AX2550/2850
Dual Channel
High Power
Digital Motor
Controller
User’s Manual
v1.7, February 1, 2005
visit www.roboteq.com to download the latest revision of this manual
©Copyright 2003-2005 Roboteq, Inc.
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Revision History
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Revision History
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AX2500/2850
Quick Start 11
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Normal and
Fault Condition LED Messages 65
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AX2500/2850 Motor Controller User’s Manual
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SECTION 1
AX2500/2850
Quick Start
This section will give you the basic information needed to quickly install, setup and
run your AX2500/2850 controller in a minimal configuration. The AX2850 is a version
of the AX2550 controller with the addition of Optical Encoder inputs.
Important Safety Warnings
The AX2500/2850 is a high power electronics device. Serious damage, includ-
ing fire, may occur to the unit, motors, wiring and batteries as a result of its
misuse. Please review the User’s Manual for added precautions prior to apply-
ing full battery or full load power.
This product is intended for use with
rechargeable batteries.
Unless special precautions are taken, damage to the controller and/or power
supply may occur if operated with a power supply alone. See“Power Regener-
ation Considerations” on page 31 of the Users Manual.
What you will need
For a minimal installation, gather the following components
•
•
•
•
•
One AX2500/2850 Controller and its provided cables
12V to 40V high capacity, high current battery
One or two brushed DC motors
One R/C to DB15 connector (provided)
Miscellaneous wires, connectors, fuses and switch
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AX2500/2850 Quick Start
Locating Switches, Wires and Connectors
Take a moment to familiarize yourself with the controller’s wires, switches and connector.
monitor the controller. The 15-pin connector provides the connection to the R/C or micro-
computer, as well as connections to optional switches and sensors.
Program Set
Reset
Connector to
Optical Encoders
(AX2850 only)
Connector to Receiver/Controls
and sensors
Operating Status
and Program LED
Display
Controller Configu-
ration buttons
FIGURE 1. Front Controller Layout
At the back of the controller (shown in the figure below) are located all the wires that must
be connected to the batteries and the motors.
Controller Power
Power Control
Yellow
Ground (-)
Black
(top)
Motor (+)
White
Motor (-) 12 to 40V (+) Ground (-)
12 to 40V (+) Motor(+)
Motor (-)
Green
Green
Red
Black
Red
Yellow or
White
Motor 1
Motor 2
FIGURE 2. Rear Controller Layout
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Connecting to the Batteries and Motors
Connecting to the Batteries and Motors
Connection to the batteries and motors is shown in the figure below and is done by con-
necting the set of wires coming out from the back of the controller.
Motor
Battery
Power Cables
Optional
Power on/off
switch
Cables
+
Motor2
Motor1
Fuse
-
+
-
Power Control
Wire
12V to 40V
Motor Battery
Controller
Notes:
-
The Battery Power connection are doubled in order to provide the maximum current to the controller. If
only one motor is used, only one set of motor power cables needs to be connected
-
-
Typically, 1, 2 or 3 x 12V batteries are connected in series to reach 12, 24 or 36V respectively
The Power Control wire may be used to turn On and Off the controller, or to provide a separate and sta-
ble supply to the controller’s logic (See discussion below)
FIGURE 3. Electrical Power Wiring Diagram
1- Connect the two thick black wires to the minus (-) terminal of the battery that will be
used to power the motors. Connect the two thick red wires to the plus (+) terminal of the
battery. The motor battery may be of 12 to 40 Volts. There is no need to insert a switch on
Motor Power cables, although one is suggested.
Avoid extending the length of these wires as the added inductance may cause dam-
age to the controller when operating at high currents. Try extending the motor wires
instead since the added inductance on this side of the controller is not harmful.
The two red wires are connected to each other inside the controller. The same is true
for the black wires. You should wire each pair together as shown in the diagram
above.
2- You may leave the yellow Power Control wire and the thin black wire unconnected, or
you may connect them to a power switch. If left floating, protect these wires from touching
any metallic part of the controller or chassis.
more information about batteries and other connection options.
3- Connect each motor to one of the two output cables pair. Make sure to respect the
polarity, otherwise the motor(s) may spin in the opposite direction than expected
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AX2500/2850 Quick Start
Important Warning
The controller includes large capacitors. When connecting the Motor Power Cables,
a spark will be generated at the connection point. This is a normal occurrence and
should be expected.
Using the Power Control Wire
The AX2500/2850 includes a DC/DC converter that will generate a 12V internal supply from
the main +12 to +40V battery. As a result, the controller will turn On as soon as its Battery
Wires (thick red and black wires) are connected to the battery.
In order to turn On and Off the controller without the need for a bulky and expensive
switch or relay on the high current wires, the AX2500/2850 uses a Power Control wire to
enable or disable the internal DC/DC converter. When left unconnected, the DC/DC con-
verter is On. When grounded, the DC/DC converter is Off.
The Power Control wire can also be used to feed a separate supply to the controller so that
it will continue to operate if and when the main batteries’ voltage dips below 12V. The table
on page 25 for more details on the use and operation of the Power Control signal.
TABLE 1. Use of Power Control wire
Power Control input connected to
Action
Floating
Controller is On
Controller is Off
Ground
Separate 12V to 40V supply
Controller is On. Controller will draw power from
the Power Control wire if main battery voltage
dips below 12V.
Connecting the R/C Radio
Connect the R/C adapter cables to the controller on one side and to two or three channels
on the R/C receiver on the other side. The third channel is for activating the accessory out-
puts and is optional.
When operating the controller in “Separate” mode, the wire labelled Ch1 controls Motor1,
and the wire labelled Ch2 controls Motor2.
When operating the controller in “Mixed” mode, Ch1 is used to set the robot’s speed and
direction, while Ch2 is used for steering.
R/C commands, calibration and other options.
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Powering On the Controller
Channel 3
Channel 2
3:
4:
6:
7:
8:
Channel 1 Command Pulses
Channel 2 Command Pulses
Radio battery (-) Ground
Radio battery (+)
Channel 1
Channel 3 Command Pulses
8
9
Pin 1
Wire loop bringing power from
controller to RC radio and
to optical isolators
15
FIGURE 4. R/C connector wiring for 3 channels and battery elimination (BEC)
This wiring - with the wire loop uncut - assumes hat the R/C radio will be powered by the
of the User’s Manual.
Important Warning
Do not connect a battery to the radio when the wire loop is uncut. The RC battery
voltage will flow directly into the controller and cause permanent damage if its volt-
age is higher than 5.5V.
Connecting the optional channel 3 will enable you to turn on and off two accessory out-
Powering On the Controller
Important reminder: There is no On-Off switch on the controller. You must insert a switch
To power the controller, center the joystick and trims on the R/C transmitter. Then turn on
the switch that you have placed on the Battery Power wire or on the Power Control wire.
If the R/C transmitter and/or receiver is powered off, the display on the controller will alter-
nate the letters spelling “no ctrl” to indicate that it is On but is not receiving a control sig-
nal.
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AX2500/2850 Quick Start
FIGURE 5. “no control” scroll message indicates no valid R/C signal is present
Turn the R/C transmitter On. The “no ctrl” scrolling message will disappear and the display
will show steady patterns depending on the motors’ selected direction.
Move the joystick on the transmitter to activate the motors to the desired speed and direc-
tion.
many features and options available in the R/C mode.
Button Operation
The AX2500/2850 has three buttons: Set, Program and Reset. These buttons are not
needed for normal operation, as the controller is immediately operational upon power up.
The Reset button will restart the controller. This button is recessed and you will need a
paper clip to press it. Reset is also accomplished by turning the controller’s power Off and
back On.
The Set and Program buttons have the following functions depending how and when they
are pressed:
TABLE 2. AX2500/2850 Buttons Function
Prog and Set button status
Function
Press and hold Program alone during reset or power up
Press and hold Set alone during reset of power up
Enter the Programming Mode.
Press and hold Program and Set together during reset or
power up
Reset configuration parameters to factory
default
Press Program while Programming Mode
Accept previous parameter change and
select next parameter
Press Set while in Programming mode
Change value of selected parameter
No effect
Press Program pressed alone during normal operation
Press Set alone during normal operation
No effect
Press Program and Set together during normal operation
Emergency stop
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Default Controller Configuration
Default Controller Configuration
Version 1.7 of the AX2500/2850 software is configured with the factory defaults shown in
the table below. Although Roboteq strives to keep the same parameters and values from
one version to the next, changes may occur from one revision to the next. Make sure that
you have the matching manual and software versions. These may be retrieved from the
User Manual for a complete configuration parameter list and their possible values.
TABLE 3. AX2500/2850 Default Settings
Parameter
Default Values
Letter
Input Command mode:
Motor Control mode
Amp limit
(0) = R/C Radio mode
(0) = Separate A, B, speed control, open loop
(5) = 105A
I
C
A
S
U
b
d
E
F
L
Acceleration
(2) = medium-slow
Input switch function
Brake/Coast
(3) = no action
(0) = brake when idle
(2) = 16%
Joystick Deadband
Exponentiation on channel 1
Exponentiation on channel 2
Left / Right Adjust
(0) = Linear (no exponentiation)
(0) = Linear (no exponentiation)
(7) = no adjustment
Checking and Changing Configurations
either using the controller’s buttons or your PC with the Roboteq Configuration Utility.
The example below shows how to use the buttons to select and change the Motor Control
their meanings.
Restart
Press & hold Prog
Press and hold the Prog button for 10 seconds while
resetting or powering on the controller
Program mode entered
after 10 seconds
After 10 seconds, the controller will enter the program-
ming mode and flash alternatively the current parame-
ter (I= Input Mode) and its value (0= R/C mode).
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AX2500/2850 Quick Start
Press Prog to select
Press the Prog button to move to the next parameter
next parameter
(C= Motor Control Mode) and its value (0= Separate)
Press Set to select
next value for parameter
Press the Set button to change the parameter’s value
(1= Combined)
Press Prog to store change
and select next parameter
Press the Prog button record the change and move to
the next parameter (A= Amps limit) and it’s value (2=
75A)
Reset controller
to exit
Press the Reset button or power off/on the control to
restart the controller using the new parameters.
Connecting the controller to your PC using Roborun
Connecting the controller to your PC is not necessary for basic R/C operation. However, it
is a very simple procedure that is useful for the following purposes:
•
to Read and Set the programmable parameters with a user-friendly graphical inter-
face
•
•
•
•
•
to obtain the controller’s software revision and date
to send precise commands to the motors
to read and plot real-time current consumption value
Save captured parameters onto disk for later analysis
to update the controller’s software
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Obtaining the Controller’s Software Revision Number
FIGURE 6. Roborun Utility screen layout
To connect the controller to your PC, use the provided cable. Connect the 15-pin connector
to the controller. Connect the 9-pin connector to your PC’s available port (typically COM1).
Apply power to the controller to turn it on.
Load your CD or download the latest revision of Roborun software from
www.Roboteq.com, install it on your PC and launch the program. The software will auto-
matically establish communication with the controller, retrieve the software revision num-
ber and present a series of buttons and tabs to enable its various possibilities.
The intuitive Graphical User Interface will let you view and change any of the controller’s
parameters. The “Run” tab will present a number of buttons, dials and charts that are used
for operating and monitoring the motors.
Obtaining the Controller’s Software Revision Number
One of the unique features of the AX2500/2850 is the ability to easily update the control-
ler’s operating software with new revisions downloaded from Roboteq’s web site at
www.roboteq.com. This is useful for adding features and/or improving existing ones.
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AX2500/2850 Quick Start
Each software version is identified with a unique number. Obtaining this number can be
done using the PC connection discussed previously.
It is also possible to get the controller to display the software version number by following
these simple steps
•
•
Disconnect the power from the motor batteries
Press and hold the Set button while powering or resetting the controller
The LED will display a sequence of two numerical digits and an optional letter separated by
dashes as shown in the examples below.
= Software version 1.7
FIGURE 7. Press and hold “Set” to display version number and enter self-test
After these digits are displayed, the controller will attempt to power the motors as part of
detailed explanation). This is why the motor’s battery must be disconnected. After about
30 seconds, the software revision number will be displayed every 30 seconds.
You will need to reset, or power down and up, the controller to exit and resume normal
operations.
Now that you know your controller’s software version number, you will be able to see if a
new version is available for download and installation from Roboteq’s web site, and which
features have been added or improved.
Exploring further
By following this quick-start section, you should have managed to get your controller to
operate in its basic modes within minutes of unpacking.
Each of the features mentioned thus far has numerous options which are discussed further
in the complete User’s Manual, including:
•
•
•
•
•
•
•
•
Self test mode
Emergency stop condition
Joystick calibration
Using Inputs/Outputs
Current limiting
Closed Loop Operation
Software updating
and much more
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SECTION 2
AX2500/2850
Motor Controller
Overview
Congratulations! By selecting Roboteq’s AX2500/2850 you have empowered your-
self with the industry’s most versatile and programmable DC Motor Controller for
mobile robots. This manual will guide you step by step through its many possibili-
ties.
Product Description
The AX2500/2850 is a highly configurable, microcomputer-based, dual-channel digi-
tal speed or position controller with built-in high power drivers. The controller is
designed to interface directly to high power DC motors in computer controlled or
remote controlled mobile robotics and automated vehicle applications.
The AX2500/2850 controller can accept speed or position commands in a variety of
ways: pulse-width based control from a standard Radio Control receiver, Analog
Voltage commands, or RS-232 commands from a microcontroller or wireless
modem.
The controller's two channels can be operated independently or can be combined to
set the forward/reverse direction and steering of a vehicle by coordinating the
motion on each side of the vehicle. In the speed control mode, the AX2500/2850
can operate in open loop or closed loop. In closed loop operation, actual speed mea-
surements from tachometers or optical encoders are used to verify that the motor is
rotating at the desired speed and direction and to adjust the power to the motors
accordingly.
The AX2500/2850 can also be configured to operate as a precision, high torque
servo controller. When connected to a potentiometer coupled to the motor assem-
bly, the controller will command the motor to rotate up to a desired angular position.
Depending on the DC motor's power and gear ratio, the AX2500/2850 can be used
to move or rotate steering columns or other physical objects with very high torque.
The AX2500/2850 is fitted with many safety features ensuring a secure power-on
start, automatic stop in case of command loss, over current protection on both
channels, and overheat protection.
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AX2500/2850 Motor Controller Overview
The motors are driven using high-efficiency Power MOSFET transistors controlled using
Pulse Width Modulation (PWM) at 16kHz. The AX2500/2850 power stages can operate
from 12 to 40VDC and can sustain up to 120A of controlled current, delivering up to
4,800W (approximately 6 HP) of useful power to each motor.
The many programmable options of the AX2500/2850 are easily configured using one-
touch Program and Set buttons and a 7-segment LED display. Once programmed, the con-
figuration data are stored in the controller's non-volatile memory, eliminating the need for
cumbersome and unreliable jumpers.
The AX2850 is the AX2550 controller fitted with a dual channel optical encoder input mod-
ule. Optical Encoders allow precise motor speed and position measurement and enable
advance robotic applications.
Technical features
Fully Digital, Microcontroller-based Design
•
•
Multiple operating modes
Fully programmable using either built-in switches and 7 segment display or through
connection to a PC
•
•
•
Non-volatile storage of user configurable settings. No jumpers needed
Simple operation
Software upgradable with new features
Multiple Command Modes
•
•
•
Radio-Control Pulse-Width input
Serial port (RS-232) input
0-5V Analog Command input
Multiple Advanced Motor Control Modes
•
•
•
•
•
Independent operation on each channel
Mixed control (sum and difference) for tank-like steering
Open Loop or Closed Loop Speed mode
Position control mode for building high power position servos
Modes selectable independently for each channel
Automatic Joystick Command Corrections
•
•
•
•
Joystick min, max and center calibration
Selectable deadband width
Selectable exponentiation factors for each joystick
3rd R/C channel input for weapon and accessory output activation
Special Function Inputs/Outputs
2 Analog inputs. Used as
•
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Technical features
•Tachometer inputs for closed loop speed control
•Potentiometer input for position (servo mode)
•Motor temperature sensor inputs
•External voltage sensors
•User defined purpose (RS232 mode only)
One Switch input configurable as
•
•Emergency stop command
•Reversing commands when running vehicle inverted
•General purpose digital input
•
•
Up to 2 general purpose outputs for accessories or weapon
•One 24V, 2A output
•One low-level digital output
Up to 2 general purpose digital inputs
Optical Encoder Inputs (AX2850 only)
•
•
•
•
Inputs for two Quadrature Optical Encoders
up to 250khz Encoder frequency per channel
two 32-bit up-down counters
Inputs may be shared with four optional limit switches per channel
Internal Sensors
•
•
•
•
Voltage sensor for monitoring the main 12 to 40V battery system operation
Voltage monitoring of internal 12V
Temperature sensors on the heat sink of each power output stage
Sensor information readable via RS232 port
Low Power Consumption
•
•
On board DC/DC converter for single 12 to 40V battery system operation
Optional backup power input for powering safely the controller if the motor batteries
are discharged
•
•
Max 200mA at 12V or 100mA at 24V idle current consumption
Power Control wire for turning On or Off the controller from external microcomputer
or switch
•
•
No power consumed by output stage when motors are stopped
Regulated 5V output for powering R/C radio. Eliminates the need for separate R/C
battery
High Efficiency Motor Power Outputs
•
•
•
•
•
•
Two independent power output stages
Dual H bridge for full forward/reverse operation
Ultra-efficient 2.5mOhm ON resistance (RDSon) MOSFET transistors
12 to 40 V operation
High current 8 AWG cable sets for each power stages
SmartAmps Automatic current limitation
•120A up to 15 seconds (per channel)
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AX2500/2850 Motor Controller Overview
•100A up to 30 seconds
•80A extended
•High current operation may be extended with forced cooling
250A peak Amps per channel
•
•
•
•
16kHz Pulse Width Modulation (PWM) output
Auxiliary output for brake or clutch
Heat sink extruded case
Advanced Safety Features
•
•
•
Safe power on mode
Optical isolation on R/C control inputs
Automatic Power stage off in case of electrically or software induced program fail-
ure
•
•
•
Overvoltage and Undervoltage protection
Regeneration current limiting
Watchdog for automatic motor shutdown in case of command loss (R/C and RS232
modes)
•
•
•
•
•
Large, bright run/failure diagnostics on 7 segment LED display
Programmable motor acceleration
Built-in controller overheat sensor
Motor temperature sensing and protection
Emergency Stop input signal and button
Data Logging Capabilities
•
13 internal parameters, including battery voltage, captured R/C command, tempera-
ture and Amps accessible via RS232 port
•
Data may be logged in a PC, PDA or microcomputer
Sturdy and Compact Mechanical Design
•
•
•
Built from aluminum heat sink extrusion with mounting brackets
Efficient heat sinking. Operates without a fan in most applications.
7” (178mm) long (excluding mounting brackets) by 5.5” wide (140mm) by 1.8”
(40mm) high
•
•
-20o to +70o C operating environment
3.3 lbs (1500g)
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Connecting Power
SECTION 3
Connecting
Power and
Motors to the
Controller
This section describes the AX2500/2850 Controller’s connections to power sources and
motors.
Important Warning
Please follow the instructions in this section very carefully. Any problem due to wir-
ing errors may have very serious consequences and will not be covered by the prod-
uct’s warranty.
Connecting Power
The AX2500/2850 has 2 sets of Ground (black) and Vmot (red) power cables and a Power
Control wire (yellow):
The power cables are located at the back end of the controller. The various power cables
are identified by their position, wire thickness and color: Red is positive (+), black is nega-
tive or ground (-).
The power cables to the batteries and motors are shown in the figure below.
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Connecting Power and Motors to the Controller
Controller Power
Power Control
Ground (-)
Black
Yellow
(top)
Motor (+)
White
Motor (-) 12 to 40V (+) Ground (-)
12 to 40V (+) Motor(+)
Motor (-)
Green
Green
Red
Black
Red
Yellow or
White
Motor 1
Motor 2
FIGURE 8. Controller rear plate and power wiring
Controller Power
The AX2500/2850 uses a flexible power supply scheme that is best described in Figure 9.
On this diagram, it can be seen that the Control Logic requires a stable 12V supply, while
the Power Output stage that drives the motors can tolerate a very wide voltage range.
Because of its wide operating voltage range, the Power Output stage is wired directly to
the Main Battery.
The control logic is connected to both the DC/DC converter as well as the Power Control
wire. If the voltage applied to the DC/DC converter’s input is lower than the 12V needed for
its proper operation, the Control Logic will stop unless the Power Control wire is con-
nected to a separate 12V power source. The diode circuit is designed to automatically
select one power source over the other. The diodes will let through the source that is
higher than the other.
The Power Control input also serves as the Enable signal for the DC/DC converter. When
floating or pulled to above 1V, the DC/DC converter is active and supplies the AX2500/
2850’s control logic, thus turning it On. When the Power Control input is pulled to Ground,
the DC/DC converter is stopped and the controller is turned Off.
All 3 ground wires (-) are connected to each other inside the controller. The two main bat-
tery wires are also connected to each other internally. However, you must never assume
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Controller Power
that connecting one wire of a given battery potential will eliminate the need for connecting
the other. Malfunction or even damage may occur if one wire is assuming the load of all
two.
Mot1(-)
Mot1(+)
VBatt Vmot
5Vmin
Channel 1 MOSFET Power Stage
40V max
GND
Power
Control
&Backup
ENABLE
Microcomputer &
MOSFET Drivers
9.5V min
13V max
10.5V min
40V max
DC/DC
GND
GND
5Vmin
40V max
Channel 2 MOSFET Power Stage
VBatt Vmot
Mot2(+)
Mot2(-)
FIGURE 9. Representation of the AX2500/2850’s Internal Power Circuits
TABLE 4. Effect of Power Control under various voltage conditions
Power Control input is
connected to
And Main Battery
Voltage is
Action
Ground
Floating
Floating
Any Voltage from 0V to 40V
Below 9V
Controller is Off
Controller is Off
Between 9V and 10.5V
Controller Logic is On
Power Stage is Disabled (under-
voltage condition)
Floating
Between 10.5 and 40V
Controller is On. Drawing power
from Main Battery
Power Stage is Active
10.5V to 40V
Lower than Voltage on Power
Control input - or Off
Controller is On. Drawing power
from external source (backup
battery)
Power Stage is Active
10.5V to 40V
Higher than Voltage on Power
Control input
Controller is On. Drawing power
from Main Battery
Power Stage is Active
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Connecting Power and Motors to the Controller
Powering the Controller using the Motor Batteries
The AX2500/2850 included a DC/DC converter to generate the internal 12V required for its
cuit and the two options for turning the power On and Off. The diagram shows two
switches, although switching either one alone will power the controller Off.
In a typical configuration, it is recommended that the Motor Power be always applied and
that the Controller’s Power be controlled using a switch on the Power Control wire (yellow).
When the controller is Off, the output transistors are in the Off position and no power is
drawn on the Motor Power battery.
For safety reasons, however, it is highly recommended that a way of quickly disconnecting
the Motor Power be provided in the case of loss of control and all of the AX2500/2850
safety features fail to activate
Note, however, that eventually the motor batteries will get weaker and the voltage drop
below the level needed for the internal DC/DC converter to properly operate. For all profes-
sional applications it is therefore recommended to add a separate 12V (to 40V) power sup-
ply to ensure proper powering of the controller under any conditions.
Important Warning
Unless you can ensure a steady 12V voltage in all conditions, it is recommended that
the battery used to power the controller’s electronics must be separate from the one
used to power the motors. This is because it is very likely that the motor batteries
will be subject to very large current loads, which may cause the voltage to eventually
dip below 12V as the batteries’ charge drops. The separate backup power supply
should be connected to the Power Control input.
Important Warning
On versions of the AX2550 with PCB revision number lower than 5.2, the backup
power supply applied on the Power Control wire must NEVER EXCEED 13V. Perma-
nent damage may otherwise occur. PCB revision number can be found on the sticker
on the case’s bottom.
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Controller Power
Swich on
Power Control
Swich on
Main Battery
(optional)
Controller
2 x 12V Batteries = 24V
3 x 12V Batteries = 36V
Notes:
-
Only one switch is actually needed to turn On/Off the controller. If either one is used,
the other can be omitted.
FIGURE 10. Powering the controller from the Motor Batteries
Using a Backup Battery
To ensure that the controller will always be operational, regardless of the charge left in the
main battery, it is recommended to add a 12V backup battery connected as shown in
Battery
Power Cables
Power Control
Wire
Motor
Cables
-
Motor2
Motor1
Fuse
+
On
Off
-
+
Controller
12V to 40V
12V
Motor Battery
Controller
Battery
FIGURE 11. Power wiring using a two-battery system
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Connecting Power and Motors to the Controller
Make sure that your motors have their wires isolated from the motor casing. Some
motors, particularly automotive parts, use only one wire, with the other connected
to the motor’s frame.
If you are using such a motor, make sure that it is mounted on isolators and that its
casing will not cause a short circuit with other motors and circuits which may also
be inadvertently connected to the same metal chassis.
Power Fuses
For low Amperage applications (below 30A per motor), it is recommended that a fuse be
The fuse will be shared by the two output stages and therefore must be placed before the
Y connection to the two power wires.
Automotive fuses are generally slow and the following values are recommended depend-
ing on the desired level of protection. It should be noted that the current values listed will
apply to the sum of the current drawn by each channel. Practically, a fuse will be of limited
effectiveness. In very high current application (80A or more per channel), it will simply not
be possible to find a fuse with the necessary Amps rating and speed needed to provide
adequate protection. In such situation, the fuse may be just as well omitted keeping in
mind that the controller’s current limiting circuit may not be able to protect it against short
circuits and other abnormal situations.
TABLE 5. Fuse selection table
Desired Current Protection (total for
Channel 1 + Channel 2)
Fuse
100A
80A
60A
50A
40A
35A
120A
100A
80A
60A
50A
40A
Important Warning
Fuses are typically slow to blow and will thus allow temporary excess current to flow
through them for a time (the higher the excess current, the faster the fuse will blow).
This characteristic is desirable in most cases, as it will allow motors to draw surges
during acceleration and braking. However, it also means that the fuse may not be
able to protect the controller.
