5.2.1 Copley Drive Configuration Operation Guide

Description

This document outlines the automated transformation process for robots, which guarantees that the company's products adhere to industry standards, maintain consistent product quality, and provides technical personnel with guidelines to follow throughout the transformation process.

Robot automation transformation requires the use of numerous sensors. We suggest utilizing our standard core controller wiring harnesses, TE23 and TE35. This document serves as a guide for operating with the standard wiring harness of the core controller.

1. Scope of Application

This technical specification applies to the company's research and development, production, and debugging technicians for robot automation transformation.

Second, Debugging Resources

3. Transformation Process

Retrofit (Chassis Driver Part)

1. The driver must be securely attached to the car body and ensure that it is properly connected to the three-phase wire and encoder line of the corresponding motor.

2. If the robot is equipped with multiple drives (number ≥2), the CAN_L and CAN_H pins of the slave station can be directly connected and connected in series, as illustrated in Figure 4.3.1. Insert the can_H into a Decci cartridge connector, insert the can_L into a Decci cartridge connector, and connect the Decci DT06-2S male connector. Finally, connect it to line 32,33 (can1) in TE35.

    Figure 4.3.1

    Figure 4.3.1 - Enhanced visualization of data

3. In order to guarantee the quality of CAN communication, activate the 120Ω terminal resistance on the driver that is farthest from the core controller. For instance, activate the terminal resistance on Driver1 through the dial shown in Figure 4.3.1.

4. SRC2000 utilizes the method of controlling the motor's enablement to achieve the emergency stop function. The level of the corresponding IO port on the Copley driver determines whether the motor can be enabled or not.

5. The Enable signal for the Copley driver is controlled by the "IN1(Enable)" 4-wire connection on the J3 connector. Using the software, IN1 can be configured as "AMP Enables-LO Enables With Clear Faults" (a low-level input will enable the driver). Additionally, IN1 can be configured as "Pull up +5V" (with an internal pull-up of +5V). At this point, the low-level signal enabled by the driver can be provided by the No.15 [Signal Gnd] wire on the J3 connector, as shown in FIG. 4.3.2 and FIG. 4.3.3.

Figure 4.3.3:

6. Remove [IN1 Enable] No. 4 from the J3 connector of both drivers and insert it into the corresponding Dechi cartridge connector. Extract No. 15 [Signal] wire from both drivers and insert it into the corresponding Decci needle tube connecting machine. Finally, insert the two-pin tube connector into the DT06-2S female head and connect the female head to the male head of the TE35 wire harness with [4] emergency stop output 1- and [5] emergency stop output 1+.

7. The installation and emergency stop of the Copley driver have been completed. To fully utilize the driver's optimal performance, it is necessary to conduct driver debugging after assembling the motor reducer and wheel, as shown in Figure 4.3.4. Figure 4.3.4

Four, Drive Configuration

4.1 Commissioning Preparations

1. Download and install the CME2 debugging software from www.copleycontrols.com/Motion/Products/Software/index.html; Copley
2. It is recommended to use RS232 communication mode to establish communication between the debugging computer and the driver. It is also recommended to use a USB-232 converter and create a connection cable by referring to Copley J6, as shown in Figure 4.1.1;
Figure 4.1.1
3. After powering on the drive, double-click the CME2 software icon. The software will prompt you to use the "F12" key on the keyboard to enable the drive. Click "OK" directly, as shown in Figure 4.1.2:Figure 4.1.2

4. Choose the software connection mode by selecting [Tools] - [Communications Wizard] - [Serial Ports] - then choose the com port connected to the drive - [Next], as shown in Figure 4.1.3 and Figure 4.1.4:

Figure 4.1.3

Figure 4.1.4
5. At this point, you will see software debugging, as shown in Figure 4.1.5, and the meanings of each icon are displayed in Figure 4.1.6:Figure 4.1.5

Figure 4.1.6

6. Set up the motor type by clicking the icon on the motor toolbar and then selecting [Change Settings], as illustrated in FIG. 4.1.7:

FIG. 4.1.7

7. Specify the motor type and configure it as necessary, as illustrated in Figure 4.1.8. Note: Brushless rotary motors are typically utilized.

