3DCrane

Installation Manual
PCI version

www.inteco.com.pl

3DCRANE INSTALLATION MANUAL

3DCRANE INSTALLATION MANUAL

SAFETY OF THE EQUIPMENT

The equipment, when used in accordance with the instructions supplied within the parameters set for its mechanical and electrical performance, should not cause any danger to health or safety if normal engineering practices are observed. If, in specific cases, circumstances exist in which a potential hazard may be brought about by careless or improper use, these will be pointed out and the necessary precautions emphasised. While we provide the fullest possible user information relating to the proper use of this equipment, if there is any doubt whatsoever about any aspect, the user should contact the Producer (Inteco Ltd). Some National Directives require indicating on our equipment certain warnings that require attention by the user. These have been indicated in the specified way by labels. The meaning of any labels that may be fixed to the equipment instrument are explained in this manual.

Risk of electric shock

PRODUCT IMPROVEMENTS
The Producer maintains a right of continuous product improvement by incorporating the latest developments and components into his equipment. All major changes are incorporated into up-dated editions of manuals and this manual is believed to be correct at the time of printing. However, some product changes, which do not affect the capability of the equipment, may not be included until it is necessary to incorporate other significant changes.

3DCRANE INSTALLATION MANUAL

ELECTROMAGNETIC COMPABILITY
This equipment, when operated in accordance with the supplied documentation, does not cause electromagnetic disturbance outside its immediate electromagnetic environment.

COPYRIGHT NOTICE Inteco Limited

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Inteco Ltd.

ACKNOWLEDGEMENTS
Inteco Ltd acknowledges all trademarks. IBM, IBM - PC are registered trademarks of International Business Machines. MICROSOFT, WINDOWS are registered trademarks of Microsoft Corporation. MATLAB and Simulink are registered trademarks of Mathworks Inc.

3DCRANE INSTALLATION MANUAL

CONTENTS

1. INTRODUCTION .................................................................................................... 6 2. COMPONENTS OF THE SYSTEM ........................................................................ 7 3. MECHANICAL ASSEMBLY................................................................................... 8 4. RT-DAC/PCI CARD INSTALLATION .................................................................. 17
4.1 RT-DAC/PCI card connectors ..................................................................................................................... 18 4.2 Driver Installation......................................................................................................................................... 19

5. POWER INTERFACE........................................................................................... 20
5.1 Connecting the cables ................................................................................................................................... 20 5.2 Testing............................................................................................................................................................ 22

3DCRANE INSTALLATION MANUAL

1. INTRODUCTION
This manual contains a description of the components of the 3DCrane System, assembly instructions and test procedures. The procedures described in this manual will ensure correct: assembly of the system, RT-DAC/PCI interface card installation and driver installation, cable connections between the 3DCrane, 3DCrane Power Interface and PC, proper operation of the encoders, Power Interface unit and DC motors.

3DCRANE INSTALLATION MANUAL

2. COMPONENTS OF THE SYSTEM

To use the 3DCrane system the following software and hardware components are required: Pentium or AMD based personal computer Microsoft Windows 2000/XP 1 PCI slot available, MATLAB version 7 (SP2, SP3), R2006a/b or R2007a with Simulink, RTW and RTWT toolboxes (not included), RT-DAC/PCI Programmable I/O board to install in the PC, Inteco 3DCrane System consisting of 3DCrane Mechanical Unit and 3DCrane Power Interface Unit, The 3DCrane toolbox and pdf manuals stored on CD. There are the following manuals: Installation Manual and Users Manual.

3DCRANE INSTALLATION MANUAL

3. MECHANICAL ASSEMBLY
Step 1: unpacking and checking the items
Carefully unpack the items, and remove all packaging and securing material. You should have the following items (Fig.3.1): 3DCrane Mechanical Unit: - supporting construction - lower part SL (4 pieces), - legs L (4 pieces) - supporting construction-upper part, consisting of 2 elements (SU1) connected with y- tracks and 2 elements (SU2) integrated with the power transmission shafts. The toothed belts, pulleys and DC motors are attached. - rail for the cart to move on (R), - ribbon signal cables and power cables, couplings bolts and special allen wrench, 3DCrane Power Interface, RT-DAC/PCI card with ribbon cables, Documentation (Users Manual, this manual) CD-ROM, Packing List

The exact specification you will find on the Packing List. If any item is missing or is damaged please report to Inteco.

Carefully follow the assembling steps described below. Only correct assembling procedure ensures a proper operation of the system.

Attention: If your 3DCrane is standard size lower and upper supporting constructions are combined in the factory. In this case assembling of 3DCrane model is very fast and easy.

3DCRANE INSTALLATION MANUAL

upper support
X - encoder

cart

Z - motor

Y-rail

rail of cart belt

X-rail

belt Y- motor belt

upper support

X - motor

leg

lower support

SU 2

SU 1 R

L L

SL

Fig 3.1 The crane assembled and disassembled

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3DCRANE INSTALLATION MANUAL

Step 2: assembly of the mechanical construction

It is recommended cooperation of two persons when assembling the mechanical part of the 3DCrane.

