Mar 18, 2003 PFIS CDR 1

Control SystemSummary of Changes

Since PDR

• All the motors, drivers, sensors, switches, etc. have been chosen

• Built up a mechanism using typical parts, a slit mask elevator mockup

• Designed and built a client/server system in LabVIEW: uses all proposed LabVIEW functions: data sockets, queues, string parsing, analog input, closed loop motion control.

• Ran the mechanism at all three proposed levels of control: actuator, mechanism, and system level (with a slit mask searching procedure)

• Control System wiring has been completely designed.

PFIS “Generic Mechanism”Used for proof-of-concept testing

Mar 18, 2003 PFIS CDR 2

Control SystemHardware Block

Diagram

• Control fiber to payload

• AC & RS232 from payload back to top hex, for Etalon controllers

• 3 PFIS cooled electronics boxes inside PFIS structure

• Main (Chassis, power supplies)

• Box 1 (Slit mask, wave plate, shutter, focus)

•Box 2 (Beam splitter, Grating, Filter, Articulation)

Mar 18, 2003 PFIS CDR 3

Control SystemPower Management

and Distribution

• SALT Isolator switch provides power to all of PFIS

•Within PFIS, PXI & sensors can be powered without power to actuators

•Motors and pneumatics are each powered separately

•Etalon High Voltage is interlocked with sensors near HV connectors.

Mar 18, 2003 PFIS CDR 4

Control SystemStatus of Electrical Design

• All components have been identified and assigned locations:– Main box with PXI chassis, power supplies, digital & analog inputs– Satellite box 1: slit mask, wave plate, focus, and shutter– Satellite box 2: grating, filter, articulation, and beam splitter

• Wiring diagrams & interlock logic are complete - ready to buy & build• Each satellite box implements its interlocks with a Programmable Logic

Device– All end-of-travel conditions are sensed– We use a “fail asserted” approach: a broken wire looks like a hard limit– Each hardware interlock is backed up by a matching software interlock– The low-level software interlocks are avoided by the configuration state

machine• Shutter interface with SAAO detector subsystem is final

Mar 18, 2003 PFIS CDR 5

Control SystemHeat Budget

• Steady-state heat is all in cooled boxes; 400 W is well below PFIS allocation of 1.3 kW

• Primary source of uncooled heat is motors

•Most motors have very low duty cycle, and are not used during observing; time-averaged power is about 1 W

•Exceptions are polarimetric modes - in the high-speed shuffle modes, duty cycle can be very high. For a 25% duty cycle, add 0.8 W for linear and another 0.8 W for circular.

PFIS Steady-state Power

Power(W)

Comment

Top Hex

2 x etalon ctlr 184 Mfgr spec; measured power is about half this

PFIS Main Box

PXI Chassis 4 Data sheet

3 x Motion Ctlr 15

Power Supplies 36 15A, 24V, 90% efficiency

PFIS Box 1

4 x Drivers 9.6 estimate based on measured Oriental Motors board

Interlocks 1 estimate from EE

PFIS Box 2

4 x Drivers 9.6 estimate as above

Interlocks 1 estimate from EE

SAAO CCD Boxes

SDSU Array Ctlr 4.3

SDSU Pwr Supply 80

CCD Ion Pump Ctlr 40

Star Tracker

Base 15 Measured

Total

399.5

Mar 18, 2003 PFIS CDR 6

Control SystemMotors and Drivers

What MotorMaker

MotorNumbe

r

Phases

WindingVoltage

Ampsper

phase

DriverMaker

DriverNumber Comment

S.5.1

MaskElevator

OrientalMotors

PK266-02A 2 3.6 2 Oriental

Motors CSD2120-TCSKSeriesCombo

S.6.1

HWPRotate

OrientalMotors

PMC35A3 5 0.35 Oriental

Motors PMD03CA

S.6.2

QWPRotate

OrientalMotors

PMC35A3 5 0.35 Oriental

Motors PMD03CA

S.8.1 Focus Polytec

PI

M-230DCMike

IntelligentMotionSystems

INT-481ReplacesNI7602/04

S.10.1

GratingMagazine

OrientalMotors(OEM)

A6088-9015KM

5 0.75 IKOTDS1-5071(see jwp forpaper manual)