Figure 4.1.8

8. Configure feedback options. Please note that the Hall type is set to None, Motor Feedback is set to Primary Incremental, and Load Feedback is set to None, as illustrated in Figure 4.1.9:

Figure 4.1.9

9. Configure the motor's working mode by setting [Operating Mode] to Position and [Command Source] to CAN, as illustrated in Figure 4.1.10:

Figure 4.1.10

10. To select a different option, choose Sinusoidal for the 【Commutation Mode】 and select the corresponding Multi-mode Port from FIG. 4.1.11. Since we are not using a Multi-mode Port signal source, we have the freedom to choose this option, as illustrated in Figure 4.1.11:

Figure 4.1.11

11. Configure the parameters of the Motor. "Motor/Feedback" on the interface of the Motor will call up the "Motor/ feedback-rotary motor" dialog box and operate according to the sequence shown. As shown in Figure 4.1.12:
Note: Parameters 4.1.13, 4.1.14, 4.1.15 can be found in the motor design drawing.

Figure 4.1.12

Figure 4.1.13

Figure 4.1.14

Figure 4.1.15
13. Adjust the three-phase and Hall of the Motor -- click the autoreversing tool in the number 1 circle in FIG. 4.1.16 to call up the [Motor Direction Setup] dialog box in the Auto Phase, as shown in FIG. 4.1.16:

Figure 4.1.16
14. Facing the Motor wheel, rotate the wheel clockwise to ensure that the value in [Motor Actual Position] is greater than 500, as shown in Figure 4.1.16; Then click the "Next" option to bring up the "Auto Phase" dialog box, as shown in Figure 4.1.17.

Figure 4.1.17
15. Click the [start] option marked by number 3 in Figure 4.1.17, and the motor will rotate slightly. Please ensure that the robot has been lifted and the wheels can rotate freely before this step. After [Next] becomes black (it enters the available state), click [Next] to bring up the [Phase Count Test] dialog box, as shown in Figure 4.1.18.

Figure 4.1.18
16. Click [Start] marked by number 5 in Figure 4.1.18, then the drive will carry out automatic phase detection, as shown in Figure 4.1.19; Note: If steps 4.1.16 and 4.1.17 are done well, it is unnecessary to click [Skip] button and a dialog box as shown in Figure 4.1.20 will appear, click [Next] at this time, and the software will enter the [Hall Wiring Setup] interface at this time.

Figure 4.1.19

 Figure 4.1.20

17. Click on the [Start] button labeled as number 8 in Figure 4.1.20, and then observe the changes in light and dark in the Hall States. Finally, click on the [Next] button labeled as number 9 to complete the Auto Phase debugging process;
18. Set the Current Loop by clicking on the [I loop] button in Figure 4.1.21 to open the Current Loop dialog box;

Figure 4.1.21

19. In the Current Loop dialog box, set the Cp (scale parameter) and Ci (integral parameter) parameters to 0. Then, click the [Auto Tune] button to initiate the setup process, as depicted in Figure 4.1.22;

Figure 4.1.22

Select "Medium" from the parameter settings, then select "Save Cp and Ci to Flash" and finally click "OK". The current ring debugging is now complete, as shown in Figure 4.4.23 below:

Figure 4.1.23

To adjust the parameters of the Velocity Loop, click on [V loop] in Figure 4.4.24 to open the Velocity Loop dialog box;

Figure 4.1.24

22. Modify the Vel.Limit value in the Velocity Loop dialog box to match the rated maximum speed of the motor. If high motor stiffness is not necessary, maintain the default Vp\Vi settings. However, if high motor stiffness is required, proceed to Step 4.1 to manually adjust the speed loop parameters.

