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IRIS ORCA Reference Manual

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Version 1.0.3

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Summary of Contents for IRIS ORCA

  • Page 1 Version 1.0.3...

  • Page 2: Table Of Contents

    Force ................................. 12 Shaft ................................. 13 Modbus ..............................14 Kinematic ..............................15 Logging ..............................17 Current ..............................18 ORCA REGISTERS ............................19 SENSORS ................................. 19 Force Sensor ............................... 19 Position Sensor ............................19 Power Sensor .............................. 20 Temperature Sensors ..........................20 CONTROLLERS ...............................
  • Page 3 Configuration Errors ..........................28 Force Clipping ............................28 Temperature Exceeded ......................... 28 Force Exceeded ............................28 Power Exceeded ............................. 28 Shaft Image Failed ..........................28 Communications Timeout ........................28 APPENDIX ................................ 30 Orca Memory Map ............................. 30 REVISION HISTORY ............................40...

  • Page 4: List Of Tables

    Figure 5: RJ45 Splitter ............................7 Figure 6: IrisControls4 Settings panel ......................8 Figure 7: IrisControls4 connection information ................... 9 Figure 8: Orca Series GUI with home page open ..................9 Figure 9: IrisControls4 Position page ......................10 Figure 10: IrisControl4 Force Page ......................12 Figure 11: IrisControl4 Shaft page ......................

  • Page 5: Introduction

    INTRODUCTION This document describes the functions and operation of Orca™ series linear motors having integrated drivers and an integrated sensor suite. BLOCK DIAGRAM Figure 1: Block Diagram...

  • Page 6: Powering The Motor

    Flying lead power connections are provided for each motor with ring terminals by default. Most Orca products are configured to be able to draw significant currents, up to and exceeding 40 amps, and proper attachment of the power lines to a suitable power source is important.

  • Page 7: Getting Started With Iriscontrols4

    Orca series motors can be configured through an integrated graphical user interface (GUI). To connect to an Orca motor’s GUI, first download the latest version of the IrisControls4 software on a Windows PC. The latest release is always available here. Next, open the IrisControls4 application.

  • Page 8: Connecting To Iriscontrols4

    CONNECTING TO IRISCONTROLS4 After ensuring your Orca is connected properly to your PC, open the IrisControls4 application. The software will start up trying to establish a connection automatically. If the motor does not automatically connect toggle the connect button off and press the gear icon in the top right of the IrisControls4 window and select a baudrate of 460800 from the dropdown menu, and press apply.

  • Page 9: Navigating The Gui

    Using the COM selection dropdown menu at the bottom of the window, select either Orca (if it is present) or the COM port of your USB to RS485 connection. If neither option is present, ensure that your hardware is connected correctly as outlined in the “Getting Started” section.

  • Page 10: Gui Pages

    GUI PAGES Home The home page is the default page opened upon connecting to an Orca motor. A screenshot of the home page is shown in figure 8. This page displays the firmware version, hardware version, firmware build date and the motor serial number. There are no interactive elements on this page.
  • Page 11 The number on the left of the arrow is the actual position controller gain that is in effect and is not editable. The number on the right side of the arrow is the target gain value saved to the Orca memory map.

  • Page 12: Force

    Force The force page provides a plot of the force calibration lookup table and an interface for testing force output. Figure 10: IrisControl4 Force Page Force Calibration Plot This plot shows the results of the saved force calibration. Force Target Slider This slider can be used to command test force values when the test button is engaged.

  • Page 13: Shaft

    Shaft The shaft page provides information about the shaft calibration and live updates on shaft position. Figure 11: IrisControl4 Shaft page Shaft Calibration Graph This plot shows a representation of the saved shaft calibration, with live hall sensor sensed positions. Output Sliders These four sliders show the calculated acceleration, speed, absolute position, and position within each section of the shaft...

  • Page 14: Modbus

    Modbus The Orca series motors support the Modbus RTU communication protocol as a control method. This GUI page allows the user to view the status of a Modbus connection. Figure 12: IrisControl4 Modbus page Last Received Modbus Message The last received Modbus message is displayed on this page, with the length, address, function code and CRC bytes shown on the left, and the data payload on the right.

