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0001768 Basic User Manual v2, English

1. Fig 5 1 Fig 5 2 RECORD OF PUSH FOR RING NO Record sh aranh s 5 MACHINE OPERATOR _ DATE r TIME UP 25 20 2 15 _I 10 5 O o LE s5 e 10 gt 15 20 25 DOWN S M FIRST 1 THIRD QUARTER x QUARTER PUSH PUSH 42 5 Tur p lt x i 4 SECOND LAST x QUARTER QUARTER PUSH gar x PUSH 25 i gt lt 20 E 15 10 E NS E 5 10 15 20 25 RIGHT The rings of circles indicate the hydraulic rams To mark which rams have been used for a push the circles can be crossed through The boxes at the top of the page correspond to the main views of the application software Looking at the record sheets it is possible to see how by selecting different hydraulic rams the machine has moved in different ways and so resulted in new machine positions as indicated by the ZED System This box method of showing results as indicated by the ZED system is easier to show on paper but if the operator has difficulty in understanding the meaning of the numbers then a graphical method can improve comprehension This is shown in Fig 5 2 ND 0001768 Basic User Manual v2 English Page 50 BASIC SYSTEM USER MANUAL 5 2 MOVING THE TARGET In curved tunnels or when the machine gets excessively out of alignment the laser beam may miss th
2. OFFSETS Note Offsets are perpendicular to W Axis Positive Y Direction OFFSETS Gagana Y Direction Laser Beam SIDE ELEVATION Designed Tunnel Axis It is assumed that the Principal Machine Axis coincides with the curved tunnel axis both at the Present Position and at the Predicted Position Since a different pair of Offset values is used for Present Position and for Predicted Position a zero value on the present position display should correspond to a zero value on the predicted display PREDICTED POSITION The X and Y co ordinates of the Predicted Position of the machine define the position of the Predicted Position Point 1 e a point on the Principal Machine Axis a defined distance ahead of the target face with respect to the designed tunnel centreline ND 0001768 Basic User Manual v2 English Page 80 BASIC SYSTEM Fig A 7 Predicted Position ND 0001768 Basic User Manual v2 English USER MANUAL Predicted Position Point nce giction 0912 X component of PREDICTED POSITION Designed Tunnel Centreline Negative X direction Positive X direction Machine is shown pointing DOWN and to PLAN VIEW the LEFT Positive Y direction Designed Tunnel Centreline Negative N Y direction Y component P of T REDICTED POSITION Predicted Position Point SIDE ELEVATION The Prediction Distance which is the distance between the plane of the t
3. 4 6 SPOT POSITION This display simply shows the position of the centre of the laser beam spot where it hits the Combined Target Unit screen The centre of the screen is the origin If the spot is left of the centre the value in millimetres is shown on the left of the page If the spot is at the top it is shown at the top of the page and so on The reason for showing this information is so the user can check that the spot remains on the target screen If the spot position moves to the far edge of the screen then the Combined Target Unit or laser should be moved to compensate The information obtained from the Combined Target Unit is more accurate when the beam hits the screen near the centre As the spot position moves to the edge the accuracy especially of the Lead measurement diminishes Fig 4 5 m Negative Positive Spot Position X direction X direction not to scale NEN Spot X 2 ce px Positive SptYi Z Y direction Left Right Target Negative Axis Y direction Vertical Target END ELEVATION Axis viewed from Laser Example In this example the number 1 is shown on the left of the screen This means that the laser beam is hitting the target screen 1mm to the left of its centre The number 16 is shown at the bottom This means that the laser beam is hitting the target screen 16mm below its centre ND 0001768 Basic User Manual v2 English Page 31 BASIC SYSTEM USER MANUAL 4
4. Log Transfer 2004 03 05 G log xcation not found 18 8 P This menu is used to transfer daily log files to or from an attached device using the arrow or all buttons The log date is included in the log filename The above screenshot shows the menu page when a device is not attached If a removable device is attached and contains a LOG folder then its contents is shown in the right hand list History Options ND 0001768 Basic User Manu m ge 40 aur gt BASIC SYSTEM USER MANUAL Show History All Logged Auto Time Manual To select and show logged data via different types of trigger Show History Yes No Errors Enables showing of all logged data including those with an error ND 0001768 Basic User Manual v2 English Page 41 BASIC SYSTEM USER MANUAL Print Options Print Button Enables or Disables the print button in the views if Enabled available 4 10 3 System Configuration System Connections ND 0001768 Basic User Manual v2 English Page 42 BASIC SYSTEM USER MANUAL Operational Mode Normal Simulation Not operational The Normal setting enables the software to gather the required data from any attached devices and to perform the necessary calculations In Simulation mode all measured data from attached devices becomes user editable only available if installed The Not operational mode will be used if the software is run wit
5. The Target Unit may not function correctly if bright light sources other than the laser are visible from its viewpoint It is therefore useful to mount the unit in a darkened part of the machine or to shield it from direct light sources The operation of the unit will also be impaired if the screen is allowed to become dirty so that a periodic wipe with a damp cloth may be advisable in very dusty atmospheres When the system 15 to be used in tightly curved tunnels then the laser beam will tend to move across the Target screen as the TBM progresses and the laser must be adjusted to a new position periodically To minimise this problem it is possible to mount the Target Unit on a sliding bracket This allows the Target to be moved horizontally so that if the laser spot is to the side of the Target it can again be made to hit the screen Movement along this bracket should be adjustable by 50 mm steps to allow use of the related software facilities Should the angle that the laser beam hits the Target exceed five degrees it is necessary to rotate the Target Unit on a more complicated rotating bracket also available from ZED Tunnel Guidance Movement on this bracket 1s adjustable three degree steps Having selected the best position for the Target Unit it must be mounted within the following limits Roll 0 59 to the vertical machine axis Look up 0 5 to the principal machine axis Lead 0 5 to the principal machine axis Combined Target U
6. The number 26 is shown at the top of the roll lookup display This means that the machine is heading uphill at the rate of 26mm for every metre pushed Page 28 BASIC SYSTEM 4 4 Fig 4 4 Predicted Position exaggerated angles USER MANUAL PREDICTED POSITION 2 The information shown on the PREDICTED POSITION page is similar to the PRESENT POSITION The difference is that the values refer to the position for a plane passing through the machine ahead of the Present Position Plane In fact this Predicted Position Plane can be ahead of the machine The values shown on the display indicate the distance from the designed tunnel centre to the machine centre in this Predicted Position Plane Predicted Position Point nce A edicto pe X component of PREDICTED POSITION x an Designed Tunnel Negative Centreline X direction Positive X direction Machine is shown pointing DOWN and to PLAN VIEW the LEF Positive Y direction Designed Tunnel Negative Centreline Y direction Y component of f SIDE ELEVATION PREDICTED POSITION Predicted Position Point 4 4 The purpose of this information is to indicate how far off course the front of the machine 15 If the Predicted Position Plane 15 ahead of the machine s cutters then the machine can be moved to rectify an error before it becomes too large Hence the Predicted name A general idea 15 to steer the machine so that the v
7. Basic Global Upgraded Global A basic system normally used in straight tunnels but with some capacity for curves Combined Target and separate application software An intermediate system Combined Target and separate application software Curves are pre programmed within the application software A basic system normally used in straight tunnels but with some capacity for curves Combined Target and Processor Display Unit Intermediate core system Curves are pre programmed within the Processor Display Unit Combined Target and Processor Display Unit A series of more advanced configurations based on the Global System suite of upgrades and additions available to meet specific project demands 1 Ring Sequencing compensating for an articulated double shielded machine EtherNet IP links to PLC s amp remote PC s etc The purpose of the ZED tunnel guidance system is to provide the user with details of the tunnelling machine s deviations from its planned route so that corrections can be made quickly This should enable a highly accurate tunnel to be built with increased speed and at a lower cost ND 0001768 Basic User Manual v2 English Page 5 BASIC SYSTEM USER MANUAL 1 2 A BRIEF DESCRIPTION OF THE SYSTEM The equipment works by calculating the position of the machine based on a beam from a laser at a fixed point By knowing the position of the machine it can then calculate its deviation from the planned ro
8. INCLINOMETER LASER LASER POSITION LEAD DIFFERENT TYPES OF LEAD LEAD STEPS LOOKUP MACHINE REFERENCE PLANE OFFSETS PREDICTED POSITION PRESENT POSITION ROLL SPOT POSITION TARGET POSITION COMBINED TARGET UNIT ZERO LEAD ZERO LOOKUP ZERO ROLL APPENDIX B RECORD SHEET ND 0001768 Basic User Manual v2 English USER MANUAL 49 49 51 25 x x5 257 lt T 257 S 59 60 61 262 62 63 67 61 68 69 69 Ts EA NE se 293 73 e qas mr e TS T 6 76 s 7 R Q 80 ew EPA EUN 83 84 2 95 99 87 E V Page 4 BASIC SYSTEM USER MANUAL 1 INTRODUCTION 1 1 BACKGROUND The first tunnel guidance system from ZED Tunnel Guidance Ltd was manufactured in 1977 Since then continuous development has resulted in a comprehensive range of computerised guidance systems that are now in use throughout the world This work has resulted in ZED Tunnel Guidance Ltd receiving the Queen s Award for Technological Achievement in 1986 and the Queen s Award for Export Achievement in 1987 and 199 A range of systems are currently produced to cater for different levels of tunnel complexity The systems in this range all have certain standard items and common features The range at present consists of the following Minimised Basic Minibasic System Minimised Global
9. PRED SPOT POSN POSN POSN POINTS TO CHECK ERROR Cable between units SYMBOL e Combined Target Unit power e aser beam e Ambient light e Combined Target Unit e Excessive Lead e aser beam e Target sensor e Target sensor i e Excessive Roll e Inclinometer transducer e Excessive Lookup e Inclinometer transducer e Check Target Type setting in System Connections menu is correct TRANSMIT LIGHT OUT OF LIMITS DATA FORMAT The most common faults are related to cables and connections the laser or excessive machine movement IMPORTANT NOTE Continuity checks should be carried out with multimeter type instruments only Buzzers inductors high voltage testers insulation testers battery lamp type indicators may cause serious damage ND 0001768 Basic User Manual v2 English Page 68 BASIC SYSTEM USER MANUAL 8 3 FAULT CORRECTION The following repairs may be undertaken on site Replacing fuses b Replacing cables Replace a unit All units are directly interchangeable without the need for internal calibration Check and if necessary reset the Zero values Some problems are easy to solve but others require more expertise The following sections deal with each unit in turn and gives some ideas for problem solving We do not recommend dismantling units without first contacting ZED Tunnel Guidance Ltd Also note that ZED Tunnel Gu