Wire Length Limits
The AX2500/2850 regulates the output power by switching the power to the motors On
and Off at high frequencies. At such frequencies, the wires’ inductance produces undesir-
able effects such as parasitic RF emissions, ringing and overvoltage peaks. The controller
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Electrical Noise Reduction Techniques
has built-in capacitors and voltage limiters that will reduce these effects. However, should
the wire inductance be increased, for example by extending the wire length, these effects
will be amplified beyond the controller’s capability to correct them. This is particularly the
case for the main battery power wires (thick red and black cables).
Important Warning
Avoid extending the black and red Motor Power wires beyond their original length as
the added inductance may cause damage to the controller when operating at high
currents. Try extending the motor wires instead since the added inductance is less
harmful on this side of the controller.
Electrical Noise Reduction Techniques
As discussed in the above section, the AX2500/2850 uses fast switching technology to
control the amount of power applied to the motors. While the controller incorporates sev-
eral circuits to keep electrical noise to a minimum, additional techniques can be used to
keep the noise low when installing the AX2500/2850 in an application. Below is a list of
techniques you can try to keep noise emission low:
•
•
•
•
Keep wires as short as possible
Loop wires through ferrite beads
Add snubber R/C circuit at motor terminals
Keep controller, wires and battery enclosed in metallic body
Power Regeneration Considerations
When a motor is spinning faster than it would normally at the applied voltage, such as
when moving downhill or deccelerating, the motor acts like a generator. In such case, the
current will flow in the opposite direction, back to the power source.
It is therefore essential that the AX2500/2850 be connected to rechargeable batteries. If a
power supply is used instead, during regeneration the current will attempt to flow back in
the power supply potentially damaging it and/or the controller.
Regeneration can also cause potential problems if the battery is disconnected while the
motors are still spinning. In such a case, and depending on the command level applied at
that time, the regenerated current will attempts to flow back to the battery but since none
is present, the voltage will rise to potentially unsafe levels. The AX2500/2850 includes an
Important Warning
Use the AX2500/2850 only with a rechargeable battery as supply to the Motor Power
wires (thick black and red wires). If a transformer or power supply is used, damage to
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Connecting Power and Motors to the Controller
Important Warning
Avoid switching Off or cutting open the main power cables (thick black and red
wires) while the motors are spinning. Damage to the controller may occur.
Overvoltage Protection
The AX2500/2850 includes a battery voltage monitoring circuit that will cause the output
transistors to be turned Off if the main battery voltage applied on the thick red and black
wires rises above 43V.
This protection is designed to prevent the voltage created by the motors during regenera-
tion to be “amplified” to unsafe levels by the switching circuit.
The controller will resume normal operation when the measured voltage drops below 43V.
Undervoltage Protection
In order to ensure that the power MOSFET transistors are switched properly, the AX2500/
2850 monitors the internal 12V power supply that is used by the MOSFET drivers. If the
internal voltage drops below 10V, the controller’s output stage is turned Off. The rest of the
controller’s electronics, including the microcomputer will remain operational as long as the
internal voltage is above 8V.
The internal voltage will be the output of the DC/DC converter which will be a solid 12V as
long as either of the main battery or backup voltage is higher than 12.5V. If the main and
backup voltage drop below 12.V, the DC/DC converter’s output will be approximately 0.5V
lower than the higher of the main or backup voltage.
Using the Controller with a Power Supply
Using a transformer or a switching power supply is possible but requires special care as
the current will want to flow back from the motors to the power supply during regenera-
able to absorb and dissipate regenerated current, the voltage will increase until the over-
voltage protection circuit cuts off the motors. While this process should not be harmful to
the controller, it may be to the power supply, unless one or more of the protective steps
below are taken:
•
Use a power supply that will not suffer damage in case that a voltage is applied at
its output that is higher than the transformer’s own output voltage. This information
is seldom published in commercial power supplies, so it is not always possible to
obtain positive reassurance that the supply will survive such a condition.
•
Avoid deceleration that is quicker than the natural deceleration due to the friction in
the motor assembly (motor, gears, load). Any deceleration that would be quicker
than natural friction means that braking energy will need to be taken out from the
•
Place a battery in parallel with the power supply output. This will provide a reservoir
into which regeneration current can flow. It will also be very helpful for delivering
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Using the Controller with a Power Supply
high current surges during motor acceleration, making it possible to use a lower
current power supply. Battery mounted in this way should be connected for the first
time only while fully charged and should not be allowed to discharge. The power
supply will be required to output unsafe amounts of current if connected directly to
a discharged battery.
•
Place a resistive load in parallel with the power supply, with a circuit to enable that
load during regeneration. This solution is more complex but will provide a safe path
for the braking energy into a load designed to dissipate it. To prevent current from
flowing from the power supply into the load during normal operation, an active
switch would enable the load when the voltage rises above the nominal output of
the power supply.
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Connecting Power and Motors to the Controller
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Basic Operation
SECTION 4
General
Operation
This section discusses the controller’s normal operation in all its supported operating
modes.
Basic Operation
The AX2500/2850’s operation can be summarized as follows:
•
•
•
Receive commands from a radio receiver, joystick or a microcomputer
Activate the motors according to the received command
Perform continuous check of fault conditions and adjust actions accordingly
Multiple options are available for each of the above listed functions which can be combined
to produce practically any desired mobile robot configuration.
Input Command Modes
The controller will accept commands from one of the following sources
•
•
•
R/C radio
Serial data (RS232)
Analog signal (0 to 5V)
A detailed discussion on each of these modes and the available commands is provided in
The controller’s factory default mode is R/C radio. The mode can be changed using any of
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General Operation
Selecting the Motor Control Modes
For each motor, the AX2500/2850 supports multiple motion control modes. The controller’s
factory default mode is Open Loop Speed control for each motor. The mode can be
Open Loop, Separate Speed Control
In this mode, the controller delivers an amount of power proportional to the command
information. The actual motor speed is not measured. Therefore the motors will slow
down if there is a change in load as when encountering an obstacle and change in slope.
This mode is adequate for most applications where the operator maintains a visual contact
with the robot.
In the separate speed control mode, channel 1 commands affect only motor 1, while chan-
Controller
FIGURE 12. Effect of commands to motors examples in
separate mode
Open Loop, Mixed Speed Control
This mode has the same open loop characteristics as the previously described mode. How-
ever, the two commands are now mixed to create a tank-like steering when one motor is
used on each side of the robot: Channel 1 is used for moving the robot in the forward or
reverse direction. Channel 2 is used for steering and will change the balance of power on
each side to cause the robot to turn.
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Selecting the Motor Control Modes
Controller
FIGURE 13. Effect of commands to motors examples in
mixed mode
Closed Loop Speed Control
only) is used to measure the actual motor speed. If the speed changes because of changes
in load, the controller automatically compensates the power output. This mode is preferred
in precision motor control and autonomous robotic applications. Details on how to wire the
Tachometer or
Optical Encoder (AX2850 & AX3500 only)
Speed Feedback
FIGURE 14. Motor with tachometer or Encoder for Closed Loop Speed operation
Close Loop Position Control
potentiometer that is used to compare the angular position of the axle versus a desired
position. This AX2500/2850 feature makes it possible to build ultra-high torque “jumbo ser-
vos” that can be used to drive steering columns, robotic arms, life-size models and other
heavy loads. Details on how to wire the position sensing potentiometers and operating in
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General Operation
Position Feedback
Position Sensor
Gear box
FIGURE 15. Motor with potentiometer assembly for Position operation
Current Limit Settings
The AX2500/2850 has current sensors at each of its two output stages. Every 16 ms, this
current is measured and a correction to the output power level is applied if higher than the
user preset value.
The current limit may be set using the controller’s switches or the supplied PC utility. Using
the switches, 7 limits may be selected as shown in the table below.
TABLE 6. Current limit settings using the switches
Setting
Continuous High Amps
0
30A
45A
60A
75A
90A
105A
120A
1
2
3
4
5 - default
6
Using the PC utility is it possible to set the limit with a 1A granularity from 15A to 120A
During normal operation, current limiting is further enhance by the techniques described in
the following sections.
Continuous and Extended Current Limitation
The AX2500/2850 features active current limitation with a Smart Amps control algorithm.
This capability ensures that the controller will be able to work safely with practically all
motor types and will adjust itself automatically for the various load conditions.
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Temperature-Based Current Limitation
You can select one of 7 current limit settings based on your robot’s component capabilities
(motors, battery, wiring), up to the controller’s own limit. The available current limit values
are shown in the table below.
TABLE 7. Continuous vs. Extended Amp limits table
Setting
Continuous High Amps
Extended Safe Amps
0
1
2
3
4
5
6
30A
45A
60A
75A
90A
105A
120A
30A
45A
60A
75A
80A
80A
80A
The controller will assume that any consumption above the safe continuous amps value
will cause more heat to be generated than can be safely dissipated. The controller will
keep an internal total of the estimated heat balance and will begin gradually reducing the
output power when a maximum threshold has been reached. The higher the current is over
the Continuous Safe Amps limit, the quicker it will reach the maximum threshold.
In practice, assuming the maximum Amps limit setting (120A), this means that the control-
ler will allow up to 1 minute of operation at 100A or 15 seconds at 120A. When the control-
ler runs below the Continuous Safe Amps limit, the controller will assume that it is cooling
off and will allow for higher amp consumption at a later time. In practical robot maneuver-
ing situations where stop and go is very common, the controller will be capable of deliver-
ing the maximum Momentary High Amps whenever it is needed.
Temperature-Based Current Limitation
The AX2500/2850 also features active current limitation with a SmartAmps control algo-
rithm. On the AX2500/2850, this current limiting is based on the actual measured tempera-
ture of the heat sink, near the mounting point of the Power MOSFET transistors inside the
controller. While the temperature is below 60oC, the controller will deliver up to 120A Con-
tinuous Amps. For every degree of temperature rise above that threshold value, the limit is
reduced from this absolute maximum amount. Furthermore you can select one of 7 cur-
rent limit settings based on your robot’s component capabilities (motors, battery, wiring),
up to the controller’s own limit. The current limit that is applied at any given time is the
lesser value of your selected value, the computed limit using the SmartAmps algorithm
and the maximum Amps the controller is allowed to deliver at its current temperature
point. This capability ensures that the controller will be able to work safely with practically
all motor types and will adjust itself automatically for the various load and environmental
conditions. The time it takes for the heat sink’s temperature to rise depends on the current
output, ambient temperature, and available air flow (natural or forced).
Note that the measured temperature is on the inside of the heat sink and will rise and fall
faster than the outside surface.
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General Operation
Surge Current Protection
During exceptionally high load conditions such as motor stalls, the motors may make
demands on the controller in excess of several hundred Amps. The current limiting fea-
tures described above will automatically reduce the power output so that the consumption
does not exceed the maximum limit.
For example, if the motor attempts to draw 1000A, the controller will throttle back the
power to 10% so that the average consumption becomes 100A.
However, the controller’s MOSFET transistors will still see these 1000A pulses during the
10% ON time of the Pulse Width Modulation. This level of current would be damaging to
the controller.
Therefore, the AX2500/2850’s will continuously compute the peak current consumption as
the average measured Amps divided by the PWM ratio and automatically reduce the
power output if the computed peak Amps exceeds 250A.
This current protection scheme operates in addition to the Continuous Current Limitation
described above.
Regeneration Current Limiting
The AX2500/2850’s current sensor is capable of measuring current in the reverse flow
(regeneration). Using this capability, the controller will automatically relax the braking effect
of the power output stage to keep the regeneration current within safe values. Because of
the controller’s high current handling capabilities, this regeneration mechanism activates
only when abrupt deceleration are applied to high-inertia, ultra-low impedance motors.
Programmable Acceleration
When changing speed command, the AX2500/2850 will go from the present speed to the
desired one at a user selectable acceleration. This feature is necessary in order to minimize
the surge current and mechanical stress during abrupt speed changes.
This parameter can be changed using the controller’s front switches or using serial com-
from very soft(0) to very quick (6). The AX2500/2850’s factory default value is medium soft
(2).
When using the serial port, acceleration can be one of 24 possible values, selectable using
the Roborun utility, or entering directly a value in the MCU’s configuration EEPROM.
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Programmable Acceleration
Numerically speaking, each acceleration value corresponds to a fixed percentage speed
increment, applied every 16 milliseconds. The value for each setting is shown in the table
below.
TABLE 8. Acceleration setting table
Acceleration
Setting Using
RS232
Acceleration
Setting Using
Switches
%Acceleration
per 16ms
Time from 0 to
max speed
30 Hex
20 Hex
10 Hex
00 Hex
31 Hex
21 Hex
11 Hex
01 Hex
32 Hex
22 Hex
12 Hex
02 Hex
33 Hex
23 Hex
13 Hex
03 Hex
34 Hex
24 Hex
14 Hex
04 Hex
35 Hex
25 Hex
15 Hex
05 Hex
0.78%
1.56%
2.05 seconds
1.02 seconds
0.68 second
0.51 second
0.41 second
0.34 second
0.29 second
0.26 second
0.23 second
0.20 second
0.19 second
0.17 second
0.16 second
0.15 second
0.14 second
0.128 second
0.120 second
0.113 second
0.107 second
0.102 second
0.097 second
0.093 second
0.089 second
0.085 second
2.34%
3.13%
3.91%
4.69%
5.47%
6.25%
7.03%
0
1
-
-
7.81%
-
8.59%
9.38%
10.16%
10.94%
11.72%
12.50%
13.28%
14.06%
14.84%
15.63%
16.41%
17.19%
17.97%
18.75%
2 (default)
-
-
-
3
-
-
-
4
-
-
-
5
When configuring the acceleration parameter using the Roborun utility, for additional accel-
eration steps can be selected between the six ones selectable using the switch, extending
page 164 for details on how to configure this parameter using Roborun.
Important Warning
Depending on the load’s weight and inertia, a quick acceleration can cause consider-
able current surges from the batteries into the motor. A quick deceleration will cause
an equally large, or possibly larger, regeneration current surge. Always experiment
with the lowest acceleration value first and settle for the slowest acceptable value.
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General Operation
Command Control Curves
The AX2500/2850 can also be set to translate the joystick or RS232 motor commands so
that the motors respond differently whether the joystick is near the center or near the
extremes.
The controller can be configured to use one of 5 different curves independently set for
each channel.
The factory default curve is a “linear” straight line, meaning that after the joystick has
moved passed the deadband point, the motor’s speed will change proportionally to the joy-
stick position.
Two “exponential’ curves, a weak and a strong, are supported. Using these curves, and
after the joystick has moved past the deadband, the motor speed will first increase slowly,
increasing faster as the joystick moves near the extreme position. Exponential curves allow
better control at slow speed while maintaining the robot’s ability to run at maximum speed.
Two “logarithmic” curves, a weak and a strong, are supported. Using these curves, and
after the joystick has moved past the deadpoint, the motor speed will increase rapidly, and
then increase less rapidly as the joystick moves near the extreme position.
The graph below shows the details of these curves and their effect on the output power as
the joystick is moved from its center position to either extreme. The graph is for one joy-
stick only. The graph also shows the effect of the deadband setting.
% Forward
(Motor Output)
100
80
Logarithmic Strong
Logarithmic Weak
60
Linear (default)
40
Exponential Weak
Exponential Strong
20
% Command Input
0
20
Deadband
40
60
80
100
% Reverse
FIGURE 16. Exponentiation curves
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Left / Right Tuning Adjustment
The AX2500/2850 is delivered with the “linear” curves selected for both joystick channels.
To select different curves, you will need to change the values of “E” (channel 1) and “F”
page 159 for instructions on how to program parameters into the controller.
TABLE 9. Exponent selection table
Exponentiation Parameter Value
Selected Curve
E or F = 0
E or F = 1
E or F = 2
E or F = 3
E or F = 4
Linear (no exponentiation) - default value
strong exponential
normal exponential
normal logarithmic
strong logarithmic
Left / Right Tuning Adjustment
By design, DC motors will run more efficiently in one direction than the other. In most situ-
ations this is not noticeable. In others, however, it can be an inconvenience. When operat-
ing in open loop speed control, the AX2500/2850 can be configured to correct the speed in
one direction versus the other by as much as 10%. Unlike the Joystick center trimming tab
that is found on all R/C transmitters, and which is actually an offset correction, the Left/
Right Adjustment is a true multiplication factor as shown in Figure 17
% Forward
% Forward
(Motor Output)
100
(Motor Output)
0%
-3%
100
-5.25%
80
60
40
20
80
60
40
20
% Command Input
0
0
20
20
40
60
80
40
60
80
5.25%
3%
100
100
% Reverse
% Reverse
0%
% Forward
(Motor Output)
FIGURE 17. Left Right adjustment curves
The curves on the left show how a given forward direction command value will cause the
motor to spin 3 or 5.25% slower than the same command value applied in the reverse
direction. The curves on the right show how the same command applied to the forward
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General Operation
direction will case the motor to spin 3 to 5.25% faster than the same command applied in
the reverse direction. Note that since the motors cannot be made to spin faster than
100%, the reverse direction is the one that is actually slowed down.
In applications where two motors are used in a mixed mode for steering, the Left/Right
Adjustment parameter may be used to make the robot go straight in case of a natural ten-
dency to steer slightly to the left or to the right.
The Left/Right adjustment parameter can be set from -5.25% to +5.25% in seven steps of
The Left/Right adjustment is performed in addition to the other command curves described
in this section. This adjustment is disabled when the controller operates in any of the sup-
ported closed loop modes.
TABLE 10. Left/Right Adjustment Parameter selection
Parameter Value
Speed Adjustment
Parameter Value
Speed Adjustment
None (default)
0.75%
7
0
1
2
3
4
5
6
-5.25%
-4.5%
-3.75%
-3%
8
9
1.5%
10
11
12
12
14
2.25%
3%
-2.25%
-1.5%
3.75%
4.5%
-0.75%
5.25%
Emergency Shut Down Using Controller Switches
In case of emergency, it is possibly to cause the controller to cut off the power to the
motors by depressing the Program and Set buttons simultaneously as shown in the figure
below. The controller will stop immediately without delay.
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Emergency Stop using External Switch
Program Set
Reset
Press the two buttons
simultaneously to cause an
emergency stop
FIGURE 18. Activating an Emergency Stop
After and Emergency Stop condition, the controller must be reset or powered Off
and On to resume normal operation.
Emergency Stop using External Switch
An external switch can be added to the AX2500/2850 to allow the operator to stop the con-
troller’s output in case of emergency. This controller input can be configured as the
“Inverted” detection instead of Emergency Stop. The factory default for this input is “No
Action”.
tion and closed to signal an emergency stop command.
After and Emergency Stop condition, the controller must be reset or powered Off
and On to resume normal operation.
Inverted Operation
For robots that can run upside-down, the controller can be configured to reverse the motor
commands using a gravity activated switch when the robot is flipped. This feature is
enabled only in the mixed mode and when the switch is enabled with the proper configura-
the normal position and closed when inverted. When the status of the switch has changed,
the controller will wait until the new status has remained stable for 0.5s before acknowl-
edging it and inverting the commands. This delay is to prevent switch activation triggered
by hits and bounces which may cause the controller to erroneously invert the commands.
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General Operation
Special Use of Accessory Digital Inputs
The AX2500/2850 includes two general purpose digital inputs identified as Input E and
Input F. On the AX2850, input E is disabled. The location of these inputs on the DB15 con-
By default, these inputs are ignored by the controller. However, the AX2500/2850 may be
configured to cause either of the following actions:
•
Activate the buffered Output D (Output D is not available when Encoder module is
installed)
•
or Turn Off/On the power MOSFET transistors
Using the Inputs to Activate the Buffered Output
When this setting is selected, the buffered Output C will be On when the Input line is
pulled to Ground (0V). The Output will be Off when the Input is pulled high.
This function makes it possible to drive solenoids or other accessories up to 2A at 24V
using a very low current switch, for example.
Using the Inputs to turn Off/On the Power MOSFET transistors
When this setting is selected, the controller’s Power MOSFET transistors will be active,
and the controller will be operating normally, only when the input is pulled to ground.
When the input is pulled high, all the power MOSFETs are turned Off so that the motors
are effectively disconnected from the controller.
This function is typically used to create a “dead man switch” when the controller is driven
using an analog joystick. The motors will be active only while the switch is depressed. If
the switch is left off for any reason, the motors will be disconnected and allowed to free-
wheel rather than coming to an abrupt stop.
Self-Test Mode
The AX2500/2850 incorporates a simple Self-Test mode that performs the following func-
tions:
•
•
•
Display the software revision number on the LED display
Ramp each motor up and down in both directions
Internal parameters on the serial port output
The Self Test mode can be conveniently initiated using only the controller’s switches so
that no radio or computer is needed.
To enter the Self Test mode, press and hold the Set button while resetting or powering up
the controller.
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Self-Test Mode
After a few seconds, the LEDs will display a sequence of two numerical digits and an
optional letter separated by dashes as shown in the examples below.
= Software version 1.7
FIGURE 20. Press and hold “Set” to display version number and enter self-test
After these digits are displayed, the controller will attempt to power the motors. Motor 1
will be ramped from stop to full speed forward, to full speed reverse and back to stop.
Then the same operation will repeat on motor 2. After both motors have completed their
ramps, the software revision will be displayed again and the motors will be ramped again.
This sequence will repeat itself indefinitely until the controller is powered off or reset.
While in the Self Test mode, the AX2500/2850 will continuously send a string of characters
on the RS232 output line. This string will contain 12 or 13 two-digits hexadecimal number
representing the 13 following operating parameters.
•
•
•
•
•
•
•
•
Captured R/C Command 1 and 2
Power Applied to Controller’s output stage
Values applied to Analog inputs 1 and 2
Amps on channel 1 and 2
Internal Heat Sink temperatures 1 and 2
Main Battery voltage
Internal 12V voltage
Encoder Speed or Position if module is installed
The entire string is repeated every 208 or 224 milliseconds (depending whether the
encoder module is present) with the latest internal parameter values. This information can
Important Warning
Disconnect the Motor Power (thick red wires) from the battery and power the con-
troller by applying 12V on the Power Control input if you do not wish the motors to
be activated while in Self Test mode.
This could be the case if you only wish to use the Self Test sequence to read the software
revision number or to monitor the joystick capture.
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General Operation
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AX2500/2850 Connections
SECTION 5
Connecting
Sensors and
Actuators to
Input/Outputs
This section describes the various inputs and outputs and provides guidance on how to
connect sensors, actuators or other accessories to them.
AX2500/2850 Connections
The AX2500/2850 uses a set of power wires (located on the back of the unit) and a DB15
connector for all necessary connections. The diagram on the figure below shows a typical
wiring diagram of a mobile robot using the AX2500/2850 controller.
The wires are used for connection to the batteries and motors and will typically carry large
The DB15 connector is used for all low-voltage, low-current connections to the Radio,
Microcontroller, sensors and accessories. This section covers only the connections to sen-
sors and actuators.
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Connecting Sensors and Actuators to Input/Outputs
2
1
3
4
3
t
t
e
es
R
t
e
S
5
m
gra
o
Pr
7
9
8
6
1- DC Motors
5- Controller
2- Optional sensors:
6- R/C Radio Receiver, microcomputer, or
wireless modem
- Tachometers (Closed loop Speed mode)
- Potentiometers (Servo mode)
- Optical Encoder (AX2850 only - all closed
loop modes)
7- Command: RS-232, R/C Pulse
8- Miscellaneous I/O
9- Running Inverted, or emergency stop
switch
3- Motor Power supply wires
4- Power Control wire
FIGURE 21. Typical controller connections
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AX2500/2850’s Inputs and Outputs
AX2500/2850’s Inputs and Outputs
In addition to the RS232 and R/C channel communication lines, the AX2500/2850 includes
several inputs and outputs for various sensors and actuators. Depending on the selected
operating mode, some of these I/Os provide feedback and/or safety information to the con-
troller.
When the controller operates in modes that do not use these I/O, these signals become
available for user application. Below is a summary of the available signals and the modes in
which they are used by the controller or available to the user.
TABLE 11. AX2500/2850 I/O functions
Signal
I/O type
2A Digital Output User
defined
User
Use
Activated
Out C
Always active. Activated using R/C channel 3 (R/C
mode), or serial command (RS232 mode)
Out D
Inp F
Low Current
Always active. Activated using R/C channel 3 (R/C
mode), or serial command (RS232 mode) - (Not
available on AX2850)
Digital Output
defined
Digital Input
User
Active in RS232 mode only. Read with serial com-
mand (RS232)
defined
Activate
When Input is configured to drive Output C
Output C
Turn FETs
On/Off
When Input is configured as “dead man switch”
input
Inp E
Digital Input
Digital Input
Same as Input F - (Not available on AX2850)
EStop/Invert
Emer-
When Input is configured as Emergency Stop
gency stop
switch input.
Invert
Controls
When Input is configured as Invert Controls
switch input.
User
defined
When input is configured as general purpose.
Read with serial command (RS232).
Sensor 1
Analog Input
Tachome-
ters input
When Channel 1 is configured in Closed Loop
Speed Control
Position
sensing
When Channel 1 is configured in Closed Loop
Position Control
Tempera-
ture sensor
When Channel 1 is configured is Open Loop
Speed Control and Motor Temperature protection
is enabled
User
defined
When Channel 1 is configured as Open Loop
Speed Control and Temperature protection is dis-
abled. Read with serial command (RS232).
Sensor 2
Analog Input
Same as Sensor 1
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Connecting Sensors and Actuators to Input/Outputs
I/O List and Pin Assignment
The figure and table below lists all the inputs and outputs that are available on the AX2500/
2850.
