IRIS ORCA User manual

Version 1.0.3

CONTENTS
LIST OF TABLES ................................................................................................................................................4
LIST OF FIGURES ..............................................................................................................................................4
INTRODUCTION.................................................................................................................................................5
BLOCK DIAGRAM ..............................................................................................................................................5
POWERING THE MOTOR.................................................................................................................................6
Fuse .................................................................................................................................................................6
Ground.............................................................................................................................................................6
Chassis............................................................................................................................................................6
GETTING STARTED WITH IRISCONTROLS4 ...............................................................................................7
Required Software ....................................................................................................................................7
Required Hardware...................................................................................................................................7
CONNECTING TO IRISCONTROLS4..........................................................................................................8
NAVIGATING THE GUI .................................................................................................................................9
GUI PAGES................................................................................................................................................... 10
Home........................................................................................................................................................ 10
Position .................................................................................................................................................... 10
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............................................................................................................................................... 20
PID Position Controller.............................................................................................................................. 20
General tuning guide ............................................................................................................................. 20
Proportional action ................................................................................................................................ 21
Integral action......................................................................................................................................... 21
Derivative action..................................................................................................................................... 21

Saturation level....................................................................................................................................... 21
Force Controller.......................................................................................................................................... 21
Kinematic Controller.................................................................................................................................. 22
Software Triggering............................................................................................................................... 22
Hardware Triggering.............................................................................................................................. 22
Configuring a Motion............................................................................................................................. 23
MODES OF OPERATION................................................................................................................................ 24
Sleep Mode (1)............................................................................................................................................ 24
Force Mode (2) ........................................................................................................................................... 24
Position Mode (3)....................................................................................................................................... 24
Kinematic Mode (5) ................................................................................................................................... 24
COMMUNICATIONS INTERFACES ............................................................................................................. 25
RJ45 Cable .................................................................................................................................................. 25
Windows USB Graphical User Interface ................................................................................................ 26
MODBUS Interface..................................................................................................................................... 26
USER CONFIGURATIONS ............................................................................................................................. 26
Maximum Temperature........................................................................................................................ 26
Maximum Force..................................................................................................................................... 27
Maximum Power.................................................................................................................................... 27
Communication Timeout ..................................................................................................................... 27
ERRORS............................................................................................................................................................ 27
Active and Latched Error Registers ........................................................................................................ 27
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

LIST OF TABLES
Table 1: Sensors............................................................................................................................................. 19
Table 2: Kinematic Motion Configuration Registers................................................................................ 23
Table 2: Communication Interfaces ........................................................................................................... 25
Table 3: RJ 45 Pinout..................................................................................................................................... 25
Table 4: User Configurations........................................................................................................................ 26
Table 5: Errors and their Impact .................................................................................................................. 27
LIST OF FIGURES
Figure 1: Block Diagram...................................................................................................................................5
Figure 2: IrisControls4 application with no device connected ..................................................................7
Figure 3: Orca Series Linear Motor.................................................................................................................7
Figure 4: RS485 to USB cable .........................................................................................................................7
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 .............................................................................................................. 13
Figure 12: IrisControl4 Modbus page ......................................................................................................... 14
Figure 13: IrisControls4 Kinematic Page ................................................................................................... 15
Figure 14: IrisControls4 Logging page ....................................................................................................... 17
Figure 15: IrisControls4 Current Page ........................................................................................................ 18

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

POWERING THE MOTOR
All Orca devices are powered by a DC voltage.
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.
Suitable power sources for Orca motors are AC-to-DC converters, batteries of various chemistry,
capacitor banks, or other sources of DC voltages. Engineering support from Iris 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
must be made which can be accommodated by threading a conductive bolt into any of the
provided thread patterns on the enclosure.