10. LA EI 3 i 05 03 2010 09 50 37 EN The memorystick is examined and all backups found on the memorystick are added to the list of available backups along with the date and time each backup was taken If more than five backups are located the list will become scrollable Click the backup you want to use to select it To apply a backup you need to have the software modules available which were active when the backup was taken If a ND 0001768 Basic User Manual v2 English Page 63 BASIC SYSTEM USER MANUAL module is missing the symbol is shown in the backup list and upon selection the following 15 shown 1 Te 04 03 2010 13 34 58 Kl 04 03 2010 14 23 07 To configure the required modules the guidance software Install menu page detailed in section 6 2 4 needs to be used Pressing the y button will restart the main guidance software used to launch the restorer Once the required software modules available the selected backup restored by pressing the SD button To confirm this action the following warning message is displayed As stated in the message all data currently on the PDU will be lost and replaced with the data stored in the backup There is no undo facility so care needs to be taken during this procedure ND 0001768 Basic User Manual v2 English Page 64 BASIC SYSTEM USER MANUAL Pressing the OK button will start the restore process The
11. LOOKUP as 59 14 2 which is 22 5mm m The lookup of the target unit shown is 26mm m which equals the calculated lookup 22 5 plus the desired tunnel grade which in this example is set to 3 5mm m GRAPHICAL VIEW This display shows a graphical representation of the present and predicted position The colours of the circles correspond to the colour of the text used for the positions i e blue for present position and green for predicted position The roll of the machine is also indicated by the circles being drawn at the roll angle The small solid circle indicates the top of the machine and the scale in the bottom right corner shows the distance each mark on the axes corresponds to The icon in the top left corner indicates that the display mode of this information box can be changed note that this icon 1s only displayed when viewed in the central box Lead Pressing the change mode icon toggles the display to the one shown on the left The top half shows the horizontal Page 30 BASIC SYSTEM USER MANUAL offsets for both the present and predicted positions These points are joined with a line to indicate the horizontal angle of the machine The bottom half shows the vertical offsets and they are joined by a line to indicate the vertical angle of the machine This display is drawn with a fixed scale capable of showing up to 200mm horizontal offset and 00mm vertical offset Values larger than this will not be shown
12. Target Unit Fig A 9 Roll Units Polarity SPOT POSITION VERTICAL Left Right Machine Axis ROLL in positive direction END ELEVATION viewed from Laser Vertical Machine Axis millimetres per metre mm m i e equivalent offset in mm of a Im long plumb line positive Roll is clockwise as viewed from the laser The X and Y co ordinates of the centre of the laser beam on the target screen are defined with respect to the target axis ND 0001768 Basic User Manual v2 English Page 82 BASIC SYSTEM USER MANUAL Fig A 10 Spot Position Negative Positive X direction X direction Spot X Left Right j Target Negative Axis Y direction Positive Spot Yt me Vertical Target END ELEVATION Axis viewed from Laser The centre of the beam 15 determined as the point at which equal amounts of light reach the target to left and right above and below These values are averaged over approximately one third of a second so that a steady reading is obtained even if the beam is unstable due to atmospheric disturbances Units millimetres Polarity positive X direction is to the right looking from the laser positive Y direction 15 upwards TARGET POSITION Fig A 11 Target co ordinates X iecion Positive X direction Target X Left Right Machine Axis Positive Y direction Negative Y direction End Elevation view
13. angle of the swivel mount must be entered into the system by the user When Lead Steps is zero this corresponds to the target axis being parallel to the Principal Machine Axis Positive Lead Steps are defined as rotations of the swivel mount clockwise viewed from above The Lead Steps value entered is converted into milliradians and added to the displayed lead value before being used in calculating the predicted position The value is usually quoted in degrees unlike the other values which are usually specified in mm m Since the bracket can only be adjusted to 3 intervals then this value is also a multiple of 39 Whilst the bracket will rotate to 21 in either direction it is not normally useful over 9 The conversion figures for degrees to mm m are ND 0001768 Basic User Manual v2 English Page 77 BASIC SYSTEM Fig A 4 Lookup LOOKUP USER MANUAL Lookup is defined as rotation of the machine in the vertical plane with respect to gravity Lookup is measured by the inclinometer transducer in the Combined Target Unit Units mm of a Im long plumb line Polarity viewed from the laser Machine is shown pointing up MACHINE REFERENCE PLANE The Machine Reference Plane is defined as a plane normal to the Principal LOOKUP Vertical Negative Positive o Principal Machine Axis SIDE ELEVATION millimetres per metre mm m 1 equivalent offset in Lookup 1s positive if the mach
14. appropriate software modules will be enabled to match the modules used at the time of the backup menu settings and data values will be reset to the values stored in the backup AII existing data files e g log and DTA files will be deleted and replaced with the backed up data files Once the restore 1s complete the main guidance software is automatically restarted ND 0001768 Basic User Manual v2 English Page 65 BASIC SYSTEM USER MANUAL ND 0001768 Basic User Manual v2 English Page 66 BASIC SYSTEM USER MANUAL 8 TROUBLESHOOTING 8 1 ERROR MESSAGES When the system 1s not receiving sufficient data to compute the displayed values the last valid values will have one of the following error symbols appended to it and the relevant display box on the view will turn red LIGHT indicates that the target cannot detect the laser beam The most likely causes of this error are Laser beam missing the target Laser beam too weak Laser beam too strong Excessive ambient light in tunnel Lead angle outside permitted range OUT OF LIMITS indicates that one of the axes of the inclinometer transducer is working outside its operational limits TRANSMIT indicates that data 1s not being received correctly from the Combined Target Unit The most likely causes of this error are Combined Target Unit not connected Combined Target Unit faulty Cable damaged DATA FORMAT indicat
15. is complete errors indicated by OUT OF LIMITS should be ignored If at this stage the equipment is fully assembled powered and otherwise ready but there is no obvious fault then please refer to Section 7 or telephone ZED Tunnel Guidance Ltd for assistance Present OFFSET X and Present OFFSET Y These are the present position offset values that tell the system that the tunnel is not straight They are found on the main view and the ref view If the tunnel is straight these values are both zero If the tunnel is curved then offset values at this point must be calculated Please refer to Section 5 4 for information on how to do this Predicted OFFSET X and Predicted OFFSET Y These are the predicted position offset values that tell the system that the tunnel 15 not straight They are found on the main view and the ref view If the tunnel is straight these values are both zero If the tunnel is curved then offset values at this point must be calculated Please refer to Section 5 4 for information on how to do this TARGET X OFFSET ND 0001768 Basic User Manual v2 English Page 19 BASIC SYSTEM USER MANUAL The set up view allows for the movement left or right of the Combined Target Unit along a support beam This is to let the laser beam hit the target for longer without the laser itself being moved The movement on the beam 15 set in 50mm steps If such a support beam 15 being used then one position must be selected as a startin
16. keypad will appear next to the selected value allowing numerical input These values are also editable through the menu pages If a security pincode has been set then these values will only be editable on the menu pages ND 0001768 Basic User Manual v2 English Page 33 BASIC SYSTEM USER MANUAL 4 9 HISTORY VIEW The optional history view allows the user to view previously logged data This logged data is viewed using the same two views as the current machine position data The History views are obtained by pressing the HISTORY VIEW History view is indicated by blue borders around each display if they do not contain errors the time and date are highlighted and a block of selection buttons are displayed Comms ZEDBasic 3 0 7 The logged data is stored in dated files such that the data for a full days logging is all stored in one file whilst the logged data for the previous day is stored in a separate file ND 0001768 Basic User Manual v2 English Page 34 BASIC SYSTEM 4 10 USER MANUAL To view the different sets of logged data you can use the single left or right arrows on the bottom button bar To jump to the previous or next days logged data you can press the double arrow The other views can be selected whilst in history mode The icon between the bottom button bar arrows depicts what type of log the data represents Either a to indicate that the data was logged by a manual press of th
17. views by the application software on the computer The information displayed can be changed by use of the pushbuttons on the display When this 1s done to display a different set of 1nformation we say that a different view has been selected On a Basic System the operator has access to two views of information Full details of these views are given in Section 4 but the following summarises the information given The main view shows the distances in a horizontal and vertical direction of the centre of the machine from the centreline of the tunnel as designed One of these shows this for the part of the machine where the Combined Target Unit 1s mounted the other for a certain distance ahead of this usually the cutterhead or just in front of the cutters Also angular movement of the machine i e Roll Lookup and Lead and the point where the laser beam hits the target screen To summarise most of the information displayed by the main view shows the difference between where the machine should be and where it 1s How this information is used by the operator is explained in Section 5 HOW THE SYSTEM FINDS ITS RESULTS To be able to show the position as described above the software application requires information to be input by both the sensors and the user The basis for its calculations are the position and angle of the laser and the designed tunnel path specified by offsets from a straight line During installation of the system cert
18. 0 3 6 6 BEAM X and BEAM Y 21 3 607 ZERO ROLL 21 3 6 8 ZERO LOOKUP 22 3 6 9 ZERO LEAD 22 3 6 10 GRADE 23 3 6 11 PREDICTION DISTANCE 23 3 6 12 LANGUAGE SELECTION 23 3 7 RECORDING PARAMETERS 22 3 8 CHECKING THE SETUP 23 4 INFORMATION DISPLAYED 24 4 MAIN VIEW PRESENT POSITION 25 4 2 ROLL 27 4 3 LEAD AND LEAD 28 4 4 PREDICTED POSITION 29 4 5 GRAPHICAL VIEW 30 4 6 SPOT POSITION 3 4 7 MAIN VIEW TOOLBAR 32 4 8 REFERENCE VIEW 33 4 9 HISTORY VIEW 34 4 10 MENU SYSTEM 35 4 10 1 UNIT SETUP 36 4 10 2 DOCUMENTATION OPTIONAL SOFTWARE UPGRADE 39 4 10 3 SYSTEM CONFIGURATION 42 4 10 4 GUIDANCE DATA 45 ND 0001768 Basic User Manual v2 English Page BASIC SYSTEM 5 OPERATION 5 1 USE BY THE MACHINE OPERATOR 3 2 MOVING THE TARGET 5 3 THE ENGINEER S OR SURVEYOR S USE OF THE SYSTEM 5 4 USING OFFSETS 6 MAINTENANCE 6 1 REGULAR CHECKS 6 1 1 COMBINED TARGET UNIT 6 1 2 CABLES and CONNECTORS 6 2 OVERAHAULS 6 3 TOOLKIT 7 SETTINGS 7 1 MEMORY STICK FUNCTIONS 7 2 PAUSING THE GUIDANCE SYSTEM 7 9 PDU BACKUP AND RESTORE 73 1 BACKUP 7 3 2 PDU RESTORE 8 TROUBLESHOOTING 8 1 ERROR MESSAGES 8 2 DIANOSING FAULTS 8 3 FAULT CORRECTION 7 3 1 COMBINED TARGET UNIT 8 4 USING THE LASER POWER METER 8 5 CONTACTING ZED TUNNEL GUIDANCE LTD 8 6 PART NUMBERS APPENDIXA GLOSSARY ABBREVIATIONS ANGULAR UNITS BEAM POSITION GRADE
