial bus Another benefit is that the size of the Operator Station communications option is offered for the ACR1200, reduces substantially and allows the industrial user to ACR2000, ACR8010 and the ACR8020. IEEE-1394, also tuck away the motion and other wiring in a remote known as FireWire, replaces the slower RS232/RS422/ controls enclosure. RS485 and USB serial communication methods for Phase 1 of the AcroWire offering is to connect the communicating between the PC and the Motion Control ACH3120, ACH3200, ACH4800, ACH6200 and system. ACH6800 chassis' to the PC. Multiple chassis' can be AcroWire currently communicates at 400Mbits/sec cascaded on the same AcroWire port. Up to 63 nodes (downward compatible with the older 200Mbits/sec chips) can be accessed. and will upgrade to 800Mbits/sec and 1.6Mbits/sec as the Phase 2 of the AcroWire offering will be to connect to newer medium becomes available. remote I/O and Motor Amplifiers. This phase will allow Unlike USB, AcroWire is deterministic in nature. It is different types of motor amplifier to co-exist on the same supported by Windows98 and Windows 2000 (NT V5) cable loop. This will substantially simplify wiring and operating systems. labor costs. This means the the user can remove the motion controller AcroWire protocol is intended to be an open standard from inside the PC without loss of throughput. This avoids and will be shared with different vendors to allow mixing the fight to find open slots, port addresses and unused of multiple sources components in a total system. interrupts. Windows DLL's and Drivers, supplied by Acroloop, Further, newer PC's are getting smaller and making it harder make it a transparent switch for users that are currently for users to get inside the box itself. Instead, the PC's offer plugging the controllers into the PC to switch to USB ports for mouse, keyboard, display monitor and printer AcroWire, and remote mount the motion controller and IEEE-1394 for the higher speed video and motion chassis from the PC. control applications. 53 ACROLOOP in Action ADE Corporation Westwood, MA ADE’s Galaxy AFS-300 is the first automated production 300mm wafer flatness measurement system. The AFS-300 is capable of accurate and precise measurements at the 0.12 µm site flatness specification level, which supports both 0.25 µm and 0.18 µm design rules, as defined by the NTRS road map. The AFS-300 offers the optimal combination of measurement accuracy, contamination-free handling and throughput for production wafer flatness and shape measurements. Coe Press Equipment Corporation Sterling Heights, MI Coe Press Equipment Corporation has built a reputation on manufacturing Roll Feed machines that get the job done quickly, efficiently, and economically. Coe Press consistently and continually designs and engineers press equipment whose performance keeps metal stampers running at full speed. Acroloop helps Coe Press Roll Feed machines maintain that reputation in performing precisely controlled operations with lightning speed. Design Service Corporation Yakima, WA Design Service Corporation (DSC) is a specialty equipment designer for factory automation machinery. In this bag making machine application, DSC has integrated the Acroloop Motion Controller and the ACH4800 chassis. DSC engineered the web handling, flying knife, and a heated seal bar into the design. By implementing the Acroloop controller, DSC achieved a 30% increase in production and a 10% reduction is scrap material offering substantial value for their customer. 54 ACROLOOP MOTION CONTROL SYSTEMS