Introduction to DELTA TAU 603605-106
Product Description
The DELTA TAU 603605-106 is an advanced industrial motion controller module, belonging to the next generation of Delta Tau’s PMAC (Programmable Multi-Axis Controller) family. Developed by Delta Tau Data Systems (a subsidiary of Analog Devices), this module is engineered to deliver superior performance in high-precision, multi-axis motion control applications, including advanced CNC machining centers, robotic manipulators, semiconductor wafer handlers, and precision metrology systems.
Building on the legacy of its predecessors, the 603605-106 integrates a more powerful processing architecture with enhanced connectivity options, making it capable of handling complex motion tasks such as 5-axis contouring, synchronized multi-axis interpolation, and real-time adaptive control. Its rugged design ensures reliability in industrial environments, while expanded I/O capabilities and support for the latest feedback technologies enable seamless integration with modern drive systems and sensors. This module is particularly suited for applications requiring sub-micron positioning accuracy and ultra-fast servo loop response.
Technical Parameters
- Processor: Dual-core 32-bit floating-point DSP with 500 MHz clock speed (main core) + 300 MHz coprocessor (for I/O and communication)
- Axis Capacity: Up to 12 axes of motion control (configurable with optional expansion)
- Control Modes: Position, velocity, torque, electronic gearing, camming, and 5-axis spline interpolation
- Feedback Support:
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- Encoders: Incremental (TTL, HTL), absolute (SSI, BiSS, Profinet IO)
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- Resolvers: 4-wire, 5-wire (integrated 16-bit resolver-to-digital converter)
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- Linear scales: Analog (sin/cos) with 24-bit A/D conversion; digital (Heidenhain, Fanuc)
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- Laser interferometers (via optional interface)
- Servo Loop Update Rate: Up to 20 kHz per axis (configurable)
- I/O Interfaces:
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- Digital: 64 general-purpose inputs, 32 general-purpose outputs (TTL/HTL, 24V)
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- Analog: 16 inputs (16-bit, ±10V), 8 outputs (16-bit, ±10V)
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- High-speed capture: 8 dedicated inputs (for position latching, 1µs resolution)
- Communication Interfaces:
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- Ethernet: 2x 10/100/1000BASE-T (Modbus TCP/IP, TCP/IP, EtherNet/IP)
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- Fieldbus: Native EtherCAT (100Mbps), optional Profibus-DP, CANopen
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- Serial: RS232/RS485 (Modbus RTU)
- Programming: PMAC IDE v4.0 with support for IEC 61131-3 (ST, FBD, LD), C/C++ libraries, and G-code interpreter
- Power Supply: 24V DC (18-32V DC), power consumption ≤25W
- Operating Temperature: -10°C to +70°C (14°F to +158°F)
- Storage Temperature: -40°C to +85°C (-40°F to +185°F)
- Relative Humidity: 5-95% RH (non-condensing)
- Protection Rating: IP20 (module); IP54 when installed in a ruggedized chassis
- Dimensions: 200mm × 140mm × 35mm (L × W × H)
- Weight: Approximately 400g
- Certifications: CE, UL 508, RoHS, IEC 61131-2
Usage Methods
- Installation:
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- Mount the module in a compatible backplane chassis or on a DIN rail using the supplied hardware, ensuring secure fixation to withstand vibration (up to 10g peak).
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- Install in a control cabinet with forced-air cooling (if ambient temperature exceeds 50°C) and maintain a minimum clearance of 70mm around the module for airflow.
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- Separate signal wiring (feedback, I/O) from power cables (motor drives) to minimize electromagnetic interference.
- Wiring and Connection:
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- Connect servo/stepper drives to the module’s output terminals, using twisted-pair, shielded cables for each axis. Verify phase assignments to ensure correct motor rotation.
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- Wire feedback devices to the dedicated high-speed feedback ports, with shields grounded at both the module and sensor ends. For absolute encoders, ensure proper termination resistors are used.
