Digital Dream DM500T3

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Overview

Function Description
Important Technical Specifications
Usage Features
Wiring Features
Maintenance Features

The DM500 is a handheld motion controller designed for engraving machines, milling machines, and cutting machines. It is a professional 4-axis CNC motion controller that operates as a standalone system without the need for a computer. The device utilizes an embedded operating system, which enhances its reliability and makes it resistant to viruses. Its compact size and user-friendly interface make it suitable for various engraving, milling, and cutting applications.

Function Description

The DM500 motion controller provides comprehensive control over an engraving machine, supporting 4-axis linear interpolation and 2-axis circular interpolation. It features 7 opto-isolated digital outputs and 8 opto-isolated digital inputs, ensuring robust and reliable signal processing. The controller requires a single 24V, 2A power supply for its system power, and an additional power supply for input and output ports. The open-collector output current is 500mA, capable of powering relays directly.

The device supports differential pulse and direction signals, with a maximum frequency of 500kHz per axis. It offers spindle control with 3 I/O ports for 8 different speeds (3 lines, 8 speeds), 1 I/O control for Start/Stop, and 1 I/O for CW/CCW direction. The system supports standard G-code and advanced CAD/CAM software, including ArtCam, MasterCam, and ProE. It also includes a USB flash disk for G-code file input.

The DM500 allows for tool path preview, smooth motion, and acceleration/deceleration mode (S curve). It supports unlimited size file for machining, manual/automatic machining functions, and the ability to start a G-code from a specific line. The controller also features support for "Power Cut" recovery, ensuring data is automatically saved in case of power interruptions. Time-lock functions are available, and it supports 4 kinds of operation rights: visitor, operator, admin, and super admin.

Important Technical Specifications

Axis Control: 4-axis linear interpolation, 2-axis circular interpolation.
Digital I/O: 7 opto-isolated digital outputs, 8 opto-isolated digital inputs.
Power Supply: 24V, 2A for system power; additional power supply for I/O ports.
Output Current: 500mA (open-collector).
Pulse/Direction Signal: Differential, max 500kHz per axis.
Spindle Control: 3 I/O ports for 8 speeds, 1 I/O for Start/Stop, 1 I/O for CW/CCW.
G-code Support: Standard G-code, CAD/CAM software (ArtCam, MasterCam, ProE).
File Input: USB flash disk.
Display: 3.5" (480x320) LCD screen.
Keys: 23 user keys.
Dimensions (Handheld Controller): 230 mm (length) x 116 mm (width) x 93 mm (thickness).
Dimensions (Wiring Board): 118 mm (length) x 88 mm (width) x 72 mm (thickness).

Usage Features

The DM500 is designed for ease of use with a clear 3.5" LCD screen and 23 user keys. The front panel provides direct access to common functions. The manual defines various abbreviations used on the screen, such as FRO (Feed Rate Override), SRO (Spindle Rate Override), SRJ (Jog Speed Setting), and BUSY (System is busy).

The controller supports various operational modes, including READY, RESET, CONT (Continuous mode), STEP (Manual Step Mode), MPG (Manual Pulse Generator), and AUTO (Run G code). Users can easily navigate through the main page, file page, and parameter page using the dedicated menu keys.

Main Page: Displays absolute and mechanical coordinates, feed rate override, spindle rate override, jog speed, output signal status, version information, and programming date.
File Page: Allows users to load, copy, paste, and delete G-code files from a U-disk. It displays file names, sizes, and directories.
Parameter Page: Provides access to various parameters for motor settings, hand settings, automatic settings, and spindle settings. Users can adjust values and save changes.

The DM500 offers several key functions for machine operation:

Work Zero Setting: Users can set the work zero for all axes (X, Y, Z, A) or clear individual axes.
Find Mach Zero: Automatically finds the machine zero for all axes or individual axes.
Probe Function: Supports automatic tool measurement to determine cutter position and thickness. It can be used with fixed tool sensors or floating tool sensors.
Run G Code: Allows users to load and run G-code files from a U-disk. It supports breakpoint operation, enabling the system to automatically record breakpoints and continue processing from that point.
Feed Rate Override (FRO): Adjusts the real-time feed speed from 0% to 300%.
Spindle Speed Setting: Allows adjustment of spindle speed, with 3 output pins to define 8 spindle speeds.
Input and Output Ports Inspection: Users can check the status of input and output ports.

Wiring Features:

The wiring board for the DM500 is designed for straightforward connection. It includes input ports (X01-X08) and output ports (Y01-Y07) with clear labels for various functions such as home switches, probe, spindle control, cooling, and lubrication. The board also features RS232 communication ports (RXD, TXD) and connections for servo/stepper drivers (XP+, XP-, XD+, XD-).

The power supply for input/output ports is 24VDC. The main controller system also requires 24VDC. The manual provides detailed wiring diagrams for input ports (COM+, COM-) and output ports, including recommendations for connecting relays with diodes. Pulse and direction signals for servo/stepper drivers are differential, and shielding cables are recommended for connections.

Maintenance Features

The DM500 is designed for reliability and ease of maintenance.

System Update: The system supports updating firmware from a U-disk. Users can copy the update file to the U-disk root directory and restart the controller to initiate the update process.
Parameter Management: Parameters can be backed up to a U-disk and restored, ensuring that settings can be recovered in case of data loss or system issues.
Password Setting: The system supports multiple user levels (visitor, operator, admin, super admin) with distinct passwords, enhancing security and preventing unauthorized changes.
Error Handling: The controller provides status indicators for various conditions, such as E-stop, reset key press, and limited switch triggers, helping users diagnose and resolve issues.
Power Cut Recovery: The "Power Cut" recovery feature automatically saves data, allowing operations to resume from the point of interruption after a power failure.

The DM500 is a robust and versatile motion controller, offering comprehensive features for precise and reliable control of engraving, milling, and cutting machines. Its user-friendly interface, extensive functionality, and maintenance-friendly design make it a valuable tool for various industrial applications.