19. 7 MAIN VIEW TOOLBAR Symbol pesmipie device communication is working Some device communication is failing Comms Simulation 1s active Software 1s not operational All data 1s valid At least one data item 1s in error Test mode 15 active Main View History View optional Perform a manual log optional Print the data currently being viewed optional ZE This menu icon in the top left corner provides access to the menu pages where configuration data is stored This clock icon in the top right corner provides access to a dialog box to allow user to update the software or set the system time It also provides contact information for ZED Tunnel Guidance ND 0001768 Basic User Manual v2 English Page 32 BASIC SYSTEM USER MANUAL 4 8 REFERENCE VIEW HA _ inina IE NER 12 10 53 Daa 16 03 2009 Z Es EE EE REFERENCE Present X Offset Present Y Offset e Predicted X Offset 3 Predicted Y Offset ZEDBasic 3 0 7 The reference view displays the current offset at both the present and the predicted position plane Also the X and Y co ordinates of the laser beam along with its grade are shown The blue border around these values indicates that they can be edited by clicking the individual value boxes A
20. 768 Basic User Manual v2 English Page 57 BASIC SYSTEM USER MANUAL 6 3 TOOLKIT To assist with maintenance and setting up the system can be supplied with an optional toolkit which contains 4 Anti vibration mounts 10 2A anti surge fuses Laser Power Meter Linkback connector 2 User Manuals ND 0001768 Basic User Manual v2 English Page 58 BASIC SYSTEM 7 SETTINGS USER MANUAL The settings menu dialog can be accessed by pressing the top right logo button ZPL The dialog shown below will appear detailing contact information for ZED Tunnel Guidance along with an indication of free memory and disk space ZEI ZEDGlobal 3 1 3 ZED Tunnel Guidance Ltd Unit 1 Russell House Molesey Road Walton on Thames Surrey KT12 3PJ England Phone 44 0 1932 251440 Fax 44 01932 244971 Disk Free 201 MB Memory Free 201 MB Set Time USB MemoryStick Functions Pause Application Minimise Shutdown Application Close Dialog QOO 0 00 ND 0001768 Basic User Manual v2 English This allows the user to set the correct date and time of the unit This launches the MemoryStick Function dialog shown in section 7 1 handling transferring data to and from a USB memorystick This provides the facility to pause the guidance system see section 7 2 for further details This minimises the ZEDGlobal application This shuts down the ZEDGlobal application This closes the dial
21. BASIC SYSTEM USER MANUAL BASIC SYSTEM USER MANUAL Ref 00001768 Issue 2 00 Date 20 January 2011 ZED Tunnel Guidance Ltd Unit 1 Russell House Molesey Road Walton on Thames Surrey KT12 3PJ UK Tel 44 0 1932 251 440 Fax 44 0 1932 244 971 Email sales zed tg co uk Website www zed tg co uk ND 0001768 Basic User Manual v2 English Page 1 BASIC SYSTEM USER MANUAL ZED Tunnel Guidance Ltd 2009 The information in this document is confidential and the property of ZED Tunnel Guidance Ltd It is released on condition that it shall not be disclosed to a third party without the prior written consent of ZED Tunnel Guidance Ltd ND 0001768 Basic User Manual v2 English Page 2 BASIC SYSTEM USER MANUAL CONTENTS 1 INTRODUCTION 5 1 1 BACKGROUND 5 1 2 A BRIEF DESCRIPTION OF THE SYSTEM 6 2 INSTALLATION 7 24 GENERAL 7 2 2 COMBINED TARGET UNIT 8 2 3 JUNCTION BOX 10 2 4 PROCESSOR DISPLAY UNIT 11 2 5 CABLING 14 3 SETTING UP 17 3 1 INFORMATION DISPLAYED BY THE SYSTEM 17 3 2 HOW THE SYSTEM FINDS ITS RESULTS 17 3 3 DISPLAYING DATA ON THE APPLICATION SOFTWARE 18 3 4 COMMISSIONING THE SYSTEM 18 35 SURVEY INFORMATION REQUIRED 19 3 6 CALCULATION AND SETTING OF VALUES 19 3 6 1 Present OFFSET X and Present OFFSET Y 19 3 6 2 Predicted OFFSET X and Predicted OFFSET Y 19 3 605 TARGET X OFFSET 9 3 64 LEAD STEPS 20 3 605 TARGET X and TARGET Y 2
22. REGULAR CHECKS The system requires minimum regular maintenance Protect all units against direct exposure to water mud and mechanical damage by careful siting and the use of simple hoods guards etc Inspect regularly A weekly visual check should be carried out to ensure that the Combined Target Unit and Target Support Beam are correctly positioned 1 their mountings have not been disturbed Every two weeks surveying checks should be performed on all units and zero settings re adjusted as necessary Combined Target Unit Keep the target screen clean If necessary wipe clean with a damp cloth A mild detergent may be used Be careful not to scratch the glass It is not generally possible for the user to repair the Combined Target Unit in the event of a fault occurring Finding the exact location of a fault in the Combined Target Unit needs expertise and reassembly 1s likely to require the use of a calibration rig Do not attempt to repair a unit that you consider to be faulty without first contacting ZED Tunnel Guidance Ltd Cables and connectors Cables and connectors are probably the most vulnerable parts of the system Protect from mechanical damage excessive moisture and dirt by careful siting and regular inspection Keep connector caps on connectors whenever connections are uncoupled OVERHAULS ZED Tunnel Guidance Ltd will gladly quote for a complete professional check out and overhaul between major jobs ND 0001
23. about 50mm from centre ZERO LEAD To cancel out any inaccuracies in the mounting of the target a Zero Lead input to the system is provided for calibrating the Lead value Units millimetres per metre mm m This value assumes that the Combined Target Unit has not been rotated on a bracket see Lead Steps ND 0001768 Basic User Manual v2 English Page 84 BASIC SYSTEM USER MANUAL Fig A 12 Must be equal to actual Function of Zero Lead conventional surveying Measured FROM TARGET lt gt Lead value CALCULATIONS Lead value MANUAL INPUT 34 zee KS TO DISPLAY To cancel out any inaccuracies in the mounting of the inclinometer a Zero Lookup input to the system is provided for calibrating the Lookup value Units millimetres metre mm m Fig A 13 Must be equal to actual Function of Zero Lookup conventional surveying metnoas FROM Measured NCUNOMETER Ne Sie Corrected MANUAL INPUT yae S TO DISPLAY To cancel out any inaccuracies in the mounting of the inclinometer a Zero Roll input to the system is provided for calibrating the Roll value Units millimetres metre mm m Fig A 14 Must be equal to actual Function of Zero Roll Conventional surveying methods FROM Measured INCLINOMETER Roll value CALCULATORS Corrected Roll value MANUAL INPUT N Zero j TO DISPLAY value or ND 0001768 Basic User Manual v2 English Page 85 BASIC SYSTEM USER MANUAL ND 0001768 B
24. adjusting the value on the set up view see Section 3 6 3 and mark and record the new position Check that the display readings before and after the rotation are consistent ND 0001768 Basic User Manual v2 English Page 51 BASIC SYSTEM 5 3 Fig 5 4 Recording present and predicted positions USER MANUAL NOTE The LEAD STEPS setting affects the PREDICTED POSITION display only It has no effect on the other primary page displays since rotation is about a point directly below the target screen and so rotation does not affect the spot position THE ENGINEER S OR SURVEYOR S USE OF THE SYSTEM This section deals with the work necessary to ensure that the ZED System continues to provide useful data The person who does this work is usually an engineer or surveyor We will refer to this person as the ES This person must also know how the machine operator uses the equipment as explained in Section 5 1 The ES must ensure that the laser is mounted in the correct position and pointing in the correct direction Whenever the laser becomes too far from the target or the laser is obscured by part of the tunnel or some other object then the laser will need to be repositioned The BEAM X and BEAM Y values will need to be checked and possibly changed If the slope of the tunnel changes then the GRADE will also change The ES would also be responsible for providing the machine operator with the necessary OFFSET X and OFFSET Y values
25. ain measurements are entered into the application software to inform it of the position of the Combined Target Unit relative to the axis of the machine Using the above user supplied information the application software takes data from the sensors to calculate the position of the machine The inclinometer transducer in the Combined Target Unit transmits to the application software the Roll and Lookup of the machine The Combined Target Unit also detects the position of the laser beam where it hits the screen From the information above it then calculates the actual position of the centre of the machine in the plane of the screen of the ND 0001768 Basic User Manual v2 English Page 17 BASIC SYSTEM USER MANUAL target It is then a simple calculation to find and show the deviation of this position from the designed position This is the Present Position The Combined Target Unit also measures the angle of incidence of the laser beam that is the angle with which the beam hits the screen compared with the centreline of the Combined Target Unit This can be used to provide the Predicted Position which 15 the difference between the actual and the designed positions of the machine at the front of the machine The distance between the present and the predicted positions is called the Prediction Distance and is set in the set up view 3 3 DISPLAYING DATA ON THE APPLICATION SOFTWARE When the application software is first turned on the display wi
26. alues on the Predicted Position page are as small as possible 1 e close to zero The distance between the Present and Predicted Position planes is specified by the Prediction Distance setting ND 0001768 Basic User Manual v2 English Page 29 BASIC SYSTEM ND 0001768 Ba 4 5 USER MANUAL Example In this example the number 28 is shown on the left of the screen This means that at the prediction distance ahead of the target the machine is 28mm left of where it should be The number 59 is shown at the top This means that at the same distance ahead of the target the machine is 59mm higher than its desired position Obviously as shown in the diagrams the machine does not extend as far as the distance given by the Prediction Distance This means that the value given is a prediction of where the machine would be if no course correction was applied The machine is rolling clockwise at 7mm m 59 28 If we assume that no offsets are being used and that all five examples given in this section apply at the same time then we can see the correlation between the results On the present display the position 15 Imm left the predicted display it is 28mm left This means that the machine is heading left If we further assume that the Prediction Distance 1s 2 metres then we calculate that the machine is heading left at a rate of 28 1 2 mm m which 15 13 5mm m This is the LEAD shown as 14mm m Similarly we can calculate the
27. anual v2 English USER MANUAL ROLL gt Roll 1s the rotation of the machine about its own principal axis The axis running from the rear to the front of the machine This is measured with respect to gravity The units are millimetres per metre If a one metre long plumb line were hung from the centre of the machine then the distance that it swung away from the machine s vertical axis would be the Roll The machine s vertical axis is one defined at manufacture or some other time and is not referenced to gravity On the display there are two values The Roll value can be either on the left or the right of the display If it is on the left then it indicates that the machine has rolled anticlockwise as viewed from the laser This 1s negative Roll Clockwise or positive Roll is shown on the right VERTICAL Left Right Machine Axis ROLL in positive direction Vertical END ELEVATION Machine viewed from Laser Axis i Example In this example the number 7 is shown on the right of the screen This means that the machine has rotated 7mm m in the clockwise direction This is also indicated by the yellow triangle which moves left and right as the machine rolls Page 27 BASIC SYSTEM 4 3 Fig 4 3 Lead and Lookup exaggerated angles ND 0001768 Basic User Manual v2 English USER MANUAL LEAD AND LOOKUP Lookup is the name given to the measurement of the tilt of the machine from front to rear It measure
