Product Overview

• Brand: Galil Motion Control (a leading global provider of motion control solutions for industrial, research, and OEM applications)
• Model: DMC-9940
• Series: DMC-9000 Series (Distributed Networked Motion Controllers)
• Type: 32-Bit Distributed Motion Controller with 4 Independent Axes
• Industry: Large-scale automation (automotive assembly lines, material handling systems), robotics (multi-robot cells, gantry robots), CNC machining (multi-station machining centers), aerospace (large component test rigs), and industrial IoT (IIoT)-enabled smart factories.
• Function: Controls up to 4 independent or coordinated axes of motion (e.g., linear slides, rotary stages, servo/stepper motors) as part of a distributed control network. It executes motion profiles (point-to-point, linear interpolation, electronic gearing) and processes real-time encoder feedback. Unique to the DMC-9000 Series, the DMC-9940 communicates with a central master controller (e.g., Galil DMC-9900) via Galil’s proprietary SyncLink network, enabling synchronization of up to 64 axes across multiple DMC-9940 nodes. This distributed architecture reduces wiring complexity and enables scalable, modular motion systems.

Key Features

1. Distributed 4-Axis Control with Network Synchronization
   • Supports 4 local axes per module, with the ability to scale to 64 axes total by connecting multiple DMC-9940 nodes via Galil’s SyncLink network. SyncLink ensures ultra-low latency (<1 μs) between nodes, enabling tight multi-axis synchronization (e.g., coordinating 10 DMC-9940 modules for a 40-axis material handling system).
   • Coordinated motion across distributed axes: Enables linear interpolation (up to 64 axes) and electronic gearing/camming between axes on different DMC-9940 nodes—critical for large-scale systems like automotive body welding lines or multi-robot assembly cells.
   • Compatible with diverse motor types:
     • Servo Motors: DC brush, DC brushless (BLDC), and AC servo motors (via ±10V analog command or PWM outputs for drives).
     • Stepper Motors: Bipolar stepper motors with microstepping (up to 512 microsteps/step) for cost-effective, low-vibration motion.
2. High-Resolution Feedback & Dynamic Performance
   • High-speed feedback integration: Accepts 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 linear encoders).
   • Advanced motion modes for industrial flexibility:
     • Point-to-Point (PTP): Moves axes to target positions with trapezoidal or S-curve acceleration/deceleration, reducing mechanical stress.
     • Electronic Gearing/Camming: Synchronizes local axes to a master axis (on the same or a remote DMC-9940 node) or follows user-defined position profiles—ideal for packaging lines with distributed conveyors.
     • Torque/Force Control: Switchable control modes (position → velocity → torque) for delicate tasks (e.g., robotic assembly of large components).
3. Dual-Layer Communication Architecture
   • SyncLink Network: Proprietary high-speed network for inter-node communication (up to 1 Gbps) between DMC-9940 modules and a central master controller (e.g., DMC-9900). Ensures deterministic synchronization for distributed motion.
   • Host Communication Interfaces: For integration with PC-based systems or industrial networks:
     • Gigabit Ethernet (10/100/1000 Mbps): Supports TCP/IP, UDP, and Galil’s protocol for remote monitoring and programming.
     • USB 2.0: For direct PC connection, firmware updates, and local configuration.
     • Optional Fieldbus Support: PROFINET, EtherCAT, or Modbus TCP (via add-on modules) for compatibility with PLCs and DCS systems (e.g., Siemens S7-1500, Allen-Bradley ControlLogix).
4. Robust I/O & Industrial Safety Compliance
   • Equipped with 16 digital inputs (24V DC, sinking/sourcing) and 8 digital outputs (24V DC, 0.5A per channel; 2A max total) per DMC-9940 node for local sensor/actuator integration (e.g., limit switches, solenoids).
   • Safety features meeting IEC 61508 (SIL 2) and ISO 13849-1 (Cat. 3) standards:
     • Local Emergency Stop (E-Stop) Input: Hardwired input to disable motion on the node in critical situations, with network-wide E-Stop propagation via SyncLink.
     • Redundant Limits: Software/hardware travel limits for each axis to prevent overtravel.
     • Fault Diagnostics: Real-time monitoring of encoder loss, overcurrent, and network errors, with centralized alarm logging via the master controller.