Notice, that elements of the supporting construction are clearly marked using the following convention: the element market by the letter # must be connected in mounting position with the element marked also by the letter # (see example in Fig 3.2).

Fig 3.2 Connection marks

Fig 3.3 Coupling bolts and coupling method

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3DCRANE INSTALLATION MANUAL

Mechanical construction assembly phases are described below and illustrated in Fig. 3.4. Select four elements of the crane supporting construction lower part (SL) and place them on a level surface. Connect the elements. Insert coupling bolts into mounting positions and loosely tighten them with the allen key provided (Fig.3.4A). Select four legs (L) and connect them with the lower support SL (Fig.3.4B)

SL

SU1

SU2

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3DCRANE INSTALLATION MANUAL

SU1

SU2

D
Fig 3.4 Assembly of mechanical construction

Select four elements of the 3DCrane supporting construction upper part (SU1 and SU2) and place them on a level surface. Connect the elements according to the marks given on it (Fig.3.4C). Tighten the bolts with the key provided. Fix the rails for the cart (R), using special 8 mm bolts and the key (Fig.3.4D). Apply a correct location of the rail: notice that X and Y motors are located on the same side of the upper frame ( see Fig.3.1). Check movement of the rails. If they are not moving freely inspect position of the blue carts inside the X rails. They must be located parallel to the X rails. If not, loosen the 8 mm bolts, adjust position of the cart and tighten again the bolts. Locate the upper part of the construction (integrated with the track and the cart) on the legs (Fig.3.4E), insert the coupling bolts and tighten with the key. Tighten all the construction bolts. Most parts of the mechanical construction are made of aluminium and plastic. Therefore, it is not recommended to use a forces exceeding 1-3 Nm when tightening the bolts.

Attach the payload (1000 gram) to the cord unrolled from the cart.

The basic phases of assembly are illustrated in photos 3.5 3.10.

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3DCRANE INSTALLATION MANUAL

Fig 3.5 The lower support assembled

Fig 3.6 The legs assembled

Fig 3.7 Fixing rails (R) to the upper frame

Fig 3.8 Upper support assembled and connected with the rails

Fig 3.9 Mounting the upper part of the construction

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3DCRANE INSTALLATION MANUAL

Step 3: connecting and clipping the cables

There are two kinds of cables attached: flat cables from the encoders and round cables controlling the motors. Fix two flat cables from the encoders to the X-motor support (Fig. 3.10) Fix two round cables controlling the motors to the X-motor support (Fig.3.10). All above cables and third flat cable from X encoder locate inside the cover available on the crane leg (Fig.3.11).

Fig 3.10. Fixing the cables: clip for cables

Fig 3.11. Fixing the cables: cables inside the cover

Connect the flat cable to the Y-encoder. Notice: only one position is correct. The red point on the cover of Y encoder indicates correct location of the red side of the connector (see Fig. 3.12).
encoder shaft

plexiglas

flat cable

Fig 3.12. Connecting cable to Y-encoder Fix the cable using two screws located on the upper frame.
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3DCRANE INSTALLATION MANUAL

Step 4: Adjustment of the belts

Start adjustment from the X encoder side of the crane(see Fig.3.1): Pass the belt through the pulleys at each end of the track and fix it under the clip of the tension adjustment bolt (Fig.3.13) Fix the cart rails at the limit position (Fig.3.14). Check the belt tension. When ballast 200 grams in the middle of the belt run between the pulleys, there should be total 25 mm vertical movement (Fig.3.15). If the belt is slack, use the screwdriver to slack off the belt tension screw bolts and move the end of belt until the belt is tighten. Tighten the adjustment screw. Go to the motor side of the crane. Loose head-less screws located by the pulleys (Fig.3.16). Pass the belt through the pulleys. Fix the belt under the clip of the tension adjustment bolt.

belt tension adjustment bolt

Fig 3.13. Tightening the belt Check tension of the belt (see Fig.3.15).

Fig.3.14. Fixing the rails

Fix the pulleys by tightening the head-less screws (Fig.3.16) Check tension of the Y axis belt. Free the rails and check if the rails and the cart are moving smoothly.

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3DCRANE INSTALLATION MANUAL

25 mm

200 G

Fig 3.15. Measurement belt tension

headless screw

pulley

Fig.3.16. Adjustment of the belt: loosing the pulleys (motor side)

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3DCRANE INSTALLATION MANUAL

4. RT-DAC/PCI CARD INSTALLATION

The RT-DAC/PCI board contains sensitive electric components, which can be easily damaged by static electricity, therefore the card should be kept in its original anti-static packing until it is installed. During installation the card should be handled carefully only by the edges to avoid static electric discharge

To install the board: Turn off the computer and remove the cover, Find adjacent empty PCI slot and remove the metal bracket. Insert the RT-DAC/PCI card into the slot, then secure the card by the screw, Replace the cover of the computer. Now ready to connect the cables to the 3DCrane Power Interface (section 5). Turn on the computer and install the driver for RT-DAC/PCI board (section 4.2).