28. arget face and the plane ahead of the target face measured along the principal machine axis may be specified by the user Units millimetres positive X direction 15 to the right looking from the laser positive Y direction is upwards Polarity PRESENT POSITION The X and Y co ordinates of the Present Position of the machine define the Present Position Point 1 e the intersection of the Principal Machine Axis and the plane of the target screen with respect to the designed tunnel centreline Roll data from the inclinometer transducer in the Combined Target Unit is used in calculating the Present Position If the machine rolls about its own axis the displayed Present Position value is not affected Units millimetres positive X direction 15 to the right looking from the laser positive Y direction is upwards Polarity Page 81 BASIC SYSTEM Fig A 8 Present Position Machine is shown pointing up and to the right ROLL USER MANUAL Laser beam Present Position T Negative X direction Designed Tunnel is Positive X direction X component of PRESENT POSITION PLAN VIEW Y component of Present Position Plane PRESENT POSITION Positive Y direction Negative Present Position Y direction Point Principal Machine Axis SIDE ELEVATION Roll is defined as rotation of the machine about its principal axis with respect to gravity Roll is measured by the inclinometer transducer the Combined
29. asic User Manual v2 English Page 86 BASIC SYSTEM USER MANUAL APPENDIX B RECORD SHEET This Appendix contains a record sheet which may be photocopied Basic Tunnel Guidance System ND 0001768 Basic User Manual v2 English Page 87 BASIC SYSTEM USER MANUAL RECORD OF PARAMETER SETTINGS Offset X Offset Y Target X Offset Lead Steps Target X Target Y Beam X Beam Y Zero Roll Zero Lookup Zero Lead Grade Prediction Distance Language Select Project Date ND 0001768 Basic User Manual v2 English Page 88
30. ata ND 0001768 Basic User Manu System Data System Language English Distance Units e 36 ABCDEFGHI m JKLMNOPQ RSTUVWXY 2 BASIC SYSTEM USER MANUAL System Language Sets the language of the Software Distance Units Switches the units of operation between Metric and Centi Feet If Cent Feet is selected an additional field becomes available to allow entry of a custom conversion factor This value specifies how many feet there are per metre System Views Default Centre View Selects the default central view displayed when the software starts Centre View Locked Enables or disables changing the central view System Installation vi vi ND 0001768 Basic User Manu MI x Ld 123456789 27 BASIC SYSTEM USER MANUAL This page is used to install disable and view the current software modules configured on the system Module selection is achieved by clicking the item which will toggle its selected state Selected items are shown with a grey background This is the software serial number for the system When modifying permissions this number will need to be provided to ZED Tunnel Guidance This 15 the keycode entered to install the selected modules and will be provided by ZED Tunnel Guidance Unlock button Once the keycode has been entered press this button to attempt to install the selected modules Disable button This can be used to disable currently active modu
31. differentiate between these terms Raw Lead The horizontal component of the laser beam s angle of incidence on the target screen Lead to Laser The horizontal component of the angle between the laser beam and the Principal Machine Axis In the Basic System this 1s the value displayed on the main view and is the parameter most normally referred to as Lead The system calculates Lead to Laser by adding the ND 0001768 Basic User Manual v2 English Page 76 BASIC SYSTEM USER MANUAL manually entered Zero Lead parameter to the measured Raw Lead value Zero Lead 16 used to compensate for any inaccuracy in mounting the Combined Target Unit Lead to Axis The horizontal component of the angle between the Principal Machine Axis and the Designed Tunnel AXIS As the laser beam in a Basic System is always parallel to the theoretical axis this parameter 15 equivalent to Lead to Laser and is not generally used LEAD STEPS This is not a measurement but is the value of the angle through which the Combined Target Unit has been deliberately rotated on the optional rotating bracket In curved drives the laser beam may strike the target screen at angles of incidence that exceed the operational limits of the target 1 90mm m or approximately 5 2 The angle may be reduced by rotating the Combined Target Unit on a swivel mount The swivel mount may be locked in accurate fixed steps of 3 between 21 and 21 The actual
32. e 3 6 10 GRADE Displayed on the ref view 15 used to specify the GRADE of the laser This is the angle that the laser is set relative to horizontal It is measured millimetres per metre Positive values mean that the laser is pointing uphill Normally this Grade is the same as the grade of the tunnel but this 15 not the case when the tunnel is curving in a vertical direction If the tunnel curves then offsets must be used but the Grade remains the angle of the laser 3 6 11 PREDICTION DISTANCE This value which is entered as a number of millimetres on the set up view specifies the distance from the Machine Reference Plane or Present Position Plane to the Predicted Position Plane Usually this is set so that the Predicted Position is shown for a point slightly ahead of the cutters at the front of the machine The exact value used 15 chosen by the user 3 6 12 LANGUAGE SELECTION At present only English is available 3 RECORDING PARAMETERS Normally the application software will retain the set up information However should a fault develop the initial settings may be lost To avoid having to remeasure the parameters we recommend recording them whenever they are changed A suitable form is provided in Appendix B 3 8 CHECKING THE SETUP Checking that all the correct parameters have been entered is a useful procedure but one which can only be done if the actual position of the machine is known The measurements needed to find th
33. e LOG button or a to indicate that the data was automatically logged by a time interval MENU SYSTEM The menu system allow the user to configure the system view all system values and transfer any logged data files to a removable device IEEF Pressing the menu button toggles between the menus and the normal views The following menus are available Vertical Menu Horizontal Sub Menu Unit Setup System Data System Views System Installation System Securit Ja Log Options Log Transfer Log History Options Tm Log Print Options System Connections Configurations Comms Viewer im ND 0001768 Basic User Manual v2 English Page 35 BASIC SYSTEM 4 10 1 USER MANUAL Guidance Data Present Position Predicted Position Laser Parameters m 1 Machine Parameters EE Target Data The menu system consists of initial setup options concerning attached system devices Layout of views Documentation settings and System data The following sections detail each of the options available for the user to alter Not all menus are available in this configuration as some are used with optional software modules In each view Items that can be altered are enclosed in a black border Any item with a 3 symbol attached is cyclic and each time you press the item you change to the next setting Other items will bring up a Numerical Keypad UNIT SETUP System D
34. e and entering the new number in the numerical keyboard that appears and pressing enter to confirm ND 0001768 Basic User Manual v2 English Page 20 BASIC SYSTEM USER MANUAL Fig 3 1 Negative Target co ordinates X direction Eo M Positive X direction Target X Left Right Machine Axis Positive Y direction Negative Y direction End Elevation viewed from laser Vertical Machine Axis 3 6 6 BEAM X and BEAM Y On the ref view beam X and Y specify the position of the laser relative to the centreline of the designed tunnel BEAM X is the horizontal distance to the Laser and BEAM Y is the vertical distance When viewed looking from the laser to the machine X 1s positive to the right of centre and Y positive above the centre The value 15 entered in millimetres Fig 3 2 Beam X and Y Negative Positive X direction X direction or Tunnelling Positive Y direction Horizontal Tunnel Negative Y direction Tunnel End Elevation viewed from Laser 3 6 7 ZERO ROLL ND 0001768 Basic User Manual v2 English Page 21 BASIC SYSTEM 3 6 8 3 6 9 USER MANUAL This value can be measured only if the Combined Target Unit is properly mounted and the application software 1s operational and connected to it The Roll of the machine must be measured using normal surveying methods The purpose of the ZERO ROLL value is to compensate for any inaccuracies in the mounting of the inclin
35. e position of the machine are not complicated but we cannot explain how to do them here because they differ from one particular machine to another Section 4 explains the meaning of the main view and are the ones that should be used to check whether the parameters are correct Compare the surveyed position of the Present Position Predicted Position etc with the calculated values to see if ND 0001768 Basic User Manual v2 English Page 23 BASIC SYSTEM USER MANUAL there is any discrepancy If an unacceptable difference is found then the parameters should be rechecked ND 0001768 Basic User Man INFORMATION DISPLAYED The application software has two views See Section 3 1 for the difference between views The main view 15 used to show the operator the position of the machine thus enabling the operator to steer the machine in order to keep it on 11 20 28 Comms 16 03 2009 1 7 oce Course BASIC SYSTEM 4 1 USER MANUAL Each numerical display on the right hand side has four positions in which to show values The bottom message line shows the application title and software version The four value positions are arranged so that positive values are at the top or right and negative values are at the bottom or on the left The meaning of each value is explained below If a number has an error symbol and the box outline 15 red then there is an error You should not continue to steer the mac
36. e target screen To avoid frequent re siting of the laser the following adjustments may be made Shifting the target The target can be mounted on a support beam with pre drilled and tapped positions precisely 50mm apart The procedure for shifting the target is as follows a Mark and record the initial position of the target b Undo the two fixing bolts secured by chain C Slide the target to the required position d Secure the two fixing bolts in the new position eJ Setthe new TARGET X OFFSET by adjusting the value on the set up view see Section 3 6 2 and mark and record the new position f Check that the display readings before and after the shift are consistent Fig 5 3 Combined Target Unit on rotary mounting bracket and target support beam Holes 20mm Dia tapped through Rotating the target In addition to a linear shift the target may be rotated on a swivel mount in order to minimise the angle between the laser beam and the normal to the target screen The swivel mount can be locked in accurate steps of 3 from 21 to 21 called LEAD STEPS A LEAD STEPS value of zero corresponds to the target axis being parallel to the Principal Machine Axis LEAD STEPS are positive when the target is rotated clockwise viewed from above The procedure for rotating the target is as follows a Undo the locating pin b Rotate the target mount C Secure the locating pin d Set the new LEAD STEPS by
37. ed from laser 1 Vertical Machine Axis The X and Y co ordinates of the centre of the target are defined with respect to the machine axes and not relative to gravity Units millimetres Polarity positive X direction is to the right looking from the laser positive Y direction 15 upwards ND 0001768 Basic User Manual v2 English Page 83 BASIC SYSTEM USER MANUAL COMBINED TARGET UNIT The Combined Target Unit is mounted on the tunnelling machine and contains electro optical sensors that receive the laser beam 50 of the beam is used to generate the X and Y horizontal and vertical co ordinates of the centre of the beam The other 50 of the beam generates the Lead angle of the beam i e the angle of incidence of the beam with respect to the axis of the target The effective target screen size may be extended if necessary by repositioning the unit in accurate preset steps of 50mm see Target X Offset The Combined Target Unit has a robust aluminium housing containing no moving parts and is sealed for life The unit has no controls or adjustments and it requires no maintenance or calibration The usable screen area will be smaller than the target screen size This 15 because a the laser spot will have a diameter of several millimetres b the angle of incidence cannot be measured if the spot hits the screen too close to the edge For example for the Combined Target Unit maximum usable spot position will be
