Control Engineering August 1995 - Motion Software
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`Control Engineering, August 1995.
`
`This article ©1995 Cahners Publishing, reprinted with permission. All company and product names are
`trademarks of their respective owners.
`
`Customer
`Service
`Software
`Services
`Product
`Catalog
`
`coNrRa. GAINLYV
`ENGINEERING
`
`rueuunmr4
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`Motion Software Heads Toward Friendlier User Environments
`
`KEVIN HOLLOWAY, Parker Hannifin Corp., Compumotor Division, Rohnert Park, Calif.
`
`Software is the driving force in the motion control market. Here is a survey of what some companies are doing today as they
`strive towards the future. The 14 companies included in this article are representative suppliers of products or services to the
`motion control industry. Their technical input formed the basis of this article.
`
`Compumotor's Motion Architect directs the functions of a surface-mount machine at the
`company's manufacturing facility. The software automatically generates set-up code and also
`edits and executes motion programs.
`
`Motion control hardware and software for factory automation equipment have
`developed in significant ways over the past 15 years. The number of companies
`offering software has grown rapidly. Motion software is a particularly important
`topic today, since software rather than hardware is driving the market. With
`some notable exceptions, motion control hardware has entered the commodity
`stage.
`
`The future direction of motion control software, and thus the options available to
`the motion engineer, can be viewed by examining the major software types and
`the nature of motion control companies. Naturally, these companies have
`different philosophies on how to conduct business, the types of products they
`want to develop, and their concept of the "right" approach to solve their
`customers' motion control problems.
`
`Motion control software can be divided into two distinct varieties. The first is the operating system (OS) software that resides
`in Read Only Memory on motion controllers. This often is referred to as firmware. The second variety comprises motion
`software and development tools written for personal computers (PCs).
`
`Motion software must cater to non-specialist programmers
`
`Controller operating software
`
`Let's first look at firmware and how it relates to motion control hardware architecture, which in turn is divided into two
`general categories:
`
` Products that have a processor (intelligent peripheral) and a proprietary operating system; and
` Products that rely on a host processor for executing motion functions.
`
`In the first category, each controller contains one (or more) processor to control the motors, monitor I/O points, communicate
`with the operator interface, and execute the motion control commands. There is no need for any external microprocessor.
`Emerson Electronic Motion Control (Chanhassen, Minn.), Compumotor, and other motion companies design intelligent
`peripheral controllers that are processor-based.
`
`In short, these specialized "computers" use their internally stored operating system like a PC uses MS-DOS. Each company
`
`ABB Inc.
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`that designs this type of motion controller has its own proprietary operating system, with unique instructions that the customer
`uses to program the "computer."
`
`The main advantage here is the ability of the motion controller to run the entire machine. (Since extra processor power isn't
`needed, the host CPU is free to do other tasks such as data acquisition, quality management, or even create the next motion
`program for the controller to execute.) Designing products with onboard processors and an OS allows them to reside either
`inside the PC, like a fax/modem card, or outside the PC like a printer. The primary difference is the communication path.
`Internal products communicate across the PC bus. External products are typically controlled serially, via one of the PC's serial
`ports.
`
`The second type of motion controller architecture employs minimal hardware on the plug-in card, but uses the host PC's
`microprocessor to calculate motion trajectories and monitor all other aspects of motion. Some of these products have no
`processor onboard, while others include a processor to perform functions not feasible for the host CPU.
`
`For instance, an onboard digital signal processor (DSP) may exclusively close the servo loop while the host calculates all
`motion set-points for the DSP. Examples of companies using the host PC design are Technology 80 Inc. (Minneapolis, Minn.)
`and Motion Engineering Inc. (MEI, Santa Barbara, Calif.).
`
`This design approach offers advantages as well. The motion controller requires less hardware-usually a lower cost solution.
`Because the host processor performs all (or most) of the functions, synchronization between the motion and other machine-
`related functions is maintained. A disadvantage is that the approach can't offer the parallel-processing capabilities of the
`intelligent peripheral designs. Programmers typically use a library of built-in motion functions to get the motion controller to
`perform its tasks.
