IRIS ORCA RM220115 User manual

ORCA™ SERIES MOTOR
RM220115
ORCA™ SERIES MOTOR
Reference Manual 220115
This document applies to the following Orca Series linear motor firmware:
●6.1.7
For more recent firmware versions, please download the latest version of this reference manual at
https://irisdynamics.com/downloads
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ORCA™ SERIES MOTOR
RM220115
CONTENTS
List of Tables....................................................................................................................................................... 4
List of Figures......................................................................................................................................................4
REVISION HISTORY........................................................................................................................................... 5
Introduction......................................................................................................................................................... 6
Powering the Motor........................................................................................................................................... 7
Fuse.................................................................................................................................................7
Ground.............................................................................................................................................7
Chassis........................................................................................................................................... 7
Communication Interfaces...............................................................................................................................8
Methods of Motor control.................................................................................................................................9
IrisControls Software..................................................................................................................... 9
Modbus RTU................................................................................................................................... 9
Orca Analog Interface.................................................................................................................... 9
Autonomous................................................................................................................................... 9
Modes of Operation.........................................................................................................................................10
Sleep Mode (1)............................................................................................................................. 10
Force Mode (2)............................................................................................................................. 10
Position Mode (3).........................................................................................................................10
Haptics Mode (4)......................................................................................................................... 10
Kinematic Mode (5)......................................................................................................................10
Getting Started with IrisControls...................................................................................................................11
Required Software..............................................................................................................................11
Required Hardware............................................................................................................................ 11
Connecting to IrisControls...........................................................................................................12
Troubleshooting Connection............................................................................................................12
Navigating the GUI....................................................................................................................... 13
Home Page................................................................................................................................... 13
Position / Kinematics Page......................................................................................................... 14
Tuning Panel........................................................................................................................................15
Kinematic Panel..................................................................................................................................16
Application Note:................................................................................................................................ 17
Force / Haptics Page................................................................................................................... 18
Application Notes:.............................................................................................................................. 19
Modbus / OAI Page......................................................................................................................21
Modbus Server Status.......................................................................................................................21
Orca Analog Interface........................................................................................................................22
IrisControls Logging.....................................................................................................................22
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ORCA™ SERIES MOTOR
RM220115
Orca Registers.................................................................................................................................................. 22
Control Registers..........................................................................................................................23
CTRL_REG_0...........................................................................................................................23
CTRL_REG_1...........................................................................................................................23
CTRL_REG_2...........................................................................................................................23
CTRL_REG_3...........................................................................................................................24
CTRL_REG_4...........................................................................................................................24
Sensors.............................................................................................................................................................. 26
Force Sensor.................................................................................................................................26
Position Sensor............................................................................................................................ 26
Power Sensor............................................................................................................................... 26
Temperature Sensors...................................................................................................................27
Controllers......................................................................................................................................................... 28
Force Controller............................................................................................................................28
Position Controller....................................................................................................................... 28
General Tuning Guide........................................................................................................................ 28