9
15
8
Pin1
FIGURE 22. Controller’s DB15 connector pin numbering
TABLE 12. DB15 connector pin assignment
Pin
Number
Wire
Color*
Input or
Output
Signal
Description
1 and 9
Orange
Output
Output C
2A Accessory Output C
RS232 Data Logging Output
RS232 Data Out
R/C: RS232 data
RS232: Data Out
Analog: RS232 Out
R/C: Ch 1
2
White
Output
RS232 Data Logging Output
R/C radio Channel 1 pulses
RS232 Data In (from PC/MCU)
Unused
3
4
Input
Input
RS232: Data In
Analog: Unused
R/C: Ch 2
R/C radio Channel 2 pulses
Digital Input F in RS232 mode
Controller ground (-)
Purple
Black
Ana/RS232: Input F
Ground
5 and 13
Power Out
Power In
Power In
6
7
Ground
Connect to pin 5**
+5V
Connect to pin 14**
R/C: Ch 3
R/C radio Channel 3 pulses - (Not avail-
able on AX2850)
8
Gray
Input
Input E
Accessory input E in RS232 mode
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Connecting devices to Output C
TABLE 12. DB15 connector pin assignment
Pin
Number
Wire
Color*
Input or
Output
Signal
Description
RC/RS232: Ana in 2
Channel 2 speed, position or temp
input
10
11
Green
Blue
Analog in
Analog in
Analog: Command 2
RC/RS232: Ana in 1
Analog command for channel 2
Channel 1 speed, position or temp
input
Analog: Command 1
Output D
Analog command for channel 1
12
Yellow
Output
Low Current Accessory Output D -
(Not available on AX2850)
14
15
Red
Power Out
Input
+5V
+5V Power Output (100mA max.)
Brown
Input EStop/Inv
Emergency Stop or Invert Switch input
*The wire colors are those used by Roboteq on our prefabricated cables. It is recom-
mended you use these colors for consistency.
**These connections should only be done in RS232 mode or R/C mode with radio pow-
ered from the controller. Otherwise connect to radio battery.
Connecting devices to Output C
Output C is a buffered, Open Drain MOSFET output capable of driving over 2A at up to 24V.
Relay, Valve
Motor, Solenoid
or other Inductive Load
Lights, LEDs, or any other
non-inductive load
+
+
-
5 to
24V
DC
5 to
24V
DC
AX2500 Internal
MOSFET
AX2500 Internal
MOSFET
Output C 1,9
Ground 5
Output C 1,9
Ground 5
-
FIGURE 23. Connecting inductive and resistive loads to Output C
This output can be turned On and Off using the Channel 3 Joystick when in the R/C mode.
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Connecting Sensors and Actuators to Input/Outputs
When the controller is used in RS232 mode, this output can be turned On and Off using
more information.
Important warning:
This output is unprotected. If your load draws more than 2A, permanent damage
may occur to the power transistor inside the controller. A 1A fuse may be used in
series with the load for increased protection.
Overvoltage spikes induced by switching inductive loads, such as solenoids or
relays, will destroy the transistor unless a protection diode is used.
Connecting devices to Output D
Output D is a low-current, unbuffered output. When Off, this output will be pulled to
ground through a 10Kohm resistor. When On, this output will be pulled to around 4.5V
through that same resistor.
The D output cannot drive any load directly and requires an external transistor or solid state
relay to drive high current accessories. Because they are external, the size, voltage, and
power of these transistors can be selected to best suit a particular need.
a Power MOSFET widely available at most electronic component distributors. The MOS-
FET must conduct with a gate voltage of 4V or higher.
The D output can be toggled On and Off using the Channel 3 Joystick when in the R/C
When the controller is used in RS232 mode, this output can be turned On and Off using
more information.
Use Diode for Relay, Valve
Motor, Solenoid
or other Inductive Load
+
AX2500 Internal
5 to
24V
DC
Buffer and Resistor
IRF1010
10kOhm
Output D 12
-
1MOhm
Ground 5
FIGURE 24. Connecting external MOSFET and load to Output D
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Connecting Switches or Devices to Input E
This output is not available on the AX2850 or on the AX2550 with the Encoder Mod-
ule installed.
Connecting Switches or Devices to Input E
Input E is a general purpose, digital input. This input is only active when in the RS232 and
Analog modes. In R/C mode, this line is used as the radio channel 3 input.
Input E is a high impedance input with a pull-up resistor built into the controller. Therefore
essary to activate it.
+5V Out 14
10kOhm
10kOhm
Input E 8
AX2500 Internal
Buffer and Resistors
Ground
5
FIGURE 25. Switch wirings to Input E
The status of Input E can be read in the RS232 mode with the ?i command string. The con-
troller will respond with three sets of 2 digit numbers. The status of Input E is contained in
the first set of numbers and may be 00 to indicate an Off state, or 01 to indicate an On
state.
This input is not available on the AX2850 or on the AX2550 with the Encoder Module
installed.
Connecting Switches or Devices to Input F
Input F is a general purpose digital input. This input is only active when in the RS232 mode.
In R/C mode, this line is used as the radio channel 2 input.
Input F is an opto-coupled input and requires the opto coupler buffer to be powered for it to
Seen from the outside, Input F is similar to input E, but with a lower impedance of
10kOhm. If left unconnected, this input will report an Off state. As a result, this input may
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Connecting Sensors and Actuators to Input/Outputs
be activated by a simple switch connected to +5V and no external resistor, as show in the
Figure.
+5V Out 14
AX2500 Internal
Buffer equivalent
Circuit
+5V In 7
Input F 4
10kOhm
Opto
GND In 6
GND Out 5
FIGURE 26. Switch wiring to Input F
The status of Input F can be read in the RS232 mode with the ?i command string. The con-
troller will respond with three sets of 2 digit numbers. The status of Input F is contained in
the second set of numbers and may be 00 to indicate an Off state, or 01 to indicate an On
state.
Connecting Switches or Devices to EStop/Invert Input
This input is used to connect various switches or devices depending on the selected con-
troller configuration.
The factory default for this input is “No Action”.
This input can also be configured to be used with an optional “inverted” sensor switch.
When activated, this will cause the controls to be inverted so that the robot may be driven
upside-down.
When neither Emergency Stop or Inverted modes are selected, this input becomes a gen-
eral purpose input like the other two described above.
This input is a high impedance input with a pull-up resistor built into the controller. There-
fore it will report an On state (no emergency stop, or not inverted) if unconnected. A sim-
Emergency Stop, or to detect robot inversion this input must be pulled to ground.
Figure 27 show how to wire the switch to this input.
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Connecting Position Potentiometers to Analog Inputs
AX2500 Internal
Buffer and Resistor
+5V 14
10kOhm
Input
EStop/Inv 15
Ground 5
FIGURE 27. Emergency Stop / Invert switch wiring
The status of the EStop/Inv can be read at all times in the RS232 mode with the ?i com-
mand string. The controller will respond with three sets of 2 digit numbers. The status of
the ES/Inv Input is contained in the last set of numbers and may be 00 to indicate an Off
state, or 01 to indicate an On state.
Connecting Position Potentiometers to Analog Inputs
When configured in the Position mode, the controller’s analog inputs are used to obtain
position information from a potentiometer coupled to the motor axle. This feature is useful
in order to create very powerful servos as proposed in the figure below:
Position Feedback
Potentiometer
Gear box
FIGURE 28. Motor and potentiometer assembly for position servo operation
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Connecting Sensors and Actuators to Input/Outputs
Connecting the potentiometer to the controller is as simple as shown in the diagram on
+5V 14
AX2500 Internal Resistors
and Converter
Input Pos 1 11
or Pos 2 10
47kOhm
A/D
10kOhm
10kOhm
47kOhm
Ground 5
FIGURE 29. Potentiometer wiring in Position mode
The potentiometer must be attached to the motor frame so that its body does not move in
relationship with the motor. The potentiometer axle must be firmly connected to the gear
box output shaft. The gearbox must be as tight as possible so that rotation of the motor
translates into direct changes to the potentiometers, without slack, at the gearbox’s out-
put.
ing and operation.
Important Warning
Beware that the wrong + and - polarity on the potentiometer will cause the motor to
turn in the wrong direction and not stop. The best method to figure out the right
potentiometer is try one way and change the polarity if incorrect. Note that while
you are doing these tests, the potentiometer must be loosely attached to the
motor’s axle so that it will not be forced and broken by the motor’s uncontrolled
rotation in case it was wired wrong.
Connecting Tachometer to Analog Inputs
When operating in closed loop speed mode, tachometers must be connected to the con-
troller to report the measured motor speed. The tachometer can be a good quality brushed
DC motor used as a generator. The tachometer shaft must be directly tied to that of the
motor with the least possible slack.
Since the controller only accepts a 0 to 5V positive voltage as its input, the circuit shown in
Figure 30 must be used between the controller and the tachometer: a 10kOhm potentiom-
eter is used to scale the tachometer output voltage to -2.5V (max reverse speed) and
+2.5V (max forward speed). The two 1kOhm resistors form a voltage divider that sets the
idle voltage at mid-point (2.5V), which is interpreted as the zero position by the controller.
The voltage divider resistors should be of 1% tolerance or better. To precisely adjust the
2.5V midpoint value it is recommended to add a 100 ohm trimmer on the voltage divider.
With this circuitry, the controller will see 2.5V at its input when the tachometer is stopped,
0V when running in full reverse, and +5V in full forward.
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Connecting External Thermistor to Analog Inputs
+5V 14
1kOhm
AX2500 Internal Resistors
and Converter
Max Speed Adjust
10kOhm pot
Input Ana 1 11
47kOhm
or Ana 2 10
0 Adjust
100 Ohm pot
Tach
A/D
10kOhm
47kOhm
1kOhm
Ground 5
FIGURE 30. Tachometer wiring diagram
The tachometers can generate voltages in excess of 2.5 volts at full speed. It is important,
therefore, to set the potentiometer to the minimum value (cursor all the way down per this
drawing) during the first installation.
Since in closed loop control the measured speed is the basis for the controller’s power out-
put (i.e. deliver more power if slower than desired speed, less if higher), an adjustment and
Important Warning
The tachometer’s polarity must be such that a positive voltage is generated to the
controller’s input when the motor is rotating in the forward direction. If the polarity
is inverted, this will cause the motor to run away to the maximum speed as soon as
the controller is powered with no way of stopping it other than pressing the emer-
gency stop button or disconnecting the power.
Connecting External Thermistor to Analog Inputs
Using external thermistors, the AX2500/2850 can be made to supervise the motor’s tem-
perature and adjust the power output in case of overheating. Connecting thermistors is
10kOhm Negative Coefficient Thermistor (NTC) with the temperature/resistance character-
istics shown in the table below. This 10kOhm thermistor model can be found at the com-
ponent section of every Radio Shack stores under the product reference 271-110A.
TABLE 13. Recommended NTC characteristics
Temp (oC)
-25
0
25
50
75
100
Resistance (kOhm)
86.39
27.28
10.00
4.16
1.92
0.93
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Connecting Sensors and Actuators to Input/Outputs
+5V 14
AX2500 Internal Resistors
and Converter
10kOhm
Input Ana 1 11
47kOhm
or Ana 2 10
A/D
10kOhm
10kOhm
NTC
Thermistor
47kOhm
Ground 5
FIGURE 31. NTC Thermistor wiring diagram
will read the following values (represented in signed binary) according to the temperature.
100
50
0
-50
-100
-150
Temperature in Degrees C
FIGURE 32. Signed binary reading by controller vs. NTC temperature
To read the temperature, use the ?p command to have the controller return the A/D con-
verter’s value. The value is a signed 8-bit hexadecimal value. Use the chart data to convert
the raw reading into a temperature value.
Using the Analog Inputs to Monitor External Voltages
The analog inputs may also be used to monitor the battery level or any other DC voltage. In
this mode, the controller does not use the voltage information but merely makes it avail-
able to the host microcomputer via the RS232 port. The recommended schematic is
shown in Figure 33.
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Connecting User Devices to Analog Inputs
To Battery
+Terminal
+5V 14
AX2500 Internal Resistors
and Converter
47kOhm
4.7kOhm
10
or 11
47kOhm
A/D
10kOhm
47kOhm
Ground 5
FIGURE 33. Battery voltage monitoring circuit
Using these resistor values, it is possible to measure a voltage ranging from -5V to +60V
with a 0.25V resolution. The formula for converting the A/D reading into a voltage value is
as follows.
Measured volts = ((controller reading + 128) * 0.255) -5
Note: The A/D converter’s reading is returned by the ?p command and is a signed 8-bit
hexadecimal value. You must add 128 to bring its range from -127/+127 to 0/255.
Connecting User Devices to Analog Inputs
The two analog inputs can be used for any other purpose. The equivalent circuit for each
value of 0 at 0V and 255 at +5V. Care should be taken that the input voltage is always posi-
tive and does not exceed 5V. The converter’s intrinsic diodes will clip any negative voltage
or voltage above 5V, thus providing limited protection. The value of the analog inputs can
be read through the controller’s RS232 port.
+5V 14
Input Ana 1 11
or Ana 2 10
47kOhm
A/D
10kOhm
47kOhm
Ground 5
FIGURE 34. AX2500/2850 Analog Input equivalent circuit
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Connecting Sensors and Actuators to Input/Outputs
Internal Voltage Monitoring Sensors
The AX2500/2850 incorporates voltage sensors that monitor the Main Battery voltage and
the Internal 12V supply. This information is used by the controller to protect it against over-
port using the ?e query.
The returned value are numbers ranging from 0 to 255. To convert these numbers into a
Voltage figure, the following formulas must be used:
Measured Main Battery Volts = 55 * Read Value / 256
Measured Internal Volts = 28.5 * Read Value / 256
Internal Heatsink Temperature Sensors
The AX2500/2850 includes temperature sensors making contact with the each of the two
Heatsink sides of the controller.
These sensors are used to automatically reduce the maximum Amps that the controller
can deliver as it overheats. However, the temperature can be read using the RS232 port
The analog value that is reported will range from 0 (warmest) to 255 (coldest). Because of
the non-linear characteristics of NTC thermistors, the conversion from measured value to
temperature must be done using the correction curve below.
It should be noted that the temperature is measured inside the controller and that it may
be temporarily be different than the temperature measured outside the case.
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Temperature Conversion C Source Code
300
250
200
150
100
50
0
0
0
0
0
0
0
0
0
0
0
0
10
20
30
40
50
60
70
80
90
-4
-3
-2
-1
10
11
12
13
14
15
Temperature in Degrees C
FIGURE 35. Analog reading by controller vs. internal heat sink temperature
Temperature Conversion C Source Code
The code below can be used to convert the analog reading into temperature. It is provided
for reference only. Interpolation table is for the internal thermistors.
int ValToHSTemp(int AnaValue)
{
// Interpolation table. Analog readings at -40 to 150 oC, in 5o intervals
int TempTable[39] ={248, 246, 243, 240, 235, 230, 224, 217, 208, 199, 188, 177,
165, 153, 140, 128, 116, 104,93, 83, 74, 65, 58, 51, 45, 40, 35, 31, 27, 24, 21,
19, 17, 15, 13, 12, 11, 9, 8};
int LoTemp, HiTemp, lobound, hibound, temp, i;
i = 38;
while (TempTable[i] < AnaValue && i > 0)
i--;
if (i < 0)
i = 0;
if (i == 38)
return 150;
else
{
LoTemp = i * 5 - 40;
HiTemp = LoTemp + 5;
lobound = TempTable[i];
hibound = TempTable[i+1];
temp = LoTemp + (5 * ((AnaValue - lobound)*100/ (hibound - lobound)))/100;
return temp;
}
}
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Use of the LED Display
SECTION 6
Normal and
Fault Condition
LED Messages
This section discusses the meaning of the various messages and codes that may be dis-
played on the LED display during normal operation and fault conditions.
Use of the LED Display
The AX2500/2850 uses a single 7-segment LED display to report a number of operating or
fault conditions. The type of reported information depends on the controller’s operating
context:
During normal motor operation:
•
Motor direction
During Parameter Settings
•
Selected parameter and its value
In R/C mode with Radio off
•
No control message
During Error condition
•
Error condition (overheat, emergency stop, short circuit)
During Self-Test mode
•
•
Software revision number
Motor direction
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Normal and Fault Condition LED Messages
Motor Direction Status
When the controller is running, two pairs of LED segments are directly related to com-
mand informations to the Power Output stage. The position and meaning of the segments
is shown in the figure below.
Motor 2
Direction
Lit: Forward
Off: Reverse
Motor 1
Direction
Lit: Forward
Off: Reverse
FIGURE 1. Each command bit is wired to 2 LED segments
Note that the display does not provide Power information. Therefore it is possible that the
motor be stopped while the display indicates that the direction is forward. In such a situa-
tion is set to apply the power in the forward direction to the output stage but the motor is
stopped because the applied power is zero.
The LED can display a total of 5 patterns summarized in Table 14.
TABLE 14. Motor Commands and resulting display
Possible Display Motor 1 Motor 2
Comment
Is also displayed when con-
troller is active with a 0 com-
mand on each channel (i.e.
motors at speed 0)
Forward
Forward
Reversed
Forward
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Fault Messages
TABLE 14. Motor Commands and resulting display
Possible Display
Motor 1
Motor 2
Comment
Forward
Reversed
Reversed
Reversed
MOSFET Transistors are OFF
Will occur during Overvolt-
age or Undervoltage condi-
Dead-man switch is acti-
vated (see page 46)
Motors are freewheeling
Fault Messages
The AX2500/2850 uses the LED display to report fault conditions. When these messages
are displayed, the motors are normally stopped.
No Control
This message is displayed in the R/C mode to indicate that no valid radio signal has been
detected at its inputs, or that radio signal has been lost. When the controller is configured
in the mixed mode, signals on channel 1 and channel 2 must be present to enable the con-
troller. When the controller is configured in the separate mode, a signal received on either
channel will enable the controller. When enabled, the controller will display the normal
motor status described previously.
The “no control” messages is displayed using the following sequence of digits.
FIGURE 36. No Radio signal scrolling message
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Normal and Fault Condition LED Messages
Emergency Stop
The “Emergency Stop” message is displayed after the motors have stopped following an
sage is displayed using the following sequence of digits.
FIGURE 37. Emergency Stop scrolling message
Self-Test Display
Self test is a special condition that is entered by holding the Program and Set button imme-
diately after power-on or reset. During self test, the LEDs will display the controller’s soft-
ware revision number by flashing a sequence of digits as shown in the figure below. Then
the each motor will, in turn, be ramped to maximum forward and maximum reverse. When
the motors are operating, the LED will display one of the patterns described in Table 14.
The cycle will repeat indefinitely until the controller is powered Off or reset.
= Software version 1.7
= Software version 2.0.c
FIGURE 38. Example of Software revision number display
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Mode Description
SECTION 7
R/C Operation
This section describes the controller’s wiring and functions specific to the R/C radio control
mode.
Mode Description
The AX2500/2850 can be directly connected to an R/C receiver. In this mode, the speed or
position information is contained in pulses whose width varies proportionally with the joy-
sticks’ positions. The AX2500/2850 mode is compatible with all popular brands of R/C
transmitters. A third R/C channel can be used to control the On/Off state of two outputs
that may be connected to electrical accessories (valves, lights, weapons,...)
The R/C mode provides the simplest method for remotely controlling a robotic vehicle: little
else is required other than connecting the controller to the R/C receiver (using the provided
cable) and powering it On. For better control and improved safety, the AX2500/2850 can be
configured to perform correction on the controls and will continuously monitor the trans-
mission for errors.
FIGURE 39. R/C radio control mode
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R/C Operation
Selecting the R/C Input Mode
The R/C Input Mode is the factory default setting.
If the controller has been previously set to a different Input Mode, it will be necessary to
reset it to the R/C mode using one of the following methods:
•
Restoring the factory defaults by pressing and holding the Program and Set but-
tons while powering on the controller until the LED display flashes
•
Setting the “I” parameter to the value “0” using one of several methods described
Typical Wiring
The diagram below shows all the required and optional connections when using the R/C
mode.
1 or 2
DC Motors
Speed , Position or
Temperature Sensors (Optional)
Controller Power
Control
Common Power Supply
for both Motor Channels
t
e
s
e
R
t
e
S
m
a
r
g
o
r
P
R/C Receiver
R/C Receiver
Battery (Optional)
1 or 2 user
accessory
(Optional)
"Emergency Stop"
or "Inverted" Switch
(Optional)
The required connections are the following:
a 12V to 40V to Main Battery
•
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Connector I/O Pin Assignment (R/C Mode)
•
•
•
at least one motor
optional 12V backup power supply for the controller
R/C radio
R/C radio is further detailed n this chapter.
The optional connections are the following:
•
•
•
•
•
•
•
optional 12V backup power supply for the controller
the speed or position sensors required for closed loop speed or position operation
1 or 2 electrical accessory (valve, weapon, solenoid, ...)
thermistor for motor temperature monitoring
gravity actuated switch for detecting inverted operation
manual switch for emergency stop
the R/C receiver’s battery may also be omitted by using the power output available
on the controller’s connector
Connector I/O Pin Assignment (R/C Mode)
9
15
Pin1
8
FIGURE 40. Pin locations on the controller’s 15-pin connector
When used in R/C mode, the pins on the controller’s DB15 connector are mapped as
described in the table below
TABLE 15. Connector pin-out in R/C mode
Pin
Number
Input or
Output
Signal
Description
1
2
3
Output C
Output
Output
Input
2A Accessory Output C (same as pin 9)
Optional. Used for Data Logging
Channel 1 input pulse (isolated)
RS232 Out
R/C Channel 1
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R/C Operation
TABLE 15. Connector pin-out in R/C mode
Pin
Number
Input or
Output
Signal
Description
4
5
6
7
8
R/C Channel 2
Ground
Input
Channel 1 input pulse (isolated)
Controller ground (-)
Power
R/C -
Power Input
Power Input
Input
R/C Battery input - (isolated)
R/C Battery input + (isolated)
R/C +
R/C Channel 3
Channel 3 input for On/Off accessories - Not avail-
able on AX2850.
9
Output C
Output
2A Accessory Output C (same as pin 1)
Channel 2 speed, position or temp feedback
Channel 1 speed, position or temp feedback
10
11
12
Speed/Pos/T 2
Speed/Pos/T 1
Output D
Analog in
Analog in
Output
Low Current Accessory Output D - Not available
on AX2850.
13
14
15
Ground
+5V
Power
Controller ground (-)
Power Output
Input
+5V Power Output (100mA max.)
Emergency Stop or Invert Switch input
Switch Input
R/C Input Circuit Description
The AX2500/2850 includes an optical isolation barrier on the Channel 1 and Channel 2 R/C
side is powered from the controller’s batteries. The R/C signals 1 and 2 activate a LED
whose light then triggers the photo transistors on the microcontroller side. The left side of
the opto isolators include an amplifier and thus need to be powered separately. Notice that
channel 3 is optional and not opto-isolated.
Optical isolation is designed to protect the R/C radio from damage that may occur inside
the controller, and vice-versa. Additionally, the isolation barrier will help prevent some of
the electrical “noise” generated inside the controller by the Microcontroller and the high
power switching from reaching and interfering with the radio.
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Supplied Cable Description
14
7
Controller
Power
Opto-
Isolators
Isolator Power
R/C Channel 1
3
4
8
6
MCU
R/C Channel 2
R/C Channel 3
Isolator Ground
5-13
Controller
Ground
FIGURE 41. AX2500/2850 R/C Input equivalent circuit
Supplied Cable Description
The AX2500/2850 is delivered with a custom cable that can easily be adapted to operate in
any of the supported isolated and non isolated modes. The figures below show the cable
and its wiring diagram
1
2
3
1
9
8
15
FIGURE 42. Cable wiring diagram
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R/C Operation
.
FIGURE 43. RC connection cable
The wire loop is used to bring power from the controller’s internal power supply to the
optocouplers and to the RC radio. Leaving the loop untouched causes the controller to
operate in non-isolated mode, with power flowing into the RC radio. The following sections
show the various power and isolation modes supported by the controller.
Cabling to R/C Receiver using Full Opto-Isolation
Full opto-isolation is achieved when the radio’s power and ground are totally separated
from the controller’s power and ground.
required.
Channel 3: Do not connect
Channel 2
3:
4:
6:
7:
Channel 1 Command Pulses
Channel 2 Command Pulses
Radio battery (-) Ground
Radio battery (+)
Channel 1
8
Note: Only one set of black and red
(battery) wires needs to be brought
to the connector.
9
Pin 1
Cut loop
15
FIGURE 44. Channel 1 & 2 wiring using external battery and full optical isolation
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Cabling to R/C Receiver with Partial Opto-Isolation
The opto isolators must be powered with a 5V supply for their built-in amplifiers to work.
This power is normally supplied from the R/C radio’s battery as detailed in the diagram on
Note that if full optical isolation is required, it is not possible to connect the third R/C
channel to the radio. Since the 3rd channel is not optoisolated, connecting it to the radio
will cause the radio’s ground to be electrically tied to the controller ground, thus breaking
the optical barrier.
This wiring, with a separate R/C battery, is the preferred method for connecting the R/C
radio.
14
Controller
Power
R/C Radio Power
7
3
Opto-
Isolators
R/C Channel 1
R/C Channel 2
Radio
Battery
R/C Radio
4
8
6
MCU
R/C Radio Ground
5-13
Controller
Ground
FIGURE 45. Fully opto-isolated connection to R/C radio
Cabling to R/C Receiver with Partial Opto-Isolation
This wiring option should be considered only when the Accessory R/C channel (Channel 3)
is required. Since Channel 3 is directly connected to the AX2500/2850’s microcontroller
without opto coupler, it is necessary to connect the radio and controller grounds together
to create a common ground reference for the signal. Since the Channel 3 connector has a
ground wire, this connection will occur when the connector is plugged in the radio. The red
loop wire must be cut to enable that mode. The radio will be powered from its own sepa-
rate battery using this wiring scheme.
By joining the grounds and having the R/C signal connected directly from the radio to the
controller, the full electrical barrier is lost. However, since the radio’s +5V and controller
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R/C Operation
power voltage are still separate, some protection remains should the controller fail and
accidentally generate a high voltage on its +5V output.