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- Connect digital I/O devices (limit switches, emergency stops, actuators) to the terminal blocks, using surge protection for high-voltage inputs.
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- Establish communication via Ethernet (primary) or fieldbus, configuring IP addresses and baud rates via the front-panel DIP switches or software.
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- Power the module with a 24V DC supply rated for ≥2A, using an isolated power source to prevent ground loops.
- Configuration and Programming:
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- Install PMAC IDE v4.0 on a PC and connect to the module via Ethernet for initial setup. Use the auto-configuration wizard to detect connected axes, drives, and feedback devices.
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- Calibrate feedback devices using the software’s calibration tools, compensating for backlash, encoder offsets, and linear scale non-linearity.
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- Program motion sequences using structured text or C++ libraries, defining complex trajectories (e.g., 5-axis tool paths) with velocity blending and jerk limitation.
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- Test motion profiles in “simulation mode” before live execution, using the software’s 3D visualization tool to verify path accuracy.
- Operation and Maintenance:
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- Monitor real-time performance via the IDE’s dashboard, tracking axis positions, velocities, and servo errors. Set up email/SMS alerts for fault conditions (e.g., following error exceeding threshold).
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- Perform weekly checks of connection integrity, focusing on feedback and power cables in high-vibration areas.
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- Back up configurations and programs to a secure server via Ethernet; enable automatic backups on a daily schedule.
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- Update firmware quarterly using the IDE’s firmware update utility, ensuring compatibility with new drive and sensor models.
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- Clean the module’s backplane connectors annually with a lint-free cloth and contact cleaner to prevent signal degradation.
System Introduction
The DELTA TAU 603605-106 serves as the central processing hub in high-precision motion control systems, integrating five key functional layers:
- Command Interpretation Layer: Receives high-level motion commands (G-code, CAD/CAM outputs) from a host system, translating them into machine-readable trajectory data.
- Trajectory Planning Layer: Generates smooth motion profiles using the dual-core DSP, optimizing acceleration, deceleration, and jerk to minimize settling time and vibration.
- Servo Control Layer: Executes advanced control algorithms (PID with feedforward, notch filters, adaptive gain scheduling) at 20 kHz, adjusting motor outputs based on real-time feedback.
- Feedback Processing Layer: Converts raw sensor data (encoder counts, resolver signals) into precise position/velocity information, compensating for temperature drift and signal noise.
- System Integration Layer: Coordinates with external devices (PLCs, HMIs, safety systems) via EtherCAT, enabling synchronized operation across the entire automation cell.
In a semiconductor wafer inspection system, the 603605-106 controls 6 axes of motion (X, Y, Z, θ, pitch, yaw) with nanometer-level precision. It processes inspection patterns from a host PC, generates synchronized trajectories for the wafer stage and inspection camera, and adjusts motion in real time based on laser interferometer feedback to correct for thermal expansion. This ensures defect detection accuracy of <10nm, critical for advanced chip manufacturing.
Related Models in the Series
- DELTA TAU 603605-206: 16-axis variant with quad-core DSP (800 MHz) and 32kHz servo loop, designed for large-scale robotics (e.g., 12-axis articulated arms).
- DELTA TAU 603605-107: Fiber-optic interface model, supporting long-distance feedback (up to 100m) for applications like large-format additive manufacturing.
- DELTA TAU 603605-105: Cost-optimized 8-axis version with reduced I/O, ideal for mid-range CNC machines and 3D printers.
- DELTA TAU 603605-106-EX: Extended-environment model (-40°C to +85°C) with conformal coating, suitable for aerospace and defense applications.
- DELTA TAU 603605-106-LV: Low-power version (12V DC, 15W max) for battery-operated precision systems (e.g., portable coordinate measuring machines).
- DELTA TAU 603605-106-AI: Artificial intelligence-enhanced model with machine learning algorithms for adaptive control in dynamic-load applications (e.g., robotic welding with variable material thickness).
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