38. ed the type of data being received is not what the system expects Check that the Target Type setting specified the System Connections menu matches the type of target actually connected An error symbol will be displayed only if there is not sufficient data to compute the displayed values If for instance the laser beam 15 lost the LIGHT error symbol will show on the PRESENT POSITION PREDICTED POSITION and LEAD displays but not on the ROLL and LOOKUP display since roll and lookup are measured solely by the inclinometer transducer in the Combined Target Unit and does not require a valid signal from the target sensors ND 0001768 Basic User Manual v2 English Page 67 BASIC SYSTEM USER MANUAL 8 2 DIAGNOSING FAULTS An additional fault finding aid is the facility to display the position of the laser beam relative to the target without Roll correction by looking at the SPOT POSITION display Note that with this display a movement of the laser spot up or to the right of the target screen will increase the displayed values in contrast to the effect such a movement would have if you were looking at the PRESENT POSITION display as in the latter case it is the machine s position that is being shown If a fault 1s indicated select the main view and check the error symbols displayed on each display The origin of the fault may be traced by referring to the table below PRIMARY PAGE SELECTED PRES ROLL LKUP LEAD
39. ent of the angle between the laser beam and the horizontal Grade is measured by conventional surveying methods and is entered into the system by the operator The value entered will not affect the Lookup value ND 0001768 Basic User Manual v2 English Page 74 BASIC SYSTEM USER MANUAL calculated and displayed but it will be taken into account in the calculation of the Predicted Position Units millimetres per metre Polarity Grade is positive if the laser is directed uphill INCLINOMETER The Combined Target Unit is mounted on the tunnelling machine It contains a high stability transducer which measures Roll rotation about the principal machine axis and Lookup rotation in the vertical plane both with respect to gravity The unit may be attached to the machine in any convenient position and must be levelled and aligned to the axis ZERO ROLL and ZERO LOOKUP values are entered into the system to cancel out mounting inaccuracies The inclinometer transducer has a range of 250mm m and an accuracy of 0 5mm m LASER Recommendations Type Helium neon HeNe or laser diode with well collimated beam without crosswires Laser wavelength gt 633nm Beam energy range 2 5mW Energy at target 0 5 2mW Spot diameter 8 25mm For practical laser target distances a beam expander telescope 15 essential It should be focused typically to a distance between 50 and 300 metres The intensity and quality of the
40. enu below shows a healthy link to an Advanced Target The text in yellow may vary slightly depending on the version of the Advanced Target o TG Link OK Advanced Laser Target Unit found Link OK Advanced Laser Target Unit found To only test the target unit cable it is possible to replace the target unit with a linkback connector supplied in the toolbox This connects onto the end of the target unit cable in place of the target unit The cable is then tested by enabling test mode and looking at the comms viewer The menu below shows a healthy cable link If the yellow T S Link text is missing or sporadic then there is a fault with the cable 75 Link OK TS Link OK TS Link OK ND 0001768 Basic User Manual v2 English Page 44 BASIC SYSTEM USER MANUAL 4 10 4 Guidance Data Present Position This page details the X and Y position of the TBM at the present position plane and allows the user to enter the X and Y offset in the present position plane Predicted Position This page details the X and Y position of the TBM at the predicted position plane and allows the user to enter the X and Y offset in the predicted position plane ND 0001768 Basic User Manual v2 English Page 45 BASIC SYSTEM USER MANUAL Target Data This page details the target data being transmitted from the Target Unit The Zero values used to setup the target unit are editable and are
41. erforming a backup is done via the MemoryStick Functions dialog and takes 1 minute but the time taken depends largely on the amount of log files on the system The data 1s stored in a single folder on the memorystick called PDUBackup date time where date and time show when the backup was taken This backup folder can be copied to other PCs or servers for safe storage but the entire folder must always be copied as a whole maintaining the sub folder structure within The following information is contained in a PDU backup e All Log files e All tunnel alignment files DTA CTA and MTA e All ZED Software files e g ZEDGlobal 3 1 3 e Values of all current data mnemonics and user settings e Permission details for each software module e Ring DLL files only applicable to systems with ring placing e Total Station and Backsight coordinate files only applicable to systems with a Station Interface Unit e ZEDIN Tag files only applicable to PLC connected systems e Boom description files only applicable to articulated boom machines ND 0001768 Basic User Manual v2 English Page 62 BASIC SYSTEM 7 3 2 USER MANUAL PDU Restore The MemoryStick Functions dialog is used to start the restore procedure which is handled by the ZED PDU Restorer software First of all the ZED Guidance software needs to be closed and the Restorer software started The following warning message is shown mmm 2 ai 04 03 2010 14 23 07
42. for a curved tunnel These must be calculated as explained in the next section HORIZONTAL X O PREDICTED X PRESENT VERTICAL Y A task which is not necessary but can be of assistance to the ES checking both ZED System and the machine operator s use of it 15 to record the Present and Predicted Position values on a chart An example of this is shown in Fig 5 4 If there is any doubt about the accuracy of the ZERO LEAD setting for example the chart showing the X Present and Predicted Positions would clearly show whether the Present Position met the Predicted Position If it does not then making slight adjustments to the ZERO LEAD as mentioned before can correct this Remember that the use of Offsets will mean that this may not be true for a curved tunnel ND 0001768 Basic User Manual v2 English Page 52 BASIC SYSTEM USER MANUAL 5 4 USING OFFSETS The Basic System is primarily designed for constructing straight or almost straight tunnels If your tunnel contains many curves or very small radii curves then you should consider upgrading your system with the Global Co ordinates and Communications options For the Basic System to work with curves in a tunnel it is possible to instruct the application software that the machine should not be moving in a straight line but will follow a series of offsets as an estimation of a curve On straight sections of drive the system follows the designed tunnel axis which
43. g point If the target is moved to the left of this point then the TARGET X OFFSET becomes negative If the target is moved to the right then the value becomes positive and larger Movement of the target on the beam is not automatic Changing the value on the application software does not move the Combined Target Unit 3 6 44 LEAD STEPS This value on the set up view performs a similar function to TARGET X OFFSET In this case the change allows for the target to be rotated in 3 steps from a central zero value Changing this value 15 done in the same way as for TARGET X OFFSET 3 6 5 TARGET X and TARGET Y The TARGET X and TARGET Y collectively known as the target co ordinates values specify the position of the target as mounted on the machine These values are measured relative to the axes of the machine and are not dependant on the attitude of the machine at the time of measuring TARGET X is the distance measured along a line parallel to the left right centreline of the machine between the centre of the screen of the target and the up down centreline of the machine Positive values are for positions to the right of the up down axis Similarly TARGET Y is the distance measured parallel to the up down axis of the machine from the centre of the target screen to the left right axis Positive values are for positions above the left right axis The values in millimetres are entered on the set up view by selecting the required display valu
44. he meter so that the laser beam strikes the window in its end When the button on the top of the unit is pressed the laser power 15 shown on the display which is calibrated in mW For optimum performance the system requires between 0 5 and 2 mW The power should preferably be measured as close to the Combined Target Unit as possible If the atmosphere in the tunnel is clean then the power will vary little between laser and target However in a dusty environment the amount of power reaching the target may be considerably reduced If the power at the target falls below 0 5mW then the LIGHT error message is likely to be displayed ND 0001768 Basic User Manual v2 English Page 70 BASIC SYSTEM USER MANUAL 8 5 CONTACTING ZED TUNNEL GUIDANCE LTD The company s address 16 ZED Tunnel Guidance Ltd Unit 1 Russell House Molesey Road Walton on Thames Surrey KT12 3PJ UK Our telephone fax numbers and email address are 44 0 1932 251 440 sales zed tg co uk 44 0 1932 244 971 The company s normal office hours are 0900 to 1300 and 1400 to 1730 Monday to Friday What we need to know if you have a problem It is very useful and saves time if you can prepare certain pieces of information before telephoning If you contact by fax the same information will be required Please remember that the person you contact at ZED Tunnel Guidance Ltd may not be familiar with your particular system This 15 especially true situations
45. her factors must be taken into account These include the shape of the machine its size and how small a radius the machine can cut and whether the trailing sections can follow ZED Tunnel Guidance Ltd cannot assist with these matters only an experienced operator can decide how to control the machine Assuming that the tunnel is either straight or the system is being used with offsets arranged to coincide with the Predicted Position then the aim of the operator should be to steer so that the numbers shown on the PREDICTED POSITION display are as small as possible This means that 0 0 on the predicted display 15 the optimum value If the machine is shown as being too far left then he should steer right and vice versa ND 0001768 Basic User Manual v2 English Page 49 BASIC SYSTEM USER MANUAL Care should be taken however to avoid trying to turn the machine too fast This could make the building of the tunnel segments very difficult To further increase the usefulness of the ZED System records of the past movement and positions of the machine should be kept If these are linked with a record of what machine controls were used to achieve that position then the effect of different manoeuvres can be easily seen To keep this record the machine operator can fill in record sheets These will need to be designed specifically for the machine in use but a typical layout is shown in
