Abstract: This paper focuses on the control requirements and characteristics of 3-axis motion control systems widely used in modern industrial processing and automated production lines. It details the composition, features, and applications of the ACR1505 multi-functional motion control card, a control system composed of a PC, motion controller, and servo motor. The motion controller, based on a DSP and a complex programmable logic device (CPLD), fully utilizes the fast data processing capabilities of the DSP and the hardware management functions of the CPLD. The design and implementation methods of the control system's hardware platform and software system are discussed in detail. Keywords: Automated packaging system; Robot; DSP; Motion control; Design 1 Introduction Modern industrial processing and automated production lines frequently use automated equipment requiring multi-axis collaborative control, such as machining centers and robots. A common control method for these devices is the "computer + motion control card + driver" approach, where computer software controls a dedicated motion control card to control the driver, achieving the goal of controlling the automated equipment. Among these, 3-axis motion control is the most common form of multi-axis collaborative control and can fulfill the vast majority of task requirements. This paper introduces the features and applications of the PARKER ACR1505 motion control card. 2 Automatic Packaging System 2.1 Mechanical System The task of the automatic packaging system is to first grab the cover plate A, then apply glue to the front side of the cover plate A, then rotate it 180° and move it down to press it onto the substrate to complete the packaging process. The automatic packaging system mainly consists of four parts: a moving platform, an automatic glue application mechanism, an automatic placement mechanism, and a control system. The main structure of the system adopts a 3-degree-of-freedom bridge-type robot. The digital controller is the core of the control system, which controls the movement of the X, Y, and Z axes in real time. At the same time, it controls the opening and closing of the solenoid valve through the output switch quantity to complete the entire packaging process of grabbing, rotating, applying glue, and pressurizing. The workflow of the control system of the automatic packaging system is as follows: (1) A "positioning groove" is provided at one end of the moving platform. The X guide rail is controlled to move the "flipping positioning groove" device to the outermost end of the plate first, and then the cover plate A is placed in the "positioning groove" with the back side facing up. There is a vacuum suction hole at the position of each corresponding cell in the positioning groove. The vacuum valve is controlled to achieve the adsorption and fixation of the cover plate A. (2) After the cover plate A is fixed, control the movement of the x-guide rail to position the "flipping positioning groove" directly above the substrate B to be packaged. Use a vacuum suction cup to flip the substrate A gripping groove 180° so that the back of the substrate A faces the bonding position and is in a state of waiting for glue to be dispensed. (3) The automatic glue dispensing system is controlled by a 3-DOF Cartesian coordinate robot to drive a row of needles to dispense glue onto the front of the fixed cover plate A. (4) Control the cylinder through the throttle valve to make the "flipping positioning groove" move slowly downward so that the cover plate A and the substrate B maintain a certain contact pressure and contact time. At the same time, control the solenoid valve of the nozzle to open and apply the set pressure evenly to the cover plate A. (5) Stop vacuuming. (6) After the bonding is completed, position and place the next set of cover plates, and so on. 2.2 Motion control system Combined with the characteristics of the automatic bonding system, the motion control form of "PC + motion controller + servo motor" is selected. The functional structure block diagram is shown in Figure 1. The motion controller utilizes a high-performance microprocessor (primarily a DSP) and a complex programmable logic device (CPLD) to achieve multi-axis coordinated control of multiple servo motors. Specifically, it integrates the underlying software and hardware for motion control, enabling various speed and position control functions required for servo motor control. These functions can be easily invoked by a computer. The computer's main function is to optimize the instruction format based on the specific motion control type of the device; it belongs to the upper-level control. The servo motor and its driver are the main execution components, specifically performing motion control. The motion control card, based on the instructions given by the upper-level computer and combined with the specific servo system type, translates the instructions into the motion of the servo motor. 3. System Hardware Design and Implementation Since DSPs have data throughput capabilities of up to tens of MHz and instruction cycles as short as tens of ns, they are very suitable for high-speed data acquisition systems and real-time control systems with large amounts of data. Using a DSP-based motion controller in conjunction with a PC to form a control system combines the powerful graphical user interface, multitasking capabilities, and strong hardware and software compatibility of Windows with the servo, interpolation, and real-time computing capabilities of the DSP-based motion controller, providing users with high-speed, high-precision, and low-cost modern control. 3.1 System Composition The DSP-based ACR1505 multi-axis motion control card uses a 120MHz, 32-byte floating-point TMS320VC33 DSP as its CPU, providing new high-performance technology and a Windows platform. It is a high-performance servo motion controller that can simultaneously control 1-4 axes (expandable to up to 8 axes) through a flexible high-level language. It can execute programs step-by-step, execute motion programs and PLC programs stored internally in the controller, perform servo loop updates, and communicate with the host computer and multiple control cards via serial port, parallel port, and bus. The hardware structure of the control system is shown in Figure 2. The core DSP mainly performs tasks with high real-time requirements, such as PID control of position and speed, interpolation iterative calculations, digital input/output PLC control, as well as program and data storage and communication between the host and host computers. A complex programmable logic device (CPLD) is used for peripheral addressing and final signal output. Due to its extremely short transmission