Huichuan AM600 Motion Controller Malfunction and Replacement Guide

The electronic cam has a large follower error between the main and slave shafts, with mismatched cycles and too few CAM points to ensure DC synchronization between the main and slave shafts; Add interpolation points to the CAM table or use a fifth degree polynomial

Zero return cannot find the origin signal. The origin switch signal is not connected to the high-speed input port, and the zero return speed is too fast. Check the wiring of the origin switch; Reduce the speed of approaching zero; Choose the correct zeroing mode

4.3 Programming and Download Issues

Possible causes and solutions for the phenomenon

Unable to connect to AM600 IP address not in the same network segment, firewall blocking IP recovery through serial port or USB (if any); Turn off the PC firewall; Using InoProShop's' Scan 'feature

When downloading, it prompts that the CPU model selected in the "Device Type Mismatch" item does not match the actual one. Modify it to the correct AM600 sub model in the device tree

After the program runs, the PLC stops the watchdog timeout and checks the program loop time in a dead loop; Add Watchdog reset command; Assign different priorities using task configuration

SD card cannot recognize format incompatibility (requires FAT32) or has a large capacity. Use an SD card with ≤ 32 GB and format it as FAT32

4.4 High speed input/output faults

The AM600 provides 16 high-speed inputs (up to 200 kHz), some of which support A/B phase pulse counting. If the pulse counting is inaccurate:

Check if the input wiring is differential or single ended (NPN/PNP).

Confirm the input filtering time setting (in hardware configuration), usually set to 1 μ s or less.

Use an oscilloscope to measure the quality of pulse signals and eliminate interference.

Example of complete process for system replacement

Assuming an old AM600 controller on site is damaged and needs to be replaced with a new controller of the same model, with the original program backed up on the PC. Perform the following steps:

Preparation:

Record the IP address of the original controller, EtherCAT slave list (station number, model), and shaft parameters (such as electronic gear ratio, limit value).

Open the backed up project file (. pro) from the PC.

Prepare a standard Ethernet cable (either crossover or direct connection, as AM600 supports Auto MDI-X).

Hardware installation:

Cut off the main power supply of the system and mark the connection positions of all I/O and EtherCAT cables.

Dismantle the old controller and install the new controller onto the DIN rail.

Reconnect the cables (24V power supply, EtherCAT Ethernet cable, I/O wiring, Ethernet programming cable) according to the original markings.

Power on and basic settings:

Only supply power to the controller (24V DC), do not connect the driver main power.

Connect the controller to the PC and modify the IP address to its original value through InoProShop.

Check firmware version: If it is lower than the original version, upgrade according to the above method.

Download program and configuration:

Open the InoProShop project, execute 'Generate Code' and 'Download'.

After downloading, switch to "Run" mode and check the system status (no red error light).

Drive parameter recovery:

If the servo drive is not replaced, its internal parameters should remain unchanged. But to avoid parameter loss, when starting through EtherCAT, AM600 will send PDO configuration parameters to the driver to ensure they match the PDO in the program.

If the driver has also been replaced, it is necessary to use Huichuan driver debugging software (such as InoDriveShop) to import the original driver parameter backup file.

System integration debugging:

Enable servo and perform low-speed jog testing on each axis.

Check the zeroing accuracy of each axis.

Perform a complete automatic loop and observe the EtherCAT communication load and CPU load.

Backup new system:

Use SD card or InoProShop's' Archive 'function to save the final project.

Performance optimization suggestions

Reduce EtherCAT bus cycle: If an application requires faster response (such as flying, high-speed patching), the synchronization cycle can be set to 1 ms, but at the same time, the number of slave stations and PDO data volume need to be reduced. The typical value for 32 axis PTP positioning is 4 ms, and forced compression is not recommended.

Use multitasking: AM600 supports multitasking (such as loop tasks, event tasks, and free running tasks). Assign motion control, logic control, and communication processing to different priority tasks to avoid blocking.

CAM point optimization: When there are more than a few thousand CAM points, it will occupy a large amount of memory and prolong the startup time. Three or five degree polynomials can be used to automatically fit and reduce the number of points, or spline interpolation can be used.

Application of high-speed input: Using a 200 kHz counting channel instead of an external high-speed counter to save costs. Note that the encoder type (NPN/PNP or differential) needs to match the input port.