4.2 Manually Adjusting Drive Parameters

1. To manually adjust the speed loop, first enter the [V Loop] interface and set the maximum speed to the rated maximum speed. Then, click the oscilloscope button on the screen to open the oscilloscope, as shown in Figure 4.2.1:

Figure 4.2.1

Note: Adjust the Velocity Limit to the rated maximum speed, not the maximum motor speed.
2. On the oscilloscope interface, define [Apply TO] on the left side as Velocity and [Function] as Square Wave. Select "Commanded Velocity" for [CH1]. Select Actual Motor Velocity for [CH2] and Actual Current for [CH3]. Select Immediate Trigger with Trigger Setup, as shown in Figure 4.2.2:

3. Click on the Gains option on the oscilloscope interface, set the Vp and Vi values to 0, and then click on Start, as illustrated in Figure 4.2.3:

Figure 4.2.3
4. Gradually increase the value of Vp until the current curve no longer converges and reaches the divergent edge, which is the maximum value that can be set for Vp. Take 80% of this value and set it as the new value for Vp. Then, gradually increase the value of Vi until the overshoot is between 10% and 15%. Finally, save the parameters to flash memory;
5. After adjusting the parameters, click on the icon in the box to download all parameters to the drive, as shown in Figure 4.2.4;

Figure 4.2.4

4.3 Setting the Baud Rate and CAN ID of the Drive CAN Communication

1. Set the baud rate of the CAN communication of the driver to 250Kbit/s. Click [Amplifier] - [Network Configuration], select the communication mode CAN, and then adjust the BitRate to 250Kbit/s.
2. Tick "Use Programmed Value" in [Address Configuration], write the corresponding value in "Programmed Value" (the motor on the left is 1, the motor on the right is 2), and click "Save & Reset" at last. See Figure 4.3.1.

Figure 4.3.1

4.4 Adjusting Drive Error Settings

1. Click the [Configure Faults] button in the drive debugging interface, open the [Fault Configuration] dialog box, and select the [Following Error] option;
2. Choose the "Over Current (latched)" option based on the actual situation, click "OK" to close the dialog box, and then click the download button on the menu bar to download all drive parameters to the driver, as shown in Figure 4.4.1.Figure 4.4.1

4.5 Configuration of Steering Motor

If you want to configure the steering motor, you also need to add the following Settings:
1. Cable connections to left and right limit DI: In addition to the emergency stop line mentioned in 4.2.4, connect the cable to left and right limit DI. Connect the brown power cable (positive terminal) of the left and right limit DI to the Pdo(24V) or terminal block (24V or 48V), and connect the blue power cable (negative terminal) to GND according to the specifications of limit DI. The left limit DI black cable (NPN output) connects to [IN2] GP wire 5 on the J3 port of the drive, and the right limit DI black cable ((NPN output) connects to [IN3] GP wire 6 on the J3 port of the drive. As shown in Figure 4.5.1:
2. Set the software parameters for left and right DI limit: Open the CME and click Input/Output, as shown in Figure 4.8.2. Inhibits_ is displayed in IN2 and NEG Limit-HI Inhibits_ is displayed in IN3. As shown in Figure 4.5.3.
Check method: You can check whether the left and right limit DI is effective by turning the mobile steering motor to the left and right limit sensor. As shown in FIG. 4.5.4, open the "Control Panel" from the main interface of the CME, tick "Enable Jog", and click "Move NEG" repeatedly. It can be seen that the steering motor slowly points to the right to turn to the right Limit sensor, triggering the status update of "Negative Limit:" to "Active". By clicking "Move POS" repeatedly in the same way, you can see that the steering motor slowly clicks left to turn to the left Limit sensor, triggering the status update of "Postive Limit:" to" Active ". As shown in Figure 45.5, the status of "Postive Limit:" is updated to" Active "when the steering motor moves to the right limit sensor.

Figure 4.5.1

Figure 4.5.2

Figure 4.5.3

Figure 4.5.4

Figure 4.5.5
3. Origin configuration: Click the Home option on the main screen, as shown in Figure 4.5.6, open the Home screen, change "Method" to "Limit Switch", Change "Offset" to "0 counts "," Direction of Motion" to "Negative", click" Home", you can see the corresponding steering motor turn clockwise until the negative limit is triggered, and a pop-up box of "Homing Complete" will pop up. Click "Confirm" to close the pop-up box, and the origin configuration is complete. Click "Save" to save the Settings, as shown in Figure 4.5.7. Click "Exit" to exit the Home screen.