`
`According to Geoffrey Grow, applications engineer at MEI, "This approach is sometimes called an application programming
`interface (API) - a portable tool kit of motion commands. MEI's Motion Control API is a set of high-level functions that
`communicates between our DSP-Series motion controllers and the machine's host computer. APIs can be designed to be
`independent of the operating system and the underlying hardware used by the machine manufacturer. As a result, a machine
`designer can choose virtually any compiler and operating system."
`
`Customers can look forward to increased motion control capabilities when using either of the two major hardware approaches.
`Performance growth will come from a continuum of advances: improvements in controllers, more powerful processors added
`to intelligent peripherals to handle new operating system software features, and motion API libraries with exciting new
`features.
`
`Supporting software
`
`PC software will promote motion control advances
`
`Some of the most significant advances in the motion control industry will be in PC software, according to the companies
`surveyed. They also tend to agree that software will make motion control hardware far easier to use in the future.
`
`Emerson EMC continues to see movement towards easier-to-use front-end software. Marketing manager Bryan McGovern
`says, "The users of our motion control products are machine builders, factory personnel, and systems integrators. Most of
`them are not full-time programmers. Yet, their applications require complex positioning. By thoroughly understanding their
`application, we are able to offer an interface software program that merely requires the user to plug in parameters unique to
`the application, such as length of move, synchronization ratio, acceleration rate, and dwell time." Emerson offers a program
`called PCX to assist its customers in configuring applications.
`
`Several companies now offer PC software that helps users set up their controllers and climb the motion control IC learning
`curve much faster.
`
`For instance, Compumotor set an industry precedent with the 1992 introduction of Motion Architect, a Windows based
`product for generating all of the set-up code needed by a motion controller, and which is specifically configured for the users
`application. Customers just provide application-specific input by filling in a series of dialog boxes. Motion Architect also lets
`users create and edit motion programs, communicate with the controller, and create a custom test panel to display desirable
`information or verify proper machine sequencing.
`
`Electro-Craft IQ Master for Windows from Reliance Motion Control (Eden Prairie, Minn.) is another example of an
`application development environment specifically designed to work with the controller manufacturers hardware.
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`Spreadsheet convenience is one f the
`features of the new Set-Up software from
`Galil Motion Control that lets motion
`system parameters be easily displayed or
`modified in this familiar format.
`
`Dr. Jacob Tal, president of Galil
`Motion Control Inc. (Sunnyvale,
`Calif.) says, "One of the most
`significant results of the progress
`in the industry is that motion
`control systems are designed by
`non-specialists." Curtis Wilson,
`VP of engineering at Delta Tau
`Data Systems (Northridge, Calif.)
`agrees, saying, "Users are coming
`to expect as a given, the ability to have the computer provide expertise where the user does not. Galil recently released a
`Windows-based, point-and-click set-up software package, allowing users to configure their products easier than in the past.
`They can view the configuration status of the controllers in a spreadsheet format and click on a cell to enter a new parameter
`setting. Dr. Tal adds, "We design products that do not require expertise in motion control or computer programming."
`
`Another area where software can lend expertise to motion control users is in the tuning of servo system loops. Most servo
`controller companies offer a servo-tuning aid program. Delta Tau and Compumotor, among others, have software for
`Windows to show how a system is performing. Compumotor's program, Servo Tuner, allows users to select and capture data
`they want to see. Data available for capture and display include the actual and commanded values for position, velocity, and
`acceleration, and the output command signal. For every servo update period, the requested- data are stored and graphically
`displayed on the computer to assist with tuning and system analysis.
`
`Breaking the language barrier
`
`Customers are still faced with translating the motion profiles of their application into the controllers unique programming
`language. This is traditionally where they must break out the motion controllers User Guide. As a result, motion control
`companies are developing tools to rapidly program their products. PC software is available to guide customers through
`programming functions ranging from feed-to-length to more complex synchronization of multiple axes.
`
`An example of a two-axis software product that generates commands for coordinated motion without the need to learn the
`programming language is Compumotor's CompuCAM. This software converts a DXF drawing from AutoCAD, an HP-GL
`plotter file, or a CNC G-code program into the proper motion commands for Compumotor's 6000 Series controllers to
`perform, the described motion. Galil offers a similar software package to translate DXF, HP-GL, or G-code files into motion
`instructions appropriate for its DMC Series controllers.