Channel 3:
Channel 2
3:
4:
6:
7:
8:
Channel 1 Command Pulses
Channel 2 Command Pulses
Radio battery (-) Ground
Radio battery (+)
Channel 1
Channel 3 Command Pulses
8
9
Pin 1
Cut red loop
15
FIGURE 46. Wiring when Ch 3 is used with radio powered by its own separate battery
14
Controller
Power
R/C Radio Power
7
3
Opto-
Isolators
R/C Channel 1
Radio
Battery
R/C Channel 2
R/C Channel 3
R/C Radio
4
8
6
MCU
R/C Radio Ground
5-13
Controller
Ground
FIGURE 47. Partial opto-isolation with Channel 3 electrical diagram
Powering the Radio from the controller
The 5V power and ground signals that are available on the controller’s connector may be
used to power the R/C radio. The wire loop is used to bring the controller’s power to the
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Powering the Radio from the controller
Channel 3
Channel 2
3:
4:
6:
7:
8:
Channel 1 Command Pulses
Channel 2 Command Pulses
Radio battery (-) Ground
Radio battery (+)
Channel 1
Channel 3 Command Pulses
8
9
Pin 1
Wire loop bringing power from
controller to RC radio and
to optical isolators
15
FIGURE 48. Wiring for powering R/C radio from controller
14
Controller
Power
R/C Radio Power
7
Opto-
Isolators
R/C Channel 1
3
R/C Channel 2
R/C Radio
4
8
6
MCU
R/C Channel 3
R/C Radio Ground
5-13
Controller
Ground
FIGURE 49. R/C Radio powered by controller electrical diagram
Important Warning
Do not connect a battery to the radio when in this mode. The battery voltage will
flow directly into the controller and cause permanent damage if its voltage is higher
than 5.5V.
Notice that in this configuration, the controller’s +5V power and ground are connected to
the floating (opto-isolated) R/C power inputs so that now the radio and the controller are no
longer optically isolated.
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R/C Operation
Losing the optical isolation increase the risks that damage in the controller will reach the
radio, although these risks remain extremely low. Without optical isolation, the radio is less
immune to electrical “noise” and therefore may operate at a reduced range.
This mode of operation is the most convenient and is the one wired in the R/C cable deliv-
ered with the controller.
Operating the Controller in R/C mode
In this operating mode, the AX2500/2850 will accept commands from a Radio Control
receiver used for R/C models remote controls. The speed or position information is com-
municated to the AX2500/2850 by the width of a pulse from the R/C receiver: a pulse
width of 1.0 millisecond indicates the minimum joystick position and 2.0 milliseconds indi-
cates the maximum joystick position. When the joystick is in the center position, the pulse
should be 1.5ms.
Note that the real pulse-length to joystick-position numbers that are generated by your R/C
radio may be different than the ideal 1.0ms to 2.0ms discussed above. To make sure that
the controller captures the full joystick movement, the AX2500/2850 defaults to the timing
values shown in Figure 50.
For best control accuracy, the AX2500/2850 can be calibrated to capture and use your
radio’s specific timing characteristics and store them into its internal Flash memory. This is
done using a simple calibration procedure described on page 82.
joystick position:
min
center max
1.05ms
0.45ms
0.9ms
R/C pulse timing:
FIGURE 50. Joystick position vs. pulse duration default values
The AX2500/2850 has a very accurate pulse capture input and is capable of detecting
changes in joystick position (and therefore pulse width) as small as 0.4%. This resolution is
superior to the one usually found in most low cost R/C transmitters. The AX2500/2850 will
therefore be able to take advantage of the better precision and better control available from
a higher quality R/C radio, although it will work fine with lesser expensive radios as well.
Internally, the measured pulse width is compared to the reference minimum, center and
maximum pulse width values. From this is generated a number ranging from -127 (when
the joystick is in the min. position), to 0 (when the joystick is in the center position) to +127
(when the joystick is in the max position). This number is then used to set the motors’
desired speed or position that the controller will then attempt to reach.
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Reception Watchdog
For best results, reliability and safety, the controller will also perform a series of correc-
tions, adjustments, and checks to the R/C commands, as described in the following sec-
tions.
Reception Watchdog
Immediately after it is powered on, if in the R/C mode, the controller is ready to receive
pulses from the R/C radio and move the motors accordingly.
If no pulses are present, the motors are disabled, and the controller’s display will scroll
FIGURE 51. “No control” message will scroll when no valid radio signal is present
After powering on the R/C radio receiver and transmitter, and if the wiring is correct, the
controller will start receiving pulses. For a preset amount of time, the controller will moni-
tor the pulse train to make sure that they are regular and therefore genuine R/C radio com-
mand pulses. After that, the motors are enabled and the LEDs will display a pattern related
This power-on Watchdog feature prevents the controller from becoming active from para-
site pulses and from moving the motors erratically as a result.
Similarly, if the pulse train is lost while the motors were enabled, the controller will wait a
short preset amount of time before it disables the motors. If the pulses reappear during
that time, the controller continues without any breaks. If the communication is confirmed
lost, the “no ctrl” message is displayed again.
Note: the Accessory Outputs C and D will be turned Off when radio is lost.
Important Notice about PCM Radios
PCM radios have their own watchdog circuitry and will output a signal (normally a
“safe condition” value) when radio communication is lost. This signal will be inter-
preted by the AX2500/2850 as a valid command and the controller will remain active.
To benefit from the AX2500/2850’s radio detection function, you will need to disable
the your PCM radio watchdog.
R/C Transmitter/Receiver Quality Considerations
As discussed earlier in this chapter, the AX2500/2850 will capture the R/C’s command
pulses with great accuracy. It will therefore be able to take advantage of the more precise
joysticks and timings that can be found in higher quality R/C radio, if such added precision
is desired in your application.
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R/C Operation
Another important consideration is the R/C receiver’s ability to operate in an electrically
noisy environment: the AX2500/2850 switches high current at very high frequencies. Such
transients along long battery and motor wires will generate radio frequency noise that may
interfere with the R/C radio signal. The effects may be reduced remote control range and/
or induced errors in the command pulse resulting in jerky motor operation.
A higher quality PCM R/C transmitter/radio is recommended for all professional applica-
tions, as these are more immune to noise and interference.
While a more noise-immune radio system is always desirable, it is also recommended to
layout the wiring, the controller, radio and antenna so that as little electrical noise is gener-
vides a few suggestions for reducing the amount of electrical noise generated in your
robot.
Joystick Deadband Programming
In order to avoid undesired motor activity while the joysticks are centered, the AX2500/
2850 supports a programmable deadband feature. A small deadband is set into the control-
ler by default at the factory. This deadband can be stretched, reduced or eliminated by
changing the “d” parameter using one of the three methods described in the chapter
set deadband values coded 0 to 7. The value 0 disables the deadband. Other values select
a deadband according to the table below. The deadband value applies equally to both joy-
sticks
The deadband is measured as a percentage of total normal joystick travel. For example, a
16% deadband means that the first 16% of joystick motion in either direction will have no
effect on the motors. If the joystick is recalibrated to operate using a shorter travel (see
TABLE 16. Selectable deadband values
Deadband Parameter Value
Deadband as Percent of full Joystick Travel
d = 0
d = 1
d = 2
d = 3
d = 4
d = 5
d = 6
d =7
No deadband
8%
16% - default value
24%
32%
40%
46%
54%
Note that the deadband only affects the start position at which the joystick begins to take
effect. The motor will still reach 100% when the joystick is at its full position. An exagger-
ated illustration of the effect of the deadband on the joystick action is shown in the
Figure 52 below.
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Command Control Curves
Deadband
(no action)
Min
Min
Reverse
Forward
Max
Max
Reverse
Forward
Centered
Position
FIGURE 52. Effect of deadband on joystick position vs. motor speed
Command Control Curves
The AX2500/2850 can also be set to translate the joystick motor commands so that the
motors respond differently whether the joystick is near the center or near the extremes.
Five different exponential or logarithmic translation curves may be applied. Since this fea-
Left/Right Tuning Adjustment
When operating in mixed mode with one motor on each side of the robot, it may happen
that one motor is spinning faster than the other one at identically applied power, causing
the vehicle to pull to the left or to the right.
To compensate for this, the AX2500/2850 can be made to give one side up to 10% more
Joystick Calibration
This feature allows you to program the precise minimum, maximum and center joystick
positions of your R/C transmitter into the controller’s memory. This feature will allow you to
use the full travel of your joystick (i.e. minimum = 100% reverse, maximum = 100% for-
ward). It also ensures that the joystick’s center position does indeed correspond to a “0”
motor command value.
Joystick calibration is also useful for modifying the active joystick travel area. For example,
the figure below shows a transmitter whose joystick’s center position has been moved
back so that the operator has a finer control of the speed in the forward direction than in
the reverse position.
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R/C Operation
There are two methods for calibrating the joysticks:
•
The automatic method is the simplest and is based on the controller “learning” the
joystick’s parameters using the simple training sequence described below.
•
The manual method lets you enter actual timing numbers directly in the controllers
flash memory using your PC running the Roborun configuration utility. This method
New Desired
Center Position
Min
Min
Forward
Reverse
Max
Max
Reverse
Forward
FIGURE 53. Calibration example where more travel is dedicated to forward motion
Automatic Joystick Calibration
To calibrate the joystick(s) follow these steps:
•
•
Press and hold the Program button while resetting or power up the controller
After 10 seconds, the controller will enter the Program mode and flash the first
parameter (I) and its value (0 if set R/C mode)
•
•
Turn the R/C transmitter and receiver On
Press the Program button several times until the letter “J” is displayed. If you
missed it, keep pressing the Program button for another cycle.
•
•
When the display flashes the letter “J” followed by the “-” sign, press the Set but-
ton
When the display flashes the letter “J” followed by “o”, the controller has entered
the joystick calibration mode
•
•
•
Move each joystick to the desired minimum and maximum position several times
Move back the joystick(s) to the desired center position
With the joystick(s) in the center position, press the Program button to record the
change permanently in the controller’s Flash memory.
•
Restart the controller by pressing the Reset button or cycling the power.
To reset the controller to factory default or to program the joystick’s positions using numer-
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Activating the Accessory Outputs
Notes:
If you attempt to calibrate the joysticks while the radio is off or not connected to the con-
troller, the calibration data will not change and the previously stored information will con-
tinue to be used.
If calibration is performed with only one R/C channel connected to the controller, then only
the joystick that is active will be calibrated. The other channel will keep its original settings.
A minimum amount of travel is required between the min, max and center joystick posi-
tions. If, while calibrating, the joystick has not been moved far enough from either side of
the center position, the controller will automatically include a minimum of travel to ensure
proper and safe operation. In most cases, this creates no undesired effect to the driving
characteristics of the robot.
R/C calibration only applies to the channel 1 and channel 2 inputs. The accessory activation
channel (channel 3) is preset at the factory and cannot be changed.
Important Notice
To ensure that only stable pulses are present, the R/C transmitter and radio must be
On before entering joystick calibration.
Activating the Accessory Outputs
The AX2500/2850 has two general purpose outputs that may be turned on and off using a
third R/C channel on the radio.
Output C is a buffered output capable of driving a 2A device at up to 24V. Output D is a
non-buffered output that requires an external relay to drive high current loads. Details on
Both outputs are controlled from a single joystick on Channel 3.
Output C is activated by pushing the joystick to the maximum position. The output turns
back off when the joystick is returned to the center position
Output D is a toggle output. When the joystick is moved from the center to the minimum
position, the output changes state (to On if it was Off, or to Off if it was On). Beware that
because this is a toggling output, it may be accidentally activated by noise in the radio
reception. Use this output to drive safe accessories. Use only with a good quality radio,
such as a PCM radio.
Note: Channel 3 and Output D are not available on the X2850, or on the AX2550 equipped
with the encoder module.
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R/C Operation
No Change
Output D
Output C
OFF
Toggle
Output D
Output C
ON
FIGURE 54. Using Channel 3 to activate accessory outputs
Data Logging in R/C Mode
While in R/C Mode, the AX2500/2850 will continuously send a string of characters on the
RS232 output line. This string will contain 12 two-digits hexadecimal number representing
the 12 following operating parameters.
•
•
•
•
•
•
•
•
Captured R/C Command 1 and 2
Power Applied to Controller’s output stage
Values applied to Analog inputs 1 and 2
Amps on channel 1 and 2
Internal Heat Sink temperatures 1 and 2
Main Battery voltage
Internal 12V voltage
Encoder Speed or Position feedback, if encoder module is present.
The entire string is repeated every 200 milliseconds with the latest internal parameter val-
placed in the mobile robot.
application.
To read the output string while operating the controller with the R/C radio, you must mod-
ify the R/C cable to add an RS232 output wire and connector that will be connected to the
modified R/C cable for connection to a PC or to a PDA, respectively.
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Data Logging in R/C Mode
DB9 Female
To PC
DB15 Male
To AX2550
1
1
2
3
4
5
6
7
8
9
9
10
11
12
13
14
15
2
RS232 Data Out
RX Data
GND
3
4
5
R/C Ch 1
R/C Ch 2
GND
6
7
8
R/C GND
R/C +5V
FIGURE 55. Modified R/C cable with RS232 output for data logging to a PC
DB9 Male
To PDA
DB15 Male
To AX2550
1
1
6
2
7
3
8
4
9
5
9
10
11
12
13
14
15
RX Data
GND
2
RS232 Data Out
3
4
5
R/C Ch 1
R/C Ch 2
GND
6
7
8
R/C GND
R/C +5V
FIGURE 56. Modified R/C cable with RS232 output for data logging to a PDA
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R/C Operation
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Use and benefits of RS232
SECTION 8
Serial (RS-232)
Controls and
Operation
This section describes the communication settings and the commands accepted by the
AX2500/2850 in the RS232 mode of operations. This information is useful if you plan to
write your own controlling software on a PC or microcomputer. These commands will also
allow you to send commands manually using a terminal emulation program. If you wish to
use your PC simply to set parameters and/or to exercise the controller, you should use the
Roborun utility described on page 87.
Use and benefits of RS232
The serial port allows the AX2500/2850 to be connected to microcomputers or wireless
modems. This connection can be used to both send commands and read various status
information in real-time from the controller. The serial mode enables the design of autono-
mous robots or more sophisticated remote controlled robots than is possible using the R/C
mode. RS232 commands are very precise and securely acknowledged by the controller.
They are also the method by which the controller’s features can be accessed and operated
to their fullest extent.
When connecting the controller to a PC, the serial mode makes it easy to perform simple
diagnostics and tests, including:
•
•
•
•
•
•
Sending precise commands to the motors
Reading the current consumption values and other parameters
Obtaining the controller’s software revision and date
Reading inputs and activating outputs
Setting the programmable parameters with a user-friendly graphical interface
Updating the controller’s software
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Serial (RS-232) Controls and Operation
Connector I/O Pin Assignment (RS232 Mode)
9
15
Pin1
8
FIGURE 1. Pin locations on the controller’s 15-pin connector
When used in the RS232 mode, the pins on the controller’s DB15 connector are mapped
as described in the table below
TABLE 17. DB15 Connector pin assignment in RS232 mode
Pin
Number
Input or
Output
Signal
Description
1
Output C
Data Out
Data In
Output
2Amp Accessory Output C (same as pin 9)
RS232 data output from the controller to the PC
RS232 data input to the controller from the PC
Accessory Input F
2
Output
3
Input
4
Input F
Input
5
Ground Out
Ground In
+5V In
Power Output
Power Input
Power Input
Input
Controller ground (-)
6
Must be wired to pin 13 or pin 5
Must be wired to pin 14
7
8
Input E
Accessory input E - (Not available on AX2850)
2Amp Accessory Output C (same as pin 1)
Channel 2 speed, position or temp feedback
Channel 1 speed, position or temp feedback
9
Output C
Speed/Pos/T 2
Speed/Pos/T 1
Output D
Output
10
11
12
Analog in
Analog in
Output
Low Current Accessory Output D - (Not available
on AX2850)
13
14
15
Ground Out
+5V Out
Power
Controller ground (-)
Power Output
Input
+5V Power Output (100mA max.)
Emergency Stop or Invert Switch input
Switch Input
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Cable configuration
Cable configuration
The RS232 connection requires the special cabling as described in the figure below. The 9-
pin female connector plugs into the PC (or other microcontroller). The 15-pin male connec-
tor plugs into the AX2500/2850.
It is critical that you do not confuse the connector’s pin numbering. The pin numbers on
the drawing are based on viewing the connectors from the front (facing the sockets or
pins). Most connectors have pin numbers molded on the plastic.
DB9 Female
To PC
DB15 Male
To AX2500
1
6
2
7
3
8
4
9
5
1
9
10
11
12
13
14
15
2
3
4
5
6
7
8
Data Out
Data In
RX Data
TX Data
GND
GND
FIGURE 57. PC to AX2500/2850 RS232 cable/connector wiring diagram
Extending the RS232 Cable
The AX2500/2850 is delivered with a 4 foot cable adapter which may be too short, particu-
larly if you wish to run and monitor the controller inside a moving robot.
RS232 extension cables are available at most computer stores. However, you can easily
build one using a 9-pin DB9 male connector, a 9-pin DB9 female connector and any 3-wire
cable. These components are available at any electronics distributor. A CAT5 network cable
diagram of the extension cable.
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Serial (RS-232) Controls and Operation
DB9 Female
DB9 Male
1
2
3
4
5
1
6
7
8
9
6
2
7
3
8
4
Data Out
Data In
RX Data
TX Data
9
5
GND
GND
FIGURE 58. RS232 extension cable/connector wiring diagram
Communication Settings
The AX2500/2850 serial communication port is set as follows:
9600 bits/s, 7-bit data, 1 Start bit, 1 Stop bit, Even Parity
Communication is done without flow control, meaning that the controller is always ready
to receive data and can send data at any time.
These settings cannot be changed. You must therefore adapt the communication setting
in your PC or microcomputer to match those of the controller.
Establishing Manual Communication with a PC
The controller can easily be connected to a PC in order to manually exercise its capabilities.
Simply connect the supplied cable to the AX2500/2850 on one end (DB-15 connector) and
to a free COM port on the other end (DB-9 connector).
Once connected, you will need a Terminal Emulation program to display the data received
from the controller on the PC’s screen and to send characters typed on the keyboard to the
controller. All Windows PC’s come with the Hyperterm terminal emulation software.
Locate the Hyperterm launch icon in the Start button: Programs > Accessories > Commu-
nication folder.
You will need to configure Hyperterm to use the COM port to which you have connected
the controller (typically COM1) and to configure the communication settings as described
in the section above.
To save time and avoid errors, a hyperterm configuration file is automatically installed in
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Establishing Manual Communication with a PC
You can easily change this setting to a different port from the program’s menus.
In all cases, immediately after reset or power up, the controller will output a short identity
message followed by a software revision number and software revision date as follows:
Roboteq v1.7 02/01/05
s
The letter below the prompt message is a code that provides information on the hardware
and can be ignored.
If in R/C or Analog mode, type the
Enter key 10 times to switch to RS232
mode and display the OK prompt
FIGURE 59. Power-on message appearing on Hyperterm
On the AX3500, AX2850, or AX2550 with an Encoder module, this first prompt is immedi-
ately followed by a second one send by the MCU dedicated to the Encoder function:
RoboEnc v1.7 02/01/05
00
Entering RS232 from R/C or Analog mode
If the controller is configured in R/C or Analog mode, it will not be able to accept and recog-
nize RS232 commands immediately.
However, the controller will be “listening” to the serial port and will enter the serial mode
after it has received 10 continuous “Enter” (Carriage Return) characters. At that point, the
controller will output an “OK” message, indicating that it has entered the RS232 mode and
that it is now ready to accept commands.
Note that for improved safety, the RS232 watchdog is automatically enabled when entering
When reset again, the controller will revert to the R/C mode or Analog mode, unless the
Input Mode parameter has been changed in the meantime.
Data Logging String in R/C or Analog mode
If the controller is in the R/C or analog mode, immediately after reset it will send a continu-
ous string of characters (one character every 8ms, one entire string every 200ms) contain-
ing operating parameters for data logging purposes.
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Serial (RS-232) Controls and Operation
This information can be safely ignored and the controller will still be able to switch to
RS232 mode upon receiving 10 continuous Carriage Returns as described above.
RS232 Mode if default
If the controller is configured in RS232 mode, it will automatically be in the RS232 mode
upon reset or power up.
In this case, the “OK” message is sent automatically, indicating that the controller is ready
to accept commands through its serial port.
RS232 Commands Set
AX2500/2850 commands and queries are composed of a series of 2 or 4 characters fol-
lowed by the “enter” (carriage return) code.
The controller will send back (echo) every character it is receiving. By checking that the
returned character is the same as the one sent, it is possible to verify that there has been
no error in communication.
After a command has been received and properly executed, the controller will send the
“+” character.
If a command has been received with errors or bad parameters, the controller will send the
“-” character.
A complete summary of the acknowledge and error messages sent by the controller can
be found on page 97.
The following is a list of the AX2500/2850 RS232 commands and queries:
Set Motor Command Value
Description:
Send a speed of position value from 0 to 127 in the forward or reverse direction for a given
channel. In mixed mode, channel 1 value sets the common forward and reverse value for
both motors, while channel 2 sets the difference between motor 1 and motor 2 as required
for steering. In all other modes, channel 1 commands motor 1 and channel 2 commands
motor 2.
Syntax:
!Mnn
Where M=
A: channel 1, forward direction
a: channel 1, reverse direction
B: channel 2, forward direction
b: channel 2, reverse direction
Where nn=
Speed or position value in 2 Hexadecimal digits from 00 to 7F
channel 1 to 0
Examples:
!A00
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RS232 Commands Set
!B7F
!a3F
channel 2, 100% forward
channel 1, 50% reverse
Notes:
The hexadecimal number must always contain two digits. For example, !a5 will not be
recognized and the controller will respond with a “-” to indicate an error. The proper com-
mand in this case should be !a05
Hexadecimal numbers are easy to generate using a microcomputer. When exercising the
controller manually, you may use the Decimal to Hexadecimal conversion table on
Set Accessory Outputs
Description:
Turn on or off one of the 2 available digital output lines on the 15-pin connector. See “Using
the General Inputs and Outputs” on page 29 for details on how to identify and wire these
signals.
Syntax:
Where
!M
M= c: output C off
C: output C on
d: output D off
D: output D on
Examples:
!C
!d
turn C output on
turn D output off
Query Power Applied to Motors
Description:
This query will cause the controller to return the actual amount of power that is being
applied to the motors at that time. The number is a hexadecimal number ranging from 0 to
+127 (0 to 7F in Hexadecimal). In most cases, this value is directly related to the command
value, except in the conditions described in the notes below.
Syntax:
Reply:
?v or ?V
nn
mm
Where:
Notes:
nn = motor 1 applied power value
mm = motor 2 applied power value
The applied power value that is read back from the controller can be different than the com-
mand values for any of the following reasons: current limitation is active, motors operate at
reduced speed after overheat detection, or mixed mode is currently active.
No forward or reverse direction information is returned by this query.
This query is most useful for providing feedback to a microcontroller commanding the con-
troller. The hexadecimal format is intended to be deciphered by a microcontroller. When
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Serial (RS-232) Controls and Operation
exercising the controller manually, you may use the Decimal to Hexadecimal conversion
table on page 103.
Query Amps Consumed by Motors
Description:
This query will cause the controller to return the actual number of Amps being consumed
by each motor. The number is an unsigned Hexadecimal number ranging from 0 to 256 (0
to FF in Hexadecimal).
Syntax:
Reply:
?a or ?A
nn
mm
Where:
Notes:
nn = motor 1 Amps
mm = motor 2 Amps
The Amps measurement has a 10% (worse case) precision. Its main purpose is to provide
feedback to the controller’s current limitation circuitry.
The hexadecimal format is intended to be deciphered by a microcontroller. When exercis-
ing the controller manually, you may use the Decimal to Hexadecimal conversion table on
Query Analog Inputs
Description:
This query will cause the controller to return the values of the signals present at its two
analog inputs. If the controller is used in close-loop speed mode with analog feedback, the
values represent the actual speed measured by the tachometer. When used in position
mode, the values represent the actual motor position measured by a potentiometer. In all
other modes, the values represent the measured voltage (0 to 5V) applied to the analog
inputs. The values are signed Hexadecimal numbers ranging from -127 to +127. The -127
value represents 0V at the input, the 0 value represents 2.5V, and the +127 value repre-
sents +5V.
Syntax:
?p or ?P
Reply:
nn
mm
Where:
Notes:
nn = analog input 1 value, speed or position
mm = analog input 2 value, speed or position
The command returns a signed hexadecimal number where 0 to +127 is represented by 00
to 7F, and -1 to -127 is represented by FF to 80 respectively. The hexadecimal format is
intended to be deciphered by a microcontroller. When exercising the controller manually,
you may use the Decimal to Hexadecimal conversion table on page 103.
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RS232 Commands Set
Query Heatsink Temperatures
Description:
This query will cause the controller to return values based on the temperature measured
by internal thermistors located at each heatsink side of the controller. Because NTC ther-
mistors are non-linear devices, the conversion or the read value into a temperature value
Sample conversion software code is available from Roboteq upon request. The values are
unsigned Hexadecimal numbers ranging from 0 to 255. The lowest read value represents
the highest temperature.
Syntax:
?m or ?M
Reply:
nn
mm
Where:
Notes:
nn = thermistor 1 read value
mm = thermistor 2 read value
The hexadecimal format is intended to be deciphered by a microcontroller. When exercis-
ing the controller manually, you may use the Decimal to Hexadecimal conversion table on
Query Battery Voltages
Description:
This query will cause the controller to return values based on two internally measured volt-
ages: the first is the Main Battery voltage present at the thick red and black wires. The sec-
ond is the internal 12V supply needed for the controller’s microcomputer and MOSFET
drivers. The values are unsigned Hexadecimal numbers ranging from 0 to 255. To convert
Syntax:
?e or ?E
Reply:
nn
mm
Where:
Notes:
nn = main battery voltage value
mm = internal 12V voltage value
The hexadecimal format is intended to be deciphered by a microcontroller. When exercis-
ing the controller manually, you may use the Decimal to Hexadecimal conversion table on
Query Digital Inputs
Description:
This query will cause the controller to return the state of the controller’s two accessory
and use these signals. The returned values are three sets of two digits with the values 00
(to indicate a 0 or Off state), or 01 (to indicate a 1 or On state).
Syntax:
?i or ?I
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Serial (RS-232) Controls and Operation
Reply:
nn
mm
oo
Where:
nn = Input E status
mm = Input F status
oo = Estop/Invert Switch Input status
Examples:
?I
Read Input status query
01
00
01
Controller replies, Input E is On
Input F is Off
Emergency stop switch is high (not triggered)
Note: the Input E value is not meaningful on the AX2850 or on the AX2550 with Encoder
module and should be discarded.
