What subjects and training do I need to get for making motion controller boards for machines without any help.
Specially for a person who is not from electronics background.
Boards should be of commercial quality.

 

I assume by 'without any help' applies to the application running un-attended?
If referring to closed loop motion control, It is an extremely wide subject to cover, especially for designing from scratch.
You need to define what your interpretation is of 'Motion Controller'.
Max.

 

I assume by 'without any help' applies to the application running un-attended?
If referring to closed loop motion control, It is an extremely wide subject to cover, especially for designing from scratch.
You need to define what your interpretation is of 'Motion Controller'.
Max.

I know its very wide and I am willing to give time. Without any help means I should be able to do hardware designing and software designing. By motion controllers I mean the boards which you attach to a machine to make it run. Example - a CNC machine, a robot, a 2 axis or three axis controller etc.

 

Your reading material choice is going to be very wide ranging.
First you need to study the normal process and how each relate to each other, for example a typical CNC motion control system would be a Human Machine Interface or HMI, This would receive the required machine path and other parameters, (G-code), such as feed rate etc, this would then, through a trajectory planner, calculate the motion path, including any interpolated moves, this information is then passed to the CNC or motion controller that typically would output a signal to the servo drives and receive feedback in the form of an encoder for e.g.
The CNC motion control itself would typically be a dedicated processor for this task, there may be a second processor to control the general machine tasks such as M, S and T coded tasks, these are machine operations other than CNC, Spindle, Tool change, coolant etc.
Both processor can communicate with each other over a common bus.
If you want to start with just the servo drives or amplifiers, then you could go to one of the micro controller manuf that offer app notes and examples for their IC's, Picmicro etc, there are some such as TI that sell servo motion IC's for integration.
You would also need to decide what type of control method is used for drive input ±10vdc, step/dir, digital.
There are manufacturers such as Galil Motion that offer motion cards that will control simple trans-conductance drives, these are simple PWM drives that require no intelligent IC's as the PID loop is closed back to the Galil or other control.
Max.

 

Your reading material choice is going to be very wide ranging.
First you need to study the normal process and how each relate to each other, for example a typical CNC motion control system would be a Human Machine Interface or HMI, This would receive the required machine path and other parameters, (G-code), such as feed rate etc, this would then, through a trajectory planner, calculate the motion path, including any interpolated moves, this information is then passed to the CNC or motion controller that typically would output a signal to the servo drives and receive feedback in the form of an encoder for e.g.
The CNC motion control itself would typically be a dedicated processor for this task, there may be a second processor to control the general machine tasks such as M, S and T coded tasks, these are machine operations other than CNC, Spindle, Tool change, coolant etc.
Both processor can communicate with each other over a common bus.
If you want to start with just the servo drives or amplifiers, then you could go to one of the micro controller manuf that offer app notes and examples for their IC's, Picmicro etc, there are some such as TI that sell servo motion IC's for integration.
You would also need to decide what type of control method is used for drive input ±10vdc, step/dir, digital.
There are manufacturers such as Galil Motion that offer motion cards that will control simple trans-conductance drives, these are simple PWM drives that require no intelligent IC's as the PID loop is closed back to the Galil or other control.
Max.

Thank you very much for your time to answer this.

But again what are the subjects that I need to study in electronics to reach this level.
Galil boards is a good example, what I want to make. I know I can not make it instantly but there should be a path to reach there, and once i have the desired knsteps.ge I can distribute the work among teams. Because one person can not do everything at same time.
So please tell me the steps

 

The Galil products are very sophisticated systems, and have evolved over the approx 40yrs they have been around.
I have never been in a position where I needed to build such as system, but if requiring to do so, you would first need a very in depth knowledge of electronics in general, both analogue and digital together with microprocessor theory and programming.
Once you have achieved this required knowledge than you may have enough to produce a product such as Galil.
There is also free software such as Kicad to assist in designing final circuitry and PCCT board layout and production.
Max.

 

The Galil products are very sophisticated systems, and have evolved over the approx 40yrs they have been around.
I have never been in a position where I needed to build such as system, but if requiring to do so, you would first need a very in depth knowledge of electronics in general, both analogue and digital together with microprocessor theory and programming.
Once you have achieved this required knowledge than you may have enough to produce a product such as Galil.
There is also free software such as Kicad to assist in designing final circuitry and PCCT board layout and production.
Max.

OK
But do you think that one person can do this ??

 

Depends on the current knowledge, if any, that the current individual would have, but if starting from scratch I don't see it being something achieved in the short term at all.
For comparison, there is the simple DIY versions such as Mach3/4 that are mainly software based, one other that comes close to Galil is the Dynomotion product you may want to study on method and devices used..
Max.

 

It took several years of study before I was able to do this. Basic physics and math are the initial requirements. Then you need to make tradeoffs between what is done in hardware and what is done in software. Then you need to design some hardware and design some firmware and be prepared for failure multiple times. Starting from scratch, your first marketable product is 5-10 years away.

 

It took several years of study before I was able to do this. Basic physics and math are the initial requirements. Then you need to make tradeoffs between what is done in hardware and what is done in software. Then you need to design some hardware and design some firmware and be prepared for failure multiple times. Starting from scratch, your first marketable product is 5-10 years away.

I am a Mechanical Engineer so I have knowledge of some common subjects.
If you want to do it, u have to start from somewhere.
Glad to know that you are doing this.
Can you provide subjects name with sequence for a general understanding.

 

Sure can. On this website you can learn about:

DC circuits
AC circuits
Transistor Circuit Design
Digital Circuit Design
Analog Circuit Design​

The sites AVRFreaks and Microchip have lots of information about microprocessors that you might use

http://www.microchip.com/
http://www.avrfreaks.net/​

You'll be wanting to learn one or more assembly languages for some processor of your choice
You'll be wanting to lean a higher level language, I suggest C

https://en.wikipedia.org/wiki/The_C_Programming_Language​

You'll be wanting to lean the use of debugging tools for firmware development
You'll be wanting to learn the use of simulators for circuit design

http://www.linear.com/solutions/ltspice​

You'll be wanting to learn about PCB layout

That should keep you off the streets for a while. A tall order but not impossible with a 5 year time horizon.

Good luck