Product Overview

• Brand: Galil Motion Control (a leading provider of motion control solutions for industrial, research, and OEM applications)
• Model: DMC-4020
• Series: DMC-4000 Series (High-Performance Multi-Axis Motion Controllers)
• Type: 32-Bit Digital Motion Controller with 2 Independent Axes
• Industry: Automation (semiconductor wafer handling, electronic assembly), robotics (2-axis gantries, pick-and-place systems), laboratory research (precision positioning stages), CNC machining (small milling/engraving machines), and medical equipment (diagnostic imaging, sample handling).
• Function: Controls up to 2 axes of motion (e.g., linear slides, rotary stages, servo or stepper motors) with ultra-high precision. It executes complex motion profiles (point-to-point, linear interpolation, electronic gearing), processes real-time feedback from encoders, and adjusts motor outputs to ensure accurate positioning. The controller supports both PC-hosted and standalone operation (via stored programs), making it versatile for both simple setups and complex automation tasks.

Key Features

1. Dual-Axis Precision Control & Motor Compatibility
   • Supports 2 independent or coordinated axes, enabling linear interpolation for 2D path following (e.g., laser cutting, PCB routing).
   • Compatible with multiple motor types to suit diverse applications:
     • Servo Motors: DC brush, DC brushless (BLDC), and AC servo motors (via analog ±10V command or PWM outputs for drives).
     • Stepper Motors: Bipolar stepper motors with microstepping (up to 512 microsteps/step) for smooth, low-vibration motion.
   • High-resolution feedback integration: Accepts signals from incremental encoders (up to 25 MHz, differential line driver) and absolute encoders (SSI, BiSS-C protocols, optional) for sub-micron positioning accuracy (down to ±0.1 μm with high-resolution encoders).
2. Advanced Motion Modes & Profiles
   • Offers a comprehensive suite of motion modes to handle specialized tasks:
     • Point-to-Point (PTP): Moves axes to target positions with configurable trapezoidal or S-curve acceleration/deceleration, reducing mechanical stress on stages.
     • Linear Interpolation: Coordinates 2 axes to move along a straight path at a constant velocity, critical for precision machining or robotic positioning.
     • Electronic Gearing/Camming: Synchronizes one axis to another (e.g., a conveyor belt to a cutting tool) or follows a predefined position vs. position profile (camming), ideal for packaging or printing machinery.
     • Jogging & Homing: Manual jog control for setup and automated homing routines (using limit switches, encoder indexes, or hall sensors) to establish a reference position.
   • Position/Velocity/Torque Control Modes: Switchable via software to adapt to load requirements (e.g., torque control for delicate assembly tasks).
3. Flexible Programming & Communication
   • Intuitive programming via Galil’s proprietary command language (text-based commands like MOVE, SPEED, HOME)—no complex syntax, enabling rapid setup.
   • Standalone operation: Stores up to 32,000 lines of program code in non-volatile flash memory, allowing the controller to run motion tasks without a host PC (e.g., embedded automation systems).
   • Multiple high-speed communication interfaces:
     • Ethernet (10/100 Mbps): For TCP/IP, UDP, and Galil’s proprietary protocol—enables remote control and data logging to a host PC.
     • USB 2.0: For direct PC connection, firmware updates, and fast program transfer.
     • RS-232/RS-485: For legacy PLC or PC communication (baud rates up to 115.2 kbps).
4. Robust I/O & Safety Features
   • Equipped with 16 digital inputs (24V DC, sinking/sourcing) and 8 digital outputs (24V DC, 0.5A per channel) for interfacing with sensors (limit switches, photoeyes), actuators (solenoids, relays), or safety circuits.
   • Built-in safety mechanisms to protect equipment and operators:
     • Software/Hardware Limits: Stops motion if axes exceed predefined travel ranges (via hardwired limit switches or software-set boundaries).
     • Emergency Stop (E-Stop) Input: A dedicated hardwired input to immediately disable motor torque in critical situations, complying with IEC 61508 safety standards.
     • Fault Detection: Monitors encoder signal loss, overcurrent, and communication failures, triggering alarms or safe shutdowns.

Key Specifications

1. Motion Performance
   • Axis Count: 2 independent axes.
   • Encoder Input:
     • Incremental Encoders: Up to 25 MHz (differential, 4x quadrature decoding).
     • Absolute Encoders: SSI, BiSS-C (optional, via adapter).
   • Motor Output:
     • Servo: ±10V analog command (for servo drives) or PWM (for BLDC servos).
     • Stepper: Step/direction signals, up to 2.5 A/phase (bipolar) with microstepping (up to 512 μsteps/step).
   • Positioning Resolution: Dependent on encoder (e.g., 1 μm with a 1000-line encoder and 4x decoding).
   • Maximum Speed: Up to 10 m/s (varies with motor, drive, and mechanical system).
2. Electrical Parameters
   • Power Supply: 24V DC (nominal), tolerance range 18–30V DC.
   • Power Consumption: ≤15W under full load (varies with motor type and I/O activity).
   • Digital I/O: 16 inputs (24V DC), 8 outputs (24V DC, 0.5A per channel; 2A max total).
3. Physical & Environmental Attributes
   • Form Factor: Compact DIN-rail or panel-mount design (saves space in control cabinets).
   • Dimensions: Approximately 100 mm (W) × 150 mm (H) × 50 mm (D) (varies slightly by mounting option).
   • Weight: Approximately 0.5 kg.
   • Environmental Ratings:
     • Operating Temperature: 0°C to +60°C.
     • Storage Temperature: -20°C to +85°C.
     • Humidity: 10–90% (non-condensing).
     • Vibration Resistance: 10g (5–500 Hz, IEC 60068-2-6).
     • Shock Resistance: 50g (11 ms half-sine, IEC 60068-2-27).
4. Software & Tools
   • Configuration Software: Galil Tools (Windows-based software for programming, tuning, and real-time monitoring; includes waveform analysis and auto-tuning for servos).
   • Development Libraries: Galil API for C/C++, Python, LabVIEW, and MATLAB—enables integration with custom software (e.g., machine vision systems for vision-guided motion).

