ADLINK CPCI-8168 Eight Axis Motion Control Card Deployment and HSL Integration Guide

Universal DO DOUT1 (66), DOUT2 (67), and other 8 channels, with open drain output, require external pull-up resistors or relays

Analog quantities AIN1 (60), AIN2 (61), etc; AOUT1 (62), AOUT2 (63) and other single ended ± 10V, AGND reference ground

Power supply E24V (68) and GND pins are externally powered by 24V to provide energy for the isolation side

Wiring suggestions:

It is recommended to use twisted pair shielded wires for pulse output signal lines, with the shielding layer grounded at one end;

The encoder feedback line uses differential pairs to avoid parallel operation with the power line;

The limit switch adopts normally closed contacts (NC) to increase wire breakage detection function and is connected to PEL/MEL input terminals;

When driving inductive loads (such as relays) with universal DO, a freewheeling diode should be connected in parallel at the load end to prevent back electromotive force from damaging the output stage.

HSL Network: A Bridge between Centralized Motion and Distributed I/O

The biggest highlight of cPCI-8168 is the integration of High Speed Link (HSL) ports (RJ45 physical interfaces). HSL is a high-speed, real-time, deterministic serial bus based on full duplex RS-485 with transformer isolation, supporting up to 200 meters of cable (shielded Ethernet cable). Its communication speed reaches 6Mbps, and the scanning time for each slave index is only 30.4 μ s. It can connect up to 63 I/O slave modules, achieving ultra fast refresh of thousands of digital/analog signals (1000 points/ms).

Typical application scenarios:

When it is necessary to control multiple sets of peripheral I/O (such as solenoid valves, sensors, indicator lights) and the distance is far, using HSL slave modules instead of traditional parallel wiring greatly simplifies the wiring harness;

The same cPCI-8168 can simultaneously execute 8-axis motion trajectories and synchronously read and write remote I/O, achieving integrated control of "motion+logic" without the need for additional PLC or bus master station.

Installation and configuration points:

Use standard shielded CAT5 Ethernet cable, up to 200 meters long, with daisy chain connection supported for bus topology;

Each slave station must set a unique ID (0-63), which can be configured through dialing or software;

The main station board automatically scans all slave stations and maps them to internal registers. The API provides functions such as HSL_ReadIO()/HSL_WriteIO() for access;

The onboard LED can indicate HSL communication errors. If the red light is constantly on, check the cable connection, terminal resistance (120 Ω), and slave power supply.

Motion control function and programming interface

1. Motion mode and interpolation

Point motion: supports absolute, relative, and continuous motion, and can change speed and target position online;

Multi axis synchronization: Multiple axes can be started/stopped simultaneously to achieve precise positioning synchronization;

Interpolation: Hardware supports 2-4 axis linear interpolation, 2-axis arc interpolation, and multi axis continuous interpolation, suitable for trajectory machining;

Speed curve: trapezoidal and S-curve acceleration, S-curve can effectively reduce start stop impact.

2. Home Return

Provides up to 13 return to origin modes, including manual search, automatic search (with limit switch), Z-phase indexing, etc., to adapt to different mechanical structures. The typical mode is to search for the origin switch at a fast speed, then search for the Z pulse at a low speed, and finally stop at the precise position.

3. Position comparison and triggering

Each axis is equipped with 5 built-in 28 bit comparison registers. When the encoder counter matches the comparison value, it automatically triggers the CMP signal output (differential, which can be used to trigger cameras or lasers), achieving high-speed position synchronization output. It is widely used in AOI aerial photography detection.

4. Software support

Provides drivers and over 400 API functions for Windows Vista/XP/2000, supporting languages such as VB, VC++, BCB, Delphi, etc. Comes with MotionCreator at the same time ™  Debugging tool that can monitor the status of each axis online, simulate motion, diagnose I/O wiring, greatly shorten the development cycle. The API functions are all thread safe, suitable for real-time multi-threaded control.

Integration of analog quantity and data acquisition

In addition to motion control, cPCI-8168 also integrates 4-channel 12 bit A/D and 4-channel 16 bit D/A, providing convenience for system integration:

A/D: ± 10V input, 110kSPS sampling rate, can be used for monitoring pressure, force sensor or potentiometer feedback;

D/A: ± 10V output, 16 bit resolution, 2 μ s setup time, can be used as an analog speed command or control signal for regulating valves.

These analog quantities can be accessed through the same API library, reducing the occupation of additional PCI data acquisition cards and lowering costs.

Interrupt management and real-time response

CPCI-8168 supports a variety of interrupt sources, including:

Limit trigger (± EL), alarm (ALM), origin ready (ORG ready);