Application and Maintenance of ADLINK PCI-8158 Multi axis Motion Control Card

Practical case: Crawling fault on XY platform of semiconductor solidification machine

Background: A certain solidification machine uses PCI-8158 to control the XY gantry axis. During high-speed mounting, the X-axis occasionally crawls (crawls), resulting in surface mount displacement.

Troubleshooting process:

Swap the X/Y axis drivers and motors, the fault still lies in the X axis, eliminate the mechanical part.

Replace the X-axis control cable, the fault has not been eliminated.

Using a logic analyzer to capture the X-axis pulse output and encoder feedback, it was found that when the Y-axis moves simultaneously, the X-axis pulse frequency experiences periodic jitter (about ± 2%).

Further inspection revealed that the PCI-8158 card shares the same PCIe channel with the graphics card, resulting in DMA transfer being preempted. Move the card to a dedicated PCIe slot (directly connected to the CPU) and turn off the graphics card's "Link Power Management" to eliminate the jitter.

Inspiration: In multi axis high-speed control, bus bandwidth allocation is crucial. It is recommended to use a dedicated PCIe root port and disable energy-saving features.

Suggestions for preventive maintenance plan

Criteria for determining the content of periodic maintenance

Monthly inspection of board temperature (infrared temperature measurement)<65 ℃ (when ambient temperature is 40 ℃)

Clean the slots and connectors quarterly, test the emergency input function, and immediately stop the pulse output (<1 μ s) after the emergency input is triggered

Calibrate the encoder counting accuracy every six months (using a laser interferometer) with a positioning error of less than 1 pulse equivalent

Update firmware and drivers annually, and re backup configuration files with the latest version number on the official website