Read and Modify Controller Settings
Description
These commands make it possible to examine and change the controller’s parameters
stored in Flash. These commands will appear cryptic and difficult to use for manual param-
eter setting. It is recommended to use the Graphical configuration utility described in
Read parameter
Syntax:
Reply:
Where
^mm
DD
mm= parameter number
DD= current parameter value
Example:
^00
Read value parameter 0
01
Controller replies, value is 01
Modify parameter
Syntax:
Reply:
^mm nn
+ if command was executed successfully
- if error
Where
mm= parameter number
nn= new parameter value
Examples:
^02 03
Store 03 into parameter 2
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Optical Encoder Commands
Notes:
All parameters and values are expressed with 2 hexadecimal digits
No changes will be made and an error will be reported (“-” character) when attempting to
read or write a parameter that does not exist or when attempting to store a parameter with
an invalid value.
Apply Parameter Changes
Description:
Many parameters will take effect only after the controller is reset. This command can be
used (instead of resetting the controller) to cause these parameters to take effect immedi-
ately.
Syntax:
Reply:
^FF
+ Success, changed parameters are now active
- if error
Reset Controller
Description:
This command allows the controller to be reset in the same manner as if the reset button
was pressed. This command should be used in exceptional conditions only or after chang-
ing the controller’s parameters in Flash memory so that they can take effect.
Syntax:
Reply:
%rrrrrr
None. Controller will reset and display prompt message
Optical Encoder Commands
The Optical Encoder included inside the AX2850 responds to its own command set
Commands Acknowledge and Error Messages
The AX2500/2850 will output characters in various situations to report acknowledgements
or error conditions as listed below.
Character Echo
At the most fundamental level, the AX2500/2850 will echo back to the PC or Microcontrol-
ler every valid character it has received. If no echo is received, one of the following is
occurring:
•
•
•
the controller is not in the RS232 mode
the controller is Off
the controller may be defective
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Serial (RS-232) Controls and Operation
Command Acknowledgement
The AX2500/2850 will acknowledge commands in one of two ways:
For commands that cause a reply, such as a speed or amps queries, the reply to the query
must be considered as the command acknowledgement.
For commands where no reply is expected, such as speed setting, the controller will issue
a “plus” character (+) after every command as an acknowledgment.
Command Error
If a command or query has been received with errors or is wrong, the control will issue a
“minus” character (-) to indicate the error.
If the controller issues the “-” character, it should be assumed that the command was lost
and that it should be repeated.
Watchdog time-out
If the RS232 watchdog is enabled, the controller will stop the motors and issue a “W”
character if it has not received a valid character from the PC or microcontroller within the
past 1 seconds.
RS-232 Watchdog
For applications demanding the highest operating safety, the controller may be configured
to automatically stop the motors (but otherwise remain fully active) if it fails to receive a
character on its RS232 port for more than 1 seconds.
The controller will also send a “W” character every second to indicate to the microcom-
puter that such a time-out condition has occurred.
The character does not need to be a specific command, but any valid ASCII code.
The RS232 watchdog is enabled or disabled depending on the value of the “Input Com-
mand Mode” parameter.
The RS232 watchdog is automatically enabled when entering the RS232 mode from the
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RS232 Accessible Parameter Table
RS232 Accessible Parameter Table
and changed using RS232 commands.
TABLE 18. AX2500/2850 Configuration parameters accessible through RS232
Param
nbr
Active See
Description
Allowed Values (default)
(0) = R/C Radio mode (default)
1 = RS232, no watchdog
2 = RS232, with watchdog
3 = Analog mode
after
pages
00
Input control mode
Reset
01
Motor Control
mode
(0) = Separate A, B, speed control, open loop
(default)
Reset
or ^FF
1 = Mixed A & B, speed control, open loop
2 = Speed control on A, open loop. Position
control on B
3 = A & B Position control
4 = Separate A, B, speed control, closed loop
5 = Mixed A & B, speed control, closed loop
6 = Speed control on A, closed loop. Position
control on B
Add 128 to use the optical encoder for speed
feedback (AX2850 only)
02
Amps limit
0 = 30A
Reset
1 = 45A
or ^FF
2 = 60A
3 = 75A
4 = 90A
(5) = 105A (default)
6 = 120A
Amps may be set with a finer resolution
using the PC utility
03
Acceleration
0 = very slow
1 = slow
Reset
or ^FF
(2) = medium-slow (default)
3 = medium
4 = fast
5 = fastest
page 40 for complete list of acceptable val-
ues
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Serial (RS-232) Controls and Operation
TABLE 18. AX2500/2850 Configuration parameters accessible through RS232
Param
Active See
nbr
Description
Allowed Values (default)
after
Reset
or ^FF
pages
04
Input switch func-
tion
Bits 0 to 3 contain the EStop/Inv input
operating mode
0 = causes emergency stop
1 = invert commands
(2) = no action (default)
Bits 4,5 and 6.7 contain the Input E and
Input F respective configurations
(0) = no action
1 = Activate Output C
2 = Turn MOSFETs On or Off
not implemented
Values are for Joystick deadband
0 = no deadband
1 = 8%
05
06
Brake/Coast
Joystick Deadband
or
Reset
or
or ^FF
Analog Deadband
(2) = 16% (default)
3 = 24%
4 = 32%
5 = 40%
6 = 46%
7 = 54%
07
08
Exponentiation on
channel 1
(0) = Linear (no exponentiation - default)
1 = strong exponential
2 = normal exponential
3 = normal logarithmic
4 = strong logarithmic
Same as E, above
Instant
Instant
Exponentiation on
channel 2
09
0A
0B
Reserved
Reserved
Left / Right Adjust
(7) = no adjustment (default)
0, 1, ..., 6 = -5.25%, -4.5%, ...,-0.75%
8, ..., D, E** = +0.75, ..., +4.5%, +5.25%
Do not use
Reset
or ^FF
0C to
OE
Reserved
0F
Gain Integral for
PID
0 to 64 (16) default
Instant
10
11
Gain Diff for PID
Gain Prop for PID
0 to 64 (16) default
0 to 64 (16) default
Instant
Instant
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Automatic Switching from RS232 to RC Mode
TABLE 18. AX2500/2850 Configuration parameters accessible through RS232
Param
nbr
Active See
Description
Allowed Values (default)
after
pages
12
13
14
15
Joystick Center 1
MS
00 to FF (06) default
Reset
Joystick Center 1
LS
00 to FF (40) default
00 to FF (06) default
00 to FF (40) default
Reset
Reset
Reset
Joystick Center 2
MS
Joystick Center 2
LS
16
17
Joystick Min 1 MS
Joystick Min 1 LS
Joystick Min 2 MS
Joystick Min 2 LS
Joystick Max 1 MS
Joystick Max 1 LS
Joystick Max 2 MS
Joystick Max 2 LS
00 to FF (11) default
00 to FF (30) default
00 to FF (11) default
00 to FF (30) default
00 to FF (0C) default
00 to FF (80) default
00 to FF (0C) default
00 to FF (A8) default
Reset
Reset
Reset
Reset
Reset
Reset
Reset
Reset
18
19
1A
1B
1C
1D
Automatic Switching from RS232 to RC Mode
In many computer controlled application, it may be useful to allow the controller to switch
back to the RC mode. This would typically used to let a user to take over the control of a
robotic vehicle upon computer problem.
While the AX2500/2850 can operate in either RC Radio or RS232 mode, the RS232 Data
Input and RC Pulse Input 1 share the same pin on the connector. External hardware is
therefore needed to switch this pin from the RS232 source or the RC Radio. The diagram in
Figure 60 shows the external hardware required to perform such a switch.
A third RC channel is used to activate a dual-throw relay. When the radio is Off, or if it is On
with the channel 3 off, the relay contact brings the RS232 signal to the shared input. The
second relay contact maintains the Power Control wire floating, so that the controller
remains on.
When the RC channel 3 is activated, the relay turns On and brings the RC radio signal 1 to
the shared input. The second relay contact brings a discharged capacitor onto the Power
Control wire causing the controller to reset. Resetting the controller is necessary in order
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Serial (RS-232) Controls and Operation
to revert the controller in the RC mode (the controller must be configured to default to RC
mode).
RC Activated
Switch
4.7k
RC3
RC1
RC2
Power Control
RC Radio
220uF
RC1/RxData
TxData
RxData
RC2/InputF
TxData
Controller
Computer
FIGURE 60. External circuit required for RS232 to RC switching
The switching sequence goes as follows:
Upon controller power on with Radio off: (or Radio on with RC ch3 off)
•
•
Controller run in RC mode (must be configured in RC mode)
Computer must send 10 consecutive Carriage Returns. Controller enters RS232
mode
Controller is on, Radio urns On with RC ch3 On
•
•
Controller is reset, returning to RC mode
Controller will output the continuous parameter strings on the RS232 output.Com-
puter thus knows that RC mode is currently active. Computer sends Carriage
Return strings to try to switch controller back in RS232 mode. Since the RS232 line
is not connected to the controller, mode will not change
Controller is on, Radio is turned Off (or Radio On with RC ch3 Off)
•
•
•
Relay deactivates. RS232 now connected to shared input
String of Carriage Returns now received by controller.
Computer looks for OK prompt to detect that RS232 mode is now active. Then
resumes normal operation.
Note: Wait 5 seconds for the capacitor to discharge before attempting to switch to RC
mode if doing this repeatedly. Controller will not reset otherwise.
Analog and R/C Modes Data Logging String Format
When the controller is configured in R/C or Analog mode, it will automatically and continu-
ously send a string of ASCII characters on the RS232 output.
This feature makes it possible to log the controller’s internal parameters while it is used in
the actual application. The data may be captured using a PC connected via an RS232 cable
or wireless modem, or into a PDA installed in the actual robot. Details on how to wire the
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Data Logging Cables
mode.
This string is composed of a start character delimiter, followed by 12 or 13 two-digit Hexa-
decimal numbers representing 12 or 13 internal parameter values, and ending with a Car-
riage Return character. The figure below shows the structure of this string.
s
o
pd/P
2
1
lts
s
er
t
o
t V
l
Vo
miter
ower 1
ower 2
and 1
t Deli
mperature
mperature
e
e
T
Internal Encoder S
End Delimit
Amps 1
Analog In 2
Analog In 1
Output P
Main Bat
T
Amps 2
Output P
Command 2
Comm
Star
: 00 11 22 33 44 55 66 77 88 99 AA BB CC
FIGURE 61. ASCII string sent by the controller while in R/C or Analog mode
The hexadecimal values and format for each parameter is the same as the response to
parameter is output only on the AX2850 or the AX2550 with Encoder module.
Characters are sent by the controller at the rate of one every 8ms. A complete string is
sent in 213ms or 224ms.
Data Logging Cables
The wring diagrams shown in the figures below describe an easy-to-assemble cable
assembly for use to create insertion points where to connect the PC for debug and data
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Serial (RS-232) Controls and Operation
logging purposes. This cable has a 15-pin male connector and 3 15-pin connectors. The
Front View
Rear View
Female to PC with RxData Only
Female to PC with Rx andTx Data
4
3
1
1
1
Cut
Wire
Female to Application
Male to controller
2
1
1
FIGURE 62. ASCII string sent by the controller while in R/C or Analog mode
male connector plugs into the controller. The application cable that would normally plug
into the controller may now be plugged into one of the adapter’s female connector 2. The
PC can be plugged into connector 3 or 4. Connector 3 has the Rx and Tx data lines needed
for full duplex serial communication, thus allowing the PC to send commands to the con-
troller. Connector 4 has the Rx line cut so that only a data flows only from the controller to
the PC. This configuration is for capturing the data logging strings sent in the RC or Analog
modes.
Decimal to Hexadecimal Conversion Table
The AX2500/2850 uses hexadecimal notation for accepting and responding to numerical
commands. Hexadecimal is related to the binary system that is used at the very heart of
microcomputers. Functions for converting from decimal to hexadecimal are readily avail-
able in high level languages such as C.
If you intend to enter commands manually using the terminal emulation program, you can
numbers for 0 to 127 decimal (00 to 7F hexadecimal). The AX2500/2850’s speed com-
128 and 255 (unsigned) and between -1 and -128 (signed)
TABLE 19. 0 to +127 signed or unsigned decimal to hexadecimal conversion table
Dec
Hex
00
01
Dec
32
Hex
20
Dec
64
Hex
40
Dec
96
Hex
60
0
1
2
3
4
5
33
21
65
41
97
61
02
34
22
66
42
98
62
03
35
23
67
43
99
63
04
36
24
68
44
100
101
64
05
37
25
69
45
65
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Decimal to Hexadecimal Conversion Table
TABLE 19. 0 to +127 signed or unsigned decimal to hexadecimal conversion table
Dec
6
Hex
06
07
08
09
0A
0B
0C
0D
0E
0F
10
Dec
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
Hex
26
27
28
29
2A
2B
2C
2D
2E
2F
30
31
32
33
34
35
36
37
38
39
3A
3B
3C
3D
3E
3F
Dec
70
71
72
73
74
Hex
46
47
48
49
4A
4B
4C
4D
4E
4F
50
51
52
53
54
55
56
57
58
59
5A
5B
5C
5D
5E
5F
Dec
102
103
104
105
106
107
108
109
110
111
Hex
66
67
68
69
6A
6B
6C
6D
6E
6F
70
71
72
73
74
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
11
12
13
14
15
16
17
75
76
77
78
79
7A
7B
7C
7D
7E
7F
18
19
1A
1B
1C
1D
1E
1F
TABLE 20. +128 to 255 unsigned and -1 to -128 signed decimal to hexadecimal conversion table
UDec
-128
-127
-126
-125
-124
-123
-122
-121
Dec
128
129
130
131
132
133
134
135
Hex
80
81
82
83
84
85
86
87
UDec
-96
-95
-94
-93
-92
-91
-90
-89
Dec
160
161
162
163
164
165
166
167
Hex
A0
A1
A2
A3
A4
A5
A6
A7
UDec
-64
-63
-62
-61
-60
-59
-58
-57
Dec
192
193
194
195
196
197
198
199
Hex
C0
C1
C2
C3
C4
C5
C6
C7
UDec
-32
-31
-30
-29
-28
-27
-26
-25
Dec
224
225
226
227
228
229
230
231
Hex
E0
E1
E2
E3
E4
E5
E6
E7
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Serial (RS-232) Controls and Operation
TABLE 20. +128 to 255 unsigned and -1 to -128 signed decimal to hexadecimal conversion table
UDec
-120
-119
-118
-117
-116
-115
-114
-113
-112
-111
-110
-109
-108
-107
-106
-105
-104
-103
-102
-101
-100
-99
Dec
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
Hex
88
89
8A
8B
8C
8D
8E
8F
90
91
92
93
94
95
96
97
98
99
9A
9B
9C
9D
9E
9F
UDec
-88
-87
-86
-85
-84
-83
-82
-81
-80
-79
-78
-77
-76
-75
-74
Dec
168
169
170
171
172
173
174
Hex
A8
A9
AA
AB
AC
AD
AE
AF
B0
B1
B2
B3
B4
B5
B6
B7
B8
B9
BA
BB
BC
BD
BE
BF
UDec
-56
-55
-54
-53
-52
-51
-50
-49
-48
-47
-46
-45
-44
-43
-42
-41
-40
-39
-38
-37
-36
-35
-34
-33
Dec
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
Hex
C8
C9
CA
CB
CC
CD
CE
CF
D0
D1
D2
D3
D4
D5
D6
D7
D8
D9
DA
DB
DC
DD
DE
DF
UDec
-24
-23
-22
-21
-20
-19
-18
-17
-16
-15
-14
-13
-12
-11
-10
-9
Dec
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
Hex
E8
E9
EA
EB
EC
ED
EE
EF
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
FA
FB
FC
FD
FE
FF
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
-73
-72
-71
-70
-69
-68
-67
-66
-65
-8
-7
-6
-5
-4
-3
-98
-2
-97
-1
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Mode Description
SECTION 9
Analog Control
and Operation
This section describes how the motors may be operated using analog voltage commands.
Mode Description
The AX2500/2850 can be configured to use a 0 to 5V analog voltage, typically produced
using a potentiometer, to control each of its two motor channels. The voltage is converted
into a digital value of -127 at 0V, 0 at 2.5V and +127 at 5V. This value, in turn, becomes the
command input used by the controller. This command input is subject to deadband thresh-
old and exponentiation adjustment. Analog commands can be used to control motors sep-
arately (one analog input command for each motor) or in mixed mode.
Important Notice
The analog mode can only be used in the Closed Loop speed or position modes
when Optical Encoders are used for feedback. Position potentiometers or tachome-
ters cannot be used since there is only one analog input per channel and that this
input will be connected to the command potentiometer.
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Analog Control and Operation
Connector I/O Pin Assignment (Analog Mode)
9
15
Pin1
8
When used in the Analog mode, the pins on the controller’s DB15 connector are mapped
as described in the table below
TABLE 21. DB15 Connector pin assignment in Analog mode
Pin
Input or
Output
Number
Signal
Output C
Data Out
Data In
Description
1
2
3
4
Output
Output
Input
2Amp Accessory Output C (same as pin 9)
RS232 data output to the PC for data logging
unused
Input F
Input
5
Ground Out
Ground In
+5V In
Power Output
Power Input
Power Input
Input
Controller ground (-)
6
unused
7
unused
8
Input E
Not available on AX2850
2Amp Accessory Output C (same as pin 1)
Channel 2 analog input
Channel 1 analog input
Not available on AX2850
Controller ground (-)
9
Output C
Output
10
11
12
13
14
15
Channel 2 In
Channel 1 In
Output D
Ground Out
+5V Out
Analog in
Analog in
Output
Power
Power Output
Input
+5V Power Output (100mA max.)
Emergency Stop or Invert Switch input
Switch Input
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Connecting to a Voltage Source
Connecting to a Voltage Source
The analog inputs expect a DC voltage of 0 to 5V which can be sourced by any custom cir-
cuitry (potentiometer, Digital to Analog converter).
The controller considers 2.5V to be the zero position (Motor Off). 0V is the maximum
reverse command, +5V is the maximum forward command.
+5V
14
AX2500 Internal Resistors
and Converter
Analog
Input 1 or 2
10
11
47kOhm
0V = Min
2.5V = Off
5V = Max
A/D
10kOhm
47kOhm
13
Ground
FIGURE 63. Analog input circuit
Notice the two 47K resistors, which are designed to automatically bring the input to a mid-
point (Off) position in case the input is not connected. The applied voltage must have suffi-
cient current (low impedance) so that it is not affected by these resistors.
Connecting a Potentiometer
to ground and the other to 5V, the potentiometer acts as an adjustable voltage divider. The
voltage will thus vary from 0V when the tap is at the minimum position and to 5V when the
tap is at the maximum position.
The controller considers 2.5V to be the zero position (Motor Off). 2.5V is the potentiome-
ter’s mid point position.
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Analog Control and Operation
+5V
14
AX2500 Internal Resistors
and Converter
Analog
Input 1 or 2
10
11
47kOhm
A/D
10kOhm
10kOhm
47kOhm
13
Ground
FIGURE 64. Potentiometer connection wiring diagram
The controller includes two 47K ohm resistors pulling the input to a mid-voltage point of
2.5V. When configured in the Analog Input mode, this will cause the motors to be at the
Off state if the controller is powered with nothing connected to its analog inputs.
Important Notice
The controller will not activate and will display the “no ctrl” message after power up
or reset until the analog inputs are at 2.5V
FIGURE 65. “no control” message indicates that joystick is not centered at power up
Selecting the Potentiometer Value
The potentiometer can be of almost any value; however, undesirable effects occur if the
value is too low or too high.
If the value is low, an unnecessarily high and potentially damaging current will flow through
the potentiometer. The amount of current is computed as the voltage divided by the poten-
tiometer’s resistance at its two extremes. For a 1K potentiometer, the current is:
I = U/R = 5V / 1000 Ohms = 0.005A = 5mA
For all practical purposes, a 1K potentiometer is a good minimal value.
If the value of the potentiometer is high, then the two 47K resistors built into the controller
will distort the reading. The effect is minimal on a 10K potentiometer but is significant on a
110
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Analog Deadband Adjustment
ous potentiometer positions, for three typical potentiometer values. Note that the effect is
an exponentiation that will cause the motors to start moving slowly and accelerate faster
as the potentiometer reaches either end.
This curve is actually preferable for most applications. It can be corrected or amplified by
Voltage at Input
5V
1K Pot
4V
3V
10K Pot
100K Pot
2V
1V
0V
Min
Center
Max
Potentiometer Position
FIGURE 66. Effect of the controller’s internal resistors on various potentiometers
Analog Deadband Adjustment
The controller may be configured so that some amount of potentiometer or joystick travel
off its center position is required before the motors activate. The deadband parameter can
be one of 8 values, ranging from 0 to 7, which translate into a deadband of 0% to 16%.
Even though the deadband will cause some of the potentiometer movement around the
center position to be ignored, the controller will scale the remaining potentiometer move-
ment to command the motors from 0 to 100%.
Note that the scaling will also cause the motors to reach 100% at sightly less than 100% of
the potentiometer’s position. This is to ensure that 100% motor speed is achieved in all cir-
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Analog Control and Operation
TABLE 22. Analog deadband parameters and their effects
Pot. Position resulting in
Motor Power at 0%
Pot. Position resulting in
Motor Power at -/+100%
Parameter Value
0
0%
2.5V
94%
96%
93%
95%
93%
95%
94%
96%
0.15V and 4.85V
0.10V and 4.90V
0.18V and 4.83V
0.13V to 4.88V
0.18V and 4.83V
0.13V to 4.88V
0.15V and 4.85V
0.10V and 4.90V
1
0% to 2.4%
0% to 4.7%
0% to 7.1%
0% to 9.4%
0% to 11.8%
0% to 14.2%
0% to 16.5%
2.44V to 2.56V
2.38V to 2.62V
2.32V to 2.68V
2.27V to 2.74
2.21V to 2.80V
2.15V to 2.86V
2.09V to 2.91V
2
3 (default)
4
5
6
7
Important Notice
Some analog joysticks do not cause the potentiometer to reach either extremes.
This may cause the analog voltage range to be above 0V and below 5V when the
stick is moved to the extremes, and therefore the controller will not be able to
deliver full forward or reverse power.
Power-On Safety
When powering on the controller, power will not be applied to the motors until both the
Channel 1 and Channel 2 potentiometers have been centered to their middle position (2.5V
on each input). This is to prevent the robot or vehicle from moving in case the joystick was
in an active position at the moment the controller was turned on. The “no ctrl” message
will scroll on the LED display while the controller is disabled.
Under Voltage Safety
If the controller is powered through the Power Control input, and the motor battery voltage
drops below 5V, then the controller will be disabled until the analog commands are cen-
tered to the midpoint (2.5V on each input).
Data Logging in Analog Mode
While in Analog Mode, the AX2500/2850 will continuously send a string of characters on
the RS232 output line. This string will contain 12 or 13 two-digits hexadecimal number rep-
resenting the following operating parameters.
•
•
•
•
Captured Analog Command 1 and 2
Power Applied to Controller’s output stage
Raw analog command values
Amps on channel 1 and 2
112
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Data Logging in Analog Mode
•
•
•
•
Internal Heat Sink temperatures 1 and 2
Main Battery voltage
Internal 12V voltage
Encoder Speed or Position (AX2850)
The entire string is repeated every 213 milliseconds with the latest internal parameter val-
placed in the mobile robot.
application.
To read the output string while operating the controller with an analog command, you must
modify the cable to add an RS232 output wire and connector that will be connected to the
for connection to a PC or to a PDA, respectively.
DB9 Female
To PC
DB15 Male
To AX2500
1
1
6
2
7
3
8
4
9
5
9
10
11
12
13
14
15
2
RS232 Data Out
RX Data
GND
Ana Ch2
Ana Ch1
3
4
5
6
7
8
GND
+5V
FIGURE 67. Modified Analog cable with RS232 output data logging for PC
DB9 Male
To PDA
DB15 Male
To AX2500
1
1
6
2
7
3
8
4
9
5
9
10
11
12
13
14
15
RX Data
GND
2
RS232 Data Out
Ana Ch2
Ana Ch1
3
4
5
6
7
8
GND
+5V
FIGURE 68. Modified Analog cable with RS232 output data logging for PDA
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Analog Control and Operation
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Mode Description
SECTION 10
Closed Loop
Position Mode
This section describes the AX2500/2850 Position mode, how to wire the motor and posi-
tion sensor assembly, and how to tune and operate the controller in this mode.
Mode Description
In this mode, the axle of a geared down motor is coupled to a position sensor that is used
to compare the angular position of the axle versus a desired position. The controller will
move the motor so that it reaches this position.
This unique feature makes it possible to build ultra-high torque “jumbo servos” that can be
used to drive steering columns, robotic arms, life-size models and other heavy loads.
The AX2500/2850 incorporates a full-featured Proportional, Integral, Differential (PID) con-
trol algorithm for quick and stable positioning.
Selecting the Position Mode
The position mode is selected by changing the Motor Control parameter in the controller to
either
•
•
•
A Open Loop Speed, B Position
A Closed Loop Speed, B Position
A and B Position
Note that in the first two modes, only the second motor will operate in the Position mode.
For safety reasons and to prevent this mode from being accidentally selected, Position
modes CAN NOT be selected by configuring the controller using the built-in switches and
display.
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Closed Loop Position Mode
Position Sensor Selection
The AX2500/2850 may be used with the following kind of sensors:
Potentiometers
Hall effect angular sensors
Optical Encoders
•
•
•
The first two are used to generate an analog voltage ranging from 0V to 5V depending on
their position. They will report an absolute position information at all times.
Optical encoders report incremental changes from a reference which is their initial position
when the controller is powered up or reset. Using Optical Encoders in this mode is possi-
Sensor Mounting
Proper mounting of the sensor is critical for an effective and accurate position mode opera-
Position Feedback
Position Sensor
Gear box
FIGURE 69. Typical motor/potentiometer assembly in Position Mode
The sensor is composed of two parts:
•
a body which must be physically attached to a non-moving part of the motor assem-
bly, or the robot chassis, and
•
an axle which must be physically connected to the rotating part of the motor you
wish to position.
