DeviceCraft Revision #2 4/13/2014 Illustration 1: Wiper Motor Controller, Sensor, and optional programmer DC Wiper Motor H-Bridge Servo / Speed Controller P/N 4900 Features: Powerfull servo or reversible speed controller Green, reuse of equipment 6v to 24v operation Forward/Reverse operation Analog, RS232 ttl serial, PCM, or self control Soft and hard position limits Adjustable acceleration, max duty, limits, temperature, speed, PID parameters High Power Discrete MOSFET H-Bridge configuration On board regulator with a +5v regulated output for powering circuitry Thermistor based over temperature protection Ultra Quiet ~15Khz Pulse Width Modulation >99% Duty cycle Led indicators for normal and fault condition Insensitive to noise on power line. Several modes require no external circuitry: temperature open, back and forth, and multiple back and forth rotation. Blade fuse protection
Enable, forward/reverse, clockwise and counter clockwise stop digital inputs. Illustration 2: Wiper Motor Controller Installed in assembly
Improvements over prior version: Hall effect postion sensing to improve operation life 8P8C control connector for easier connection to unit Input protected digital inputs to allow inputs up to 24volts on digital lines Wired power connector to allow connection with wire nuts Blade fuse protection Enclosed side opening with fuse 8p8c connector and led Lower resistance MOSFETs Lower operating voltage from 12v to 6v Improved serial port code More modes of operation Remote setting control board available
Wiper motor required: 1996-2004 S10 BLAZER JIMMY SONOMA WINSHIELD WIPER MOTOR CHEVY GMC P/N 15036008 some say 98 to 2005 98 99 00 01 02 03 04 05 BLAZER JIMMY 98 99 00 01 02 03 04 05 BRAVADA 98 99 00 01 ENVOY 98 99 00 01 02 03 04 05 S10 PICK UP 98 99 00 01 02 03 04 05 SONOMA Applications: Animated displays Camera/Spotlight rotation Window and door opening Steering systems Torque controller for valves Axis movement Machine tools Cleaning equipment Antenna rotation Description The DeviceCraft wiper motor servo/speed controller is a low cost reliable solution to many geared motor projects. The motor controll allow the reuse to automobile wiper motor which would normally be disgaurded. The controller allow the unit to operate as a servo positioning system or a reversing speed controller. The controller is energy efficient and has numberous features and capabilities.
Specifications Operating Voltage Motor Current draw 6V to 24V damage over ~30Vdc ~1 to 10 Amps Depends on load speed and acceleration Over Temperature On Over Temperature Off Startup Time Ramp Rate (stop to full speed) Duty Cycle PWM switching rate Digital Input low Digital Input High Quiescent Current 80C 70C ~.5Sec ~0 to 4Sec 0 to ~99.9% ~15 Khz 0 to.8v 3.5 to 5V ~40mA MOSFET On resistance Less than 4milliohm Reversing Delay Time Speed Rotation Degrees Position Resolution 0 sec (depends on ramp rate) 70rpm at 12v 140rpm at 24v 360 degrees 10 bits
Input/Output Pins: Pin Name Function 1 +5v 2 Gnd +5v DC output Only a small <50ma of current should be drawn from this pin for powering external circuits Do not connect external 5v to this unit (output only) Connected to common gound for potentiometers or external circuitry otherwise no connection 3 Ain Analog input (0v to 5v) Selects duty cycle 0-~99.5% or PCM duty cycle digital input 50k at input to ground Small filter on input 4 F/R Digital Input Forward/Reverse selection Input Range Open, 0 to 24volts Low: open, 0 to.8v High: 2volts to 24 volts Function can be enable or disable Function can be inverted 5 En Enable input, enables or disables unit allowing motor leads to float. Input Range: Open, 0 to 24volts Low: open, 0 to.8v High: 2volts to 24 volts Function can be enable or disable Function can be inverted 6 7 8 ST Rx Tx LED and status output pin RS232 serial input TTL RS232 serial output TTL 0 to 5v Gnd Gnd Power Power Black/Green wire <16 awg Red wire <16 AWG for power unit
