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Leica PaveSmart 3D for Milling Machines Technical Reference

1. Before a new Project can be created a DBX file for the project must be available Refer to chapter 2 4 Converting Data With the Design to Field Tool A project within Leica PaveSmart 3D contains the design data necessary to control the milling machine This must contain at least 1 3 dimensional stringline on a specific layer A project may consist of many stringlines on many layers but only one stringline can be active as reference line at any given time A second line can be chosen as slope line The Leica PaveSmart 3D calculates the actual cross slope between the reference line and the slope line at any position After the data has been converted in to the DBX Road format the following files need to be transferred to Leica PaveSmart 3D E Stringline_Indoor02_120706_0712_163640 x15 e Stringline_Indoor02_120706_0712_163640 x16 E Stringline_Indoor02_120706_0712_163640 x22 E Stringline_Indoor02_120706_0712_163640 x23 E Stringline_Indoor02_120706_0712_163640 x24 e Stringline_Indoor02_120706_0712_163640 x30 e Stringline_Indoor02_120706_0712_163640 XCF These files must be stored on the USB storage device under the Folder D DBX New or existing PaveSmart 3D Projects are managed in the Menu Projects Current dialog Menu Projects Current Project Straight_Line_1000 Multi_Stringline_Cigar Dog_Bone Parking_Lot cigar_R4 Comment CONT NEW DELETE BACK gt 4 oe eo In this dialog it is possible to create a new project
2. er The transformation parameters will be set in the Coord System field 2 Select a typical configuration set with lt R Time Mode Rover gt The GNSS GPS GLONASS on the milling machine must always be the rover Select the appropriate antenna type Ni WwW CONT F1 to access SURVEY Survey The arrow of the real time device and real time status icon flashes when real time messages are being received Fixing ambiguity begins The current position status is indicated by the position status icon When working with code only corrections an ambiguity solution is not attempted The position mode icon is the moving icon This indicates that the antenna can be moved around and that no static observations are being recorded Coordinates of the milling machines position are now being calculated Ensure that the 3D quality is under 0 02 m before starting to mill Setting up the Measurement Sensors PaveSmart 3D Milling TR 93 Setting up the Measurement Sensors PaveSmart 3D Milling TR 94 Step Description 6 The GNSS GPS GLONASS should be left in this state while milling S Do not press the OCUPY button S Refer to the GPS1200 Technical Reference Manual for more information 7 Setting the Operators Preferences Introduction Leica PaveSmart 3D gives the operator the ability to change a number of user preferences to customise the system to the
3. PaveSmart 3D Milling TR 110 Setting the leapfrog method The leapfrog command will automatically take the nearest or furthest TPS measuring out of active control of the milling machine and replace it with the spare TPS This is set in the lt Work Sensors Arrange gt dialog If the lt Take over from shortest measuring distance gt check box is selected the TPS with the shortest measuring distance will be removed from active control of the milling machine and replaced with the spare TPS If the lt Take over from shortest measuring distance gt check box is not selected the TPS with the longest measuring distance will be removed from active control of the milling machine and replaced with the spare TPS this is the default setting The maximum allowable deviation between the existing TPS coordinates and the new TPS coordinates is set in the lt Work Sensors Arrange Leapfrog tolerance gt If this deviation is exceeded a warning message will be displayed informing the operator This may occur if the set up quality of either the TPS in active control of the milling machine or the spare TPS is not acceptable If using a Hybrid GNSS GPS GLONASS TPS solution the leapfrog will always swap the Spare TPS to the Primary position sensor Leapfrog Parameter Leapfrog Tololerance 0 061 m oO Use shortest measuring distance Swapping TPS Making a leapfrog step by step Step Description l Set up the Spare TPS an
4. e lt Time gt Seconds s default e lt Stationing gt 1234 56 7 8 8 1 Description se Before taking as built measurements Taking As built con trol measurements Quality Control Taking and Recording As Built Measurements To check elevation and position during production Leica PaveSmart 3D has an integrated as built lt Control gt function to replace the manual dipping method used when milling on stringline The tool is very helpful to check and compare the design height and the projected milling depth at the start points It will recommend to calibrate the system using the set value at the controller or the here function at Leica PaveSmart 3D Ensure the client project owner accepts this method of as built check before produc tion starts For the integrated as built control function to operate correctly the instrument must be turned on running MGuide and in radio contact with the MPC Measurements are only possible if the instrument is correctly positioned and orientated within the project coordinate system Resection or Known Point set up As Builts checks can only be performed with the spare TPS sensor while the system is in active control All lt Control gt measurements are relative to the actively selected reference line When using single stringline design files the elevation deviation between the design and the as built measurement is given to the top back of kerb Cross slope
