CO2 Laser
The motor controller is a custom-built unit that integrates custom printed circuit boards, the Pico Systems Universal Stepper Controller card, Gecko G320 motor drives, and an internal power supply. It also interfaces with servos requiring DC power and motor encoders, as well as limit switches that detect when the table nears the maximum length of each ballscrew. The Universal Stepper Controller connects to the computer's parallel port via a DB-25 cable, and the EMC2 software includes a driver and documentation for operating this controller. Additionally, there are sets of EMC configuration files that facilitate the use of the USC card with EMC. The documentation outlines the connections on the stepper controller, detailing the signal connectors that control step and direction for each motor while monitoring the status of the limit switches. A circuit diagram of a custom circuit board called the USC_bridge provides insight into how it connects to three connectors (P2, P4, and P5) of the Universal Stepper Controller. The USC_bridge simplifies the connections to the rest of the system by breaking them into logical components. For instance, the bridge includes individual RJ-45 connectors for "cat-5" Ethernet cables to connect to each E3 servo motor encoder manufactured by US Digital, as well as separate cat-5 connections for limit switches and emergency-stop switches. The limit switches utilize optocouplers instead of mechanical switches, requiring additional onboard circuitry to drive the emitter and detector of the optocoupler. The motor controller features a 12V DC and 5V DC power supply that powers both the Universal Stepper Controller and the USC_bridge. The USC_bridge was designed using Labcenter's Proteus, and a modeled PCB was produced. Most components were sourced from Mouser, and a bill of materials for the USC_bridge is available. Connections to the Gecko drives are straightforward, following the documentation provided by Gecko and the Universal Stepper Controller. Voltage is supplied via 12 AWG wires from the motor power supply, connecting to Gecko terminals (1 and 2). A 1000 µF capacitor is placed across these terminals, encapsulated in heat shrink tubing. The motor connects to terminal 3, and a 15-amp fast blow fuse is placed in series with terminal 4 leading to the motor. The motor controller is designed to operate a total of four servos, although only two motors are currently in use. The physical construction incorporates laser-cut brackets that secure all boards, connectors, switches, and a 110V plug leading to the 12/5V DC power supply. Many components were laser-cut, and an SVG file of all parts is available. When assembling such a unit, it is advisable to mount everything on a board that serves as a platform for all components, which can then be placed into a larger enclosure once debugging is complete. Following the Gecko instructions for tuning the Gecko servo motor controller is essential. The group of Gecko motor drives receives power from the motor power supply and is activated by signals from the Pico Systems Universal Stepper Control card. Although the control card is well-designed, the connection process using the provided wire adapters can be complex. To simplify this, all adapters were replaced with plug/pin connectors that link to the other components. The control card is depicted at the top of the accompanying image, showcasing the wiring connectors. The backend of the motion controller features various connections to large servos, with a more organized management system compared to earlier designs.
The motor controller's architecture is designed for versatility and efficiency in controlling multiple servos. The integration of the Universal Stepper Controller with Gecko drives allows precise control over motor movements. The use of optocouplers for limit switches enhances reliability and reduces mechanical wear, which is crucial in applications requiring frequent operation. The USC_bridge acts as a central hub, streamlining communication between the various components and simplifying troubleshooting and maintenance.
The power supply design ensures that both 12V and 5V requirements are met, allowing for stable operation of the controller and connected devices. The choice of using RJ-45 connectors for encoders and switches facilitates easy connections and replacements, leveraging standard Ethernet cabling for simplicity and availability.
The design considerations taken during the development of the USC_bridge and the overall layout of the motor controller emphasize modularity and ease of assembly, which are critical in prototyping and production environments. The use of laser-cut components not only provides precision but also enables rapid prototyping and adjustments as needed.
In conclusion, this motor controller system exemplifies a well-thought-out approach to servo control, combining robust hardware with thoughtful design to achieve reliable performance in various applications. The documentation and resources available further enhance the usability and effectiveness of the system, making it suitable for both hobbyists and professional users.The motor controller is a custom built box that is a combination of custom printed circuit boards, the Pico Systems Universal Stepper Controller card, gecko G320 motor drives and internal power supply. The motor controller also links to the servos which require DC power and motor encoders, as well as limit switches which detect when the table its
nearing the either maximum length of each ballscrew. The Universal Stepper Controller connects to the computer`s parallel port via a DB-25 cable and the EMC2 software comes with a driver ( documentation ) that handles the driving this controller. There is also sets of EMC configuration files that are really useful for working with the USC card and EMC.
The documentation for the connections on stepper controller is here and signals connectors control step and direction for each motor, as well as monitoring the status of the limit switches. The best way to understand the motor controller is to take a look at this drawing is a circuit diagram of custom circuit board called the USC_bridge that serves as a link between most of the components of the motor controller.
This shows how the USC_bridge connects to three connectors ( P2, P4 and P5 ) of the Universal Stepper Controller. Part of the motivation for making the USC_bridge was that it broke the connects to the rest of the system into more logical components so for example the bridge has individual RJ-45 connectors to use "cat-5" ethernet cables to connect to each E3 servo motor encoders made by US Digital, as well as separate cat-5 connects to limit switches and emergency-stop switches.
The limit switches are not mechanical switches but are actually composed of optocouplers - these also require a little extra on board circuitry to drive the emitter and detector on the optocoupler. The motor controller also has a 12vdc and 5 vdc power supply which is used to power the Universal Stepper Controller and the UCS_bridge.