Mode Description 0 Duty Cycle/Speed Control Separate Forward/Reverse line Ain controls duty cycle (0 to 5v) 0v stop, 5v full speed Software limits CWS CCW (0 to 1023) sets movement limits Clockwise and counter hardware limits can be set. Limits must be activated with STE command to enable limit stopping F/R line reverses movement EN line will enable or disable unit (must be activated) F/R and EN can be inverted with INV command 1 PID servo positioning MODE Analog input Ain (0v to 5v) determines position POR (0-1023) sets porportional multiplier INT controls intergral multiplier F/R inverts movement 2 Forward/Reverse on one analog input Ain controls duty cycle(0v to 5V) 2.5v stop, 0v full reverse, 5v full forward F/R inverts movement 3 Same as Mode 0 except modified inpuy range to allow for hall effect input throttles. Below 1 volts stop Above 4 volts full speed 4 Same as Mode 2 except modified input range to allow for hall effect input throttles. Below 1 volts full reverse Above 4 volts full forward 2.5v stop F/R inverts movement 5 Same as Mode 0 execpt wider.250 volt gaps at ends 6 Same as Mode 2 execpt wider.250 volt gaps at ends 7 PCM speed control mode. PCM digital pulse on Ain Line
1.5msec stop, 1msec full reverse, 2msec full forward F/R line reverses movement 8 PCM PID servo mode. PCM digital pulse on Ain Line 1.5msec 180 degrees, 1msec 0 degrees, 2msec 360degrees F/R line inverts movement 9 to 12 Future modes 13 Temperature mode Cold at CCW position Hot at CW position The open temperature is set with the OPN settting The temperature is a binary number, measured at the junction of a 10k resistor and a 10k thermistor. The range is 0 to 1023. At room temperature the reading is approximately 500. At 90F the number will be ~440 At 50F the number will be ~660 B constant 3434 14 Back and forth INT/10 rotations. Hardware stops will reverse. 15 Back and forth to CW and CCW positions. Delay in between controlled by POR 16 Serial Port speed control Setting SDC command from -1023 to 1023 controls the speed 17 Serial Port position control Setting SDC command from 0 to 1023 controls the position
Illustration 3: HyperTerminal Wiper Motor Serial Port Output
LED indicators: 1) Green LED A) Continuously ON normal operation B) Off no power C) D) E) F) Flash 1/2 second interval Over temperature active Flash 1/4 second interval Under Voltage active Flash 1/8 second interval Over Voltage active Flash 1/16 limit reached or Enable line not active The Green Led output connects to the ST pin on the 8p8c connector also. Power Supply The motor controller will handle the maximum current required by the motor. The maximum stall current under full load is ~8Amps at 12Volts and ~16Amps at 24Volts. The power supply required depends on the application and controller settings. Limiting the load on the motor, maximum duty cycle, accelerations, and speed will reduce the required current. A 2 amps power supply can be used under light loads. The voltage of the power supply will effect the maximum speed of the wiper. Power supplies and batteries from 6v to 28v will power up the unit. Running the motor over the 13 volt should be performed with care and possibly reduce the maximum duty to prevent damage. Normally the unit will draw the maximum current during acceleration. During deceleration the unit may regenerate power. Some power supplies may overvoltage trip during deceleration. A diode in series with the power line and a TVS on the motor controller size will reduce over voltage problems. Installation Remove the cover to the wiper motor with a star wrench. Ease out the old controller. Clean the gear standoff. Install the sensor cup with a rubber mallot. Install the devicecraft motor controller assembly. Optionally reinstall cover and power up the unit. Wires to the motor controller can be connected with wire nuts. Control Connector The connection to the control connector is made with a standard 8 pin Ethernet cable.
Illustration 4: Keystone Snap-In Insert Punch Down Jack Various length cables and accessories can be purchased for connecting to the 8pin cable.