Proportional Action............................................................................................................................ 28
Integral Action.....................................................................................................................................29
Derivative Action.................................................................................................................................29
Saturation Level.................................................................................................................................. 29
Kinematic Controller.................................................................................................................... 30
Software Triggering........................................................................................................................... 30
Hardware Triggering.......................................................................................................................... 30
Configuring a Motion......................................................................................................................... 31
Haptic Controller.......................................................................................................................... 32
Effects...................................................................................................................................................32
Configuring Effects............................................................................................................................ 33
User Configurations.........................................................................................................................................34
Maximum Temperature.................................................................................................................... 34
Maximum Force..................................................................................................................................34
Maximum Power................................................................................................................................ 34
Communication Timeout..................................................................................................................34
Errors.................................................................................................................................................................. 35
Active and Latched Error Registers.............................................................................................35
Configuration Errors...........................................................................................................................35
Force Clipping..................................................................................................................................... 35
Temperature Exceeded..................................................................................................................... 36
Force Exceeded.................................................................................................................................. 36
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ORCA™ SERIES MOTOR
RM220115
Power Exceeded................................................................................................................................. 36
Shaft Image Failed............................................................................................................................. 36
Voltage Invalid.....................................................................................................................................36
Communications Timeout................................................................................................................36
APPENDIX : Orca Memory Map.....................................................................................................................37
LIST OF TABLES
Table 1:RJ45 Pinout 7
Table 2: Communication Interfaces 8
Table 3: Sensors 24
Table 4: Kinematic Motion Configuration Registers 29
Table 5: Haptic Effect Configuration Registers 31
Table 6: User Configuration Registers 32
Table 7: Errors and their Impact 33
LIST OF FIGURES
Figure 1: Block Diagram 6
Figure 2: Initial Orca Series Motor Setup 6
Figure 3: IrisControls Software without an Orca Series motor connected 11
Figure 4: Orca Series Linear Motor 11
Figure 5: RS485 to USB cable 11
Figure 6: RJ45 Splitter 11
Figure 7: IrisControls Connection Information 12
Figure 8: IrisControls Settings Dialog 12
Figure 9: Orca GUI with Home Page Open 13
Figure 10: IrisControls Position Page 14
Figure 11: IrisControls Tuning Panel 15
Figure 12: IrisControls Kinematic Panel 16
Figure 13: IrisControls Force Page 18
Figure 14: IrisControls Modbus Panel 21
Figure 15: IrisControls Orca Analog Interface Panel 22
Figure 16: Changing logging period through console 22
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ORCA™ SERIES MOTOR
RM220115
REVISION HISTORY
Version
Date
Author
Reason
0.0
January, 2022
kh
Initial Draft
1.0
April, 2022
sj
Include GUI and Kinematic sections
1.2
August, 2022
kh
Review and update
1.3
September, 2022
sj
Update for 6.x.5 changes.
1.4
February, 2023
Sj
Update for 6.1.6 changes.
1.5
April, 2023
rm
Formatting, memory map update
1.6
May, 2023
rm, ab,
sj
Update GUI, add Haptics section, change section order
1.7
Aug, 2023
kh, sj
Expand on control register
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ORCA™ SERIES MOTOR
RM220115
INTRODUCTION
This document describes the functions and operation of Orca™ Series linear motors having
integrated drivers and an integrated sensor suite.
Figure 1: Block Diagram
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ORCA™ SERIES MOTOR
RM220115
Figure 2: Initial Orca Series Motor Setup
POWERING THE MOTOR
Orca Series motors are powered by DC voltage. The Orca Series variant name specifies the
voltage at which the motor is most efficient, however all Orca Series motors can be powered by
12 – 60 VDC.
Flying lead power connections are provided for each motor. Orca Series motors are configured to
be able to draw significant currents and proper attachment of the power lines to a suitable power
source is important.
Suitable power sources for Orca Series motors are AC-to-DC converters, batteries of various
chemistry, capacitor banks, or other sources of DC voltages. Engineering support from Iris
Dynamics on the selection of a suitable power source is available.
Fuse
A 30-amp fast-blow fuse must be installed between the power supply and the motor. This fuse
will be destroyed if negative voltage is applied to the motor.
Ground
In all cases, the black power lead is “Ground” and should be connected to the negative terminal of
the power supply or battery.
It is important that the power supply Ground, and the Ground of any electronics attached to the
device’s communication cable is kept at the same level. Usually this is done by making sure the
power supplies of the motor and external controller (if different) are connected to Earth at both
their chassis and negative output terminal.
Chassis
As an important safety measure, the chassis of the motor must be securely connected to Earth.
Proper grounding of the chassis is also important for proper operation of the motor.
The motor enclosure and cable shields are connected but these are not connected to the Ground
circuit of the on-board electronics. Therefore, a separate connection from the Chassis to Earth
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ORCA™ SERIES MOTOR
RM220115
must be made which can be accommodated by threading a conductive bolt into any of the
provided thread patterns on the enclosure.
COMMUNICATION INTERFACES
Communication cables are typically terminated with an RJ45 connector. The 5V and GND lines on
the connector can be used to power the motor’s logic so that communications and diagnosis can
continue when the motor’s power source is switched off or disconnected.
Table 1:RJ45 Pinout
Pin
Signal
Notes
1
RX2+
Modbus
2
RX2-
3
TX2+
4
RX/TX1+
IrisControls™
5
RX/TX1-
6
TX2-
Modbus
7
+5V
Can be used to power logic,
or indicate logic power
status
8
GND
Must be connected to the
communication hub
ground.