A gear box is necessary in order to greatly increase the torque of the assembly. It is also
necessary in order to slow down the motion so that the controller has the time to perform
the position control algorithm. If the gearing ratio is too high, however, the positioning
mode will be very sluggish.
A good ratio should be such that the output shaft rotates at 1 to 10 rotations per second
(60 to 600 RPM) when the motor is at full speed.
116
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Potentiometer wiring
The mechanical coupling between the motor and the sensor must be as tight as possible.
If the gear box is loose, the positioning will not be accurate and will be unstable, potentially
causing the motor to oscillate.
Some sensor, such as potentiometers, have a limited rotation range of typically 270
degrees (3/4 of a turn), which will in turn limit the mechanical motion of the motor/potenti-
ometer assembly. You may consider using a multi-turn potentiometer as long as it is
mounted in a manner that will allow it to turn throughout much of its range, when the
mechanical assembly travels from the minimum to maximum position.
Important Notice:
Potentiometers are mechanical devices subject to wear. Use better quality potenti-
ometers and make sure that they are protected from the elements. Consider using a
solid state hall position sensor in the most critical applications. Optical encoders
Potentiometer wiring
When using a potentiometer, it must be wired so that it creates a voltage that is propor-
tional to its angular position: 0V at one extreme, +5V at the other. A 10K potentiometer
value is recommended for this use.
Connecting the potentiometer to the controller is as simple as shown in the diagram on
+5V 14
AX2500 Internal Resistors
and Converter
Input Pos 1 11
47kOhm
or Pos 2 10
A/D
10kOhm
10kOhm
47kOhm
Ground 5
FIGURE 70. Potentiometer wiring in Position mode
Using Optical Encoders in Position Mode
Sensor and Motor Polarity
The sensor polarity (i.e. which rotation end produces 0 or 5V) is related to the motor’s
polarity (i.e. which direction the motor turns when power is applied to it).
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Closed Loop Position Mode
In the Position mode, the controller compares the actual position, as measured by the sen-
sor, to the desired position. If the motor is not at that position, the controller will apply
power to the motor so that it turns towards that destination, until reached.
Important Warning:
If there is a polarity mismatch, the motor will turn in the wrong direction and the
position will never be reached. The motor will turn continuously with no way of
stopping it other than cutting the power or hitting the Emergency Stop buttons.
Determining the right polarity is best done experimentally using the Roborun utility (see
1. Disconnect the controller’s Motor Power (thick power wires).
2. Configure the controller in Position Mode using the PC utility.
3. Loosen the sensor’s axle from the motor assembly.
4. Launch the Roborun utility and click on the Run tab. Click the “Start” button to
begin communication with the controller. The sensor values will be displayed in the
Ana1 and Ana2 boxes.
5. Move the sensor manually to the middle position until you measure “0” using
Roborun utility
6. Verify that the motor sliders are in the “0” (Stop) position. Since the desired posi-
tion is 0 and the measured position is 0, the controller will not attempt to move the
motors, and the Power graph on the PC must be 0.
7. Apply power to the Motor Power wires (thick power wires). The motor will be
stopped.
8. With a hand ready to disconnect the Motor Power cable, or ready to press the “Pro-
gram” and “Set” buttons at the same time (Emergency Stop), SLOWLY move the
sensor off the center position and observe the motor’s direction of rotation.
9. If the motor turns in the direction you moved the sensor, the polarity is correct. You
may tighten the sensor axle to the motor assembly.
10. If the motor turns in the direction away from the sensor, then the polarity is
reversed. You should either exchange the wire polarity on the motors. If you are
using a potentiometer as sensor, you can instead the 0 and +5V wires on the poten-
tiometer. If you are using an Optical Encoder, you can swap its ChA and ChB out-
puts.
11. Move the sensor back to the center point to stop the motor. Cut the power if you
feel you are losing control.
12. If the polarity was wrong, invert it and repeat steps 8 to 11.
13. Tighten the sensor.
Important Safety Warning
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Adding Safety Limit Switches
Never apply a command that is lower than the sensor’s minimum output value, or
higher than the sensor’s maximum output value as the motor would turn forever try-
ing to reach a position it can’t. For example if the max position of a potentiometer is
4.5V, which is a position value of 114, a destination command of 115 cannot be
reached and the motor will not stop.
Adding Safety Limit Switches
The Position mode depends on the position sensor providing accurate position information.
If the potentiometer is damaged or one of its wire is cut, the motors may spin continuously
in an attempt to reach a fictitious position. In many applications, this may lead to serious
mechanical damage.
To limit the risk of such breakage, it is recommended to add limit switches that will cause
the motors to stop if unsafe positions have been reached, independently of the potentiom-
eter reading.
Two simple and low cost methods are proposed to implement safety limit switches:
motor terminals. As the motor reaches one of the switches, the lever is pressed, cutting
the power to the motor. The diode in parallel with the switch allows the current to flow in
the reverse position so that the motor may be restarted and moved away from that limit.
The diode polarity depends on your particular wiring and motor orientation. If the diode is
mounted backwards, the motor will not stop once the limit switch lever is pressed. If this is
the case, reverse the diode polarity.
The diodes may be eliminated, but then it will not be possible for the controller to move the
motor once either of the limit switches has been triggered.
The main benefit of this technique is its total independence on the controller’s electronics
and its ability to work in practically all circumstances. Its main limitation is that the switch
and diode must be capable of handling the current that flows through the motor. Note that
the current will flow though the diode only for the short time needed for the motor to move
away from the limit switches.
SW1
SW2
Motor
AX2550
FIGURE 71. Safety limit switches interrupting power to motors
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Closed Loop Position Mode
The second method uses the AX2500/2850’s Emergency Stop input to shut down the con-
this case. Each of the limit switches is a Normally Open switch. Two of these switched are
typically required for each motor. Additional switches may be added as needed for the sec-
ond motor and/or for a manual Emergency Stop. Since very low current flows through the
switches, these can be small, low cost switches.
The principal restriction of this technique is that it depends on the controller to be fully
functioning, and that once a switch is activated, the controller will remain inactive until the
switch is released. In most situations, this will require manual intervention. Another limita-
tion is that both channels will be disabled even if only one channel caused the fault.
Manual
Emergency
Stop Switch
SW1
SW2
Motor
AX2550
Ground
Emergency Stop Input
FIGURE 72. Safety limit using AX2500/2850’s Emergency Stop input
Important Warning
Limit switches must be used when operating the controller in Position Mode. This
will significantly reduce the risk of mechanical damage and/or injury in case of dam-
age to the position sensor or sensor wiring.
Using Current Limiting as Protection
It is a good idea to set the controller’s current limit to a low value in order to avoid high cur-
rent draws and consequential damage in case the motor does not stop where expected.
Use a value that is no more than 2 x the motor’s draw under normal load conditions.
Control Loop Description
The AX2500/2850 performs the Position mode using a full featured Proportional, Integral
and Differential (PID) algorithm. This technique has a long history of usage in control sys-
tems and works on performing adjustments to the Power Output based on the difference
measured between the desired position (set by the user) and the actual position (captured
by the position sensor).
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Control Loop Description
ler measures the actual motor position and substracts it from the desired position to com-
pute the position error.
The resulting error value is then multiplied by a user selectable Proportional Gain. The
resulting value becomes one of the components used to command the motor. The effect
of this part of the algorithm is to apply power to the motor that is proportional with the dis-
tance between the current and desired positions: when far apart, high power is applied,
with the power being gradually reduced and stopped as the motor moves to the final posi-
tion. The Proportional feedback is the most important component of the PID in Position
mode.
A higher Proportional Gain will cause the algorithm to apply a higher level of power for a
given measured error thus making the motor move quicker. However, because of inertia, a
faster moving motor will have more difficulty stopping when it reaches its desired position.
It will therefore overshoot and possibly oscillate around that end position.
Proportional
Gain
x
E= Error
Desired Position
dE
dt
x
Σ
-
Output
Analog Position
Sensor
A/D
Measured Position
Integral
Gain
or
Optical Encoder
dE
dt
x
Differential
Gain
FIGURE 73. PID algorithm used in Position mode
The Differential component of the algorithm computes the changes to the error from one
16 ms time period to the next. This change will be a relatively large number every time an
abrupt change occurs on the desired position value or the measured position value. The
value of that change is then multiplied by a user selectable Differential Gain and added to
the output. The effect of this part of the algorithm is to give a boost of extra power when
starting the motor due to changes to the desired position value. The differential component
will also greatly help dampen any overshoot and oscillation.
The Integral component of the algorithm perform a sum of the error over time. In the posi-
tion mode, this component helps the controller reach and maintain the exact desired posi-
tion when the error would otherwise be too small to energize the motor using the
Proportional component alone. Only a very small amount of Integral Gain is typically
required in this mode.
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Closed Loop Position Mode
PID tuning in Position Mode
As discussed above, three parameters - Proportional Gain, Integral Gain and Differential
Gain - can be adjusted to tune the position control algorithm. The ultimate goal in a well
tuned PID is a motor that reaches the desired position quickly without overshoot or oscilla-
tion.
Because many mechanical parameters, such as motor power, gear ratio, load and inertia
are difficult to model, tuning the PID is essentially a manual process that takes experimen-
tation.
The Roborun PC utility makes this experimentation easy by providing a screen for changing
the Proportional, Integral and Differential gains and another screen for running and monitor-
ing the motors.
When tuning the motor, first start with the Integral Gain at zero, increasing the Proportional
Gain until the motor overshoots and oscillates. Then add Differential gain until there is no
more overshoot. If the overshoot persists, reduce the Proportional Gain. Add a minimal
amount of Integral Gain. You may further fine tune the PID by varying the gains from these
positions.
To set the Proportional Gain, which is the most important parameter, use the Roborun util-
ity to observe the three following values;
•
•
•
Command Value
Actual Position
Applied Power
With the Integral Gain set to 0, the Applied Power should be:
Applied Power = (Command Value - Actual Position) * Proportional Gain
Experiment first with the motor electrically or mechanically disconnected an verify that the
controller is measuring the correct position and is applying the expected amount of power
to the motor depending on the command you give it.
Verify that when the Command Value equals the Actual Position, the Applied Power equals
to zero. Note that the Applied Power value is shown without the sign in the PC utility.
In case where the load moved by the motor is not fixed, you will need to tune the PD with
the minimum expected load and tune it again with the maximum expected load. Then try
to find values that will work in both conditions. If the disparity between minimal and maxi-
mal possible loads is large, it may not be possible to find satisfactory tuning values.
Note that the AX2500/2850 uses one set of Proportional, Integral and Differential Gains for
both motors and therefore assumes that similar motors, mechanical assemblies and loads
are present at each channel.
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Mode Description
SECTION 11
Closed Loop
Speed Mode
This section discusses the AX2500/2850 Close Loop Speed mode.
Mode Description
In this mode, an analog or digital speed sensor measures the actual motor speed and com-
pares it to the desired speed. If the speed changes because of changes in load, the control-
ler automatically compensates the power output. This mode is preferred in precision motor
control and autonomous robotic applications.
The AX2500/2850 incorporates a full-featured Proportional, Integral, Differential (PID) con-
trol algorithm for quick and stable speed control.
Selecting the Speed Mode
The speed mode is selected by changing the Motor Control parameter in the controller to
either
•
•
•
A and B Closed Loop Speed Separate
A and B Closed Loop Speed Mixed
A Closed Loop Speed, B Position
Note that in the last selection, only the first motor will operate in the Closed Loop Speed
mode.
For safety reasons and to prevent this mode from being accidentally selected, Closed Loop
Speed modes CAN NOT be selected by configuring the controller using the built-in
switches and display.
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Closed Loop Speed Mode
Using Optical Encoder for Speed Feedback (AX2850 only)
Digital Optical Encoders may be used to capture accurate motor speed. This capability is
only available on the AX2850 or AX2550 fitted with the optional encoder module.
If using optical encoders, you may omit the Analog Tachometer discussion in this section
page 131 for a detailed discussion.
Tachometer or Encoder Mounting
Proper mounting of the speed sensor is critical for an effective and accurate speed mode
Tachometer or
Optical Encoder (AX2850 & AX3500 only)
Speed Feedback
FIGURE 74. Motor + tachometer assembly needed for Close Loop Speed mode
Tachometer wiring
The tachometer must be wired so that it creates a voltage at the controller’s analog input
that is proportional to rotation speed: 0V at full reverse, +5V at full forward, and 0 when
stopped.
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Speed Sensor and Motor Polarity
Connecting the tachometer to the controller is as simple as shown in the diagram in the
figure below.
+5V 14
1kOhm
AX2500 Internal Resistors
and Converter
Max Speed Adjust
10kOhm pot
Input Ana 1 11
47kOhm
or Ana 2 10
0 Adjust
100 Ohm pot
Tach
A/D
10kOhm
47kOhm
1kOhm
Ground 5
FIGURE 75. Tachometer wiring diagram
Speed Sensor and Motor Polarity
The tachometer or encoder polarity (i.e. which rotation direction produces a positive of
negative speed information), is related to the motor’s rotation speed and direction the
motor turns when power is applied to it.
In the Closed Loop Speed mode, the controller compares the actual speed, as measured
by the tachometer, to the desired speed. If the motor is not at the desired speed and direc-
tion, the controller will apply power to the motor so that it turns faster or slower, until
reached.
Important Warning:
If there is a polarity mismatch, the motor will turn in the wrong direction and the
speed will never be reached. The motor will turn continuously at full speed with no
way of stopping it other than cutting the power or hitting the Emergency Stop but-
tons.
Determining the right polarity is best done experimentally using the Roborun utility (see
1. Disconnect the controller’s Motor Power (thick power wires).
2. Configure the controller in Open Loop Mode using the PC utility. This will cause the
motors to run in Open Loop for now
3. Launch the Roborun utility and click on the Run tab. Click the “Start” button to
begin communication with the controller. The tachometer values will be displayed
in the appropriate Analog input value boxe(s) which will be labeled Ana 1 and Ana 2.
If encoders are used, look for the reported speed value in the Enc boxes.
4. Verify that the motor sliders are in the “0” (Stop) position.
5. If a tachometer is used, verify that the measured speed value read is 0 when the
motors are stopped. If not, trim the “0” offset potentiometer.
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Closed Loop Speed Mode
6. Apply power to the Motor Power wires (thick power wires). The motor will be
stopped.
7. Move the cursor of the desired motor to the right so that the motor starts rotating,
and verify that a positive speed is reported. Move the cursor to the left and verify
that a negative speed is reported.
8. If the tachometer or encoder polarity is the same of the applied command, then the
wiring is correct.
9. If the tachometer polarity is opposite to the command polarity, then you can either
reverse the motor’s wiring, or reverse the tachometer wires. If an encoder is used,
you may swap its CHA and ChB outputs
10. If a tachometer is used, proceed to calibrate the Max Closed Loop speed.
11. Set the controller parameter to the desired Closed Loop Speed mode using the
Roborun utility
Adjust Offset and Max Speed
For proper operation, the controller must see a 0 analog speed value (2.5V voltage on the
analog input).
To adjust the 0 value when the motors are stopped, use the Roborun utility to view the
analog input value while the tachometer is not turning. Move the 0 offset potentiometer
until a stable 0 is read. This should be right around the potentiometer’s middle position.
The tachometer must also be calibrated so that it reports a +127 or -127 analog speed
value (5V or 0V on the analog input, respectively) when the motors are running at the max-
imum desired speed in either direction. Since most tachometers will generate more than
+/- 2.5V, a 10kOhm potentiometer must be used to scale it’s output.
To set the potentiometer, use the Roborun utility to run the motors at the desired maxi-
mum speed, while in Open Loop mode (no speed feedback). While the tachometer is spin-
ning, adjust the potentiometer until the analog speed value read is reaching 126.
Note: The maximum desired speed should be lower than the maximum speed that the
motors can spin at maximum power and no load. This will ensure that the controller will be
able to eventually reach the desired speed under most load conditions.
Important Warning:
It is critically important that the tachometer and its wiring be extremely robust. If the
tachometer reports an erroneous voltage, or no voltage at all, the controller will con-
sider that the motors has not reached the desired speed value and will gradually
increase the applied power to the motor to 100% with no way of stopping it until
power is cut off or Emergency Stop is activated.
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Control Loop Description
Control Loop Description
The AX2500/2850 performs the Closed Loop Speed mode using a full featured Propor-
tional, Integral and Differential (PID) algorithm. This technique has a long history of usage in
control systems and works on performing adjustments to the Power Output based on the
difference measured between the desired speed (set by the user) and the actual position
(captured by the tachometer).
ler measures the actual motor speed and subtracts it from the desired position to compute
the speed error.
The resulting error value is then multiplied by a user selectable Proportional Gain. The
resulting value becomes one of the components used to command the motor. The effect
of this part of the algorithm is to apply power to the motor that is proportional with the dif-
ference between the current and desired speed: when far apart, high power is applied,
with the power being gradually reduced as the motor moves to the desired speed.
A higher Proportional Gain will cause the algorithm to apply a higher level of power for a
given measured error thus making the motor react more quickly to changes in commands
and/or motor load.
The Differential component of the algorithm computes the changes to the error from one
16 ms time period to the next. This change will be a relatively large number every time an
abrupt change occurs on the desired speed value or the measured speed value. The value
of that change is then multiplied by a user selectable Differential Gain and added to the out-
put. The effect of this part of the algorithm is to give a boost of extra power when starting
the motor due to changes to the desired speed value. The differential component will also
greatly help dampen any overshoot and oscillation.
The Integral component of the algorithm perform a sum of the error over time. This compo-
nent helps the controller reach and maintain the exact desired speed when the error is
reaching zero (i.e. measured speed is near to, or at the desired value).
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Closed Loop Speed Mode
Proportional
Gain
x
x
E= Error
Desired Speed
dE
dt
Σ
-
Output
Tachometer
A/D
Measured Speed
Integral
Gain
or
Optical Encoder
dE
dt
x
Differential
Gain
FIGURE 76. PID algorithm used in Speed mode
PID tuning in Speed Mode
As discussed above, three parameters - Proportional Gain Integral Gain, and Differential
Gain - can be adjusted to tune the Closed Loop Speed control algorithm. The ultimate goal
in a well tuned PID is a motor that reaches the desired speed quickly without overshoot or
oscillation.
Because many mechanical parameters, such as motor power, gear ratio, load and inertia
are difficult to model, tuning the PID is essentially a manual process that takes experimen-
tation.
The Roborun PC utility makes this experimentation easy by providing a screen for changing
the Proportional, Integral and Differential gains and another screen for running and monitor-
ing the motors. Run first the motor with the preset values. Then experiment different val-
ues until a satisfactory behavior is found.
In Speed Mode, the Integral component of the PID is the most important and must be set
first. The Proportional and Differential component will help improve the response time and
loop stability.
In case where the load moved by the motor is not fixed, you will need to tune the PID with
the minimum expected load and tune it again with the maximum expected load. Then try
to find values that will work in both conditions. If the disparity between minimal and maxi-
mal possible loads is large, it may not be possible to find satisfactory tuning values.
Note that the AX2500/2850 uses one set of Proportional Integral and Differential Gains for
both motors and therefore assumes that similar motors, mechanical assemblies and loads
are present at each channel.
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PID tuning in Speed Mode
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Closed Loop Speed Mode
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Optical Incremental Encoders Overview
SECTION 12
Installing,
Connecting and
Using the
Encoder Module
This section describes the Encoder input module that is factory installed inside the
AX2850, or that may be added onto the AX2550.
Optical Incremental Encoders Overview
Optical incremental encoders are a mean for capturing speed and travelled distance on a
motor. Unlike absolute encoders which give out a multi-bit number (depending on the reso-
lution), incremental encoders output pulses as they rotate. Counting the pulses tells the
application how many revolutions, or fractions of, the motor has turned. Rotation velocity
can be determined from the time interval between pulses, or by the number of pulses
within a given time period. Because they are digital devices, incremental encoders will
measure distance and speed with perfect accuracy.
Since motors can move in forward and reverse direction, it is necessary to differentiate the
manner that pulses are counted, so that they can increment or decrement a position
counter in the application. Quadrature encoders have dual channels, A and B, which are
electrically phased 90° apart. Thus, direction of rotation can be determined by monitoring
the phase relationship between the two channels. In addition, with a dual-channel encoder,
a four times multiplication of resolution can be achieved by counting the rising and falling
edges of each channel (A and B). For example, an encoder that produces 250 Pulses per
Revolution (PPR) can generate 1,000 Counts per Revolution (CPR) after quadrature.
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Installing, Connecting and Using the Encoder Mod-
A Channel
1 Pulse
= 4 Transitions
= 4 Counts
B Channel
Quadrature
Signal
Count Up
Count Down
FIGURE 77. Quadrature encoder output waveform
The figure below shows the typical construction of a quadrature encoder. As the disk
rotates in front of the stationary mask, it shutters light from the LED. The light that passes
through the mask is received by the photodetectors. Two photo detectors are placed side
by side at so that the light making it through the mask hits one detector after the other to
produces the 90o phased pulses.
LED light source
Rotating
encoder disk
Stationary mask
Photodetector
FIGURE 78. Typical quadrature encoder construction
Unlike absolute encoders, incremental encoders have no retention of absolute position
upon power loss. When used in positioning applications, the controller must move the
motor until a limit switch is reached. This position is then used as the zero reference for all
subsequent moves.
Recommended Encoder Types
The module may be used with most incremental encoder module as long as they include
the following features:
•
•
•
Two quadrature outputs (Ch A, Ch B), single ended signal
2.5V minimum swing between 0 Level and 1 Level on quadrature output
5VDC operation. 100mA or less current consumption per encoder
More sophisticated incremental, encoders with differential outputs, index, and other fea-
tures may be used but these additional capabilities will be ignored.
The choice of encoder resolution is very wide and is constrained by the module’s maxi-
mum pulse count at the high end, and measurement resolution for speed at the low end.
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Installing the Encoder Module
Specifically, the encoder module can process 250,000 counts per seconds. As discussed
in the previous section, a count is generated for each transition on the Channel A and
Channel B. Therefore the module will work with encoders outputting up to 62,500 pulses
per second.
Commercial encoders are rated by their numbers of “Pulses per Revolution” (also some-
times referred as “Cycles per Revolution). Carefully read the manufacturer’s datasheet to
understand whether this number represents the number of pulses that are output by each
channel during the course of a 360o revolution, rather than the total number of transitions
on both channels during a 360o revolution. The second number is 4 times larger than the
first one.
The formula below give the pulse frequency at a given RPM and encoder resolution in
Pulses per Revolution.
Pulse Frequency in Hz = RPM / 60 * PPR * 4
Example: a motor spinning at 10,000 RPM max, with an encoder with 200 Pulses per Rev-
olution would generate:
10,000 / 60 * 200 * 4 = 133.3 kHz which is well within the 250kHz maximum supported by
the encoder module.
An encoder with a 200 Pulses per Revolutions is a good choice for most applications.
A higher resolution will cause the counter to count faster than necessary and possibly
reach the encoder module’s maximum frequency limit.
An encoder with a much lower resolution, will cause speed to be measured with less pre-
cision.
Installing the Encoder Module
The Encoder module is available in kit form for installation by the user inside the AX2550
controller. It may also be ordered factory-installed in the controller by using the product ref-
erence AX2850.
FIGURE 79. Encoder Module for AX2550. Factory installed in AX2850
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Installing, Connecting and Using the Encoder Mod-
When installing yourself, follow these simple steps
1- With the power removed, remove controller’s face plate and slide off the cover
2- Carefully insert the encoder module on top of the two headers present on the control-
cisely aligned
FIGURE 80. Position of Encoder Module on Controller’s main board
3- The encoder module will be held in place by the connectors and the new front bracket’s
opening around the RJ11 connector. For added stability, place the foam pad on top of the
use in harsh shock and vibration environment, you may instead solder a metal wire inside
the 0.1” hole found on the main board (next to one of the two header) and solder the other
en inside the matching hole on the encoder module, as shown on Figure 82.
Cover
Place Foam Block on Encoder module
Encoder Module
Main Board
FIGURE 81. Place foam block between module and cover to hold in place
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Connecting the Encoder
Encoder Module
Solder wire
Main Board
FIGURE 82. Solder wire for more robust assembly
4- Slide the cover back on. Install the new face plate
5- Power on the controller and install version 1.6 or newer of the controller firmware and PC
utility. Update the encoder firmware if a new version exists.
Connecting the Encoder
The Encoder module uses a widely available 8-pin RJ45 connector identical to these found
on all Ethernet devices. The connector provides 5V power to the encoders and has inputs
for the two quadrature signals from each encoder. Using multi-level signaling, it is also pos-
sible to share the quadrature inputs with limit switches. The figure and table below
describes the connector and its pin assignment.
1
8
8
1
FIGURE 83. Encoder connector
TABLE 23. Encoder connector pin descriptions
Cable Color
Pin
1
Name
(when using standard network cable)
Encoder 2 - Channel B. Optional Limit Switch 4
Encoder 2 - Channel A. Optional Limit Switch 3
Ground
Orange/White
Orange
2
3
Green/White
Blue
4
5V Out
5
Encoder 1 - Channel B. Optional Limit Switch 2
Encoder 2 - Channel A. Optional Limit Switch 1
Blue/White
Green
6
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Installing, Connecting and Using the Encoder Mod-
TABLE 23. Encoder connector pin descriptions
Cable Color
Pin
7
Name
Ground
5V Out
(when using standard network cable)
Brown/White
Brown
8
Motor - Encoder Polarity Matching
When using the Encoder module for closed loop speed control, it is imperative that when
the motor is turning in the forward direction, the counter increments its value, and that a
positive speed value is measured.
Using the PC utility, it is possible to exercise the motors and view the encoder readings.
If the Encoder counts backwards when the motor moves forward, you may correct this by
either:
1- Swap Channel A and Channel B on the encoder connector. This will cause the encoder
module to reverse the count direction
2- Swap the leads on the motor. This will cause the motor to rotate in the opposite direc-
tion.