Key Specifications

1. Motion Performance
   • Local Axis Count: 4 independent/coordinated axes per DMC-9940 node.
   • Total Scalable Axes: Up to 64 axes (16 DMC-9940 nodes via SyncLink).
   • 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, up to 20 kHz).
     • Stepper: Step/direction signals, up to 2.5 A/phase (bipolar) with microstepping (up to 512 μsteps/step).
   • Synchronization Latency: <1 μs between DMC-9940 nodes (via SyncLink).
   • Control Loop Update Rate: 1 kHz (position loop), 10 kHz (velocity loop).
2. Electrical Parameters
   • Power Supply: 24V DC (nominal), tolerance range 18–30V DC.
   • Power Consumption: ≤20W per node (varies with motor type and axis activity).
   • Analog I/O (Optional): 4 analog inputs (12-bit, 0–10V) and 2 analog outputs (12-bit, ±10V) per node for sensor data (e.g., force sensors) and auxiliary control.
3. Physical & Environmental Attributes
   • Form Factor: Compact DIN-rail mount (saves space in distributed control cabinets), compatible with standard 35mm DIN rails.
   • Dimensions: Approximately 120 mm (W) × 100 mm (H) × 60 mm (D).
   • Weight: Approximately 0.8 kg per node.
   • 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).
4. Software & Tools
   • Configuration Software: Galil Tools (Windows-based suite for programming, tuning, and monitoring distributed nodes; includes SyncLink network configuration and multi-axis motion simulation).
   • Development Libraries: Galil API for C/C++, Python, LabVIEW, and MATLAB—enables integration with custom software (e.g., MES systems for production tracking).
   • Master Controller Software: Compatible with Galil DMC-9900 master controller software for centralized network management and motion coordination.

Applications

• Large-Scale Automotive Automation:
  • Controls distributed conveyors and robotic arms in automotive assembly lines (e.g., 40-axis body-in-white welding systems), with SyncLink enabling synchronized motion across multiple workstations.
• Multi-Robot Cells:
  • Coordinates up to 16 DMC-9940 nodes (64 axes) to control delta robots, SCARA robots, and gantries in high-throughput packaging or electronics assembly facilities.
• Aerospace Test Rigs:
  • Integrates with large structural test rigs (e.g., wing load testing) to control distributed actuators, ensuring synchronized force application across multiple axes.
• Material Handling Systems:
  • Powers automated guided vehicles (AGVs) and overhead gantry systems in warehouses, with distributed DMC-9940 nodes managing individual axis motion while maintaining network-wide synchronization.

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, SyncLink network guides, and programming manuals are accessible via Galil’s Support Portal.
  • Galil offers technical support for network configuration, distributed motion tuning, and system integration, including on-site training for large-scale deployments.

Compatibility and Similar Products

• Compatible Components:
  • Master Controllers: Galil DMC-9900 (central master for SyncLink network management).
  • Servo Drives: Galil AMP-4600 (4-axis servo drive) or third-party drives (Yaskawa Sigma-7, Kollmorgen AKD) via analog/PWM signals.
  • Feedback Devices: Incremental encoders (Renishaw, Heidenhain), absolute encoders (Sick, Baumer), and linear scales.
• Similar Galil Models:
  • DMC-9920: 2-axis variant of the DMC-9000 Series (for smaller distributed systems, e.g., 2-axis AGVs).
  • DMC-4080: 8-axis centralized controller (DMC-4000 Series) for non-distributed multi-axis applications (e.g., 5-axis CNC machines).

Installation and Maintenance Notes

1. Setup Requirements:

• Mount each DMC-9940 node on a DIN rail in local control cabinets, with ≥30 mm clearance for cooling. Ensure SyncLink network cables (Cat 6a or higher) are routed separately from power cables to minimize EMI.
• Configure via Galil Tools: Set up the SyncLink network (assign node IDs, verify latency), define master/slave relationships between axes, and tune servo gains for local axes. Calibrate network synchronization to ensure <1 μs latency between nodes.

2. Wiring Guidelines:

• Use shielded, twisted-pair cables for encoder and SyncLink signals. Ground the shield at one end only to prevent ground loops.
• 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 local E-Stop inputs and connect them to the SyncLink network’s E-Stop bus for centralized emergency shutdown capability.

3. Safety & Troubleshooting:

• Follow lockout-tagout (LOTO) procedures when servicing nodes—disconnect power to the local cabinet and disable the SyncLink network via the master controller.
• Common issues and fixes:
  • SyncLink Latency Errors: Check cable continuity, update firmware on all nodes, and re-calibrate the network.
  • Distributed Axis Misalignment: Verify encoder alignment on remote nodes and re-tune synchronization parameters in Galil Tools.
  • Loss of Communication: For Ethernet: Confirm IP settings; for SyncLink: Check node ID conflicts and cable connections.

Critical Notes

1. SyncLink Network Requirements: The DMC-9940 requires a Galil DMC-9900 master controller to manage the SyncLink network—standalone operation (without a master) is not supported for distributed motion.
2. Scalability Limits: While the network supports up to 64 axes, ensure total network bandwidth (1 Gbps) is sufficient for your application (e.g., 64 axes at 1 kHz update rate is well within bandwidth limits).
3. Genuine Parts Only: Use genuine Galil DMC-9940 controllers and SyncLink cables. Aftermarket components may degrade synchronization latency or network reliability, leading to motion errors in large-scale systems.