`
`More of these PC software products will be available as motion control companies race to capture market share by making
`their hardware easier to apply. Customers will be drawn to programs requiring the least amount of work to reliably solve
`problems.
`
`Use of the PC as the motion controller platform is another major development. Pacific Scientific, Motion Technology Div.
`(MTD, Boston, Mass.), recently introduced Advanced Motion Language (AML), a Windows-based development and
`debugging environment, designed to create multiaxis motion programs for fieldbus-based drives. AML's novelty is that it's
`essentially a "soft" motion controller, with the program it generates targeted to run on a PC platform. The only hardware
`required for the controller to work is the fieldbus communication port. AML supports the SERCOS fiber-optic
`communication protocol between controls and drives, and is being enhanced to handle a variety of I/O bus networks. (For
`more about AML, refer to CE, July 1995, P. 119.) W. Hal Gurley, Pac Sci MTD director of marketing, says AML reflects his
`company's vision of things to come. "In the future, multiaxis motion controllers may be almost 100% soft versus hard,
`because it will be the only way to capitalize on the rapid advances in PC-compatible technologies. Suppliers in the motion
`control industry that have invested in 'black box' hardware solutions will ultimately die if they do not embrace more of a soft
`solution."
`
`Visual programming is a new frontier in motion control
`
`Icons - a new frontier
`
`Visual programming - of the newest frontiers in motion control - lets customers program controllers without having to learn a
`
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`Control Engineering August 1995 - Motion Software
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`written language or syntax. Users first drop visual icons onto the screen that correspond to specific functions they want to
`implement. Clicking on the icons with a mouse opens dialog boxes that allow the icons to be configured to a specific
`application. Next, the icons are connected to indicate the program flow. Once all functions are in place, configured, and
`linked, the application can be compiled and executed.
`
`Allen-Bradley's Motion Control Group (Mequon, Wis.) was the first to offer this type of visual programming in a package
`called GML (Graphical Motion Language). After a GML diagram is developed and downloaded to a controller, the
`application can be completely debugged using the graphical trace feature. It allows the programmer to graphically view
`program execution as it was entered. GML's on-line manager further simplifies axis configuration and tuning.
`
`Once entered, tuning parameters are executed by a mouse click. All axis gain values and dynamics are calculated and saved in
`the GML diagram.
`
`"We have found that GML significantly reduces program development time by allowing the programmer to focus on
`application details without having to first learn the syntax of a specific programming language," explains Bob Hirshinger,
`product manager for A-B's Motion Drives Systems. Future enhancements of GML include support for OLE and Windows 95,
`as well as on-line help and documentation.
`
`Motion Builder is Compumotor's latest software product. It uses a graphical
`environment to configure, program, compile, run, and debug a motion system, all
`with the same tool.
`
`Full Graphical Contgurat
`
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`Compumotor's latest software offering, Motion Builder, is also a
`graphical environment. It can completely configure the motion
`controller; program the motion with visual icons; and compile, run, and
`debug the program, all from the same tool. Users need only to select
`the specific Compumotor 6000 Series stepper or servo controller being
`applied.
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`Motion Builder is configured by answering a series of questions
`contained within drop-down dialog boxes. Programming is done by
`selecting motion functions from a floating palette and dropping them '
`one by one, onto the chart. Each function's action is set up by a dialog
`box associated with an icon. When all functions are on the screen, a
`special palette tool connects the icons in a manner indicating the program flow. At this point the program is compiled and can
`be executed. Three debug modes are included in Motion Builder.
`
`-
`
`•
`
`Dan Snider, president of Snider Consultants Inc. (Cary, N.C.)-a leading developer of systems integration software-likes the
`visual approach. Mr. Snider comments, "One trend in motion software is the use of visual development at the controller level.
`Unlike application software, visual development tools at this level are used to write 'controller targeted' programs. One
`approach is to provide a graphical front end that ultimately generates conventional controller code. Though useful for initial
`development, the benefits are diminished when faced with unfamiliar generated code at the debug phase.
`
`To be effective, vendors need to supply a visual environment that allows the user to remain in the 'graphical domain' for all
`steps of the development process and insulates them from any low-level code required by the controller."
`
`Application software
`
`The next tier in PC motion software is intended to create programs to control the entire machine. Motion control is only one
`part of these higher-level applications. All that's left to do is configure software for a machine's specific requirements.