GETTING STARTED WITH IRISCONTROLS4 TM
Required Software
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. With no device connected, the
IrisControls4 window should open with an empty
console and a status of disconnected.
Once you have confirmed you have a working copy of
the IrisControls4 software you can move on to the next
section of this guide.
Required Hardware
Besides the motor itself, connecting to the IrisControls4
application requires two additional pieces of hardware
detailed below.
Connect the RJ45 communication cable from the Orca
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
IrisControls4.
Figure 3: Orca Series Linear
Motor
Figure 4: RS485 to USB
cable
Figure 5: RJ45
Splitter
Figure 2: IrisControls4 application
with no device connected

Figure 6: IrisControls4 Settings panel
CONNECTING TO IRISCONTROLS4TM
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.
Settings
button
Baudrate
selection
dropdown
Connect button
Connection
status

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.
Figure 7: IrisControls4 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.
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+
Figure 8: Orca Series GUI with home page open
COM selection
dropdown
Connect button
Connection
status

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.
Position
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.
Figure 9: IrisControls4 Position page
Position and Force Graph
This graph will plot the position controller’s target position, the commanded force used to reach
that position and the measured shaft position. The left y-axis is position, and the right y-axis is
force.
The green “Target” line will show the active commanded position, but the targets for each source
(MODBUS, GUI, Kinematic Controller) are always shown on the graph as well.
Enable Position Control Button
This button will toggle the motor between Position and Sleep modes.
Zero Position Button
This button will reset the position zero point to the current physical position of the shaft.

Save Tuning Button
This button will save the gain target values and the max force value to permanent memory.
Gain Adjustment Inputs
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. This value can be manually edited.
Gain Adjustment Inputs
To update the gains to their target values while operating in position mode, press the update
gains button.
Max Force Input
This number can be manually edited to define the largest force value the position controller will
command.

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.
Force Sensed Slider
This slider shows the measured force output of the motor.
Test Button
This button toggles the motor between Force and Sleep modes, enabling the force target slider as
an input when toggled on.

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
Calibration Information
The C45, C90, Signal Strength and Image Quality elements reflect the status of the saved
calibration.
Zero Position Button
This button will reset the position zero point to the current physical position of the shaft.

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. Additional pages of data
bytes can be viewed using the left and right arrow buttons.
Diagnostic Counters
Modbus diagnostic counters are shown below the last received message, on the left-hand side of
the page. See Modbus RTU specification for more information on each counter.
Connection Info
Connection information is shown below the last received message, on the right-hand side of the
page. Information shown includes current baudrate, rate of successful messages and connection
status.

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.
Motions configurations exceeding the number shown on the slider (starting from ID zero) will be
greyed out and unconfigurable.
Hardware Trigger Debounce Buttons
The four buttons labeled debounce allow you to select the amount of time a hardware trigger
signal must be maintained before triggering a motion.
Hardware Trigger Enable Button
The hardware trigger enable button will be grey if the feature is disabled, and blue if it is enabled.
When it is disabled, only software triggering is available.
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.
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.
Preview Motion Button
Triggers the Preview Graph to redraw.
Save Configuration Button
Saves the global settings (number of motions, hardware trigger) and motion configurations to
permanent memory.
Enable Kinematic Mode Button
This button toggles the motor between Kinematic and Sleep modes.
Software Trigger Test Input
Entering a value into this field will trigger the motion with the matching ID, if that motion is
enabled.
Hardware Trigger Test Button
This button will simulation a hardware trigger event on press.
Configuring a Motion
1. Adjust the Num. Motions slider high enough so that the motion ID you want to configure is
enabled.
2. Use the page buttons to navigate to the page with the motion ID you want to configure.
3. In the configuration box with the desired motion ID, enter the motion parameters (position,
time, type, delay and chain.) Ensure that you press the enter key after inputting a value in
one of the text boxes.
4. Preview or test your configured motion settings.
5. Press the Save Configuration button to save your changes to permanent memory.