Voltage Levels, Thresholds and Limit Switches
The encoder module’s input uses a comparator to reshape the encoder’s output signal. If
the signal is below a programmable threshold level, then it is considered as a 0. If above, it
is considered at 1. The output of this comparator feeds the quadrature detector and
counters.
On the 2850 family of controllers, the threshold voltage may be changed under software
control to any value between 0 and 5V to meet unusual encoder specifications. By default,
the threshold level is 2.5V.
Another set of comparators on the same input signals detect pulses that above and below
a fixed 0.5V threshold. Using a special circuitry for creating multi-level signaling (see next
section below), the output of these comparators serves to detect the status of optional
limit switches.
case, because the encoder’s 0 level is below 0.5V, it will cause a Switch Detection condi-
tion which should be ignored.
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Wiring Optional Limit Switches
2.5V
0.5V
Signal on Channel A or B
Quadrature Signal
Switch Detect Signal
(Not meaningful)
FIGURE 84. Signals seen by encoder using direct connection and no limit switches
resistors designed to create a multi-level signal combining both information. Details on the
necessary wiring is provided in the next section.
Since the encoder output signal is “shifted-up” by a few volts, it always stays above the
Limit Switch comparator’s threshold and no Switch Detection condition is generated. How-
ever, since the limit switches connect to ground when On, the level will dip below the 0.5V
and generate a Switch Detection condition.
2.5V
Signal on Channel A or B
0.5V
Quadrature Signal
Switch Detect Signal
FIGURE 85. Signals seen by encoder using multi-levels and limit switches
Important Warning
When a limit switch is activated, the encoder signal that is shared with the switch is
not longer visible by the encoder module and pulse counting and speed measure-
ment stops.
Wiring Optional Limit Switches
If limit switches are needed by the application, additional circuitry is required in order to
create a multi-level signal that share the encoder and the switch information. shows the
electrical diagram of the required wiring.
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Installing, Connecting and Using the Encoder Mod-
5V Out
Ch A In
1kOhm
5V
Ch A
Ch B
Encoder
Encoder Module
GND
Ch B In
GND
1kOhm
SW1
SW2
FIGURE 86. Signals seen by encoder using multi-levels and limit switches
Using this circuit, when the switch is open, a 0V (low-level) output from the encoder goes
through a 1k and 4.7k voltage divider, thus creating a voltage that will never be below 0.8V
at the encoder module’s input.
When the switch is activated, the module’s input is pulled to 0V.
It is recommended to use a voltmeter and/or oscilloscope to verify that the right voltage
levels are created as the encoder rotates and the switches activated.
should increment/decrement as the motor rotate. The switch indicators should be always
off unless the switches are actually activated.
Using the Encoder Module to Measure Distance
As the encoders rotate, their quadrature outputs is automatically processed and incre-
ments/decrements two 32-bit counter inside the Encoder Module. There is one 32-bit
counter for each of the encoders.
The counter values is stored as a signed binary number, ranging from -2,147,836,648 to
+2,147,836,647 (Hexadecimal format of value 80000000 to 7FFFFFFF respectively. When
the maximum or minimum counter value is reached, the counter automatically rolls back to
zero.
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Using the Encoder to Measure Speed
Using the Encoder to Measure Speed
The encoder module will automatically compute rotation speed for each encoder. The
resulting measured speed is a value ranging from 0 to + 127 and 0 to -127, where 127 rep-
resent a relative ratio of a maximum speed value chosen by the user.
For example, if the encoder module is configured so that the highest measured speed
value is 3,000 RPM, then a reading of 63 (127/2) would be 1,500 RPM.
The relationship between the measured speed and the actual speed is a factor of two vari-
able parameters: a Time Based period value stored inside the Encoder module and the
Encoder’s number of Pulses per Revolution. Note: the Encoder’s number of Pulses per
Revolution is not stored in the controller.
The Time Base is a number of 256us time intervals between two counter reads.
A simple procedure is included in the Roborun PC utility to easily determining and set
these parameters.
For information, the exact formula is shown below:
Measured Speed Value = RPM * PPR * 4 * (Time Base+1) * 256 / (60 * 1000000)
or Measured Speed Value = RPM * PPR * (Time Base + 1) / 58593.75
Example: a motor spinning at 1,000 RPM, with an encoder with 200 Pulses per Revolution,
and a Time Base set at 4 will produce the following measurement:
1000 *200 * (4 + 1) / 58593.75 = 17
The same formula modified to show the actual RPM at a given Measure Speed Value is as
follows:
RPM = Measured Speed Value * 60 * 1000000 / (PPR * 4 * 256 * (Time Base+1))
or RPM = Measured Speed Value * 58593.75 /((Time Base + 1) * PPR)
In our example, a measured speed value of 127 correspond to the following measurable
max actual RPM values
RPM at Max Measurable Speed Value = 127 * 58593.75 / ((4 + 1) * 200) = 7441 RPM
A measured speed value of 1 correspond to the following measurable min. actual RPM val-
ues
RPM at Min. Measurable Speed Value = 1 * 58593.75 / ((4 + 1) * 200) = 58.6 RPM
The Roborun Utility automatically makes the above calculations when setting up the
encoder.
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Installing, Connecting and Using the Encoder Mod-
Using the Encoder to Track Position
The encoder module can be used to report the distance between the actual motor position
and a desired destination. The resulting measured “distance” can then be used by the con-
troller in the position mode to move the motor in the right direction until the destination is
reached. This movement is controlled by the PID position algorithm inside the controller
and is therefore best suited at tracking position.
Since the controller uses a signed 8-bit value (-127 to +127) for the distance measurement
in the Position Mode, a special algorithm is used to convert the real distance which can be
much higher than -127 to +127 as both the counter and destination registers are 32-bit
wide.
The actual formula is as follows:
Distance = (Destination - Counter value) / Divider
Where: divider is a configurable parameter of value 1, 2, 4, 8, 16, 32, 64 or 127
If computed distance is less than -127, then reported distance is -127
If computed distance is larger than +127, then reported distance is +127
Destination= 50,050
Counter= 50,000
distance
at divider
50
25
12
6
1
2
4
8
3
1
0
0
16
32
64
128
FIGURE 87. Small distance computation example
Destination= 50,000
Counter= 45,000
distance
127
127
127
127
127
127
78
at divider
1
2
4
8
16
32
64
128
39
FIGURE 88. Large distance computation example
Important Notice
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RS232 Communication with the Encoder Module
Encoders do not report an absolute position value but a count that is relative to the
point where the motor shaft was at power up. It is typically necessary to have the
motors moved to a “home” position and reset the counters at that reference point.
RS232 Communication with the Encoder Module
The Encoder Module contains its own Microcontroller and firmware in Flash. The
Encoder’s MCU communicates with the one on the main board of the controller. During
normal operations, the two MCUs exchange information as needed, invisibly to the user.
During a short time, at power up, however, the Encoder’s MCU will send data to the main
serial port.
The sent data is a separate prompt message which:
•
•
•
Announces the presence of the encoder MCU
Outputs its software revision and date
Outputs a code identifying the module’s hardware ID
This information can be visualized by connecting the controller to a PC’s serial port and run-
ning the Hyperterm terminal emulation software. Note that a link to a properly configured
Hyperterm session is automatically installed in the Start menu when installing the Roborun
utility.
Power up prompt from main MCU
Hardware Code of main board
Power up prompt from encoder MCU
Hardware Code of Encoder Module
FIGURE 89. Hyperterm session showing power up messages from both MCUs
After this information is sent, the Encoder’s MCU will “listen” for approximately 100ms
and will enter the In System Programming mode (ISP) if the letter “Z” is sent to it. While in
the ISP mode, new software can be loaded into the Encoder’s MCU via the controller’s
main serial port.
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Installing, Connecting and Using the Encoder Mod-
RS232 Encoder Command Set
The Encoder module responds to a dedicated set of commands and queries.
The serial port setting and basic command format is identical to this for all other functions
Read Encoder Counter
Description:
Read the value of the Encoder counter(s). The number is a signed 32 bit number that may
range from -2,147,836,648 to +2,147,836,647. The value is output in Hexadecimal format of
value 80000000 to 7FFFFFFF respectively. To speed up communication, only the signifi-
cant digits are sent in response to a counter query. For example, if the counter contains the
value +5 (which is the same number in decimal and hex), the response to the query will be
5 and not 00000005. The formatting algorithm takes into account the number’s sign.
Details on the data format is given in section
Counters’ values can be read as Absolute or Relative. An Absolute counter read will return
the full counter value after every read query. In a Relative counter read, the counter value is
immediately cleared immediately after it is read so that the next read query returns the
new number of counts since the last time the counter was read.
Additionally, in a couple of the query modes, the Encoder module returns the sum for both
counters. This is useful for measuring the average travelled distance by the right and left
wheels of a robotic vehicle.
Syntax:
?q or Qn
Where n=
0: Encoder 1, Absolute
1: Encoder 2, Absolute
2: Sum of Encoders 1 and 2, Absolute
4: Encoder 1, Relative
5: Encoder 2, Relative
6: Sum of Encoders 1 and 2, Relative
Reply:
nnnnnnnn
Where:
Examples:
?Q0
?Q5
Read Encoder 1, Absolute
Read Encoder 2, Relative
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RS232 Encoder Command Set
Set/Reset Encoder Counters and Destination Registers
Description:
Set one or both counters to zero or a user-defined value. The value is a signed 32 bit num-
ber that may range from -2,147,836,648 to +2,147,836,647 (Hexadecimal format of value
80000000 to 7FFFFFFF respectively.
While resetting is a single step command, setting the counters to a non-zero value requires
two steps: 1- load a 4 byte buffer (32-bit) with the desired value. 2- Transfer the buffer’s
content to the counter(s). Loading the buffer can be done using the commands described
also be altered after a Counter Read command, in which case it will contain the last read
counter value.
Syntax:
!q or !Qn
Where n=
0: Reset Encoder 1 counter
1: Reset Encoder 2 counter
2: Reset both Encoder counters
4: Set Encoder 1 counter with value in buffer
5: Set Encoder 2 counter with value in buffer
6: Set both Encoder both counters with value in buffer
7: Set Encoder 1 destination register with value in buffer
8: Set Encoder 2 destination register with value in buffer
Reply:
+ if command was properly received and executed
- if an error occurred
Examples:
!Q2
Reset both counters
!Q5
Load value contained in buffer into counter 2
?Q0, followed by
!Q1
Read counter 1 and copy its value into counter 2
Read Speed
Description:
This query will cause the controller to return the speed computed by the Encoder module.
The values are signed Hexadecimal numbers ranging from -127 to +127. The -127 value rep-
resents the maximum RPM in the reverse direction. +127 represents the maximum RPM
in the forward direction. The relation of this relative number and the actual, absolute RPM
value depends on the encoder’s resolution and a user programmable Time Base. See
Syntax:
Reply:
?z or ?Z
nn
mm
Where:
nn = speed 1 value
mm = speed 2 value
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Installing, Connecting and Using the Encoder Mod-
Notes:
The command returns a signed hexadecimal number where 0 to +127 is represented by 00
to 7F, and -1 to -127 is represented by FF to 80 respectively. The hexadecimal format is
intended to be deciphered by a microcontroller. When exercising the controller manually,
you may use the Decimal to Hexadecimal conversion table on page 103.
Read Distance
Description:
This query will cause the controller to return the distance between the current position and
the value in the destination register. The values are signed Hexadecimal numbers ranging
from -127 to +127. The -127 value represents the relative distance according to the formu-
Syntax:
Reply:
?d or ?D
nn
mm
Where:
nn = distance 1 value
mm = distance 2 value
Notes:
The command returns a signed hexadecimal number where 0 to +127 is represented by 00
to 7F, and -1 to -127 is represented by FF to 80 respectively. The hexadecimal format is
intended to be deciphered by a microcontroller. When exercising the controller manually,
you may use the Decimal to Hexadecimal conversion table on page 103.
Read Speed/Distance
Description:
This query is will cause the controller to return either the speed or the distance computed
by the Encoder module, depending on the operating mode that is selected. This command
is similar to either of the two previous ones, except that it is read from a different location
inside the controller and is a filtered value that smoothened abrupt changes.
Syntax:
Reply:
?k or K
nn
mm
Where:
nn = speed 1 or distance 1 value
mm = speed 2 or distance 2 value
Read Encoder Limit Switch Status
Description:
This query will cause the controller to return the status of the four optional Encoder limit
switches. The returned value is a two-digit (8-bit) Hexadecimal number of which the each
of the 4 least significant bit represents one of the hardware switches.
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RS232 Encoder Command Set
Note that for this function to work, limit switches must be connected to the encoder mod-
page 137. If no limit switches are present, this query will return the logic levels of each of
the encoder’s quadrature outputs, which in most cases is not a relevant information.
Syntax:
Reply:
?w or ?W
0n
Where:
n = switch status
The relationship between the value of n and the switch status is shown in the table below.
Extracting the status of a given switch from this number is easily accomplished by soft-
ware using masking.
TABLE 24. Reported value and switch status relationship
Switch
Switch
n Value
n Value
4
0
0
0
0
0
0
0
0
3
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
4
1
1
1
1
1
1
1
1
3
2
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
0
1
2
3
4
5
6
7
0
0
0
0
1
1
1
1
8
9
0
0
0
0
1
1
1
1
A
B
C
D
E
F
Note that the 0 and 1 levels represents a Closed Switch and Open Switch status, respec-
tively.
Read / Modify Encoder Module Registers and Parameters
Description
These commands make it possible to examine and change parameters that are stored in
the Encoder’s module MCU RAM. While this command provides unrestricted access to up
to 256 memory locations, a small number of these location should ever be read or altered.
Parameter address and returned values are two digit Hexadecimal numbers (8-bit).
Important Note
Command character has been changed from “$” to “*” starting in version 1.7 of the
controller firmware.
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Installing, Connecting and Using the Encoder Mod-
Read parameter
Syntax:
Reply:
Where
*mm
DD
mm= address location of parameter
DD= parameter value
Example:
*84
01
Read value of parameter at address hex 84
Controller replies, value is 01
Modify parameter
Syntax:
Reply:
*mm nn
+ if command was executed successfully
- if error
Where
mm= parameter address
nn= new parameter value
Examples:
*84 03
Store 03 into parameter at address hex 84
Notes:
All parameters and values are expressed with 2 hexadecimal digits
The table below lists maps the few relevant parameters that can be accessed using this
command.
TABLE 25.
Address
84
Parameter Description
Size
Access
Full
Encoder Hardware ID Code
1 byte
1 byte
1 byte
1 byte
85
Switches Status
Full
86
Speed or Distance 1 (depending on operating mode)
Speed or Distance 2 (depending on operating mode)
Counter Read/Write Mailbox MSB (bits 31 to 24)
Counter Read/Write Mailbox (bits 23 to 16)
Counter Read/Write Mailbox (bits 15 to 8)
Counter Read/Write Mailbox LSB (bits 7 to 0)
Counter 1 MSB (bits 31 to 24)
Full
87
Full
88
89
4 bytes
Full
8A
8B
8C
8D
8E
Counter 1 (bits 23 to 16)
4 bytes
Limited
Counter 1 (bits 15 to 8)
8F
Counter 1 LSB (bits 7 to 0)
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Register Description
TABLE 25.
Address
90
Parameter Description
Size
Access
Counter 2 MSB (bits 31 to 24)
Counter 2 (bits 23 to 16)
91
4 bytes
Limited
92
Counter 2 (bits 15 to 8)
93
Counter 2 LSB (bits 7 to 0)
94
Destination Register 1 MSB (bits 31 to 24)
Destination Register 1 (bits 23 to 16)
Destination Register 1 (bits 15 to 8)
Destination Register 1 LSB (bits 7 to 0)
Destination Register 1 MSB (bits 31 to 24)
Destination Register 1 (bits 23 to 16)
Destination Register 1 (bits 15 to 8)
Destination Register 1 LSB (bits 7 to 0)
Distance 1 (when Position Mode enabled)
Distance 2 (when Position Mode enabled)
Speed 1
95
4 bytes
4 bytes
Full
Full
96
97
98
99
9A
9B
9C
8D
86
1 byte
1 byte
1 byte
1 byte
1 byte
Full
Full
Full
Full
Full
87
Speed 2
A2
Time Base for speed computation of Encoder 1. Multiply
this number by 256us to obtain the actual Time Base period.
A3
A4
Time Base for speed computation of Encoder 2. Multiply
this number by 256us to obtain the actual Time Base period.
1 byte
1 byte
Full
Full
A5
A6
Distance divider
Mode Selection
1 byte
1 byte
Full
Limited
Important Warning
Do not alter any other area locations as this may cause program execution failure
inside the encoder module.
Register Description
Encoder Hardware ID code
Returns a 4-bit number identifying the encoder module hardware version and the status of
two on-board jumpers. For Roboteq use only.
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Installing, Connecting and Using the Encoder Mod-
Switch Status
Returns a 4 bit number (4 least significant bits of the byte), each representing the state of
Speed or Distance 1 or 2
These two registers contain either the measured speed or the measured distance.
Whether speed or distance information is returned depends on the settings contained in
the Mode register described at. This information is returned using the ?p query (see
Counter Read/Write Mailbox
Since the counters are 32 bits wide and accesses are 8 bit wide, it would normally take
four separate accesses to fully read or write any of the counters. If the motors are running
and the counter is changing in-between these accesses, inaccurate data will be either read
or written. Therefore a two step process is implemented for accessing the encoder’s
counters: for loading a new value in the counter, the value must first be loaded in the mail-
box. It is then transferred in a single step using a command. When reading a counter, a
read command is sent to the encoder module who then copies the counter value into the
mailbox. The mailbox system can be used in the same way for reading and writing the des-
tination register.
selected counter value.
Writing a user-defined value into a counter or destination register requires that the value be
Counter 1 and 2
These two 32-bit (4-bytes) registers are the actual counters. As discussed above, they
should not be accessed directly as their value may be changing in-between the four
accesses needed to read or write a complete 32-bit counter.
Destination Register 1 and 2
These two 32-bit (4-bytes) registers are used to store the desired destination when the
controller is used in position mode. These registers should always be set using the mailbox
complete description of the position mode.
Distance 1 and 2
These registers contain a signed 8-bit value (-127 to +127) that represents the distance
between the current counter position and the desired destination. This number is com-
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Counter Read Data Format
Speed 1 and 2
These registers contain a signed 8-bit value (-127 to +127) that represents the motor speed
relative to a maximum speed, which in turn depends on the number of encoder counts and
Time Base 1 and 2
Encoder Threshold
This register contains a value that is used to detect a logic level 1 vs. a 0 at any of the 4
encoder input lines. Voltage threshold is computed as follows:
Voltage Threshold = 5V * Register Value / 255
tion.
Counter Read Data Format
When receiving a counter read query, the encoder module will output the value of its 32-bit
counter. If all 32-bit are sent, this would require 8 ASCII digits to represent the value.
A 32-bit counter can store over 2 billion counts in each direction. Practically, it will be rare
that counts will be that large and therefore only a partial number of the counter’s bits will
be significant at any given time.
In order to create a more efficient data stream on the controller’s serial port, a simple com-
pression technique is implemented. The scheme eliminates all of the counter’s most signif-
icant bits if they are at 0 (for a positive count number) or F (for a negative count number).
For example, if the counter value is Hex 00000015, the value 15 will be returned after a
counter query.
For negative numbers, a count value of -5 (which is FFFFFFFB in hex), the response to the
query will be B.
To distinguish between positive and negative numbers, the Encoder module will insert a 0
ahead of any number string starting with a digit value higher than 7 (i.e. 8 to F) to signify
that the number is positive. For negative numbers, the Encoder module will insert an F
ahead of any number string starting with a digit value lower than 8 (i.e. 0 to 7). The table
below shows examples of this scheme as applied to various counter values
TABLE 26. Example counter values and RS232 output using reduction scheme
Decimal
+5
32-bit Hex
00000005
000000FA
FFFFFFFA
Controller Output
5
+250
-6
0FA
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TABLE 26. Example counter values and RS232 output using reduction scheme
Decimal
-235
32-bit Hex
FFFFFF15
056CB872
FF862455
Controller Output
F15
+91,011,186
-7,986,091
56CB872
862455
When reading the counter value into a microcomputer, the reverse operation must take
place: any output that is less than 8 digit long must be completed with a string of 0’s if the
first digit is of value 0 to 7, or with a string of F’s if the first digit is of value 8 to F.
The resulting Hex representation of a signed 32-bit number must then be converted to
binary or decimal as required by the application.
The burden of this extra processing is more than offset by the bandwidth relief on the con-
troller’s serial port.
Encoder Testing and Setting Using the PC Utility
Extensive diagnostic, calibration, setting and testing support is provided in the Roborun PC
Once the utility is up and running and the controller found and identified, click on the
below.
4
1
5
6
2
3
7
7
FIGURE 90. Encoder setup and test screen on Roborun
With this utility, the following actions can be accomplished:
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Encoder Testing and Setting Using the PC Utility
•
•
•
•
•
Set and program the Encoder module’s parameters in EEPROM
Activate the motors in each direction at variable speed
View the measured encoder counts
View the measured encoder speed
View the status of the Limit Switches
The screen is composed of the following buttons and displays:
1- Setting of the Encoder’s threshold level
2- Setting of the Time Base for speed computation
3- Setting Divider for computing relative distance
4- Measure and display speed and relative distance
5- Measure and display counter values
6- Detect and display optional limit switch status
7- Start/Stop communication with controller
8- Set motor speed and direction for testing
Encoder Module Parameters Setting
The Encoder module has 4 programmable parameters: Two Time Bases (one for each
encoder), a Divider for computing relative distance, and the voltage threshold for discern-
ing a 0 or 1 level at the encoder’s output. In the case of the AX2500/2850, the threshold is
fixed at 2.5V and cannot be changed.
The Time Base parameter is used to compute the speed measured by the module. The
measured speed is a relative number ranging from 0 to +/-127.
The relationship between this relative speed number and the actual RPM is based on the
On this screen, changing the Time Base and PPR values automatically display the “Max
RPM” values that can be measured with these settings. For example, with a default set-
ting of 16 and 200 for the Time Base and PPR respectively, the maximum RPM values is
2188. This means that when the motors rotate at 2188 RPM, the measured relative speed
is +127. If the motor spins faster, the speed is still reported to be +127.
Note that the PPR value is not stored in the controller. It is used only in Roborun to convert
relative speed into actual RPM.
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Installing, Connecting and Using the Encoder Mod-
Exercising the Motors
A set of buttons and sliders are provider to starting/stopping communication with the con-
troller and encoder.
When communication is active, the screen will be updated with Encoder data.
Moving the motor sliders will set the motors to the desired speed and direction.
Viewing Encoder Data
During operation, this screen will let you view the following information:
•
•
•
The instantaneous relative 0 to +/-127 speed value
The instantaneous relative distance to destination (0 after reset)
The actual speed computed from the measured relative speed value, encoder Time
Base, and Encoder PPR. The PPR value must be entered manually on this
screen every time you run the utility as it is not stored in the controller or on the
PC.
•
•
The Encoder counter values
The status of the optional limit switches
Updating the Encoder Software
The Encoder Module has its own dedicated MCU and software in Flash memory. It may be
updated using the Roborun Utility in the same manner as for updating the controller’s soft-
ware file to download. The file’s content automatically identifies it as software for the
Encoder MCU rather that the Controller’s MCU.
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SECTION 13
Configuring the
Controller using
the Switches
The AX2500/2850 Speed Controller can be programmed to operate in many modes
using a simple set-up procedure. Two buttons and a 7-segment LED display let the
user examine and change these settings. Alternatively, the controller may be pro-
grammed using a PC connected to the AX2500/2850 controller through the RS232
serial communication port.
The new settings are then permanently stored in the controller’s Flash memory so
that jumpers are not required, resulting in improved system reliability.
Programming Methods
There are three methods for programming the AX2500/2850’s settings:
•
•
•
Using the controller’s built-in switches and display. This method is described
in details in this chapter.
Programming using built-in Switches and Display
Two switches and an LED display are provided to let you easily configure the con-
troller in any of its many operating modes. Unlike the RS232 programming mode,
the switches will let you configure the controller without the need for external hard-
ware or special connectors. In this mode, the controller may be configured while
the placement of the switches and display.
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Configuring the Controller using the Switches
Program Set
Reset
1- Press and hold for 10 sec-
onds while resetting or
powering up to enter Pro-
gram mode
2- When in Programing
mode, display flashes
parameter and its current
value
3- Press to advance to next
value for parameter.
4- Press once to record
value change (if any) and
move to next parameter
Press and hold Program and Set buttons together
for 10 second while resetting or powering on to
restore factory defaults
FIGURE 91. Operating the controller’s buttons and display
Entering Programming Mode
Programming mode is entered by pressing and holding the Program button for 10 seconds
after resetting the controller. The controller can be reset by powering it down and up or by
pressing the Reset switch inserting a paper clip in the hole.
While the button is pressed and until the controller enters the programming mode, the dis-
play will show the following steady pattern.
After 10 seconds, the controller will enter the programming mode and flash a letter repre-
senting the first parameter in the list, followed by its numerical value.
Important Warning
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Programming using built-in Switches and Display
Be careful not to confuse the Set and Program button when entering the Program-
ming Mode. Pressing and holding the Set button alone for 10 seconds after reset will
cause the controller to enter in self-test mode. This will cause the motors to be
turned On and Off according the test sequence described in the Self Test section of
Changing parameters
Pressing the Set button while in Programming Mode will cause the value of the parameter
being inspected to be incremented by one. When the maximum valid value is reached,
pressing Set again will cause the value to restart at 0.
When the desired value is displayed, press the Program button to store it in the control-
ler’s non-volatile memory. This will also cause the controller to display the next parameter
and its current value.
Note that a new parameter value will ONLY be saved if the Program button is pressed
after the value has been changed with the Set button.
Additionally, once you have pressed the Set button and begin changing a parameter’s
value, it is not possible to cancel the change. If you wish to leave a parameter value
unchanged after you have started changing it, you must press the Set button again several
times until it goes back to its original value. Alternatively, you can reset or power Off the
controller to prevent the new value to be recorded.