46. hine on the basis of numbers that are displaying errors NOTE For each of the sections below an example of the application software display 1s shown To explain this a diagram showing the position of the machine 1s given These diagrams are not to scale and the angles and positions are very exaggerated MAIN VIEW PRESENT POSITION The PRESENT POSITION display indicates how far off course the machine is This is measured in the plane of the target screen The values indicate the distance horizontally and vertically from the centreline of the designed tunnel to the centreline of the machine the principal axis To express this in a different way imagine that the surface of the screen of the Combined Target Unit is expanded in all directions and marks made on this surface to indicate the centre of the machine and the centre of the designed tunnel If lines are now drawn vertically and horizontally that pass through the centre of the tunnel ND 0001768 Basic User Manual v2 English Page 25 BASIC SYSTEM USER MANUAL marker it is then possible to measure the distance from these lines to the centre of the machine point The display on the main view should have two values shown on it One will be to the left or right of the centre and the other above or below the centre If the centre of the machine is to the left of centre of the designed tunnel then the distance 15 shown on the left hand side of the display We say that this is a Negat
47. hout the minimum required set of permissions Target Type RL Laser Advanced Laser This specifies the type of target attached to the system For new systems select Advanced Laser Comms Viewer Comms Viewer XS D7 8 YS 05 9 LDL 024 2 LPL 002 2 00000000 LIV 006 0 RL 008 4 0 PL 46 XS D7 8 YS 05 9 LDL 024 2 LPL 002 2 00000000 LK 006 0 RL 008 9 0 PL 46 XS D7 8 YS 05 9 LDL 024 2 LPL 002 2 00000000 006 0 RL 008 4 0 PL 46 XS D7 8 YS 05 9 LDL 024 2 LPL 002 2 00000000 LK 006 0 RL 008 7 0 PL 46 XS 07 8 YS 05 9 LDL 024 2 LPL 002 2 00000000 006 1 RL 008 6 0 PL 46 The comms viewer menu page displays communication activity to attached devices e g Advanced Target Unit Selects the device for which the communication 15 being shown evice Comms Logging button Press this to enable disable logging x of communication to attached devices Test mode button Press this to enter test mode detailed below Stop button Press this button to toggle the refreshing of the scrolling display ND 0001768 Basic User Manual v2 English Page 43 BASIC SYSTEM USER MANUAL If the test mode button is pressed the system prompts the attached units with a special code to test the communication link between the units This test mode is currently only supported on Advanced Target Units and will only work if the full 4 wire data connection to the unit is present The m
48. idance Ltd cannot be held responsible for any damage or accidents that occur during any repair that you may attempt WARNING Make sure that the power has been disconnected before Opening any unit 7 31 Combined Target Unit Most of the problems associated with the Combined Target Unit will be because of an inability to accurately measure the laser beam s impact position or angle of incidence This will be indicated by LIGHT warning messages on the application software Probable causes of this are as follows a Something 15 blocking the path of the laser beam between the laser and the target This may be part of the metalwork of the machine a person walking in the path or maybe smoke etc b The power of the laser beam is out of limits 1 too weak too wide too strong etc Check the power of the beam using the Laser Power Meter supplied in the optional toolkit See Section 7 5 c There is too much ambient light This means that the interior of the tunnel is so bright that the Combined Target Unit cannot tell the difference between the laser beam and other light hitting it To test this try turning off any lights in the area or try placing a box containing a hole for the laser beam to pass through it over the window of the target Note that even a small light such as a helmet lamp can cause problems at close range When the angle of incidence of the beam on the target is large or the beam hits the target near its edges
49. ine is heading uphill as Machine Axis and passing through the centre of the target screen and the target swivel axis The point of intersection of the Machine Reference Plane and the Principal Machine Axis is known as the Present Position Point ND 0001768 Basic User Manual v2 English Page 78 BASIC SYSTEM USER MANUAL Fig A 5 Machine Reference Plane Machine Reference Plane Present Position Plane Present Position Point Principal Machine Axis Laser beam PLAN VIEW In this plane we refer to two axes X axis pointing to the right when viewed from the laser and having no vertical component also called left right axis Y axis pointing upwards also called vertical axis The origin of the Machine Reference Plane 15 the Present Position Point OFFSETS Offsets define the axis of a curved tunnel The two co ordinates Offset X and Offset Y are the horizontal and vertical deviations of the Designed Tunnel Axis from a theoretical straight axis parallel to the laser beam W axis Offset values entered into the system are deducted from the Present Position and Predicted Position values so that the operator will see on the display the actual X and Y deviations of the machine axis from the designed tunnel centreline ND 0001768 Basic User Manual v2 English Page 79 BASIC SYSTEM Fig A 6 Offsets USER MANUAL Negative PLAN VIEW X Direction z7 Positive X Direction Laser 4
50. is also known as the W axis The position of the W axis is defined with reference to the laser beam by the BEAM X and BEAM Y parameters see Section 3 6 5 When a curve is required offsets must be entered individually for each particular position in the curve when that part 15 about to be built The two co ordinates present OFFSET X and present OFFSET Y as well as predicted OFFSET X and predicted OFFSET Y are the horizontal and vertical deviations of the designed tunnel axis from the W axis The position of the W axis on a curve is purely theoretical It may be an extension of the preceding straight section s centreline but this need not be the case It is often convenient to choose the position of the W axis so that the offset values are small or so that all offsets are 1n the same direction 1 e all positive or all negative Offset values entered into the system are deducted from the PRESENT POSITION and PREDICTED POSITION values respectively so that the operator will see on the display the actual X and Y deviations of the machine axis from the designed tunnel centreline It is assumed that the Principal Machine Axis coincides with the curved tunnel axis both at the Present Position and at the Predicted Position Since a different pair of Offset values 1s used for Present Position and for Predicted Position a zero value on the present position display should correspond to a zero value on the predicted display ND 0001768 Basic User Man
51. it becomes more difficult to make an accurate measurement It is particularly difficult to measure the Lead angle under these circumstances Note also that the usable target area is smaller than the target window Check the location of the impact position using the SPOT POSITION display on the application software ND 0001768 Basic User Manual v2 English Page 69 BASIC SYSTEM 8 4 Fig 7 1 Laser Power Meter USER MANUAL The Combined Target Unit also contains a transducer for measuring angles relative to gravity in two axes If an OUT OF LIMITS fault related to the inclinometer transducer is indicated then the first task 15 to decide whether the fault affects the whole transducer or just one axis To do this it is necessary to check the Roll Lookup view on the Main Display if that value is tagged by the symbol then that transducer is tilted too far relative to vertical The unit itself should be checked to ensure it has not come loose or been damaged It is unlikely that both Roll and Lookup will be out of range but if one is then the other reading is probably incorrect In the event of a TRANSMIT error associated with the Combined Target Unit then the first thing to check is the cable between the units USING THE LASER POWER METER Button Display The Laser Power Meter which is included in the toolkit may be used to check that sufficient laser power is available to operate the system To measure the power hold t
52. ive X Present Position Negative means it is on the left and X indicates horizontal measurement The value shown 15 the actual distance in millimetres Negative values are shown on the left and do not have a minus sign attached to them A value shown on the right of the dsiplay is positive and means that the machine 15 further to the right than it should be Similar rules apply for the vertical direction A value shown at the top of the display is positive and indicates how far too high the machine 15 A value shown at the bottom of the display shows how far too low the machine is We say the value is negative if the machine 1s too low Vertical positions are the Y Present Positions Fig 4 1 Present Position exaggerated angles Negative X direction Positive X direction Machine is shown pointing up and to the right X component of PRESENT POSITION PLAN VIEW Present Position Y component Plane P of RESENT POSITION Positive Y direction Present Position i Negative Point I Y direction Principal Machi SIDE ELEVATION Example In this example the number 1 is shown on the left of the screen This means that the machine is 1mm left of where it should be The number 14 15 shown at the top This means that the machine is 14mm higher than its desired position ND 0001768 Basic User Manual v2 English Page 26 BASIC SYSTEM 4 2 Fig 4 2 Roll exaggerated angles ND 0001768 Basic User M
53. laser spot must be maintained and the laser re positioned as necessary LASER POSITION The laser should be mounted on a rigid support so that it will not move or drift The choice of location will to a large extent be decided by the position of the ND 0001768 Basic User Manual v2 English Page 75 BASIC SYSTEM Fig A 3 Lead USER MANUAL Combined Target Unit on the machine The beam must be directed parallel to the designed tunnel centreline So in order for the beam to hit the target the laser must be fixed in a similar position in the tunnel to the position of the Combined Target Unit on the machine The location of the laser is specified by the Beam Position parameters LEAD In the Basic System Lead 15 defined as the angle of incidence of the laser beam with respect to the Principal Machine Axis in the horizontal plane Lead 15 measured by the Combined Target Unit Units millimetres per metre mm m Polarity Lead is positive if the machine is heading to the right looking from the laser Principal Machine PLAN VIEW u _Axis Machine is shown pointing EM to the right Negative Designed Tunnel centreline im LEAD 5N Positive Different types of Lead Problems often arise because there are a number of different variables which are all called Lead Each has a more precise name but all tend to be shortened to Lead in speech and this causes confusion and misunderstanding It is important to
54. les This is useful if the system is being moved to a different type of TBM The keycode for disabling modules is 123456789 and can also be used to re enable the module Modules with this symbol next to them have not been installed and are not available of Modules with this symbol next to them are currently active Modules with this symbol next to them have been installed but are currently disabled System Security Security Pincode 0 ABCDEFGHI JKLMNOPQ RSTUVWXY 2 ND 0001768 Basic User Manu 38 BASIC SYSTEM USER MANUAL A Pin code can be entered to protect the menu data from being changed by unauthorised users This will also disable the editing of values on the Reference View The code only takes effect after leaving the menu pages and incorrect code entry will result in all values being read only A master reset code is available from ZED Tunnel Guidance Entering 0 ZERO disables the security mode 4 10 2 DOCUMENTATION OPTIONAL SOFTWARE UPGRADE The following pages are only enabled if the Logging Printing software modules have been installed Log Options Log Options Manual Logging Enabled Auto Log Interval Manual Enables or Disables the Manual log button in the views Logging Auto Log Edit a number in minutes in this box to enable an automatic Interval time interval log ND 0001768 Basic User Manual v2 English Page 39 BASIC SYSTEM USER MANUAL
