TMCM-1181-CABLE

MODULES MODULES FOR STEPPER MOTORS Hardware Version V3.0 HARDWARE MANUAL + + TMCM-1181 1-axis Stepper Controller / Driver up to 6.5 RMS / 24V DC USB, RS485 + UNIQUE FEATURES: TRINAMIC Motion Control GmbH & Co. KG Hamburg, Germany www.trinamic.com + TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) Table of Contents 1 2 3 Features........................................................................................................................................................................... 3 Order Codes ................................................................................................................................................................... 5 Mechanical and Electrical Interfacing ..................................................................................................................... 6 3.1 TMCM-1181 Dimensions and Mounting Holes ............................................................................................. 6 3.2 Board mounting considerations ..................................................................................................................... 6 3.3 Connectors of TMCM-1181 ................................................................................................................................. 7 3.3.1 Power Connector ........................................................................................................................................... 8 3.3.2 Motor Connector ............................................................................................................................................ 8 3.3.3 Interface Connector ...................................................................................................................................... 9 3.3.4 In/Out Connector ......................................................................................................................................... 10 3.3.5 USB Connector ............................................................................................................................................. 11 4 On-board LEDs ............................................................................................................................................................. 12 5 Operational Ratings ................................................................................................................................................... 13 6 Functional Description .............................................................................................................................................. 14 7 TMCM-1181 Operational Description ..................................................................................................................... 15 7.1 Calculation: Velocity and Acceleration vs. Microstep and Fullstep Frequency ................................ 15 8 Life Support Policy ..................................................................................................................................................... 17 9 Revision History .......................................................................................................................................................... 18 9.1 Document Revision ........................................................................................................................................... 18 9.2 Hardware Revision ............................................................................................................................................ 18 10 References .................................................................................................................................................................... 18 www.trinamic.com 2 TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 3 1 Features The TMCM-1181 is a single axis controller/driver module for 2-phase bipolar stepper motors. It is highly integrated and can be used in many decentralized applications. The module can be mounted on the back of NEMA34 (86mm flange size) stepper motors and has been designed for coil currents up to 6.5A RMS (programmable) and 24V DC supply voltage. With its high energy efficiency from TRINAMIC’s coolStep™ technology cost for power consumption is kept down. The TMCL™ firmware supports both, standalone operation and direct mode. MAIN CHARACTERISTICS Motion controller ­ Motion profile calculation in real-time ­ On the fly alteration of motor parameters (e.g. position, velocity, acceleration) ­ High performance microcontroller for overall system control and serial communication protocol handling Bipolar stepper motor driver ­ Up to 256 microsteps per full step ­ High-efficient operation, low power dissipation ­ Dynamic current control ­ Integrated protection ­ stallGuard2 feature for stall detection ­ coolStep feature for reduced power consumption and heat dissipation Encoder ­ sensOstep magnetic encoder (max. 1024 increments per rotation) e.g. for step-loss detection under all operating conditions and positioning supervision Interfaces ­ inputs for stop switches (left and right) and home switch ­ 2 analog inputs ­ 2 general purpose outputs (open collector with freewheeling diodes) ­ USB, RS485 communication interfaces Software ­ TMCL: standalone operation or remote controlled operation, program memory (non volatile) for up to 2048 TMCL commands, and PC-based application development software TMCL-IDE available for free. Electrical and mechanical data ­ Supply voltage: +24V DC nominal ­ Motor current: up to 6.5A RMS (programmable) Please