Before opening turn OFF the computer and disconnect the mains power

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3DCRANE INSTALLATION MANUAL

4.1 RT-DAC/PCI CARD CONNECTORS

RT-DAC / PCI JP1

CN3

JP4

CN2

XILINX

SW2

PLX
CN1

SW1

Fig. 4.1. RT-DAC/PCI board: location of connectors

The FPGA (XILINX) chip mounted on RT-DAC/PCI board contains unique logic of 3Dcrane system. Do not change settings of any switches on the board.

Only CN1 and CN2 connectors are used in the 3Dcrane system.

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3DCRANE INSTALLATION MANUAL

4.2 DRIVER INSTALLATION

The driver for RTDAC/PCI board has to be installed because the board is of the PCI type. Administrator privileges are required for driver installation.

Windows 2000/XP installation

Start Windows 2000/XP System detects new PCI device Select Next, then Display a list.... Select Other Devices, then Next Select Have a disk, then Browse Select path CD:\driver\Win9x2kXP\RTDAC4_PCI9030.inf, then Open Select OK and Next, and Next Select Finish If Windows propose to restart the computer select Yes.

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3DCRANE INSTALLATION MANUAL

5. POWER INTERFACE
The general diagram of power interface connections is given in Fig. 5.1 (5.1a). Figure 5.2 (5.2a) presents view of the front panel of the 3DCrane Power Interface. Two types of Power Interfaces are distributed. The first powered from ~110/220 V, and the second with external 24 V DC power supply.

Before connecting the cables turn OFF the computer

5.1 CONNECTING THE CABLES

In order to connect cables perform the following steps:

Check the position of the Power Switch it must be in 0 (OFF) position. Connect the 40-way ribbon cable to power interface, and the second side C1 (with red wire) and C2 connectors to CN1 and CN2 sockets respectively. Connect three 10-wires flat cables from encoders and limit switches to 10-pins sockets ( I, II and III ) in the power interface. Connect three round cables controlling DC motors, respectively: connector RED is for X axis motor, connector GREEN is for Y- axis motor and connector BLUE is for Z axis motor. Connect the emergency switch cable (VIOLET) to the E socket. Connect the mains power cable (POWER SUPLY UNIT is available on the right side of the front panel).

Notice, that the cables are clearly marked using the convention presented in Fig. 5.1.

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3DCRANE INSTALLATION MANUAL

STOP

E
C
Emergency switch

Y
I

II

III

0 1

40-way ribbon cable

From encoders& limit switches

to DC motors

Fig. 5.1 Power Interface and connecting cables

External power supply 24V DC

~110/220V connector

STOP

E
Emergency switch

II

III

40-way ribbon cable

From encoders& limit switches

to DC motors

Fig. 5.1a. Power Interface and connecting cables ( if external power supply id used )

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3DCRANE INSTALLATION MANUAL

5.2 TESTING

It is important that the area of 3Dcrane operation is free of obstacles and observers are located outside the mechanical construction for safety reasons.

In order to test the Power Interface perform the following steps: Install the 3DCrane software. For this purpose refer to Getting Started Manual, section 2. DO NOT SWITCH the power switch ! If the RT-DAC/PCI card was properly installed and ribbon cables are connected, turn on your PC. Start MATLAB/Simulink and invoke Manual Setup from Main Window. Mark Reset checkboxes and click Update button. Positions and angles are set to zero. Next manually move crane along X, Y and Z axis. Click Update button and read positions. If the connections are correct you will see sensors readings on the screen. Repeat the action for angles. If all measurements are correct, stop the MATLAB application. Switch the power on (POWER SWITCH). Blue LED on the front panel will alight. Invoke Basic Test application from the Main Control Window. Turn on DC motors using MOTORS ON button on the front panel. Red LED on the front panel will alight. Perform the steps of the Basic Test. The tests are detailed described in Getting Started manual in section 3. If you see any unexpected movements of the crane use the EMERGENCY SWITCH.
EMERGENCY SWITCH MOTOR X MOTORS ON BLUE LED RED

MOTOR Y

MOTOR Z

~110/220V CONNECTOR

E
C

X
1

Y
1 I

Z
1 II III 1

POWER SWITCH

POWER SUPPLY UNIT

Fig. 5.2. Front view of the power interface

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3DCRANE INSTALLATION MANUAL

EMERGENCY SWITCH

MOTOR X

MOTOR Y

MOTOR Z

MOTORS ON RED

BLUE LED

POWER

E
C

X
1

Y
1 I

Z
1 II III 1

Fig. 5.2a. Front view of the power interface ( if external power supply is used ) Socket to connecting the external power supply is placed at rear part of the power interface.

Inteco reserves the right to do changes without obligation to notify anyone of such revision or change

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