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Bachmann ISI222 Positioning Module

1. Product Overview

2. Core Specifications

3. Key Functions

3.1 Multi-Encoder Position Data Acquisition

• Dual-Channel Encoder Support: The ISI222 simultaneously processes signals from 2 encoders (e.g., one incremental encoder for motor speed feedback, one absolute encoder for linear axis position)—eliminating the need for multiple single-channel modules and simplifying system architecture for multi-axis applications (e.g., 2-axis CNC lathes).
• Dual Encoder Type Compatibility: Seamlessly connects to both incremental (TTL/HTL) and absolute (SSI) encoders—no hardware reconfiguration required. For example, it can read a 1000 PPR incremental encoder (motor shaft) and a 24-bit SSI absolute encoder (linear guide) in the same system, adapting to diverse positioning needs.

3.2 High-Precision Position Processing

• Quadrature Interpolation: For incremental encoders, 4x interpolation converts A/B phase signals into 4x the original pulse count (e.g., 1000 PPR encoder → 4000 counts per revolution), doubling the positioning resolution and enabling sub-millimeter accuracy for linear motion systems (e.g., 1mm lead screw → 0.25mm positioning step).
• SSI Absolute Position Lock: For absolute encoders, the module locks and stores the absolute position immediately after power-on—no "homing" procedure required for systems that need to resume operation quickly (e.g., emergency stop recovery in robotic assembly lines).

3.3 Real-Time Position Monitoring & Control

• Position Comparison Logic: Built-in hardware comparators allow users to set upper/lower position limits (e.g., "stop at +10000 counts" or "alert at -500 counts"). When the actual position crosses these limits, the module triggers a hardware output (for immediate machine action) or sends an alarm to the M1 controller—enabling fast overtravel protection (response time <10µs) without relying on software latency.
• Synchronous Data Transmission: Transmits position data to the M1 CPU via Bachmann’s high-speed internal bus (up to 100 Mbps) at configurable intervals (1ms–100ms). This ensures the controller receives real-time position feedback for closed-loop motion control (e.g., adjusting servo motor torque to maintain a target position).

3.4 Robust Signal Integrity & Protection

• EMC Immunity: Complies with EN 61000-6-2 industrial EMC standards, resisting interference from nearby high-voltage motors, inverters, or power cables—critical for manufacturing environments where electrical noise could corrupt encoder signals.
• Isolation Protection: 1kV AC signal-to-ground isolation prevents ground loops (common in multi-axis systems with distributed encoders) and protects the module from voltage spikes (e.g., 24V DC supply surges), ensuring stable operation in harsh industrial grids.

4. Typical Applications

• CNC Machine Tool Axis Control: Monitors 2 encoders (1 incremental encoder for spindle speed, 1 absolute encoder for X-axis linear position) — 4x interpolation ensures 0.1mm positioning accuracy for precision machining (e.g., aluminum part drilling).
• Robotic Arm Positioning: Reads a 32-bit SSI absolute encoder on the robot’s wrist joint and an incremental encoder on the elbow joint — real-time position data enables the M1 controller to adjust joint angles for smooth, precise pick-and-place operations.
• Solar Tracker Control: Connects to an absolute encoder (azimuth angle) and an incremental encoder (tilt angle) — the module sends position data to the M1 controller, which adjusts the tracker to follow the sun, maximizing energy output.
• Packaging Line Web Tension Control: Uses an incremental encoder to monitor web speed (e.g., plastic film) and an absolute encoder to track web position — position comparison logic triggers tension adjustments if the web drifts beyond set limits, preventing tearing or misalignment.

5. Usage Notes

1. Encoder Wiring & Compatibility:
   • For incremental encoders: Use twisted-pair shielded cables (0.14–0.5mm²) for TTL (5V DC) signals and 24V-rated cables for HTL signals. Keep cable length ≤50m for TTL (to avoid voltage drop) and ≤100m for HTL.
   • For SSI absolute encoders: Use shielded twisted-pair cables with 2 wires for data (DATA+, DATA-) and 2 wires for clock (CLK+, CLK-). Ensure the encoder’s baud rate matches the module’s configuration (10–100 kbaud).
2. Interpolation & Resolution Setup:
   • Enable 4x interpolation only for incremental encoders with clean A/B phase signals (no noise). For encoders with poor signal quality (e.g., old mechanical encoders), use 1x interpolation to avoid false counts.
   • Calibrate the position resolution based on the mechanical system (e.g., lead screw pitch, gear ratio) — for a 5mm lead screw with a 1000 PPR encoder (4x interpolation), 1 count = 5mm / (1000 × 4) = 0.00125mm.
3. Position Limit Configuration:
   • Set upper/lower position limits based on the mechanical travel range (e.g., a linear axis with 0–200mm travel → set limits to 0 and 200mm). Test the limit trigger function with a manual encoder move before system commissioning to avoid unexpected machine stops.
4. Maintenance & Troubleshooting:
   • Regularly inspect encoder cables for damage (e.g., cuts, loose connectors) — damaged cables cause intermittent position errors. Clean encoder connectors quarterly with isopropyl alcohol to remove dust and corrosion.
   • If position data is erratic: Check for ground loops (ensure only one end of the shield is grounded), verify encoder power (5V DC for TTL, 24V DC for HTL), and confirm the module’s EMC grounding (connect to a dedicated earth bar with ≤0.5Ω resistance).
5. Environmental Considerations:
   • Mount the ISI222 in a temperature-controlled cabinet (avoid direct exposure to heat sources like power supplies or inverters) to maintain the -25°C ~ +60°C operating range.
   • In high-humidity environments (e.g., food processing), use a cabinet dehumidifier to keep relative humidity <85% (non-condensing) — moisture causes terminal corrosion and isolation failure

The structure and details of the product：

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