  • Page 15: Kinematic

    Kinematic The kinematic page provides an interface to the kinematic controller feature of the Orca. For more information on the capabilities of the kinematic controller, refer to the kinematic controller section of this manual. Figure 13: IrisControls4 Kinematic Page Number of Motions Slider The number of queued motions can be configured using the slider on the top left of the page.
  • Page 16 Motion Configuration Boxes The motion configuration boxes above the main graph represent the configuration of four consecutive motions. The motion ID can be seen at the top of each box. Preview Graph Displays a preview of the position curves of each motion you have configured as if they were triggered back-to-back, starting from a position of zero.

  • Page 17: Logging

    Logging The logging page provides an interface for setting up periodic logging of motor data through IrisControls4. Log data will be saved to a file named “Orca_[serial number]_data_log.txt” in the logs folder of your IrisControls4 installation directory. Note that logging will only occur if the motor is actively connected to IrisControls4.

  • Page 18: Current

    Step Test Button This button will initiate a step test for one phase of the Orca motor, and redraw the duty cycle, target current and measured current plots. Note that the step test will run current through the motor for a brief period of time and may cause an installed shaft to move. Repeated presses of this button will run the step test on the next phase.

  • Page 19: Orca Registers

    Registers can be read and, in some cases, modified by the MODBUS or GUI interface. For the list and description of available registers on an Orca motor, see Orca Memory Map. For information on accessing registers from the MODBUS interface, see the Orca MODBUS User Guide.

  • Page 20: Power Sensor

    General tuning guide The easiest way to tune the position controller is using the Orca GUI. The ‘Position’ tab allows easy editing of the gains, enabling and disabling of the controller, and a realtime view of the target position, the actual position, and the controller force output.

  • Page 21: Proportional Action

    Higher P-gain results in a stronger spring effect. Orca motors have fast feedback loops which enable relatively high proportional gains. In systems where some steady-state error may be acceptable, it is possible to achieve good motion control using only the proportional action.

  • Page 22: Kinematic Controller

    • Maximum smoothness (minimum jerk). Up to 32 motions can be saved to a single Orca motor. Motions are configured either from the kinematic GUI page, or through direct writes to the Orca memory map. Motions can be initiated either by MODBUS messages, or by hardware edge detection.

  • Page 23: Configuring A Motion

    A single hardware trigger event will queue a single motion, and any further motions that are chained together, up to the number stored in KIN_CONFIG[NUM_MOTIONS]. Once the final motion has completed, the next motion queued will be motion ID 0. Configuring a Motion Individual kinematic motions consist of 5 variables: •...

  • Page 24: Modes Of Operation

    In this mode, the motions can be triggered by MODBUS messages, or by hardware edge detection. If hardware triggering is enabled, the Orca will boot up in Kinematic Mode. See the Kinematic Controller section for more details.

  • Page 25: Communications Interfaces

    When both interfaces (MODBUS and IrisControls) are to be used at once – for example when logging data in-system – an RJ45 splitter accessory allows easy connection to the shared RJ45 connection. The splitter allows both the Eagle GUI and the Orca GUI to be opened on the PC at once.

  • Page 26: Windows Usb Graphical User Interface

    STARTED WITH IRISCONTROLS4 MODBUS Interface If using Orca™ motors with Eagle™ controllers, a software development kit is available which fully implements the MODBUS interface on the available communication interfaces on those systems. For more information, see the Orca API Reference Manual.

  • Page 27: Maximum Force

    Some errors, like temperature and power, which trigger when a parameter exceeds a device maximum can be configured using Orca registers to trigger earlier as the application requires. Other errors, like force, will never trigger unless the Orca registers are configured.

  • Page 28: Configuration Errors

    Sleep Mode + Voltage 1024 MIN_VOLTAGE Position, Force, Providing a valid Invalid (0x0400) MAX_VOLTAGE Calibration voltage source Comms 2048 USER_COMMS_TIMEOUT Position, Force Sleep Mode Timeout (0x0800) COMMS_TIMEOUT Configuration Errors These errors indicate calibrations or settings have not been done or have been made invalid. These errors can be cleared by running the appropriate calibration routine, followed by committing the valid results to permanent memory.
  • Page 29 USER_COMMS_TIMEOUT register elapsed between successful messages, the ‘Comms Timeout’ error is asserted. Users can make the communications timeout shorter than the default setting by writing a non- zero value to the USER_COMMS_TIMEOUT register. This register has units of milliseconds.

