ADLINK PCI-8164 Advanced Motion Control Card Deployment Guide

ADLINK PCI-8164 Advanced Four Axis Motion Control Card Deployment and Configuration Complete Guide

In the field of precision motion control and automation detection, the system has strict requirements for the high-speed pulse output, flexibility of interpolation algorithms, and real-time position triggering/locking. ADLINK's PCI-8164 (and its MPC-8164, PXI-8164 versions) is an advanced 4-axis motion control card based on PCL6045 ASIC, supporting up to 6.55 MPPS pulse output, 2-4 axis linear interpolation, 2-axis arc interpolation, circular interpolation with acceleration and deceleration curves, 13 return to origin modes, online speed/position changes, 4K FIFO automatic loading position comparison triggering, and hardware position locking functions. This article provides a complete deployment and development reference for motion control engineers, covering hardware installation, signal connection, motion mode principles, Motion Creator debugging tools, and function library programming.

Overview of Card Board and Hardware Installation

The PCI-8164 adopts a half length PCB design (185 × 106.68 mm) and is equipped with a PCL6045 motion control ASIC. It integrates a pulse generator, encoder interface, comparator, counter, and various mechanical switch interfaces. This series offers three bus versions:

PCI-8164: 32-bit PCI bus, Plug and Play， Supports up to 12 cards (48 axes)

MPC-8164: PC104 bus, suitable for embedded compact systems, up to 4 cards (16 axes)

PXI-8164: PXI bus, 3U Eurocard specification, supports PXI triggered bus synchronization

Core performance indicators:

Pulse output: 6.55 MPPS (programmable in OUT/DIR, CW/CCW, AB phase modes)

Encoder input: up to 3.2 MHz (CW/CCW or AB × 1), up to 6.5 MHz in AB × 4 mode

Counter: 28 bits (0~268435455 or ± 134217728)

Isolation: All I/O signals are optically isolated at 2500Vrms

Position comparison: 2-axis (axis 0/1) CMP output with 4K FIFO automatic loading

Position latch: 2-axis (axis 2/3) LTC input

Installation steps (PCI-8164):

Turn off the PC power, select an idle 32-bit PCI slot, insert and secure the card board.

Connect the CN2 main connector (100 pin SCSI-II) to the external terminal board.

Connect the CN1 external+24V power supply (with accompanying cable) to provide isolated power supply for I/O.

Set the EL limit logic type through the S1 dip switch (default ON is normally open).

Set the card number (0~15) through the S2 card ID switch, supporting multi card systems.

Select the pulse output type through J1~J8 jumper: default 1-2 short circuit is differential drive; Short circuiting 2-3 is an open set output.

MPC-8164 Special note: The base address (default 0x200) and IRQ (default IRQ5) need to be manually set through SW1, not plug and play.

Detailed explanation of signal connection and interface

CN2 is the main connector, which includes pulse output for all axes, encoder feedback, limit/origin/deceleration (SD/PCS), servo interface (INP/ALM/ERC/SVON/RDY), position comparison (CMP), and position latch (LTC).

2.1 Pulse output (OUT ±, DIR ±)

Two pairs of differential signals per axis, select the mode through software _8164_det_pls_outmode():

OUT/DIR mode (0~3): OUT output pulse, DIR level direction, adjustable rising/falling edge and DIR polarity

CW/CCW mode (4-5): OUT is the forward pulse, DIR is the reverse pulse

AB phase mode (6-7): OUT and DIR output pulse pairs with a phase difference of 90 °

Jumper settings: J1~J8 correspond to the DIR and OUT signals of each axis, with differential drive by default. When opening the output, it is necessary to short-circuit 2-3 pins and apply a current of ≤ 20mA.

2.2 Encoder feedback (EA ±, EB ±, EZ ±)

Three pairs of differential inputs, supporting CW/CCW or AB phase (1 ×/2 ×/4 ×). The input circuit requires a differential voltage of ≥ 3.5V and a driving current of ≥ 6mA. When outputting, an external pull-up resistor (0 Ω for+5V, 1.8k Ω for+12V, and 4.3k Ω for+24V) is required.

2.3 Mechanical switches (ORG, PEL/MEL, SD/PCS)

ORG: Origin signal, used for 13 return to origin modes.

PEL/MEL: Positive/negative limit, stop pulse and output ERC after triggering.

SD/PCS: Can be configured as deceleration signal (SD) or position change signal (PCS), selected through _8164_Sd_pin().

2.4 Servo interfaces (INP, ALM, ERC, SVON, RDY)

INP (In Place Signal): Can be configured as a motion completion condition.

ALM (Alarm): Can be configured to immediately stop or decelerate to stop.

ERC (bias reset): Automatically outputs (pulse width adjustable from 12 μ s to 104ms or level output) upon completion of zeroing, limit triggering, alarm or emergency stop.

SVON (servo enable output) and RDY (servo ready input) are universal I/O.

2.5 Position Comparison (CMP) and Position Latch (LTC)

CMP1/CMP2 (axis 0/1): Position comparison triggers output, supports single point comparison and 4K FIFO continuous comparison, pulse width of 40 μ s, used for camera triggering.

LTC3/LTC4 (axis 2/3): Position latch input, hardware captures instantaneous values of commands/feedback/errors/general counters, with extremely short latency.

2.6 Handwheel (CN3/CN4) and synchronous start stop (CN4/K1/K2)

PCI-8164 Handwheel: CN3 provides 4-axis handwheel input (PA/PB), supports AB phase (1 ×/2 ×/4 ×) or CW/CCW, with multiplier/divider settings.