Acceleration The acceleration is controllable from 30msec seconds to ~30seconds. A controlled acceleration reduces wear on the motor, gears, and power source. A controlled acceleration can prevent the over current protection circuitry from triggering during start-up or reversing. The acceleration can be controlled by adjusting the acceleration up acceleration down and stop acceleration. The serial port commands are AUP, ADW, and ASP. Setting the acceleration to 1 will result in the slowest acceleration and setting the acceleration to 1023 will result in the quickest acceleration. Enable Input The Enable wire on the 8 pin 8P8C connector can be used to enable or disable the unit. The unit is ramped down to stop when active The input to the Enable is protected with a transistor input allow for enable inputs up to 24 volts. The input can be grounded or left floating to function as a disable input. Applying 5v to the enable line is enough to enable the unit. The enable function can be inverted by setting bit 1 of the INV command equivalent to adding 2. Hardware Stops: The hardware clockwise and counter clockwise stops can be enabled for the motor controller. The connections are located under the 8 pin 8P8C connector. The connections are made by soldering wires through the via holes. 22 awg to 28 awg stranded wire can be used for the connections. The inputs are transistor protected allowing 0v to 24v inputs. The operation can be inverted with the INV command. Setting the INV command to zero requires the input to have a voltage >2volts to stop movement. Software Stops: The software stops are settable with CCW counter clockwise and CWS clockwise command. The range for the inputs are 0 to 1023. Setting the values below 40 and above 990 will disable the position stops. Speed Control: The speed of the motor controller can be controlled by several methods.
1. Power supply voltage 2. Limiting duty cycle with the MXD command. 3. Setting the DIF parameter with the DIF command. 4. Limiting the input control signal for non servo modes. The differential speed control performs a rough speed control. When using DIF speed control the accelerations must be lowered for optional performance. The MXD will limit the maximum duty cycle delivered to the unit and is useful for limiting current draw from the power supply or battery. Power Supply Under and Over Voltage: The power supply voltage can be measured and under and over voltage can be set. The power supply voltage is measured with the VS1? Command. The output is 4bits per volt. The unit can be disable if the power supply voltage is too low or too high. The under voltage is set with the UVS command and over voltage set with the over voltage command OVS. During deceleration the unit may regenerate current, if the power supply can not handle reverse current the OVS may become active. To set the under voltage to 10volts send command UVS 40 via the serial port. To set the over voltage to 16 volts send command OVS 64 via the serial port. Wire Resistance Table AWG Diameter Resistance per foot 24 22 20 18 16 14 12 20 mils (thousands of inches) 25 mils 32 mils 40 mils 50 mils 64 mills 80 mils 26 milliohms 16 milliohms 10 milliohms 6.2 milliohms 4 milliohms 2.5 milliohms 1.6 milliohms Over Temperature Protection: The over temperature protection trigger can also be modified. The temperature sensing voltage is monitored at a junction in between a 10k thermistor TC1 and a 10k standard resistor. The voltage will drop with increasing temperature. The OTM command sets the over temperature indicator and will shut down the unit if the temperature is under this value.
Servo Postioning Modes
Several modes allow the positioning of the wiper. The range of positioning is 0 to 1023. 0 is equivalent to 1024. Values near the the 0 position are not allowed. The range of motion is about 300 degrees. The home position can be change by unbolting the blade and repostioning. The home position is also set by where the plug is placed over the internal gear. The positon can be set in several modes. In the serial port mode setting the SDC command to a value betweeen 0 and 1023 with move the position. In R/C mode the pulse width between 1000 and 2000 usec will position the blade. In analog input mode the postion is set by driving the Ain line on the 8 pin ethernet cable to a value between 0 and 5 volts. The performance and postioning speed is adjustable. The POR command controls the differential multiplier. The POR is adjustable from 1 to 1023. The differential multiplier greatly effect the speed and postioning accuracy. Too high a POR can cause overshoot and vibration. The acceleration commands for up and down acceleration, AUP and ADW with effect the postioning time and setting time. Normally higher acceleration numbers are needed for good performance. The maximum duty cycle, MXD, and max speed DIF, will help control position speed. Note: the INT is currently not active. The current postion can be queried with the POS? Command. The desired position can be queried with the SER? Command.