The UCS_bridge was designed in Labcenter`s Proteus, and a modeled PCB was sent off to Pool. Almost all parts were ordered from Mouser. A bill of materials for the UCS_bridge is here. Connections to the Gecko drives is straightforward and follows the documentation supplied by Gecko and the Universal Stepper Controller. Voltage comes in via 12 AWG wires from the motor power supply and connects to Gecko terminals (1 and 2, see pic ).
A 1000 uF capacitor is connected across these terminals and bundled in heat shrink tubing. The motor is connected to terminals 3, and a 15 amp fast blow fuse is placed in series with terminal 4 and then also run to the motor. (A pic of a gecko drive). The motor controller was desinged to run a total of four servos but only two motors are being used at this point.
Physical construction of the motor controller includes laser cut brackets that hold all boards, connectors, switches and 110v plug which leads to the 12/5vdc power supply. Many parts for the controller were cut by the laser, a svg file of all the parts are here. When building a box such as this it is always a good idea to mount everything on a board which serves as a platform for all the parts, and the platform can be dropped into a larger enclosure once you have debugged all the circutry.
Be sure to follow the Gecko instructions to tune the Gecko servo motor controller. The gang of Gecko motor drives receive power from the motor power supply and are driven with signals coming from the Pico Systems Universal Stepper control card. The control card is quite nice, except its not simple to connect using the wire adaptors that come with card.
I pulled all of them out and put in plug/pin connectors that lead to all the other components. The control card is shown at the top of this pic, with wiring connectors. The backend of the motion controller has various connects going to my monster sized servos. Management of connections are much more intelligently handled than my first generatio 🔗 External reference
The motor controller's architecture is designed for versatility and efficiency in controlling multiple servos. The integration of the Universal Stepper Controller with Gecko drives allows precise control over motor movements. The use of optocouplers for limit switches enhances reliability and reduces mechanical wear, which is crucial in applications requiring frequent operation. The USC_bridge acts as a central hub, streamlining communication between the various components and simplifying troubleshooting and maintenance.
The power supply design ensures that both 12V and 5V requirements are met, allowing for stable operation of the controller and connected devices. The choice of using RJ-45 connectors for encoders and switches facilitates easy connections and replacements, leveraging standard Ethernet cabling for simplicity and availability.
The design considerations taken during the development of the USC_bridge and the overall layout of the motor controller emphasize modularity and ease of assembly, which are critical in prototyping and production environments. The use of laser-cut components not only provides precision but also enables rapid prototyping and adjustments as needed.
In conclusion, this motor controller system exemplifies a well-thought-out approach to servo control, combining robust hardware with thoughtful design to achieve reliable performance in various applications. The documentation and resources available further enhance the usability and effectiveness of the system, making it suitable for both hobbyists and professional users.The motor controller is a custom built box that is a combination of custom printed circuit boards, the Pico Systems Universal Stepper Controller card, gecko G320 motor drives and internal power supply. The motor controller also links to the servos which require DC power and motor encoders, as well as limit switches which detect when the table its
nearing the either maximum length of each ballscrew. The Universal Stepper Controller connects to the computer`s parallel port via a DB-25 cable and the EMC2 software comes with a driver ( documentation ) that handles the driving this controller. There is also sets of EMC configuration files that are really useful for working with the USC card and EMC.
The documentation for the connections on stepper controller is here and signals connectors control step and direction for each motor, as well as monitoring the status of the limit switches. The best way to understand the motor controller is to take a look at this drawing is a circuit diagram of custom circuit board called the USC_bridge that serves as a link between most of the components of the motor controller.
This shows how the USC_bridge connects to three connectors ( P2, P4 and P5 ) of the Universal Stepper Controller. Part of the motivation for making the USC_bridge was that it broke the connects to the rest of the system into more logical components so for example the bridge has individual RJ-45 connectors to use "cat-5" ethernet cables to connect to each E3 servo motor encoders made by US Digital, as well as separate cat-5 connects to limit switches and emergency-stop switches.
The limit switches are not mechanical switches but are actually composed of optocouplers - these also require a little extra on board circuitry to drive the emitter and detector on the optocoupler. The motor controller also has a 12vdc and 5 vdc power supply which is used to power the Universal Stepper Controller and the UCS_bridge.
The UCS_bridge was designed in Labcenter`s Proteus, and a modeled PCB was sent off to Pool. Almost all parts were ordered from Mouser. A bill of materials for the UCS_bridge is here. Connections to the Gecko drives is straightforward and follows the documentation supplied by Gecko and the Universal Stepper Controller. Voltage comes in via 12 AWG wires from the motor power supply and connects to Gecko terminals (1 and 2, see pic ).
A 1000 uF capacitor is connected across these terminals and bundled in heat shrink tubing. The motor is connected to terminals 3, and a 15 amp fast blow fuse is placed in series with terminal 4 and then also run to the motor. (A pic of a gecko drive). The motor controller was desinged to run a total of four servos but only two motors are being used at this point.
Physical construction of the motor controller includes laser cut brackets that hold all boards, connectors, switches and 110v plug which leads to the 12/5vdc power supply. Many parts for the controller were cut by the laser, a svg file of all the parts are here. When building a box such as this it is always a good idea to mount everything on a board which serves as a platform for all the parts, and the platform can be dropped into a larger enclosure once you have debugged all the circutry.
Be sure to follow the Gecko instructions to tune the Gecko servo motor controller. The gang of Gecko motor drives receive power from the motor power supply and are driven with signals coming from the Pico Systems Universal Stepper control card. The control card is quite nice, except its not simple to connect using the wire adaptors that come with card.
I pulled all of them out and put in plug/pin connectors that lead to all the other components. The control card is shown at the top of this pic, with wiring connectors. The backend of the motion controller has various connects going to my monster sized servos. Management of connections are much more intelligently handled than my first generatio 🔗 External reference
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