There are two serial communication interfaces available which enable a Windows-based GUI (via
IrisControls), firmware updates, and a Modbus RTU communication stream.
Table 2: Communication Interfaces
Splitter Port
Signalin
g
Protocols
1
RS485
Half
Duplex
IrisControls (GUI)
IrisBootloader
2
RS422
Full
Duplex*
Modbus RTU
* See UG230323 – Orca Series Modbus over Half-Duplex RS485 for information on setting up a
half-duplex connection on this port.
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METHODS OF MOTOR CONTROL
IrisControls Software
The Orca Series motors can be commanded and configured through an integrated graphical user
interface (GUI). See the Getting Started With IrisControls section of this document for full details.
Modbus RTU
The Orca Series motors are Modbus RTU servers, with additional functionality to support a
high-speed stream of commands and feedback. See the UG210912 – Orca Series Modbus user
guide for further details.
All configurations and control options are available through registers on the Orca Series motors.
See the Orca Memory Map for a list of register addresses.
A PLC, PC, or other Modbus client can be used to command the motor. Third party programs with
built in Modbus libraries such as Labview, or Matlab can also be used. There is an IrisSDK for
Windows available with libraries that abstract the Modbus communications for use in custom
software solutions.
UG230503 – Orca Series Modbus RTU PLC document provides further an example of
communicating with a motor using a PLC.
Orca Analog Interface
The Orca Analog Interface allows for control of Orca Series motors in force, position, and
kinematic modes through simple digital and analog inputs. Real-time force and position data is
also fed back from the Orca to the Orca Analog Interface and provided as analog outputs.
For details on configuring the Orca Analog Interface of this manual. For further details on the Orca
Analog Interface itself see UG230424 – Orca Analog Interface user guide.
Autonomous
Orca Series motors can be configured to continuously cycle motions on power up or to move
through a set of motion profiles by connecting the Orca data cable to a hardware button.
See the autonomous looping sequence application note section for details on setting up this
option.
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MODES OF OPERATION
The motor operates in five main modes of operation: Sleep Mode, Force Mode, Position Mode,
Kinematic Mode, and Haptic Mode. Force Mode and Position Mode are meant to be used with a
Modbus communication stream and cannot be entered directly through the IrisControls GUI.
Sleep Mode (1)
In this mode, power drivers are not active and windings in the stator are all shorted (producing a
braking effect). Force and position commands are ignored.
When Sleep Mode is commanded (even when sleep mode is currently active), any active errors
will be re-evaluated and cleared where appropriate.
Force Mode (2)
The force controller will control the power delivered to the motor to achieve the forces written to
the FORCE_CMD register. Note: this register is double-wide (32 bits).
Once in Force Mode, communications must be made regularly over the Modbus interface to avoid
a timeout error. In the event of communications failure or other motor errors, the motor will cease
all power draw and put the windings into a passive braking effect.
Position Mode (3)
The position controller will calculate forces for and command the force controller according to the
configured PID tuning, the setpoint, and the current shaft position.
Before entering Position Mode, the user should make sure the shaft has been zeroed to a known
position.
Once in Position Mode, communications must be made regularly over the Modbus interface to
avoid a timeout error. In the event of communications failure or other motor errors, the motor will
cease all power draw and put the windings into a passive braking effect.
Haptics Mode (4)
The force controller works similarly to Force Mode, however, force commands will be dictated by
the haptic controller rather than a Modbus stream.
The haptic controller comprises several haptic force effects that can be configured and enabled.
The sum of forces resulting from all enabled haptic effects is used as the force target.
Kinematic Mode (5)
The position controller works similarly to when in Position Mode, however, position commands
will be dictated by the kinematic controller rather than a Modbus stream.
The kinematic controller outputs motion profiles to move to a shaft position over a specified time,
while respecting the chosen kinematic constraints.
In Kinematic 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, but MODBUS
communication will be disabled.
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ORCA™ SERIES MOTOR
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GETTING STARTED WITH IRISCONTROLS
Required Software
Orca Series motors can be configured through an integrated graphical user interface (GUI). To
connect to an Orca Series motor’s GUI, first download the latest version of the IrisControls
software on a Windows PC.