Applications

• Precision Positioning Systems:
  • Controls linear stages or rotary tables in semiconductor wafer inspection, ensuring sub-micron accuracy for defect detection.
  • Used in laboratory research (e.g., optical microscopy, atomic force microscopy) to position samples with high repeatability.
• CNC & Small-Scale Machining:
  • Drives 2-axis CNC routers, engravers, or desktop milling machines, executing linear interpolation for 2D cutting paths (e.g., woodworking, metal engraving).
• Industrial Robotics:
  • Controls 2-axis gantry robots or pick-and-place systems for electronic component assembly (e.g., placing SMD parts on PCBs) or packaging (e.g., sorting small items).
• Medical & Life Sciences:
  • Integrates with diagnostic equipment (e.g., blood analyzers) to position samples or sensors, ensuring precise test results.
  • Used in automated liquid handling systems for pipetting or sample dispensing in pharmaceutical research.

Availability and Support

• Condition: Available as new OEM (through Galil Motion Control or authorized distributors) or genuine refurbished (via Galil’s official repair services).
• Warranty: 24-month warranty for new units (covers defects in materials/workmanship); refurbished units typically include a 12-month warranty.
• Documentation:
  • Technical datasheets, programming manuals, and wiring diagrams are accessible via Galil’s Support Portal.
  • Galil offers technical support, application engineering, and training (online or on-site) for controller setup, tuning, and programming.

Compatibility and Similar Products

• Compatible Components:
  • Servo Drives: Galil AMP-2300 (2-axis servo drive), third-party drives (Yaskawa, Parker, Kollmorgen) via analog/PWM signals.
  • Motors: Galil servo/stepper motors, third-party DC brushless, AC servo, and bipolar stepper motors.
  • Feedback Devices: Incremental encoders (Renishaw, Heidenhain), absolute encoders (Sick, Baumer), and linear scales (optional).
• Similar Galil Models:
  • DMC-4040: 4-axis variant of the DMC-4000 Series (for 3D printing, 4-axis CNC machining, or multi-axis gantries).
  • DMC-4060: 6-axis controller with advanced features (hexapod control, adaptive tuning) for complex robotics or 5-axis machining.
  • DMC-1832: Older 2-axis model (DMC-1800 Series) with fewer communication options (no USB 2.0) compared to the DMC-4020.

Installation and Maintenance Notes

1. Setup Requirements:
   • Mount the controller on a DIN rail or panel in a control cabinet with ≥20 mm clearance for ventilation (prevents overheating).
   • Configure via Galil Tools: Select motor type (servo/stepper), set encoder resolution, and tune servo gains (position/velocity loop) using the auto-tuning tool or manual adjustment to balance responsiveness and stability.
2. Wiring Guidelines:
   • Use shielded, twisted-pair cables for encoder and motor signals to minimize EMI from nearby power cables.
   • For servo motors: Connect the controller’s ±10V analog output to the servo drive’s command input; for steppers: Wire step/direction signals to the stepper driver.
   • Hardwire limit switches and E-stop to digital inputs (use normally closed (NC) contacts for fail-safe operation).
3. Safety & Troubleshooting:
   • Follow lockout-tagout (LOTO) procedures when wiring—disconnect power to avoid unexpected motor motion.
   • Common issues and fixes:
     • No Motion: Check motor power, wiring continuity, and ensure the controller is not in “inhibit” mode (safety input triggered).
     • Erratic Positioning: Verify encoder alignment, check for loose wiring, or re-tune servo gains to reduce oscillation.
     • Communication Loss: For Ethernet: Confirm IP address settings; for USB: Reinstall Galil USB drivers.

Critical Notes

1. Axis Limitation: The DMC-4020 is a 2-axis controller—upgrade to the DMC-4040 (4-axis) or DMC-4060 (6-axis) for multi-axis applications (e.g., 3-axis CNC mills).
2. Absolute Encoder Support: SSI/BiSS-C absolute encoder compatibility requires an optional adapter—confirm with Galil before purchasing if absolute feedback is needed.
3. Genuine Parts Only: Use genuine Galil DMC-4020 controllers for precision-critical applications. Aftermarket alternatives may lack Galil’s proprietary motion algorithms, leading to positioning errors or system instability.