MustSupplyBlakeControl

S.10.2

GratingRotate

Nanotec(OEM)

4H4009-L03B 2 4 1.2

IntelligentMotionSystems

INT-481ReplacesNI7602/04

S.12.1

FilterMagazine

OrientalMotors

PK266-02A 2 3.6 2 Oriental

Motors CSD2120-TCSKSeriesCombo

S.13.1

Articulation Slo-Syn KML0

63F13 2 1.9 6.6 Slo-Syn SS2000-MD7

• 8 axes of motion control

• 2 NI 7334 cards (1 spare)

• 4 Oriental Motors (with drivers)

• 2 embedded (OEM) motors

• 1Slo-syn high torque motor for articulation

• 1 DC stepper mike for focus

Mar 18, 2003 PFIS CDR 7

Control SystemSoftware Block

Diagram

• Client/server design

• Client sends text strings

• Server runs mechanisms

• 3 levels of server software:

• actuator level

• mechanism level

• procedure level

• Interlocks are built in at all levels

Mar 18, 2003 PFIS CDR 8

Control SystemSoftware State

Diagram

• Operational complexity has been tamed

• Maximum time to reconfigure: spectroscopy to Fabry-Perot Imaging.

• This is driven by two mutually exclusive operations

• Other operations can be done in parallel

Mar 18, 2003 PFIS CDR 9

Control SystemSoftware Development Plan

• All LabVIEW: no custom C code needed• Top-down design

– Create LabVIEW type-def data base (data clusters & enumerated commands)

– Get astronomer and operator feedback on GUI pages & navigation– Rapidly prototype & use GUI

• Bottom-up implementation– Code & debug actuator wrappers– Integrate & test actuator wrappers at mechanism level– Assemble mechanism VIs into operational procedures

• Document each VI as we go– Use LabVIEW documentation process– Place text boxes on diagram

• Configuration management: use LabVIEW version control

Mar 18, 2003 PFIS CDR 10

Control SystemSoftware Integration & Test Plan

• Match LabVIEW coding sequence to mechanism fabrication• LabVIEW modules are ready as mechanism comes on line• Bench testing of mechanism & control software happen together• Develop mechanism acceptance test procedures during mechanism I&T• Debugged mechanism software modules get used in high level observing

procedures• High-level procedures will include short- and long-form test procedures

Mar 18, 2003 PFIS CDR 11

Control SystemState Transition

Table

• Table-driven state machine provides 3rd level of interlocks, in addition to hardware interlocks & actuator-level software interlocks

• Table prevents PFIS from being driven into a bad state

• “State detection” is part of startup & error recovery - figures out what state PFIS is in

PFIS State Transition TableHow to use this table: the rows are indexed by the state you are currently in. The columns areindexed by the final (not next) state that you want to end up in. For each (current,desired) state

pair, the indexed table cell tells which transition to execute next, and what state that takes you to.Keep iterating until you end up in the desired state (you are done when you end up on the

diagonal).

s1 s2 s3 s4 s5 s6

s1 +T1, S2 +T3, S3 +T2, S4 +T1, S2 +T3, S3

s2 -T1, S1 -T1, S1 -T1, S1 -T2, S5 -T1, S1

s3 -T3, S1 -T3, S1 -T3, S1 -T3, S1 +T2, S6

s4 -T2, S1 -T2, S1 -T2, S1 +T1, S5 +T3, S6

s5 -T2, S2 -T2, S2 -T2, S2 -T1, S4 -T1, S4

s6 -T2, S3 -T2, S3 -T2, S3 -T3, S4 -T3, S4

Example: Suppose you are in state S5 (Spectropolarimetry), and you want to be in state S3(Fabry-Perot Imaging) for the next observation.

(S5,S3) indexes the cell (-T2, S2). So execute transition -T2 (Remove waveplates). You are nowin state S2 (Spectroscopy).

(S2,S3) indexes the cell (-T1,S1). So execute transition -T1 (Articulate camera back to home).You are now in state S1 (Imaging).

(S1,S3) indexes the cell (+T3,S3). So execute transition T3 (Insert etalons). You are now in stateS3.

(S3,S3) indexes the diagonal. You are done.