Figure 4.5.6

Figure 4.5.7
At this point, the copley drive debugging is finished. Power off and restart the drive to ensure that the parameters play a role.

5. Technical Adjustment of Copley Drive Parameters (Suitable for Ground Cattle)

5.1 This title pertains solely to the regulation of debugging parameters for the Copley drive and DMKE 60M-01930C5-E motor currently utilized by the company's cattle. Its purpose is to ensure the quality of cattle drive debugging and to ensure that the adjustment of drive parameters adheres to established rules. This title must be used in conjunction with titles 1-4 of this document.
5.2 The adjustment process is as follows:

1. Confirmation of Cattle Status:
   1.1 Confirm that the driver and motor have been mechanically fixed and correctly connected;
   1.2 Confirm that the basic settings of the driver and the configuration of motor feedback parameters have been completed according to the actual configuration of the motor;
   1.3 Confirm that the driver has adjusted the three-phase motor, Hall, and current ring as described in [4.4 Driver Configuration] in this document.

2. Driver Key Parameter:
   2.1 Driver current ring parameters are obtained by referring to "4.4 Driver Configuration" in this document.
   2.2 Adjust the following parameters of the driver speed ring to the values specified in the following table, as shown in Figure 5.1 and Table 5.1;

    Table 5.1Figure 5.1
Note: 1. Retain default values for all parameters except those specified in the table.
2. If the drive is in speed mode, go to Step 3 after performing Step 2.2 (An error message is displayed for the drive). If the drive is in location mode, perform Step 2.3-2.4
2.3 Adjust the following parameters of the driver position ring to the values specified in the table below, as shown in Figure 5.2 and Figure 5.3:  Figure 5.2Figure 5.3

2.4 Adjust the driver current ring's parameters to the values specified in the following table, as shown in Figure 5.4;
Note: The current IC of Demark DCPX-090/18024-E/H is 24A and the peak current IP is 50A.

Figure 5.4

3. The drive reported an incorrect setting.
   3.1 Check the boxes for [following Error] and [Over Current]. Do not check the boxes for [Amp Over Temperature] and [Motor Over Temp], as shown in Figure 5.5.

Figure 5.5:
Note: All parameters, except for the key parameters and settings specified above, are adjusted according to [4.4 Driver Configuration] in this document.

4. Key parameters of Roboshop movement
   4.1 Based on the motion characteristics of differential ground cattle, Roboshop should modify the motion parameters of ground cattle as shown in Table 5.6.

Table 5.6

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Table 5.6:

Six, Analysis of Roboshop Error Codes

(Firmware version 1.9.20 and earlier +1.9.52 and later versions, please refer to error code parsing) Example: When Roboshop receives an alarm code: X40e002 "0", as shown in Figure 5.1, the alarm code can be converted to binary for "010000001110000000000010". Through observation, drive 1, 13, 14, 15, and 22 errors correspond to the table, and the drive errors are: Amplifier over temperature, Trying to stop motor, Motor brake activated, PWM outputs disabled, and Amplifier fault. See the fault latch for more information. Figure 5.1
(Firmware version 1.9.20 (excluding 1.9.20) to 1.9.52 (excluding 1.9.52) Please refer to error code parsing.) Example: when Roboshop receives alarm code: "0 x100", as shown in Figure 5.2, the alarm code can be converted to binary for "000100000000". By observation, the drive in the eighth error corresponds to the table, and the drive error is "Phasing error." Figure 5.2

1.1 Troubleshooting Error Guidance

Copley-CME2 Handbook -- Chinese.pdf
Please refer to Section 8.1 of the Chinese manual for comprehensive solutions.

Appendix 1: Description of Version Upgrade

Appendix II: Reference Data

Copley Driver Configuration Test (Position Mode, Load 500kg).xlsx