55. ll show the main view This is subdivided into a central display which is surrounded by eight smaller views Each of the smaller displays except the Present amp Predicted Offsets can be selected to open centrally with a larger format 3 4 COMMISSIONING THE SYSTEM Very often the first time a system 16 installed the commissioning is carried out by the staff of ZED Tunnel Guidance Ltd This manual however assumes that the user may wish to recommission the system without assistance It is also recommended that this section be read anyway because it contains full details of the secondary pages displayed The best time to commission the system 15 a few days before tunnelling 15 to start This gives enough time to correct any faults which may be detected Obviously all of the hardware must be installed and properly fitted in its correct position before commissioning can begin The laser must be installed and working at the time of commissioning To carry out the commissioning work the machine must be stationary for a period of several hours It is also better if the machine 15 close to level although this is not so important For the ZED System it is also easier if the machine is in a straight section of tunnel The machine manufacturer can make the setting up procedure easier by clearly indicating the horizontal and vertical axes of the machine If this has not been done it may be necessary to measure and make these marks ND 0001768 Basic U
56. n the machine is exactly parallel to the laser beam then the value displayed in the Lead to Laser display is zero To set the ZERO LEAD we therefore need to know the angle between the Principal Machine Axis and the laser beam Before setting ensure that the Combined Target Unit is correctly mounted and if a rotating bracket 1s used then check that it is centralised 1 e LEAD STEPS 0 By converting the angle between the Principal Machine Axis and the laser beam into a tangent expressed in millimetres per metre we can find the value which should appear on the application software This value 1s the Lead to Laser Changing the ZERO LEAD value on the set up view the displayed Lead to Laser value When the displayed Lead to Laser value equals the measured value the ZERO LEAD value is set Lead to Laser is positive if the laser beam would cross the Principal Machine Axis going from right to left as it heads towards the front of the machine That is the machine 15 heading right relative to the laser direction ND 0001768 Basic User Manual v2 English Page 22 BASIC SYSTEM USER MANUAL After some time and tunnelling for a distance of 50 to 60 metres or more it may become apparent that the movement of the machine differs from that indicated by the guidance system This can occur because tunnelling machines do not always move in a direction parallel to their own principal axis Minor modification of the Zero values can counteract this differenc
57. nit dimensions Shown with AV anti vibration mountings Leave 150mm 6 clearance for cable connectors or 75mm 3 if right angled endbells are used jeng Do not obstruct ve access to cover a S 180 i 241 NEM A BASIC SYSTEM USER MANUAL Active screen area for centre of spot before the out of limits error is given e X 60mm e Y t4 mm e Lead angle of laser beam 90 mm m approximately 5 2 Combined Target Unit mounting details 87mm Bottom View 5 285mm 1174 Laser Beam 20mm 34 4 off mounting holes n Plane of M8 x 24mm 1 deep glass screen Wl 165mm 6 2 I Combined Target Unit mounting details with anti vibration mounts Bottom View 87mm mm ge 9 3 285mm 1174 ND 0001 BASIC SYSTEM USER MANUAL 2 3 JUNCTION BOX This small rugged unit is normally placed near to the Processor Display Unit Access to this unit 15 not too important except to aid in replacing any damaged cables so positioning of the unit is not critical Junction Box mounting details ND O Rear View x4 off holes MR Leave 150mm 6 clearance BASIC SYSTEM USER MANUAL Junction Box dimensions Unit Weight 2Kg 42165 80mm 34 Leave 150mm 6 clearance for cable connectors 2 4 PROCESSOR DISPLAY UNIT The Processor Display Unit must be placed within easy reach and view
58. o connect between the unit and the computer will already have the connectors fitted at each end This will mean that running the cables through small holes 1s not possible unless the connectors are dismantled ND 0001768 Basic User Manual v2 English Page 14 BASIC SYSTEM USER MANUAL Each cable 15 identified by labelling on a yellow sleeve which names the two units that are joined by the cable The sockets on each unit are similarly named with the unit to which they connect The cables and connectors should be protected by careful siting and by anchoring them wherever possible to the permanent structure of the machine Make sure cables do not trail on the floor and avoid sharp bends fatigue and excessive heat Keep all connectors clean and dry If cables must span areas where they cannot be fixed then attempt to provide protection from snagging Do not allow cables to be used as hand or foot holds for climbing ND 0001768 Basic User Manual v2 English Page 15 BASIC SYSTEM USER MANUAL ND 0001768 Basic User Manual v2 English Page 16 BASIC SYSTEM 3 1 3 2 USER MANUAL SETTING UP The purpose of this section is to provide a basic understanding of how the system works It also describes the information needed before the system can be put into operation INFORMATION DISPLAYED BY THE SYSTEM data that the system calculates or measures 15 supplied to the machine operator in the form of numbers and graphical
59. of the operator The viewing angle is not critical but the amount of light reflected from the display may make viewing difficult Protect the unit from water spray dust mud and mechanical damage and allow easy access to the connectors The unit can be mounted either on a panel or within a panel by reversing the mounting brackets to the appropriate orientation ND 0001768 Basic User Manual v2 English Page 11 BASIC SYSTEM USER MANUAL Processor Display Unit dimensions 380mm 15 93mm 3 295mm 1172 Unit Weight 6 13lbs Cable connection to Junction Box leave 150mm 6 clearance for cable connectors Processor Display Unit mounting details x4 off holes 4 5mm 0 18 Rear View 155mm 674 ND 0 age 12 BASIC SYSTEM USER MANUAL Processor Display Unit mounting details for either Stand Alone or Console Mounting Stand Alone Console Mounting Adjustable fittings on either side of unit to permit _Stand Alone or Console Mounting installation ss o Dy mode and will need to be powered on by holding in the power push button for a short while Standby mode is indicated by two short flashes of the red LED contained within the power push button followed by a long pause On powering up the unit goes through an initialisation period before completely powering on ready for use This initialisation period is indicated by an equal interval flashing red LED bu
60. og without any action Page 59 BASIC SYSTEM USER MANUAL 7 4 MEMORYSTICK FUNCTIONS Memorystick Functions TA SB gt gt RN Backup to USB Install fEDGIobal 3 1 3 Restore from USB This dialog is split into two halves and the direction arrows on the buttons show the direction of the data flow A double arrow pointing towards the right indicates that files will be copied from the PDU onto the USB memorystick A double arrow pointing towards the left indicates that files will be copied from the USB memorystick onto the PDU DAT File This copies any available DAT files from the system to the Transfer DATA folder on an attached device This folder should be created on the device before attempting to do the export These files can be useful for sending to ZED Tunnel Guidance to aid troubleshooting Backup to This copies all relevant application data from the PDU to the USB memorystick A folder called PDUBackup along with a time date stamp is created on the memorystick AII relevant files and settings are stored within this folder Multiple backups can be stored on one memorystick Please see section 7 3 for further details on backing up and restoring a PDU Install If an application update is located on the memorystick this button Application will be displayed The version of the installation files found will be shown under the button in this case ZEDGlobal 3 1 3 Pressing this button will appl
61. ometer transducer The Combined Target Unit will measure a Roll value referred to as Raw Roll which will probably differ from the actual Roll The ZERO ROLL is the value that when added to the Raw Roll yields the actual Roll Roll values are measured in terms of the number of millimetres displacement of a plumb line one metre long A positive value indicates clockwise rotation as viewed from the laser Having measured the actual Roll of the machine look at the roll display on the set up view The Roll Zero value box should be altered so that the number on the roll display equals the actual Roll of the machine For example if the Zero Roll value is initially 0 the value on the roll display 12 and the actual value is 18 then the zero value should be changed to 6 ZERO LOOKUP This value also relates to the Combined Target Unit and 1s in many ways similar to ZERO ROLL Lookup 15 the measurement of how level the machine 15 as viewed from the side A positive Lookup means that the front of the machine is higher than the rear It is measured in millimetres per metre Entry of the value on the set up view is made in the same way as ZERO ROLL ZERO LEAD Care must be taken when setting the ZERO LEAD value Confusion arises because of the use of the name Lead for a variety of different values The ZERO LEAD setting is used to compensate for the inaccuracy of mounting the Combined Target Unit on the machine What 15 required 15 that whe
62. radian 1mR 3 438 seconds of arc O P Output PROM Programmable read only memory S W Software TG Tunnel guidance TIU Target Inclinometer Unit V Volt Ver Vn Version version number W Name of the direction roughly along the tunnel X Name of the direction roughly horizontal Y Name of the direction roughly vertical ND 0001768 Basic User Manual v2 English Page 73 BASIC SYSTEM Fig A 2 Beam co ordinates USER MANUAL ANGULAR UNITS Angles are given as linear displacements i e millimetres per metre mm m The unit mm m is approximately equal to the angular unit milliradian mR since the tangent of an angle is approximately equal to the angle itself expressed in milliradians Since 2nR 360 then 1 17mR BEAM POSITION The X and Y co ordinates of the centre of the beam are defined with respect to the designed tunnel centreline Since the laser beam 15 parallel to the designed tunnel centreline these co ordinates are independent of distance along the laser beam Units millimetres Polarity positive X direction 1s to the right looking from the 5 5 laser positive Y direction 1s upwards Negative Positive X direction X direction BEAM X 1 Tunnelling Machine Laser Beam Positive Y direction Horizontal Tunnel Negative Y direction Tunnel End Elevation viewed from Laser Vertical Tunnel Axis I GRADE Grade 15 defined as the tang
63. s by how much the front is above or below the rear The Lookup value is quoted in terms of millimetres per metre If the machine 15 going uphill then the Lookup 1s positive if it is going down then the value is negative To make this easy to interpret on the display the values are shown at the top of the Roll Lookup display if the machine is going up and at the bottom if it is going down A negative Lookup value corresponds to the tunnelling term Overhang Lead 16 the name given to the measurement of the direction of the machine in the horizontal plane relative to the laser If the machine is moving towards the left then the value expressed in millimetres per metre is shown on the left of the display If the machine 15 heading to the right then it 1s shown on the right If the tunnel is straight and parallel to the laser then the Lead indicates the direction of the machine relative to the tunnel If the tunnel is curved then this 15 not necessarily the case The term Lead is explained in more detail in Appendix A Designed Tunnel Centreline Positive PLAN VIEW Machine is shown pointing DOWN and to Principal Machine he LEF i Principal Machine Axis 4 n xum 2 3 SIDE ELEVATION LOOKUP Vertical Negative Positive Example In this example the number 14 is shown on the left of the Lead display This means that the machine is veering to the left at a rate of 14mm for every metre pushed