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.
Figure 14: IrisControls4 Logging page
Log Data Selection
The buttons in the left-hand column allow selection of what data should be logged. Toggling any
of the buttons to the on state (blue) will enable logging.
Log Period Configuration
The Log Period text box allows input of a time in milliseconds to wait between log events. Valid
range is 100 to 65535 milliseconds.
Save Button
This button will save the logging configuration to permanent memory.

Current
The current page provides an interface for testing the Orca current controller.
Figure 15: IrisControls4 Current Page
Step Test Results Graph
Displays the duty cycle, target current and measured current results of one individual current step
test.
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.
Current Controller Gain Display
The four numbers under the plot show the configuration of the current controller. These fields are
not editable through the IrisControls4 GUI.

ORCA REGISTERS
System data like sensor readings, user settings, and controller setpoints are stored in and can be
accessed from a collection of 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.
For information on accessing registers from the GUI, see Orca GUI User Guide.
SENSORS
Several solid-state, contactless sensors are embedded in each Orca motor.
Table 1: Sensors
Force
FORCE (double
wide)
Millinewtons
>6 V
Position
SHAFT_POS_UM
(double wide)
Micrometers
Any
Power
POWER
Watts
>6 V
Driver
Temperature
DRIVER_TEMP
Celsius
>6 V
Stator
Temperature
STATOR_TEMP
Celsius
Any
Force Sensor
Forces resulting from current in the motor windings, whether caused by the motor drivers, or by
currents induced due to shaft movement, is calculated, and reported with low latency and high
bandwidth.
Position Sensor
The position of the shaft is measured and reported with low latency and high bandwidth. The
reported position can be positive or negative and is set to zero by writing to the “Zero Position” bit
of “Control Register 0.”
The shaft must be zeroed at an externally known position every time the motor is power-cycled as
the absolute position will be lost if the motor loses 5V.
The shaft position is obtained by measuring and integrating the ‘shaft alignment,’ or the position
of the shaft’s magnets with respect to the stator.
The shaft alignment is absolute in nature (persists throughout power cycles); however, it repeats
every shaft period interval. This interval is listed on the motor’s datasheet as “Shaft Magnetic
Period.”
The position sensor is active in all modes of operation.

Power Sensor
Power being consumed or generated is measured and reported with low latency and high
bandwidth. This power is a measure of the heat being generated by the stators and is not
necessarily an accurate reflection of the power drawn from the power lines, especially when the
shaft is moving quickly. The power sensor reflects the rate at which the stator will be increasing
in temperature.
While the power sensor isn’t a perfect reflection of power line draw, it can be used as a ‘worst-
case’ value as the actual draw should in no case exceed the sensor’s reported value.
Temperature Sensors
The temperature of the power driver and the stator windings are measured and reported to the
Orca registers.
Power driver temperature can be obtained by reading the DRIVER_TEMP register. Stator winding
temperature can be obtained by reading the STATOR_TEMP register.
Stator winding temperature readings are active in all modes of operation, but driver temperature
readings are inaccurate when less than 12V is supplied to the Vdd.
CONTROLLERS
The integrated logic included in Orca™motors carries out several feedback controllers with very
low latency feedback loops that provide high performance motion and force control without a lot
of tuning and setup required.
PID Position Controller
A common use of linear motors, especially in kinematic robotic application, is to move to and hold
position in the presence of dynamic disturbances. The integrated PID position controller
accomplishes this by using the position sensor as feedback and generating a force command
which will realize the position setpoint effectively. Position setpoint means the position target
commanded by MODBUS.
When tuning the PID Position controller in a new system, it is always recommended to start with
as low a force saturation level as possible.
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.
There is no shortage of PID tuning guides available on the internet and tuning of the integrated
PID position controller follows most traditional PID controllers. The reader is encouraged to
research the term ‘PID position controller’ if the concepts are unfamiliar prior to using this feature.
Specific optimal tuning will depend on the nature of the load and any disturbances experienced.