  • Page 30: Appendix

    APPENDIX Orca Memory Map Address Name Width Description CTRL_REG_0 Control Register 1 CTRL_REG_1 Control Register 2 CTRL_REG_2 Control Register 3 CTRL_REG_3 Control Register 4 CTRL_REG_4 Control Register 5 CTRL_REG_5 Control Register 6 CTRL_REG_6 Control Register 7 CTRL_REG_7 Control Register 8...
  • Page 31 Commanded actuator position in POS_CMD_H micrometers. Upper 2 bytes. Reserved STATOR_CAL_VERSION Stator calibration version. BS_GAIN_CMD Hall sensor analog circuit gain. CS_GAIN_CMD Current sensor analog circuit gain. Saved zero value for Hall sensor 0. Saved zero value for Hall sensor 1. Saved zero value for Hall sensor 2.
  • Page 32 Reserved 89 - 95 SHAFT_CAL_VERSION Shaft calibration version. Maximum value read by Hall sensor 0. Maximum value read by Hall sensor 1. Maximum value read by Hall sensor 2. Maximum value read by Hall sensor 3. Maximum value read by Hall sensor 4. Maximum value read by Hall sensor 5.
  • Page 33 120 - Reserved TUNING_VERSION Tuning calibration version. CC_PGAIN Current controller proportional gain. CC_IGAIN Current controller integral gain. CC_FGAIN Current controller forward gain. Current controller maximum duty CC_MAX_DUTY cycle. PC_PGAIN Position controller proportional gain. PC_IGAIN Position controller integral gain. PC_DVGAIN Position controller velocity gain. PC_DEGAIN Position controller error derivative gain.
  • Page 34 Speed (mm per second) at which the PC_HIGH_SPEED_MMPS position controller gains will have completely to the HIGH_SPEED gains. When this register is set to 0, the gain scheduling algorithm for the position PC_GAIN_SCHEDULE_DISABLE controller is enabled and the gains fade between the LOW_SPEED and normal settings according to the shaft speed and the PC_LOW_SPEED register...
  • Page 35 Number of complete motor frames in MOTOR_FRAME_COUNT the last second. Number of successful Modbus MB_FREQ messages in the last second. 274 - Reserved Period between IrisControls GUI GUI_PERIOD communications in milliseconds. SHAFT_SIGNAL_STR BS_GAIN_ACT Hall sensor analog circuit gain. CS_GAIN_ACT Current sensor analog circuit gain. Active mode the actuator is currently MODE_OF_OPERATION running in.
  • Page 36 Sensed actuator output force in FORCE millinewtons. Lower 2 bytes. Sensed actuator output force in FORCE_H millinewtons. Upper 2 bytes. POWER Sensed actuator output power in watts. Sensed phase current for Hbridge A, in HBA_CURRENT milliamps. Sensed phase current for Hbridge B, in HBB_CURRENT milliamps.
  • Page 37 ADC_FREQ Time between succesful force or position commands before a COMMS_TIMEOUT communications error occurs. In milliseconds. 418 - Reserved Currently active error flags. Only ERROR_0 reflects error conditions that have not been cleared. Latched error flags. Reflects all errors ERROR_1 that have occurred since reset.
  • Page 38 MB_CNT15 MB_CNT16 MB_CNT17 MB_BAUD Modbus serial baudrate. Lower 2 bytes. MB_BAUD_H Modbus serial baudrate. Upper 2 bytes. Modbus interframe delay in MB_DELAY microseconds. MB_ADDRESS Modbus server address. 486 - Reserved Size of last received Modbus message MESSAGE_0_SIZE in bytes. MESSAGE_0 756 - Reserved KINEMATIC_SECTION_VERSION...
  • Page 39 KIN_MOTION_22 KIN_MOTION_23 KIN_MOTION_24 KIN_MOTION_25 KIN_MOTION_26 KIN_MOTION_27 KIN_MOTION_28 KIN_MOTION_29 KIN_MOTION_30 KIN_MOTION_31...

  • Page 40: Revision History

    REVISION HISTORY Version Date Author Reason 0.0.0 January, 2022 Initial Draft 1.0.0 April, 2022 Include GUI and Kinematic sections 1.0.2 August, 2022 Review and update 1.0.3 January, 2023 Add splitter pinout and update memory map reference...

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