delay, large number of user-available I/O ports, abundant internal wiring, and programmable resources, it can implement complex timing and combinational logic, greatly simplifying the system's hardware design. Meanwhile, due to its unreadable nature, it offers good software security when used in conjunction with a DSP, and its programming is simple and convenient. System upgrades can be easily achieved by modifying the CPLD software program without changing the hardware. The analog control circuit converts the digital speed signal into a 10V to +10V analog signal using a D/A converter, and outputs it to the motor servo drive module connected to the analog signal input. The feedback circuit is a 4-channel 12-bit reversible pulse counter composed of a CPLD, which receives the differential photoelectric encoder signal and cyclically counts the encoded pulses. The communication circuit is connected to the PC's PCI bus through a PCI interface device to achieve high-speed data transmission. The system's working process is as follows: The motor feedback signal is taken from the A-phase and Z-phase pulses generated by the photoelectric encoder coaxial with the motor, and the pulse count is cyclically recorded by the quadrature pulse counter composed of a CPLD. The DSP periodically reads the counter's count value, calculates the current speed and position of each motor, calculates the motor tracking error using the feed command calculated by the interpolation program, and obtains the control signal sent to the motor using an incremental PID algorithm, outputting it to the DAC, which then drives the servo motor through the driver. During the control operation interval, the DSP completes communication with the host computer, obtains instructions, and feeds back the motor status information to the host computer. 3.2 Control Algorithm The control of the motion control card adopts the incremental PID control algorithm. The classic PID control expression is: where uk(t) is the output function, kP is the proportional coefficient, Ti is the integral time constant, Td is the derivative time constant, and e(t) is the deviation between the given quantity and the output quantity. After digital discretization of equation (1), the incremental PID formula can be obtained: where △ui is the incremental output, T is the sampling period, ei is the current difference, ei-1 is the difference of the previous ei, and ei-2 is the difference of the previous ei-1. 4 Software Design 4.1 Features of the "PC + Motion Controller" Motion Control Software The motion control software developed for the motion control card runs on the PC. It consists of the underlying motion control software and the user interface. The underlying motion control software tells the motion controller all the parameters required for linear and circular interpolation motions and operates the I/O ports. At the same time, it receives the motion status and input port status parameters returned by the motion control card. The motion control card automatically controls the servo motor to perform interpolation motion and operates the I/O ports according to the received instructions. The user interface connects the operator with the underlying motion control software, allowing input of all motion parameters, control of the motion process, and display of various motion states. 4.2 Software Design and Implementation The focus of software development is the communication between the control card and the PC, as well as the development of upper-level system operation scheduling and management software, and the implementation of non-real-time tasks such as fault diagnosis, parameter input, and program editing. Since the control card provides the highly efficient open software package ACR-View and API functions, communication and information exchange with the control card only require calling the corresponding functions in the function library contained in the dynamic link library acront.dll or using its various events and methods. Therefore, the development of a cumbersome communication driver is eliminated, and direct interaction with the control card hardware is unnecessary. The operation of the control system can be easily implemented using Visual Basic. Under the Windows operating system, using Visual Basic 6.0 as the development tool and employing object-oriented programming methods, the servo control system software was developed by fully utilizing the functions in the control card's accompanying dynamic link library, realizing the basic functions of the control system. The specific functions achievable include a Windows-friendly human-machine interface, system initialization preprocessing, status monitoring, real-time display of coordinate position and speed, and dynamic parameterized configuration of the system. The software program acquires motor position signals, performs PID algorithm control on motor speed signals, performs interpolation calculations on multiple axes, controls and monitors various sensor signals and control switches of the controlled object, and manages the processing program in the DSP's internal memory. It can receive individual action commands from the host computer and provide real-time information feedback, enabling operation in automatic and manual modes. System initialization is completed during the ACR-View setup process, mainly involving setting the control card parameters. Many system states require real-time monitoring; a timer control is used to periodically control certain operations during program execution by generating a Timer event at regular intervals. The controller provides erasable and rewritable memory to store frequently used parameters, variables, and arrays. Therefore, some fixed parameters must be set and stored in the erasable and rewritable memory before debugging. These parameters include motor type settings, encoder feedback method, limit position settings, and torque limit settings, etc., and the parameter setting interface is shown in Figure 3. The purpose of setting these parameters is to ensure that the system does not experience runaway or to protect the system in case of abnormal conditions. For some frequently changing parameters, such as PID parameters, limit switch polarity, and motor rotation polarity, they can be continuously set during debugging to achieve the best control effect. 5 Conclusion The PCI bus-based digital control system of "PC + motion controller + servo motor" has advantages such as strong information processing capabilities, comprehensive functions, high speed, high precision, high reliability, easy expansion and upgrade, and easy human-machine interaction. It improves the reliability of the motion control system, reduces costs, and achieves significant results.