64. ser Manual v2 English Page 18 BASIC SYSTEM 3 5 3 6 3 6 1 3 6 2 3 6 3 USER MANUAL SURVEY INFORMATION REQUIRED The following data must be accurately measured and the required data fed into the application software Some of these values will not change when the machine moves but others will The things that remain constant can be entered before the others to save the amount of time the machine must remain still The data required 16 a Roll and Lookup of the machine b The distance of the centre of the Combined Target Unit screen from the horizontal and vertical axes of the machine The terms horizontal and vertical refer to the machine as designed i e as if it had no Roll distance of the centre of the laser beam from the designed tunnel centreline Note that the laser beam must be aligned parallel to the designed tunnel centreline d Grade or slope angle of the designed tunnel The actual position of the machine This means finding out the angle of the Principal Machine Axis relative to the laser beam CALCULATION AND SETTING OF VALUES This section describes the calculations necessary to find the values to be entered into the application software If at any time during the setting up procedure an error message such as LIGHT or TRANSMIT appears on the application software views then there is a problem Troubleshooting is described in Section 7 Until setting up
65. t there is enough room for the cable to be connected to the unit ND 0001768 Basic User Manual v2 English Page 7 BASIC SYSTEM ND 00017 2 2 USER MANUAL Fitting of the units may require plates or brackets to be welded to the machine Do not carry out this welding with the ZED equipment already fixed to the plate or bracket In general the Combined Target Unit is usually mounted at the top or top left top right of the shield area If the sections ahead of the target can articulate then the ZED system will not show the correct position of the cutter head unless more equipment an Articulation Interface Unit and associated transducers 1s added to the system In all cases it 1s helpful if the machine has been designed with the knowledge that a ZED system 15 to be used on it COMBINED TARGET UNIT The Target Unit must be placed in such a position that the laser beam will strike the front screen continuously This means that it is preferable if parts of the machine such as the erector cannot obstruct the path of the laser and the area around the path of the laser should be as large as possible The Target Unit will normally be mounted towards the crown of the tunnel in order to minimise interruptions by persons working in the tunnel If the TBM is articulated then the Target Unit should be mounted on the front part of the machine otherwise additional equipment will be required in order the monitor sections ahead of the Target
66. tton This LED will become constant once the initialisation sequence has finished Subsequently the PDU can be turned off and on by holding the power push button ND 0001768 Basic User Manual v2 English Page 13 BASIC SYSTEM 2 5 USER MANUAL Below the power push button are another two that can be used to vary the intensity of the display brightness Pressing increases the brightness and pressing decreases the brightness It incorporates a rugged touch screen for user interaction A USB mouse located in the toolbox is available if required Above the push buttons is a small window that contains the status indicator LED s and these are detailed in the following diagram PORT4 PORT3 PORT2 PORTI The red power LED s indicate the status of the power for each supply Each port has two LED indicators associated with it the indicates that data is being received to the port and the that data is being sent from the port The top connector at the side 1s the USB port The middle connector at the side 15 an Ethernet port The connector port on the front panel bottom right is used for diagnostic purposes only CABLING Having decided on the best location for the unit it 15 then necessary to choose the cable lengths to suit the arrangement The lengths chosen should be not too short to avoid making sharp bends but not too long to avoid coils of unnecessary cables The cable supplied by ZED Tunnel Guidance Ltd t
67. ual v2 English Page 53 BASIC SYSTEM USER MANUAL Fig 5 5 Offsets Negative PLAN VIEW X Direction Positive Bee X Direction Laser Beam ae Tunnel Note Offsets are perpendicular to W Axis Positive Y Direction E Direction Designed Tunnel SIDE ELEVATION Axis When in a curve every time the machine is moved forward the corresponding Offset values should be entered in the ref view The Offset values should obviously be prepared in advance and a table of offsets can be supplied to the machine operator A typical example of a curved tunnel and its defining Offset table 1s given below Offset no o lt o lt 2 3 4 5 6 7 8 9 0 1 _ 0 Note that Offsets are measured at right angles to the laser direction ND 0001768 Basic User Manual v2 English Page 54 BASIC SYSTEM Fig 5 6 Example showing part of a curved tunnel defined using offsets ND 0001768 Basic User Manual v2 English Offset 11 Designed Tunnel AXIS Offset 2 Offset 1 USER MANUAL Offset 9 Offset 8 Offset 7 Offset 6 Offset 5 Offset 4 Offset 3 Page 55 BASIC SYSTEM USER MANUAL ND 0001768 Basic User Manual v2 English Page 56 BASIC SYSTEM 6 1 6 1 1 6 1 2 6 2 USER MANUAL MAINTENANCE This section gives information about the minimal maintenance required by the system
68. used to display the corrected target values in the left hand column There are two boxes representing the exposure of the Target to the Laser The first represents the XY value the second the Lead value The range of these values is between and A Hex Should there be an error with the Target Unit or Laser an eight digit error code is displayed on the right on this page This code enables ZED Tunnel Guidance personnel in the diagnosis of any fault Laser Parameters This page details the laser beam position data ND 0001768 Basic User Manual v2 English Page 46 BASIC SYSTEM Machine Parameters USER MANUAL Machine Params Prediction Distance mm X Target Offset Lead Steps Target Co ordinates mm ie holes mm This page details the Machine parameter setup data Prediction Distance Target Coordinates X Target Offset Lead Steps This specifies the distance in millimetres between the present position plane and the predicted position plane These are the X amp Y coordinates where the target is mounted They are specified in millimetres from the tunnel centre If the target is moved along a ZED beam the hole number can be entered here Each hole corresponds to 50mm The hole specified by the target X amp Y coordinates is hole zero If the target is mounted on a ZED rotary bracket this field is used to tell the system how much rotation has been applied Edit each bo
69. ute of the tunnel This information is then displayed on various views of the application software contained on a rugged computer This is normally placed close to the machine operator s control console so that the operator can use the information to guide the machine The software application also stores and allows input of the information needed by the system To measure the machine s position a unit containing sensors is used known as the Combined Target Unit An optical array in this unit measures the point at which the laser beam hits it and also the angle of incidence of the beam An inclinometer transducer in the unit measures the angle of rotation of the machine in two directions ND 0001768 Basic User Manual v2 English Page 6 BASIC SYSTEM USER MANUAL 2 INSTALLATION This section describes the positioning and connection of the units of the ZED system on the tunnelling machine and elsewhere 2 1 GENERAL For the Basic System there are three units mounted on the machine the Combined Target Unit the Junction Box and the Processor Display Unit Direction of laser To Power These units should be placed in a position where they will not be damaged by movement of machinery heat hydraulic fluid large amounts of water etc Fix the units as firmly as possible to solid parts of the machine using the fixing holes and anti vibration isolators provided Do not weld the unit directly to the machine Always ensure tha
70. where your system is not supplied directly from ZED Tunnel Guidance Ltd The information we need is as follows a Your company s name b Your location Your name d A contact telephone number and or address If we have not been in contact with you recently we will also need to know The type of equipment e g Basic System fJ special items e g Articulation Interface Unit Next we need to know what the problem is or was and what action has been taken In particular if the fault is not immediately identifiable please have ready details of the displays on the application software from at least the main view ND 0001768 Basic User Manual v2 English Page 71 BASIC SYSTEM USER MANUAL 8 6 PART NUMBERS The following is a list of the units and the circuit boards inside them Combined Target Unit 1103020 MPU board 1103027 Inclinometer transducer 88 10039 ND 0001768 Basic User Manual v2 English Page 72 BASIC SYSTEM USER MANUAL APPENDIX A GLOSSARY ABBREVIATIONS Abbreviations used in this manual or by ZED staff A Ampere unit of current AC Alternating current CTU Combined Target Unit PDU Processor Display Unit DC Direct current EPROM Erasable programmable read only memory H W Hardware IC Integrated circuit chip I P Input kg kilograms 1kg 2 2046 pounds LED Light emitting diode small light m Metre 1m 39 37 inches mm Millimetre 25 4mm 1 inch mR Milli
71. x to the required value ND 0001768 Basic User Manual v2 English Page 47 BASIC SYSTEM USER MANUAL ND 0001768 Basic User Manual v2 English Page 48 BASIC SYSTEM USER MANUAL 5 OPERATION This section can be subdivided into two parts use by the machine operator or driver and use by the surveyor or engineer The first is interested in how the information helps him to steer the machine The latter needs to know what to do to keep the system operating correctly 5 1 USE BY THE MACHINE OPERATOR The machine operator driver uses the system to tell him the position of the machine Looking at the application software he can see the position and orientation of the machine in its present location What he must decide using this information is how to steer the machine in order to make a tunnel that follows the designed course Fig 5 1 Hecord sheet numerical type RECORD OF PUSH FOR RING NO DATE TIME 12 PRES 2 16 72 POSN 7 8 5 ROLL 8 8 9 8 LEAD d 5 3 ae LOOKUP 2 1 5 e AZ E 16 8 PRED Sl POSN x OF 15 WA 54 24 a 7 9 EN THIRD Ta QUARTER PUSH 57 x ut j j K 94 SECOND Y LAST QUARTER QUARTER PUSH Td PUSH Q S Wa fi 4 TIO ZED System helps with these decisions but ot
72. y the application update to the PDU The installation files should be in the INSTALL folder on the memorystick ND 0001768 Basic User Manual v2 English Page 60 BASIC SYSTEM USER MANUAL a Restore If any backups are found on the memorystick this button will be from USB displayed Pressing it will close the guidance system application and run the ZED PDU Restorer application detailed in section 7 3 7 2 PAUSING THE GUIDANCE SYSTEM Having pressed the Pause button the following confirmation dialog will be shown Pressing the OK button will result the following dialog being displayed and the system entering the paused state ND 0001768 Basic User Manual v2 English Page 61 BASIC SYSTEM USER MANUAL Whilst the system is paused no commands are sent via the different communication channels to the attached devices e g Station Interface Unit Target etc This is particularly useful when manual control of the total station is required To resume the guidance system press the button 7 3 BACKUP AND RESTORE The PDU backup and restore feature is provided to allow easy and quick configuration of a PDU to return it to a previous state This can be used if some settings are accidentally changed which may cause the PDU to stop working properly It can also be used when a replacement PDU 15 being configured to match an existing PDU setup 7 3 1 Backup P

0001768 Basic User Manual v2, English

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