see separate TMCM-1181 Firmware Manual for additional information regarding firmware functionality and TMCL programming. www.trinamic.com TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 4 TRINAMICS UNIQUE FEATURES – EASY TO USE WITH TMCL stallGuard2™ stallGuard2 is a high-precision sensorless load measurement using the back EMF on the coils. It can be used for stall detection as well as other uses at loads below those which stall the motor. The stallGuard2 measurement value changes linearly over a wide range of load, velocity, and current settings. At maximum motor load, the value goes to zero or near to zero. This is the most energy-efficient point of operation for the motor. Load [Nm] stallGuard2 Initial stallGuard2 (SG) value: 100% Max. load stallGuard2 (SG) value: 0 Maximum load reached. Motor close to stall. Motor stalls Figure 1.1 stallGuard2 load measurement SG as a function of load coolStep™ coolStep is a load-adaptive automatic current scaling based on the load measurement via stallGuard2 adapting the required current to the load. Energy consumption can be reduced by as much as 75%. coolStep allows substantial energy savings, especially for motors which see varying loads or operate at a high duty cycle. Because a stepper motor application needs to work with a torque reserve of 30% to 50%, even a constant-load application allows significant energy savings because coolStep automatically enables torque reserve when required. Reducing power consumption keeps the system cooler, increases motor life, and allows reducing cost. 0,9 Efficiency with coolStep 0,8 Efficiency with 50% torque reserve 0,7 0,6 0,5 Efficiency 0,4 0,3 0,2 0,1 0 0 50 100 150 200 250 300 350 Velocity [RPM] Figure 1.2 Energy efficiency example with coolStep www.trinamic.com TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 5 2 Order Codes Order code TMCM-1181 Description 1-Axis bipolar stepper motor controller / driver, up-to 6.5A RMS, 24V DC, with integrated sensOstep encoder and coolStep feature Table 2.1: TMCM-1181 order codes A cable loom set is available for this module: Order code TMCM-1181-CABLE Description Cable loom for TMCM-1181 1x cable loom for interface connector 1x cable loom for In/Out connector 1x cable loom for motor connector 1x cable loom for power connector 1x USB type A connector to mini-USB type B connector cable Table 2.2 Cable loom order code www.trinamic.com Size (mm3) 86 x 86 x 27 TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 6 3 Mechanical and Electrical Interfacing 3.1 TMCM-1181 Dimensions and Mounting Holes The dimensions of the controller/driver board are approx. 86mm x 86mm x 27mm in order to fit on the back of a 86mm stepper motor. Maximum component height (height above PCB level) is around 22mm above PCB level and 3mm below PCB level. There are four mounting holes for M4 screws (4.2mm diameter) for mounting the board to a NEMA34 / 86mm stepper motor. 85.9 4.55 67.45 8 2 8 2 R5.9 M4 TMCM-1181 85.9 81.35 72 67.45 18.45 13.9 4.55 13.9 18.45 72 81.35 Figure 3.1: Dimensions of TMCM-1181 and position of mounting holes 3.2 Board mounting considerations The TMCM-1181 offers one metal plated mounting hole close to the power supply connector (marked yellow in figure 3.1 above). This mounting hole is connected to board supply ground. Please keep this in mind when mounting the board to the rear side of a motor. All other mounting holes are isolated. www.trinamic.com TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 7 3.3 Connectors of TMCM-1181 The TMCM-1181 offers five connectors including the motor connector which is used for attaching the motor coils to the electronics. There is one power connector, two connectors for serial communication (one for USB and one for RS485) and one connector for I/O signals and switches. Interface In/Out connector connector 4 1 1 8 USB connector 2 1 1 Power connector 4 Motor Connector Figure 3.2 Overview connectors Domain Power Connector type JST B2P-VH (JST VH series, 2pins, 3.96mm pitch) Motor JST B4P-VH (JST VH series, 4pins, 3.96mm pitch) Interface JST B4B-EH-A (JST EH series, 4 pins, 2.5mm pitch) In/Out JST B8B-EH-A (JST EH series, 8 pins, 2.5mm pitch) USB Mini-USB type B vertical female www.trinamic.com Mating connector type Crimp connector housing: JST VHR-2N Crimp contacts: JST SVH-21T-P1.1 Wire: 0.83mm2, AWG 18 Crimp connector housing: JST VHR-4N Crimp contacts: JST SVH-21T-P1.1 Wire: 0.83mm2, AWG 18 Crimp connector housing: JST EHR-4 Crimp contacts: JST SEH-001T-P0.6 Wire: 0.33mm2, AWG 22 Crimp connector housing: JST EHR-8 Crimp contacts: JST SEH-001T-P0.6 Wire: 0.33mm2, AWG 22 Mini-USB type B, male TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 8 3.3.1 Power Connector A 2pin JST VH series 3.96mm pitch connector is used for power supply. Pin 1 2 2 1 Label GND VCC Direction Power (GND) Power (+24V) Description System and signal ground Power supply input Table 3.1 Connector for power supply CAUTION Always keep the power supply voltage below the upper limit of 28V! Otherwise the driver electronics will be seriously damaged. Especially, when the selected operating voltage is near the upper limit a regulated power supply is highly recommended. 