`
`Some application-specific software is available from motion control companies, but the motive to create this product is
`usually to sell more hardware. Third-party vendors are another source, though not numerous, mainly due to incompatibility of
`a given company's motion language with another's motion hardware. A driver must be written to support each vendor's
`products if they're to be usable with the software package.
`
`To maximize operator familiarity, Delta Tau's PMAC NC for Windows locates buttons that
`activate controller functions just like those on a CNC machine.
`
`One example of an application-specific software is a product from Delta Tau
`called PMAC-NC for Windows. According to Curtis Wilson, "PMAC-NC for
`Windows turns a PC with a Delta Tau PMAG control card into a full-fledged
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`(cid:9)
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`Control Engineering August 1995 - Motion Software
`
`Page 5 of 7
`
`CNC controller. In contrast to proprietary software and hardware architectures
`that dominate the CNC world, this offers the builder many ways to achieve greater functionality and increases product
`differentiation."
`
`The future promises to bring more software from motion control manufacturers to solve different application-specific
`machine control problems. But, until the correct software program is developed for a specific machine, customers will still
`have to write software that unifies all of their machine-related components.
`
`Several companies currently offer visual development software at the application level, including LabVIEW from National
`Instruments (Austin, Tex.). Based on the number of users, LabVIEW is the most popular visual development software on the
`market, states Mr. Snider. "Using LabVIEW with a motion software add-on such as Compumotor's Motion Toolbox, users
`can develop entire applications that integrate motion with data acquisition, process control, database access, etc. This
`approach provides the developer with an environment that integrates all aspects of a system while leveraging the benefits of
`visual programming."
`
`"Open Architectures" may expand motion software developments
`
`Windows of opportunity
`
`On the Windows side of developments, many new products are emerging. For some time, motion companies have provided
`Dynamic Link Libraries (DLLs) to Windows developers. With the growth Of Microsoft's Visual Basic and Visual C++,
`motion companies are now developing or selling Visual Basic extension (VBX) tool kits to help integrate motion hardware
`into applications. VBX tools allow programmers to purchase built-in functionality, saving the time they would otherwise have
`to spend writing code, Both Compumotor and Galil offer VBX tool kits for their latest lines of motion controllers.
`
`One of the latest trends for Windows application developers is the Object Linking and Embedding (OLE) Control extension
`(OCX) tool kit. OCX is the next generation of the VBX tool kit. VBXs are designed for today's 16-bit applications, while the
`OCXs take advantage of the OLE technology and are targeted for 32-bit development environments, such as Visual Basic 4.0
`and the 32-bit edition of Visual C++.
`
`While these tools ease the software integration task, it is still necessary that the developers use the proper VBX, OCX, or DLL
`for the specific motion control hardware. All of that may change with a new Windows development tool from ROY-G-BIV
`Corporation (Seattle, Wash.).
`
`In a recent conversation, ROY-G-BIV's President and CEO, Dave Brown, explained the need for open software systems. "We
`see a trend toward building open systems designed to work with a variety of related, but incompatible, technologies. We have
`noticed extensive efforts in this area, while working on development tools with Microsoft and other companies. Microsoft has
`even coined a term 'Windows Open System Architecture' or WOSA. WOSA compliant technologies are open systems, where
`developers program to one layer of functions, called the Application Programming Interface (API), without being concerned
`about the implementation details of another layer, called the Service Provider Interface (SPI). The SPI is used by the API
`layer, but developed by the service provider who implements the technology."
`
`In XMC, an open system for motion control from ROY-G-BIV Corp., developers program to the
`API layer, isolated from implementation details of the SPI driver that controls the underlying
`hardware.
`
`Windows Open System Architecture ..
`
`Sofmara Applicalims
`
`Mr. Brown continued, "At ROY-G-BIV, we found WOSA to be an excellent
`framework that brings together all proprietary motion control command
`languages under one API. We have designed and developed a WOSA-compliant,
`OLE-based technology called XMC. Patent pending XMC is an open system for
`motion control, designed for software application developers."
