Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

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Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

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Today, I will share with you the hardware interface and functions of the 6-axis stepper motor closed-loop EtherCAT motion controller ZMC432CL-V2.

1. Introduction to ZMC432CL-V2 Product

The ZMC432CL-V2 is a high-performance multi-axis motion controller compatible with EtherCAT bus and pulse type, featuring high-speed real-time feedback and supporting pulse closed-loop control, achieving high precision and high response speed in motion control. It provides high precision positioning, effectively eliminating mechanical transmission errors, meeting the requirements of high-precision processing application scenarios.

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

1. ZMC432CL-V2 Hardware Functions

(1) Rich motion control functions: supports linear, arc, spatial arc, helical interpolation, etc.
(2) Rich hardware interfaces: supports pulse axes (with encoder feedback) and EtherCAT bus axes, equipped with 24 input and 12 output general-purpose IO, some of which are high-speed IO, and 2 analog outputs (DA).
(3) EtherCAT refresh cycle can reach up to 250us, meeting high-speed communication needs.
(4) Supports 4-channel hardware comparison output, hardware timers, and precise output during motion, suitable for multi-channel vision applications.
(5) Supports power failure detection and storage, multiple program encryption methods, effectively preventing system failures, protecting engineering project file data, and enhancing system reliability.
(6) Project development can be carried out through the domestically produced IDE development environment RTSys, allowing real-time simulation, online tracking, diagnosis, and debugging, which is simple and easy to use, supporting various advanced host language joint programming for secondary development.
Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface
Video introduction of ZMC432CL-V2 product

For more details about ZMC432CL-V2, click →Closed-loop solutions for stepper control with 32-axis EtherCAT bus motion controller ZMC432CL-V2.

2. Hardware Interface

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

Serial Number

Interface

Description

①

Power Interface

Connect to 24V DC power supply

②

General Digital IO Input Port

NPN type, IN0-23, compatible with single-ended encoders, latching function

③

General Digital IO Output Port

NPN type, OUT0-11, compatible with single-ended pulse, HW, PWM functions

④

Analog DA Port

Single-ended type, 12bit, 0-10V

⑤

CAN Bus Interface

Connect to CAN expansion module to expand resources

RS485 Interface

Connect to host computer, using MODBUS_RTU protocol

⑥

RS232 Interface

Connect to host computer, using MODBUS_RTU protocol

⑦

UDISK Interface

Connect to USB flash drive for program upgrades, data import and export, etc.

⑧

EtherCAT Bus Interface

Connect to EtherCAT bus driver or other slave expansion modules, etc.

⑨

EtherNET Port

Connect to host computer, using MODBUS_TCP protocol, can be expanded through switches

⑩

AXIS Differential Pulse Axis Interface

Connect to servo driver, including direction pulse, encoder, dedicated digital IO

⑪

Controller Status Light

POW Power Indicator: Lights up when power is on

RUN Running Indicator: Lights up during normal operation

ALM Alarm Indicator: Lights up during operation errors

3. Hardware Wiring

1. Digital Input Wiring IN
Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

General wiring diagram for input ports

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

Single-ended encoder wiring diagram for input ports

2. Digital Output Wiring

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

General wiring diagram for output ports

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

Single-ended pulse axis wiring diagram for output ports

4. Pulse Closed-Loop Applications

1. Using Existing API Development

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

2. External Grating Scale Closed-Loop Solution for Stepper Motors
① The ZMC4 series provides efficient network read and write, PCIe/PCI series cards can share memory interface (batch read and write of shared memory 3-5us)
② Built-in backlash compensation, bidirectional pitch compensation, 2D plane compensation, etc.
③ Supports simultaneous use of pulse axes and EtherCAT axes in mixed motion
④ Open PT/PVT interface allows customers to customize acceleration and deceleration algorithms for secondary programming

3. Pulse Closed-Loop Wiring

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

The closed-loop motion controller generates corresponding control signals, sends them to the stepper driver to drive the motor, while also receiving feedback signals from the grating scale and comparing them with preset target values.
The stepper driver receives control signals from the controller and converts them into angular displacement to drive the motor. The stepper driver can precisely control the stepping angle and speed of the motor, achieving high precision motion control.
The grating scale is used for real-time monitoring of the object’s position and motion status. In a pulse closed-loop system, the grating scale is usually mounted on the moving parts of the motor to measure its actual position.
The pulse closed-loop motion control system, equipped with external grating scale closed-loop position feedback, corrects mechanical transmission errors in real-time, ensuring high precision closed-loop and processing accuracy of the stepper system through real-time feedback.

The ZMC432CL-V2 controller supports pulse sending DPOS and encoder feedback MPOS for all pulse axes Axis0~Axis5, and real-time closed-loop can be achieved through parameter settings for pulse sending and encoder feedback.

5. Stepper Driver Interface Wiring

1. ZMC432CL-V2 Wiring with Stepper Driver (Differential Connection)

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

2. ZMC432CL-V2 Wiring with Stepper Driver (Single-ended Common Anode Connection)

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

6. Grating Scale Interface Wiring

1. ZMC432CL-V2 Wiring with Incremental Grating Scale (Differential Connection)

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

2. ZMC432CL-V2 Wiring with Absolute Grating Scale

Introduction to ZMC432CL-V2 EtherCAT Motion Controller Hardware Interface

7. Pulse Closed-Loop Test Code

The test program is as follows:

'/************************************************************'Task Number:          None'Function:          System Initialization'Input:          None'Output:         None 'Return Value:          None'Remarks:               None        '*************************************************************/GLOBAL SUB SysInit()    'Test firmware information    '?

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