The latest release is always available at www.irisdynamics.com/downloads under the ‘Software’
section. Once downloaded, unzip the folder and follow in install instructions..
Figure 3: IrisControls Software without an Orca Series motor connected
Required Hardware
Besides the motor itself, connecting to the IrisControls application requires two additional pieces
of hardware detailed below.
Figure 4: Orca Series Linear Motor
Figure 5: RS485 to USB cable
Figure 6: RJ45 Splitter
Connect the RJ45 communication cable from the Orca Series motor to the single port side of the
RJ45 splitter. Connect the RJ45 connector end of the RS485 cable to the splitter input labeled 1.
Finally, connect the USB end of the RS485 cable to the Windows PC running IrisControls.
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Connecting to IrisControls
Ensure that the motor is connected to a PC with an RS-485 to USB cable. Open the IrisControls
application. 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 specified.
Figure 7: IrisControls Connection Information
Once you have selected the correct device, press the connect button to begin attempting to
connect to the motor. If successful, the Orca GUI should launch its homepage.
Troubleshooting Connection
If the motor does not connect, toggle the connect button off and press the gear icon in the top
right of the IrisControls window and select a baudrate of 460800 from the dropdown menu, and
press apply.
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ORCA™ SERIES MOTOR
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Figure 8: IrisControls Settings Dialog
Navigating the GUI
Navigation of the GUI is done using the page buttons above the console. Pressing each button will
open a different page of the GUI within the page content area. The default page upon connection
is the home page, shown below. Several other indicators, such as power draw and mode of
operation will remain visible on the GUI regardless of the page selection.
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ORCA™ SERIES MOTOR
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Figure 9: Orca GUI with Home Page Open
Home Page
The home page is the default page opened upon connecting to an Orca Series motor. A
screenshot of the home page is shown in Figure 11. This page displays the firmware version,
hardware version, firmware build date and the motor serial number. There are no interactive
elements specific to this page.
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Position / Kinematics Page
The position page provides a real time graph displaying the target position, measured position,
and target force of the motor. Below the graph, the currently set parameters of the position
controller are displayed, including proportional gain, integral gain, derivative gain, and maximum
force output. These values can be tuned and are described in further detail in the PID Position
Controller section.
Figure 10: IrisControls Position Page
Position and Force Graph
This graph will plot the position controller’s target position, the commanded force used to reach
that position, the measured shaft position, and the individual actions of each component of the
PID controller. The left y-axis is position, and the right y-axis is force.
The green “Target” line will show the active commanded position. (Modbus or Kinematic
Controller).
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Tuning Panel
Figure 11: IrisControls Tuning Panel
Gain / Max Force Adjustment Inputs
The maximum force output and position controller gains can be edited here.
The maximum force determines the upper limit of force that the position controller can
command.
The number on the left of the arrow is the actual value that is in effect and is not editable. The
number on the right side of the arrow is the target gain value. This value can be manually edited
and saved.
Error Thresholds
Allows configuration of the force, temperature and power thresholds that trigger their respective
errors when exceeded.
Update Tuning Button
To update the gains to their target values while operating in Position Mode, press the update
gains button.
Save Tuning Button
This button will save the gain target values and the max force value to permanent memory.
Zero Position Button
Set the motor’s zero position to the current location. Moving the motor past its zero position in the
negative direction will reset the zero position to the furthest negative position. Zero position does
not persist through motor power cycles.
Kinematic Page Button
This button will switch the interface to the kinematic panel.
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Kinematic Panel
The kinematic page provides an interface to the kinematic controller feature of the Orca Series
motor. For more information on the capabilities of the kinematic controller, refer to the kinematic
controller section of this manual.
Figure 12: IrisControls Kinematic Panel
Reset Defaults Button
Resets current kinematic settings to the factory default demo motion profile.
Home Motion ID
This is the ID of the motion that will start when the kinematic controller is enabled, either via the
GUI, MODBUS, or the Orca Analog Interface.
Configuration Page Buttons
The 32 possible motions can be paged through using the left and right arrow buttons at the top
right of the page. The current range of motion IDs being configured is shown between the page
buttons.