3.3.1.1 Power Supply When using supply voltages near the upper limit, a regulated power supply is mandatory. The board includes around 2000µF / 35V of filtering capacitors. Nevertheless, especially at higher motor current settings it might be necessary to add additional filtering capacitors externally. Power supply ripple due to chopper operation of the driver should be kept at a maximum of a few 100mV. It is important that the upper supply voltage limit is never exceeded during operation as this might seriously damage the driver stage. In this context special care has to be taken with regard to motor energy being fed back into supply voltage line when the motor works as generator. This might happen during de-acceleration or brake conditions especially when the motor is moving a larger mass (high inertia). Additional capacitors which are able to absorb energy might help here. Beyond that suppressor diodes or even brake resistors might be a solution. Guidelines for power supply: ­ keep power supply cables as short as possible ­ use large diameters for power supply cables ­ add additional filter capacitors near the motor driver unit especially if the distance to the power supply is large (i.e. more than 2-3m) Note: there is no protection against reverse polarity integrated on the board. 3.3.2 Motor Connector A 4pin JST VH series 3.96mm pitch connector is used for motor connection. 1 4 Pin 1 2 3 4 Label A1 A2 B1 B2 Table 3.2: Motor connector www.trinamic.com Direction Output Output Output Output Pin Pin Pin Pin 1 2 1 2 of of of of motor motor motor motor coil coil coil coil Description A A B B TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 9 3.3.3 Interface Connector A 4pin JST EH series 2.5mm pitch connector is used as Interface Connector. Pin 1 4 1 Label GND Direction Power (GND) 2 IN4 Input 3 4 RS485+ RS485- Bi-directional Bi-directional Description Module ground (system and signal ground) Analog input 4, 0… 10V (analog to digital converter range) Differential RS485 bus signal (non-inverting) Differential RS485 bus signal (inverting) Table 3.3: Interface connector +3.3V IN4 47k microcontroller 22k 100nF GND GND GND Figure 3.3 Internal circuit of analog input IN4 www.trinamic.com TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 10 3.3.4 In/Out Connector An 8pin JST EH series 2.5mm pitch connector is used as In/Out Connector. 8 Pin 1 Label GND 2 VCC_OUT 3 4 OUT0 OUT1 5 IN0 6 STOP_L/ STEP/ IN1 7 STOP_R/ DIR/ IN2 8 HOME/ ENABLE/ IN3 1 Direction Description Power (GND) Module ground (system and signal ground) Power supply output connected to VCC (pin 2) of Power power supply connector via 0.2A polyfuse. This way up-to 200mA (polyfuse protected) may be used from supply this pin for supply of external circuits (e.g. limit / output home switches, load connected to OUT0/1 etc.) Output General purpose output, open collector Output General purpose output, open collector Analog input 0, 0… 10V (analog to digital converter Input range) Digital input, +24V compatible, programmable internal pull-up.* Functionality can be selected in software: a) Left stop switch input (connected to REF1 Input input of TMC429 motion controller) b) Step signal (connected to step input of TMC262 stepper driver) c) General purpose input 1 (connected to processor) Digital input +24V compatible, programmable internal pull-up.* Functionality can be selected in software: a) Right stop switch input (connected to REF3 Input input of TMC429 motion controller) b) Direction signal (connected to direction input of TMC262 stepper driver) c) General purpose input 2 (connected to processor) Digital input +24V compatible, programmable internal pull-up.* Functionality can be chosen in software: Input a) Home switch input (connected to processor) b) Enable signal (connected to processor) c) General purpose input 3 (connected to processor) Table 3.4 In/Out connector * It is possible to enable / disables pull-ups (1k to +5V) in software for all three digital inputs. Pull-ups are always enabled / disabled for all three together / at the same time. VDD OUT0, OUT1 microcontroller GND Figure 3.4 Internal circuit of OUT0 and OUT1 www.trinamic.com TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) +3.3V IN0 47k microcontroller 22k 100nF GND GND GND Figure 3.5 Internal circuit of analog input IN0 +5V common switch for all three digital inputs 1k +3.3V IN1, IN2, IN3 10k microcontroller (all) and TMC429 (IN_0, IN_1) 22k 100pF GND GND GND Figure 3.6 Internal circuit of digital inputs IN1, IN2 and IN3 3.3.5 USB Connector 5 1 Pin 1 2 3 4 5 Label VBUS DD+ ID GND Table 3.5 Mini USB connector www.trinamic.com Description +5V power Data – Data + not connected ground 11 TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 12 4 On-board LEDs The board offers two LEDs in order to indicate board status. The function of both LEDs is dependent on the firmware version. With standard TMCL firmware the green LED should be slowly flashing during operation and the red LED should be off. When there is no valid firmware programmed into the board or during firmware update the red and green LEDs are permanently on. BEHAVIOR OF LEDS WITH STANDARD TMCL FIRMWARE Status Heartbeat Label Status LED (green) Error Error LED (red) Error LED (red) Status LED (green) Figure 4.1 on-board LEDs www.trinamic.com Description This green LED flashes slowly during operation. This red LED lights up if an error occurs. TMCM-1181 V3.0 Hardware Manual (Rev. 0.90 / 2015-JUL-10) 13 5 Operational Ratings The operational ratings shown below should be used as design values. In no case should the maximum values been exceeded during operation. Symbol Parameter Min Typ Max Unit VCC VUSB Power supply voltage for operation Power supply via USB connector 11 24 5 28 V DC V IUSB Current withdrawn from USB supply when USB bus powered (no other supply connected) Motor coil current for sine wave peak (chopper 0 regulated, adjustable via software) Continuous motor current (RMS) 0 Power supply current ICOIL_peak ICOIL_RMS ISUPPLY TENV 40 mA 9.2