The Special Case of Joystick Calibration
When the Joystick parameter is selected (“J” and “-” flashing), pressing the Set key again
will cause the controller to enter the Radio Control Joystick calibration sequence.
Once the joystick calibration mode is entered, the display will flash “J” and “o”. With the R/
C receiver and transmitter On, move both joysticks to their full forward, full back, full left
and full right positions a few times. This will cause the controller to capture the min. and
max. joystick position values.
Then move the joysticks to their central (rest) positions. Press the Program button to save
these values in the controller’s Flash memory. The min. and max. values saved are these
captured when the joystick was moved around. The center values saved are the position of
the joystick as it was when Program was pressed.
Note that once the Joystick calibration mode is entered, you must go through the com-
plete calibration sequence described above. If the joysticks are not moved, incoherent data
may be saved in the Flash causing the controller to malfunction in the R/C mode. If bad cal-
ibration data is saved in the Flash, try calibrating again by repeating the entire Joystick Pro-
gramming sequence, otherwise you may restore the factory defaults (this will cause all
parameters you have changed to be restored to their default values as well)
Restoring factory defaults
Should you, for any reason, require to reset the AX2500/2850 controller to its factory
defaults value, press and hold the Program and Set button together for 10 seconds while
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Configuring the Controller using the Switches
resetting the controller. All parameters, including Joystick limits will be reset to their
Exiting the Parameter Setting Mode
Exiting the Programming Mode can be done only by pressing the Reset button or powering
down the controller. The new parameters will be the ones in use after the controller is
reset or first powered up.
Programmable Parameters List
The following table shows the AX2500/2850’s controller parameters in the order they
appear during programming, as well as their valid values.
Important Notice
The parameter table below is guaranteed to be accurate only if your controller soft-
number.
This manual is for software version 1.7
If your controller has a more current software revision, please download an updated ver-
sion of this manual from the Roboteq web site at www.Roboteq.com.
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Programmable Parameters List
This table shows only the parameters that can be programmed using the switches
and display. Other less commonly used parameters exist and are only accessible and pro-
TABLE 27. Parameters accessible using the controller’s switches and display
See
Order
Letter
Description
Possible Values (default)
(0) = R/C Radio mode (default)
1 = RS232 full duplex, no watchdog
2 = RS232 half duplex, with watchdog
3 = Analog mode
pages
1
I
Input Command
mode:
2
C
Motor Control mode
(0) = Separate A, B, speed control, open
loop (default)
1 = Mixed A & B, speed control, open loop
For safety reasons, the modes below
cannot be selected using the switches.
2 = Speed control on A, open loop. Posi-
tion control on B
3 = A & B Position control
4 = Separate A, B, speed control, closed
loop
5 = Mixed A & B, speed control, closed
loop
6 = Speed control on A, closed loop. Posi-
tion control on B
3
A
Amp limit
0 = 30A
1 = 45A
2 = 60A
3 = 75A
4 = 90A
(5) = 105A default
6 = 120A
Amps may be set with a finer resolution
using the PC utility
4
S
Acceleration
0 = very slow
1 = slow
(2) = medium (default)
3 = medium
4 = fast
5 = fastest
Acceleration may be set with a finer resolu-
tion using the PC utility
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Configuring the Controller using the Switches
TABLE 27. Parameters accessible using the controller’s switches and display
See
pages
Order
Letter
Description
Possible Values (default)
5
U
Input switch function 0 = causes emergency stop
1 = invert commands switch
(2) = no action (default)
6
7
b
d
Brake/Coast
Not implemented
0 = no deadband ***
1 = 8%
R/C Joystick Dead-
band
Analog Input Dead-
band
(2) = 16% (default)
3 = 24%
4 = 32%
5 = 40%
6 = 46%
7 = 54%
8
E
Exponentiation on
channel 1
(0) = Linear (no exponentiation - default)
1 = strong exponential
2 = normal exponential
3 = normal logarithmic
4 = strong logarithmic
Same as E, above
9
F
L
Exponentiation on
channel 2
10
Left / Right Adjust
(7) = no adjustment (default)
0, 1, ..., 6 = -5.25%, -4.5%, ...,-0.75%
8, ..., D, E** = +0.75, ..., +4.5%, +5.25%
- = not calibrating
11
J
Joystick calibration
o = in calibration mode
*The coast function is not implemented in this revision of the software. The controller will
only operate in brake mode.
** Values are in hexadecimal numbers where the decimal values 10, 11, 12... 15 are repre-
sented with the letters A, B, C... F.
*** Deadband percent values shown are for R/C mode. For analog deadband values, see
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SECTION 14
Using the Roborun
Configuration
Utility
A PC based Configuration Utility is available, free of charge, from Roboteq. This pro-
gram makes configuring and operating the AX2500/2850 much more intuitive by
using pull-down menus, buttons and sliders. The utility can also be used to update
System Requirements
To run the utility, you will need the following:
•
•
PC compatible computer running Windows 98, Me, 2000 or XP
An unused serial communication port on your computer with a 9-pin, female
connector.
•
•
An Internet connection for downloading the latest version of the Roborun
Utility or the Controller’s Software
5 Megabytes of free disk space
If you do not have a free serial port, the Configuration Utility can still run, but you will
not be able to communicate with the controller.
If your PC is not equipped with an RS232 serial port, you may add one using an USB
to RS232 converter.
Downloading and Installing the Utility
The Configuration Utility is included on the CD that is delivered with the controller or
may be obtained from the download page on Roboteq’s web site at
www.roboteq.com. It is recommended that you use the downloaded version to be
sure that you have the latest update.
•
•
download and run he file robosetup.exe
follow the instructions displayed on the screen
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Using the Roborun Configuration Utility
•
after the installation is complete, you will be able to run the program from your Start
Menu > Programs > Roboteq
You do not need to have the controller connected to your PC to start the Utility.
Connecting the Controller to the PC
The controller must be connected to the PC if you plan to use the Utility to perform any of
the following functions
•
to read the current parameters stored in the controller and display them on the
computer
•
•
•
to store new parameters in the controller
to exercise the motors using your PC
to update the controller’s software
If the controller is not connected, the Configuration Utility can run and may be used to
Most computers have at least one, but often times two serial ports. Look for one or two
connectors resembling the illustration in Figure 92.
FIGURE 92. Look for a 9-pin male connector on your
If you have a serial port connector that is already connected to something else, you may be
able unplug your current device and temporarily connect the controller as long as the soft-
ware operating the current device is not running.
Connect the provided serial cable to the controller on one end and to the PC on the other.
Power the controller, preferably using the yellow Power Control wire, with a 12 to 40V bat-
tery or power supply with 200mA of minimum output.
Connect the thin black wire to the negative (-) terminal, and the Power Control input to the
positive (+) of the power supply. The controller will turn On. If it doesn’t, verify that you
have not reversed the polarity.
Upon powering On, the controller will display “no ctrl” if configured in the R/C mode or a
steady pattern if configured in the RS232 mode.
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Roborun Frame, Tab and Menu Descriptions
Roborun Frame, Tab and Menu Descriptions
2
1
4
3
FIGURE 93. Roborun screen layout
The Roborun screen contains the four main set of commands and information frames
described below:
1- Program Revision Number
This is the revision and date of the Roborun utility. It is recommended that you always ver-
ify that you have the latest revision of the utility from Roboteq’s web site at
www.roboteq.com
2- Controller and Communication Link Information
This frame will automatically be updated with an indication that a free communication port
was found and opened by the utility.
If no free communication port is available on your computer, it will be indicated in this win-
dow. You should try to select another port using the “Change COM Port” button or try to
free the port if it is used by a different device and program.
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Using the Roborun Configuration Utility
With the port open, Roborun will try to establish communication with the controller. If suc-
cessful, this window will display the software revision, the revision date and a set of digits
identifying hardware revision of the board inside the controller.
3- Parameter Selection and Setting, and Special Functions
This is the program’s main frame and includes several types of tabs, each of which has sev-
eral buttons, menus and other User Interface objects. These tabs and the functions they
contain are described in detail in the following sections.
You can go from one set of commands to another by clicking on the desired tab.
4- File and Program Management Commands
This frame contains a variety of buttons needed to load and save the parameters from and
to the controller or disk. This frame also contains the button needed to initiate a software
update to the controller.
Getting On-Screen Help
The Roborun buttons and fields are very intuitive and self-explanatory. Additional explana-
tions and help is provided by means of ToolTips for each command. Simply move the cur-
sor to a button, tab or other gadget on the screen and a message box will appear after a
few seconds.
Loading, Changing Controller Parameters
The first set of tabs allows you to view and change the controller’s parameters. These tabs
are grouped according to the general type of parameters (Controls, Power Setting, and R/C
Settings).
When starting Roborun, this screen is filled with the default values. If the controller is con-
nected to your PC, Roborun will automatically detect it and ask you if you wish to read its
settings.
You can read the controller’s setting in the PC at any other time by pressing the “Load from
Controller” button. After changing a parameter, you must save it to the controller manually
by pressing the “Save to Controller” button.
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Loading, Changing Controller Parameters
Controls Settings
1
2
3
4
5
FIGURE 94. Control modes setting screen
modes. Below is the list of the parameters accessible from this screen
1- Controller Input:
This pull down menu allows you to select the RS232, R/C or Analog mode of operation. If
the RS232 mode is selected, a check box will appear, allowing you to enable or disable the
RS232 Watchdog. For more information on these modes, see
•
•
•
•
2- Motor Control Mode
This pull down menu is used to choose whether the controller will operate in Separate or
3- Input Command Adjustment
These pull down menus will let you select one of five conversion curves on each of the
4- Emergency Stop or Invert Switch Select
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This pull down menu will let you select the controller’s response to changes on the
5- Effect of Digital Inputs
This pull down menu will let you select the controller’s response to changes on either of
Power Settings
1
2
3
FIGURE 95. Power settings screen
controller.
1- Amps limit
This slider will let you select the max amps that the controller will deliver to the motor
2- Left/Right Adjust
This slider will let you configure the controller so that it applies more power to the motors
3- Acceleration Setting
This slider will let you select one of seven preset acceleration values. The label on the right
shows a numerical value which represents the amount of time the controller will take to
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Loading, Changing Controller Parameters
Analog or R/C Specific Settings
1
2
FIGURE 96. Power settings screen
selected or not.
If the Analog Input mode is selected on the main screen, then this page is used to set the
Analog Deadband value. In the R/C mode, this page is used to view and change parame-
ters used in the R/C mode of operation. None of these parameters has any effect when
running the controller in RS232 mode.
If the controller is configured in RS232 mode, some of these menus will be grayed-out but
will remain active.
1- Deadband
This slider will let you set the amount of joystick motion off its center position before the
motors start moving. The slider will work identically in the R/C or analog mode, however,
2- Joystick Timing
These fields are enabled only if the R/C mode is selected. These number areas will let you
read and modify the R/C pulse timing information used by the controller. New values can
be entered manually to create different capture characteristics. They are also useful for
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Using the Roborun Configuration Utility
Closed Loop Parameters
FIGURE 97. Closed Loop parameter setting screen
gains needed for the PID algorithm. These parameters are used in the Position mode (see
Viewing the Parameters Summary
The summary page will list the command letter and value for each parameter, as defined in
the various parameter setting screens.
It is possible to print this screen and bring it to the controller in order to then quickly and
Important Notes:
Most but not all configuration parameters can be updated using the switches.
The print command will automatically use your default printer. No print setup box
will be displayed.
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Optical Encoder Operation
FIGURE 98. Viewing parameters summary
Optical Encoder Operation
The Roborun utility provides many facilities for configuring and testing the Optical Encoder
Running the Motors
The Roborun utility will let you exercise and monitor the motors, sensors and actuators
using your computer. This feature is particularly useful during development as you will be
able to visualize, in real-time, the robot’s Amps consumption and other vital statistics dur-
ing actual operating conditions.
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Using the Roborun Configuration Utility
7
4
1
3
2
8
6
5
FIGURE 99. Motor exercising and monitoring screen
1- Run/Stop Button
This button will cause the PC to send the run commands to the controller and will update
the screen with measurements received from the controller.
When the program is running, the button’s caption changes to “Stop”. Pressing it again will
stop the motors and halt the exchange of data between the PC and the controller.
If you select another tab while the program is running, the program will stop as if the Stop
button was pressed.
2- Motor Power setting
This sub-frame contains a slider and several buttons. Moving the slider in any direction
away from the middle (stop) position will cause a power command to be issued to the con-
troller. The value of the command is shown in the text field below the slider.
The stop button will cause the slider to return to the middle (stop) position and a 0-value
command to be sent to the controller. The + and ++ buttons will cause the slider to move
by 1 or 10 power positions respectively.
3- Measurement
These series of fields display the various operating parameters reported in real-time by the
controller:
The Amps field reports the current measured at each channel. The Peak Amps field will
store the highest measured Amp value from the moment the program began or from
when the peak was reset using the Clr Peak button.
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Running the Motors
The Power field displays the power level that is actually being applied to the motor. This
value is directly related to the motor command except during current limitation, in which
case the power level will be the one needed to keep the Amps within the limit. Note that
the display value is not sign and thus does not provide rotation direction information
The Ana field contains the analog input value that is measured and reported by the control-
ler. When the controller is in the position mode, this field will display the position sensed
on the potentiometer. When in speed mode, this field displays the measured speed by the
tachometer.
In all other mode, this field will display the value at the analog input pin. A small button next
to this field will toggle the display caption, and conversion algorithm from raw analog, volts
or temperature.
Note that in order to measure and display external temperature or voltage, the proper
The Enc field contains the speed or position measured by the Optical Encoder if enabled.
The Temp field displays the heat sink temperature for each channel
The Bat Volt field displays the main battery’s voltage (voltage applied to the thick red
wires).
The Ctrler Volt field displays the controller’s internal regulated 12V voltage.
4- Real-Time Strip Chart Recorder
This chart will plot the actual Amps consumption and other parameters as measured from
the controller. When active, the chart will show measurement during the last five seconds.
The two handles at the bottom of the chart are zoom in or out the history sample that is to
be displayed on the chart. Using these handles it is possible to go back and examine any
event up to 5 minutes into the past. This feature is extremely useful during development
and test of the robotic vehicle.
5- Transmit and Receive Data
These two fields show the data being exchanged between the PC and the controller. While
these fields are updated too fast to be read by a person, they can be used to verify that a
dialog is indeed taking place between the two units.
After the Start button is pressed, the Tx field will show a continuous string of commands
and queries sent to the controller.
The Rx field will display the responses sent by the controller. If this field remains blank or is
not changing even though the Tx field shows that data is being sent, then the controller is
Off or possibly defective. Try resetting the controller and pressing the Run/Stop button.
6- Input Status and Output Setting
This section includes two check boxes and three color squares. The check marks are used
to activate either of the controller’s two outputs. The color blocks reflect the status of the
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three digital inputs present on the controller. Black represents a “0”level. Green repre-
sents a “1” level.
7- Data Logging and Timer
A timer is provided to keep track of time while running the motors. An additional set of but-
tons and displays are provided to operate a data logger. The data logger is fully described in
the section that follows.
8- Joystick Enable
Enable and configure a joystick.
Logging Data to Disk
While running the motors, it is possible to have Roborun capture all the parameters that
were displayed on the various fields and charts, and save them to disk. The log function is
capable of recording 32,000 complete sets of parameters, which adds up to approximately
30 minutes of recording time. The figure below details the buttons and check boxes
needed to operate this function.
1- Log Check Box
When checked, Roborun will capture all the parameters and save them in local RAM. The
data is not saved to disk until the “Save to Disk” button is pressed. Data is being captured
for as long as the program is in the Run mode, whether or not a motor command is
applied.
2- Clear Log
This button can be pressed at any time to clear the local RAM from its content. Clearing
the log also has the effect of resetting the timer.
3- Log Fill Status
This grayed text box indicates whether the local RAM log is empty, full, or in-between.
4- Reset Timer button
The timer automatically runs when the Run button is pressed and data is being exchanged
with the controller, regardless whether logging is activated. This button resets the timer.
5- Save Log to Disk button
Pressing this button will prompt the user to select a filename and location where to copy
the logged data. The file format is a regular text file with each parameter saved one after
the other, separated by a coma. The file extension automatically defaults to .csv (coma
separated values) so that the data can be imported directly into Microsoft Excel. The first
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Running the Motors
line of the save file contains the Header names. Each following line contains a complete
TABLE 28. Logged parameters order, type and definition
Parameter Header
Seconds
Data type/range
Integer
Measured Parameter
Timer value expressed in seconds
Command applied to channel 1
Command applied to channel 2
Command1
Command2
Power1
-127 to +127
-127 to +127
0 to 127
Amount of power applied to the output stage of chan-
nel 1
Power2
0 to 127
Same for channel 2
Ana 1, Speed 1, Pos 1
or Temp 1
or Volt 1
-127 to + 127
-40 to +150
0 to 55
Value of sensor connected on analog input 1. Data is
automatically converted to the right value and format
by Roborun according to the sensor that is being used
Ana 2, Speed 2, Pos 2
Temp 2 or
Volt 2
-127 to + 127
-40 to +150
0 to 55
Same for channel 2
Amps1
0 to 255
Measured Amps on channel 1
Measured Amps on channel 2
Measured Temperature on channel 1’s heatsink.
Measured Temperature on channel 2’s heatsink.
Main Battery Voltage.
Amps2
0 to 255
FET Temp1
FET Temp2
Batt Volt
-40 to +150
-40 to +150
0 to 55
Ctrl Volt
0 to 28.5
Internal 12V Voltage.
Enc1
-127 to + 127
Measured Optical Encoder’s Speed or Position
depending on selected operating mode
Enc2
-127 to + 127
Same for channel 2
Connecting a Joystick
Exercising the motors can easily be done using a Joystick in addition to the on-screen slid-
ers. Simply connect a joystick to the PC and enable it by clicking in the Joystick check box
in the PC utility.
If the box is grayed out, the joystick is not properly installed in your PC and you can click on
the “Config Joystick” button to open a configuration screen and the joystick control panel.
Joystick movement should automatically translate into Channel 1 and Channel 2 command
values and make the sliders move. These commands are also sent to the controller.
It is strongly recommended that you use an USB rather than Analog joystick.
A joystick test program name “Joytest” is automatically installed in your Start menu when
installing the Roborun utility. This program may be used to further verify that the joystick is
properly installed in the PC and is fully operational.
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Using the Roborun Configuration Utility
Viewing and Logging Data in Analog and R/C Modes
When the controller is configured in R/C or Analog mode, it will automatically and continu-
This feature makes it possible to view and log the controller’s internal parameters while it
is used in the actual application. The data may be captured using a PC connected to the
controller via an RS232 cable or wireless modem.
When wired for R/C or Analog controls, the AX2500/2850 will not be able to receive com-
mands from the PC and the Roborun software will not recognize the controller as being
present. However, when in the Run tab and the Run button activated, Roborun will be
receiving the strings sent by the controller and display the various parameters in the right
display box and chart.
Loading and Saving Profiles to Disk
It is possible to save the configuration parameters that are read from the controller or that
have been set/changed using the various menus to the disk. This function will let you easily
recall various operating profiles at a later time without having to remember or manually
reset all the parameters that are used from one configuration to another.
To save a profile to disk, simply click on the “Save Profile to Disk” button. You will then be
prompted to choose a file name and save.
Reading a profile from disk is as simple as clicking on the “Load Profile from Disk” button
and selecting the desired profile file. The parameters will be loaded in each of their respec-
tive buttons, sliders and text fields on the various Roborun screens. The parameter will
not be transferred to the controller until you press the “Save to Controller” button.
Operating the AX2500/2850 over a Wired or Wireless LAN
The Roborun utility supports connection and operation of the AX2500/2850 controller over
a Wired or Wireless TCP/IP network. This feature makes it easy to tele-operate and moni-
tor the controller across a lab, of across the globe via Internet.
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Operating the AX2500/2850 over a Wired or Wireless LAN
The top computer is connected to the controller via its COM port. Both computers are con-
nected to a TCP/IP network.
Computer running
Roboserver
Controller
Wired or
Wireless
802.11 LAN
Computer running
Roborun Utility
FIGURE 100. Operating the controller over a LAN
The computer connected to the controller must run a communication server program
named roboserver. This program is automatically installed in the Start menu when install-
ing the Roborun utility. This program’s function it to wait for and accept TCP/IP connection
requests from the other computer and then continuously move data between the network
and the COM port. When launched, the screen shown below appears.
The second computer runs the Roborun utility. To establish contact with the server pro-
gram, click on the “Change COM/LAN Port” button and enter the IP address of the second
computer. Communication should establish immediately.
When the two computers are connected, it will be possible to operate the motors and read
the controller’s operating parameters in the Roborun Run window.
FIGURE 101. Roboserver screenshot when idle
Note that it is not possible to use this configuration to change the controller’s parameters
or update the controller’s software.
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Using the Roborun Configuration Utility
Updating the Controller’s Software
The AX2500/2850’s operating software can be easily upgraded after it has left the factory.
This feature makes it possible to add new features and enhance existing ones from time to
time.
Important Warning
Updating the controller will cause all its parameters to reset to their default condi-
tions. You should re-enter these parameters to your desired value prior to re-install-
ing and using the controller.
The upgrade procedure is quick, easy and error proof:
1- Connect the controller to the PC via the provided RS232 cable.
2- Apply a 12V to 40V power supply to the controller’s Ground and Power Control input
(thin black and yellow wires).
3- Launch the Roborun utility if it is not already running. Then click on the “Update Con-
troller Software” button.
4- If the controller is On, Roborun will find it and prompt you to select the new software
file. It may happen that the controller is not responding properly and you may be asked
to reset it while connected.
5- Press the “Program” button to start programming. Do not interrupt or cut the
power to the controller while the new program is loading into Flash memory.
6- After a verification, you will be notified that the operation was successful and you will
see the new software revision and date as reported by the controller.
Notes:
The Updating utility will automatically detect whether the new software is intended for the
main or encoder’s MCU and program one or the other accordingly.
It is a good idea to load the controller’s parameters into the PC and save them to disk prior
to updating the software. After the new software in transferred to the controller, you can
use the “Load Parameters from Disk” function and transfer them to the controller using
the “Save to Controller” button.
Creating Customized Object Files
It is possible to create versions of the controller’s firmware with default settings that are
different than those chosen by Roboteq. This capability can be used to improve system reli-
ability in the unlikely, but not impossible occurrence of a parameter loss in the controller’s
non-volatile memory. Should such an event occur, the controller would revert to the
defaults required by the application.
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Creating Customized Object Files
8
FIGURE 102. Objectmaker creates controller firmware with custom defaults
Creating a custom object file can easily be done using the Objectmaker utility. This short
program is automatically installed in the Start menu when installing the Roborun utility.
1- Use the Roborun utility to create and save to disk a profile with all the desired param-
eter value
2- Launch Objectmaker from the Start menu
3- Select the latest official controller firmware issued by Roboteq
4- Select the profile file that you created and saved earlier
5- Select a revision letter. This letter will be added at the end of Roboteq’s own version
identity number.
6- Click on the Create button and save the new customized object file
7- Click on the Done button to exit the program
8- Install the new object file in the controller using the Roborun utility
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Using the Roborun Configuration Utility
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Mechanical Dimensions
SECTION 15
Mechanical
Specifications
This section details the mechanical characteristics of the AX2500/2850 controller.
Mechanical Dimensions
The AX2500/2850 is built into a extruded aluminum case which also serves as a heat sink
mechanical dimensions.
1.60"
(40 mm)
Program Set
Reset
4.00" (102 mm)
5.50" (140 mm)
FIGURE 103. AX2500/2850 front view and dimensions
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Mechanical Specifications
5.50" (140 mm)
4.00" (101.6 mm)
3.00" (76.2 mm)
FIGURE 104. AX2500/2850 top view and dimensions
Mounting Considerations
Mounting brackets on each end are provided for durable assembly of the controller onto
any chassis.
The AX2500/2850 uses no jumpers and includes no loose parts or wires. Consequently, it
will be able to run reliably in severe shock and vibration environment.
Optional shock mount absorbers may be added for use in the most brutal environment.
Thermal Considerations
The AX2500/2850 is built into a heat-sinking aluminum extrusion. The large fin area on the
side of the extrusion ensures sufficient heat dissipation for operation without a fan in most
applications.
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Wire Dimensions
For high current applications, it is possible that the controller may heat-up faster and to a
higher temperature than can be dissipated by the heatsink enclosure using natural convec-
tion alone.
In these applications, you should ensure that air flow exists to remove the heat from the
heat sink. In the most extreme use, you should consider using external and fan to circulate
air around the controller.
Alternatively, you may mount the controller so that its bottom area is in contact with large
metallic parts of the robot’s body. This will allow some of the controller’s heat to dissipate
through conduction to additional metal mass, and therefore remain cooler for longer peri-
ods of time. Apply thermal grease between the controller’s bottom and the robot’s chassis
to ensure the best thermal conduction.
Wire Dimensions
A total of eight heavy gauge wires, and two thin wires are present at the back of the con-
TABLE 29. AX2500/2850 wire identification and dimensions
Wire
Gauge
AWG8
AWG8
AWG8
AWG8
AWG8
AWG8
AWG8
AWG8
AWG22
Outside Diameter
0.26” (6.6mm)
0.26” (6.6mm)
0.26” (6.6mm)
0.26” (6.6mm)
0.26” (6.6mm)
0.26” (6.6mm)
0.26” (6.6mm)
0.26” (6.6mm)
0.07” (1.8mm)
Color
Red
Length
Motor1 Battery+
Motor1 Battery-
Motor2 Battery+
Motor2 Battery-
Motor1 Terminal+
Motor1 Terminal-
Motor2 Terminal+
Motor2 Terminal-
17”(43mm)
17”(43mm)
17”(43mm)
17”(43mm)
17”(43mm)
17”(43mm)
17”(43mm)
17”(43mm)
17”(43mm)
Black
Red
Black
White
Green
White
Green
Yellow
Power Control or
Backup Controller
Battery
Controller Battery-
AWG22
0.07” (1.8mm)
Black
17”(43mm)
Weight
Controller weight is 3.3 lbs (1500g)
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Mechanical Specifications
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