`
`Each motion control manufacturer that wants its hardware to be compatible with
`the XMCAPI must develop the XMCSPI supporting driver. These drivers can
`then be loaded into the completed application and selected as easily as choosing a
`printer driver in Windows. "XMC minimizes, and may even eliminate, any changes in motion control applications that wish
`to use different hardware systems," added Mr. Brown.
`
`Another feature of XMC, the OLE Automation Interface, lets developers use high-level languages like Microsoft Visual
`Basic, with the benefit that applications created will work with motion hardware from any supplier that has an XMCSPI
`driver. This opens an opportunity for any software company to design an application without worry about market size limits
`
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`of any one control hardware suppliers is often the case today.
`
`Compumotor believes that such an increase in market size will entice more software to be written by third-party sources.
`OEM machine builders would also benefit from a wider appeal of their application-specific software.
`
`From the PLC arena
`
`The PC can also be a motion controller platform
`
`The emergence of the IEC 1131 standard for PLC programming has a connection to motion control. Parts of IEC 1131 are
`analogous to the XMC product from ROY-G-BIV. Whereas XMC bridges the gap between Windows development and
`different motion controller hardware, IEC 1131 allows different PLCs to be programmed under the same software
`environment. By following the IEC 1131 standard in its software development, Wizdom Controls Inc. (Naperville, Ill.)
`believes it is in the forefront of the race to integrate PLC and motion controller programming.
`
`Bruce Buscher, vp and general manager of Wizdom Controls, says of the motion control-PLC connectivity issue. "Motion
`control companies have decided that the role Windows plays in the industrial market will drive the demand for their products
`to be compatible and more user friendly in the programming environment. For this reason, they've started to seek out software
`companies with which to align."
`
`Several motion products manufacturers, among them Delta Tau, have an alliance with Wizdom Controls. Their interest lies in
`Wizdom's Paradym-31, which follows the IEC 1131 spec, outlining a unified set of five languages for PLC programming. By
`modifying Paradym-31 to work with motion control hardware, companies are able to offer a complete machine solution with
`tight integration of the motion controller program within the PLC program. Its part of the trend as companies try to offer
`customers a complete hardware and software solution.
`
`One final, observation on the future. While most of this article describes a centralized control scheme where the PC plays a
`pivotal role, there is much action in the arena of decentralized control schemes as well. Stand-alone motion products in the
`not-so-distant future will communicate via high-speed serial interfaces. Thus, it is important for communication protocols to
`adhere to some standard. The ability to interconnect the PLC, motion controller, and all other components of the machine
`must become effortless for customers.
`
`Joe Pavlat, VP of R&D at Pro-Log Corp. (Monterey, Calif.), agrees. In his opinion, "Motion control is no longer an insular
`technology. It must be integrated into the customers overall control system, which these days involves human machine
`interface, I/O control, networking, and fault monitoring. Users are increasingly unwilling to lash all of these elements together
`themselves, and look to the suppliers to provide the connectivity. Companies that provide this function will enjoy not just
`project-by-project design-ins, 'but plant-wide and enterprise-wide business. They will becomes the suppliers of choice."
`
`If standards for communication are not followed, it is arguable that they are little more than another proprietary bus and not an
`open standard, Mr. Pavlat suggests, "Customers want standard hardware interfaces like Ethernet, Arcnet, CAN (including
`DeviceNet), and Profibus," he says. "Motion control standards like SERCOS will only become popular if interoperability -
`controller from Company A usable with a drive from Company B - becomes a reality."
`
`Following current trends, both hardware and software are becoming more capable and full-featured. Though products grow in
`complexity, customers demand that they become easier to apply in all aspects: product performance, configuration tools,
`application specific design, and new development tools. In the near future, machine developers can look forward to designing
`a system, then integrating motion control components as easily as they now tie a new laser printer into a PC system.
`
`About the Author: Kevin Holloway has been the product planning manager at Parker Hannifin Corp., Compumotor Div., for
`the past four years. He also has four years' experience as field applications engineer and region manager for Compumotor
`and Texonics, a large motion control distributor in Denton, Tex. Mr. Holloway is a 1987 BSEE graduate of Georgia Tech. He
`may be reached via email at kholloway@cmotor.com.
`
`For more information on other companies or products mentioned in this article, contact Compumotor at Fax 707-584-8015.
`
`Back to Top
`
`A' ROY-G-B1V -
`
`Solietwkroverieslairas-
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