DSP-21XX CNC-controller

Short description

The DSP-CNC card is an independent autonomous computer system based upon the Analog Devices 16 bits fixed point Digital Signal Processor. Their slowest processor executes each instruction in 100 nano-seconds while the fastest processor takes less than 1.6 nS per instruction.

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The Classic DSP-CNC card

has one asynchronous RS232 communication port and 1- or 2 synchronous ports, usually used for interprocessor communication when more than one DSP-CNC card are employed in the same system. The secondary synchronous port (if available with the type of DSP used) may also be used as a programmable interrupt timer.

To interface external processes

or devices each card has 14 Ultra-High-Speed Opto-Couplers for use with auxiliary I/O. All I/O is routed through 3 EPLD's (Electrical Erasable Programmable Logic Devices) for realizing customer or application specific hardware demands without the need of changes in components or PCB layout. The EPLD's are the glue-logic between the Opto-couplers and the DSP.

Functionally the DSP-CNC card is similar to a PLC

(Programmable Logic Controller) but DSP's operate at a much higher processor frequency, have real-time (16 bits-fixed point OR 64 bits floating point) arithmetic, high performance internal busses and an instruction set optimized for generating and processing signals or pulse streams. The basic DSP-CNC card employs a 16 bit fixed point DSP powerful enough to realize control of up to 7-axis simultaneously. Optionally a 64 bits-floating-point DSP card is available for even more demanding applications.

Some of the specs of the DSP-CNC Card V1.3 are:

• Power Supply: just one single source of 5 VDC / 500 mA needed, either from a standard PC-ISA expansion slot or by connecting a PC-disk drive connector to an optional DSP power supply cable.
• I/O Control: opto Isolated inputs and outputs, for either 6V (standard) or 12V (resistor-pack exchange) control levels. Most servo's, stepper drives and encoders are therefore usable without special interfaces.
• Host Demands: while the DSP-CNC is completely autonomous, frequently no host-computer is needed, except for application software development or to serve as a remote terminal. If the DSP-card is used for Computer Numerical Control, the type and make of the HOST computer is not all that important as long as the host can route data files through an RS232 port at a minimum rate of 38400 Baud.
• Real-time Clock: to monitor date and time, store parameters in non volatile memory and generating exact signals over a longer period of time, the DSP-CNC card employs a hardware Real-time Clock onboard.
• Speed: when used as 3-axis continuous path CNC and equipped with the "slowest" DSP processor, the maximum output signal rate (step frequency) still allows feed rates of >1000 mm/sec, even when the resolution is programmed to be 0,01 mm/increment. This performance is obtained by the unique way of interpolation , similar to Superior Electric (Slo-Syn) patents from the late 1960's. In practice the better (higher speed) DSP's are used to control up to 7 axes at high speed, with resolutions programmable from FULLSTEP tot 1/40 step (micro stepping) mode.
• Calibration: ALL generated signals are software programmable and therefore no adjustments / controls are needed.
• Jumpers: ALL hardware signals/paths are realized by means of EPLD's and their software/programming. Therefore no jumpers are present nor are there any other hardware adjustments needed.
• "Green" features: by firmware the phase current of the various motors can be reduced or any other process may be automatically shut off or switched to save power whenever the positioning system is idle. Reduction of power not only saves money but heat losses are reduced also which has a positive effect on lifetime of all components of a CNC system.

Specifications short form:

• Shape / form factor half PC-AT ISA expansion card with dummy card edge connections except for power supply
• Dimensions approx. 160*100*100 mm
• Consumed power Max. 0,3 Amp @ 5 VDC
• External control by async. port, RS232 - 38400/57600 Baud
• Max. I/O-signal frequency >1 MHz
• Temperature range 5º to 50º C.
• Connections via PC-retaining bracket with integrated DB-37 female connector
• Program memory 32K * 24 Bits; expandable with another 32K * 24 Bits as an option
• Data memory depending on the type of DSP used, but always > 512 * 16 bits
• DSP-processor standard ADSP-2105; 2101, 2104 or 2115 as an option
• Internal clock frequency 40, 66, 80 or 100 MHz.
• Monitor in EEROM for firmware upload and debug features
• In-Circuit programming

DSP-CNC Card Connections:

The flat cable coming from the DB-37 is split into two discrete cables. The DB-9 end plugs directly into the COM1: port while
the DB-25 end connects to an application with machine/firmware specific I/O signals.

The monitor of the DSP-CNC

With the standard monitor in EPROM or Flash Rom, all applications compiled and/or assembled on the host computer can be uploaded into the data- and program memory of the DSP-CNC card and started.

An optional monitor program is available for OEM clients which has extra functions to read and set Real-time Clock options, manage network licenses for all available software and customizing prompts, version/serial numbers.

The monitor EEPROM is exchangeable with a customer specific program (EE)PROM. Included with the development software DvD are all tools to generate and program custom EEPROM's.

Other functions that are supported by the standard monitor in EEPROM are solely for uploading object code (application programs) which are compatible with the Analog Devices well documented file conventions.

Available standard application firmware:

• FFPE or STELZER-MOTOR controller for starting, fuel-injection and ignition control
• 2D point-to-point positioning for drilling, cutting, dispensing etc.
• 2½ D point-to-point positioning, including automatic Z-axis up/down control
• 2½ D interpolation, Z-axis timeshared with X- or Y-axis
• 2½ D interpolation, Z-axis timeshared with Y-axis and automatic Tangential- or C-axis
• 3D interpolation on X-, Y- and Z-axes simultaneously
• 3D interpolation on X-, Y- and Z-axes with automatic Tangential- or C-axis
• Lath control, including thread cutting
• Lath control, including conical / multi thread cutting
• Bridgeport, ACME, Kondia, Takang etc. closed loop Milling Controller
• Kondia and Rambaudi control with rotary table W-axis control
• Graziano, Ernault Somua, AI-Hembrug and Ferreirinha Lathe Controller
• air conditioning, air treatment aparatus
• medical breathing and gas analysis applications

An application

specific software example: DSP-CNC V25.xx as used for Xplot-machines.
With this application software a fully equipped 4-axis CNC-controller is available that controls the X-, Y- and Z-axes simultaneously by linear and circular interpolation (Continuous Path Contouring). At the same time, the fourth (tangential or C-)axis can be employed for automatically controlling the direction of a circular saw or any other cutting tool. The application software enables full control over large format 4-axes flatbed machines at high speed,with automatic Z-axis height control, software correction of machine X/Y-90º squareness and many other features which replace mechanical complexity by software complexity.

Without DSP-CNC technology the XPLOT-machine mechanics would easily cost double or triple the actual costs of today. Also maintenance would be more frequently needed to keep the machine within the mechanical specifications at all times.

The command set supported by the DSP-CNC V25.0 application is listed in the DSPCNC documentation.

With the DSP-CNC firmware (automatically uploaded through the monitor at cold-start) the program CNC.exe (for PC's) is required. The manual is supplied in the documentation (*.pdf file) of this program.