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.
Kinematic on Boot Button
This button will be grey if the feature is disabled, and blue if it is enabled. This allows kinematic
motion to be started on power up. This is best used for a motion that is looped i.e., all motions in
sequence are auto-start and last motion’s next id is the first motion.
!!WARNING!! This will disable the Modbus interface upon the next power cycle of the motor. This
is because the Modbus interface inputs can be used as hardware triggering inputs.
Save Configuration Button
Saves the global settings and motion ID configurations to permanent memory.
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Enable Kinematic Mode Button
This button toggles the motor between Kinematic and Sleep modes.
State Indicator
The state indicator will read IDLE if the kinematic controller is not currently executing a motion. It
will read RUNNING if a motion is in progress, with a number to the right indicating which motion
ID is running.
Configuring a Motion
1. Use the page buttons to navigate to the page with the desired motion ID.
2. In the configuration box with the desired motion ID, enter the motion parameters (position,
time, type, delay, next ID, and auto-start). Press the enter key after inputting a value in one
of the text boxes.
3. Enable the kinematic controller to test the configured motion settings.
Press the Save Configuration button to save changes to permanent memory.
Application Note:
Autonomous looping sequence
It is possible to set up a single motion profile that will start on motor boot up and loop indefinitely
without any external control, i.e., motor with power supply only data cable not used.
This can be done by setting a sequence of motions that all ‘Auto-start Next’ and having the last
motion’s ‘Next ID’ be the first in the sequence. The ‘Home Motion ID’ should be set to the first
motion in the sequence. In addition, ‘Kinematic on Boot’ must be toggled on and saved.
Once the motor is power cycled, the Home Motion will be triggered, and each motion will be
performed sequentially as defined by the ‘Next ID’ parameter. Delays between motions can be
added as required.
Figure 13: Autonomous kinematic looping sequence configuration
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Force / Haptics Page
The haptics page provides an interface for the haptics features of the Orca Series motor.
Figure 14: IrisControls Force Page
Force Graph
This plot displays the force sensed by the motor and the force commanded by all haptic effects.
The plot can also show the individual forces commanded for up to three haptic effects.
Enable Haptics Button
Toggling this button will switch the motor into Haptics Mode (4) and will begin applying all
enabled haptics effects. Toggling it again will return the motor to Sleep Mode (1).
Save Configuration Button
Clicking this button will save the haptic effects currently displayed on the GUI to the long-term
memory on the motor.
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Target and Sensed Force Sliders
These sliders cannot be interacted with, they display the current target (or commanded) force
along with the sensed force.
Individual Haptic Effect Panels
Each of the other panels on this page provide an interface for adjusting the various haptics
effects available to the motor. Each of the data fields in these panels can be modified to adjust the
effect. Clicking the enable button contained in a panel will enable that individual haptic effect. The
save configuration button will save any changes made here to permanent memory.
As many effects as desired can be layered on each other.
The following is a list of the effects with a brief description. For more detailed information on each
effect and their configurations, see the Haptic Controller section.
Constant
Constant force in either the positive or negative direction, regardless of shaft position. This input
can be low pass filtered with an adjustable strength to accommodate slower communication
streams.
Spring
Force that linearly increases with distance from the configured center position. Adjustable in
strength, saturation force, dead-zone, and coupling direction.
Damper
Force that linearly increases with speed to oppose the current direction of travel.
Inertia
Force that linearly increases with acceleration to maintain motion of the motor in the direction it is
moving.
Oscillator
Force waveform generator with adjustable frequency, amplitude, and wave type.
Application Notes:
50 N force for 1 second followed by 9 seconds of rest.
To accomplish this type of setup the ‘Oscillator’ and ‘Constant’ effects are used in combination.
Using a 25 N amplitude for the oscillator will give a 50 N spread between the maximum and
minimum values. Using a ‘Constant’ effect with 25 N will add an offset to the oscillator. Instead of
alternating between +25 N and -25 N, the force will alternate between 0 N and 50 N. Setting the
Frequency to 1 dHz will have the waveform repeat every 10 seconds (which is the total time ‘high’
and ‘low’). Setting the Duty to 10 will give 1 second high and 9 seconds low.
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