5. It is possible to have multiple stringlines on the same layer but each indi vidual stringline must not exceed 2000 elements If a single stringline requires more than 2000 elements it must be broken into more than one stringline which must be milled separately Projects PaveSmart 3D Milling TR 17 Projects PaveSmart 3D Milling TR 18 2 4 Introduction Converting Data With the Design to Field Tool Design to Field is the name of a software component contained within the Leica Geo Office LGO application that allows data to be imported into Leica PaveSmart 3D and used onboard Leica System 1200 sensors Design to Field allows many different data types to be imported Data may be imported using industry standard data formats such as LandXML DXF and GSI or from a number of additional formats using converters that are available in the downloads area of the Leica Geosystems website In this Technical Reference Manual the focus is set on how to prepare DXF data However there are many more available import formats Details on how to convert these are described in the Design to Field User Manual For further information on how to use the Design to Field Tool refer to the Design to Field User Manual In the Design to Field Tool terminology DBX jobs used for Leica PaveSmart 3D are called RoadRunner Jobs Opening the Design to Field Tool in LGO Ent 2920 500 _pereres ites soma me tee A ED In the Leica G
6. Straight_Line_1000 08 03 2006 13 25 Corrections Information Stationing Working Slope ee Design Slope 0 TE Of Cross slope 50 STEER ELEVATION RESET BACK 2G eo Offsets PaveSmart 3D Milling TR 119 Offsets PaveSmart 3D Milling TR 120 Cross slope conven tion a Controlpoint b Direktion of Travel Rotation Cross Slope Slope Offset Water c lanti clockwise negative catch d clockwise positive spill e positive 11 Maintenance Tasks 11 1 Weekly Maintenance Tasks Required maintenance The following steps will help minimize problems during production and should be carried out tasks on a weekly basis or if disturbance to any of the equipment is detected e Check amp Adjust all instruments Refer to TPS1200 Technical Reference Manual for further details If the required adjustments are excessive contact Leica Geosystems Support to arrange for return to base adjustment of the instrument Instruments should be returned to Leica Geosystems once every six months for a factory check and adjustment e Check the MPC1310 has sufficient flash disk space A warning message on the Leica PaveSmart 3D dashboard will flash when the disc space has reach 75 capacity e Remove all old Logfiles AsBuilt files and delete old Projects All these files should be backed up to an external data storage location first e Check amp Adjust slope sensor and ensure machine mast s
7. i e Left Front Right Front There are five tuning parameters which can be altered to achieve the desired hydraulic response The default values are Left Big Left small Dead band Right small Right big 500 mm to 50 mm to 3 mm 3 mm to 50 mm to 50 mm 3 mm 50 mm 500 mm 1 64 ft to 0 164 ft to 0 10 ft 0 10 ft to 0 164 ft to 0 164 ft 0 10 ft 0 164 ft 1 64 ft The zoom button may be used to view each of the ranges lt Range 3 gt shows all of the parameters at the same time lt Range 2 gt show the details of the first two ranges and lt Range 1 gt shows the smallest range which is generally set as a dead band for example 0 gradient Each cylinder must now be tuned independently Make sure that the Link Elevation tick box is not selected and then select each height cylinder individually making small changes to the tuning parameters e Left Front e Right Front G TCPS27 radios worldwide Checking TCPS radio modem settings Storing new TCPS radio modem settings Radio Modem Configuration The radio modem is delivered with an operational frequency band between 2401 2471 MHz which is approved world wide Changes to the standard frequency band are only possible with the external radio modems TCPS27S B R and not with the radio handle Changes can only be carried out at a Leica service centre if required Default values TCPS27S R Radio handle TCPS27B Ba
8. 2 Purpose Recording and Managing Logfiles Leica PaveSmart 3D can generate various logfiles to record system actions events Most are used only for trouble shooting support purposes but some such as the lt As Built logfile gt are very useful for Quality Assurance purposes and can be used to generate as built draw ings e As built logfiles are accessed in the lt Menu Projects AsBuilt gt e Senor logfiles are accessed in the lt Menu Projects Logfiles gt Logfiles can grow very large very quickly and may fill up the MPC1310 hard disk leading to unexpected system behavior or a Windows XP problem The user must remember to delete or export the contents of the log files and delete the original on a daily basis If the log file is too large the system may stop recording data A warning message will first appear in the dashboard informing the operator that the disk drive is reaching capacity If experiencing difficulties with Leica PaveSmart 3D system a Leica authorised Support Engi neer may request that one or more of these files are recorded and the results sent to Leica for detailed analysis Sensor Logfiles for Sensor log files are only accessible through the password protected Service Mode system supporters Senor log files are stored in the lt Menu Projects Logfiles gt dialog only All sensor components are listed as well as a machine track file which incorporates infor mation from all of the sensors If a l
9. Auto 3D gt The difference in elevation between the active measurement and the new measurement will be applied to the elevation offset at the milling drum The difference is position to the reference line between the active measurement and the new measurement will be applied to the steer offsets lt Auto Ht gt The difference in elevation between the active measurement and the new measurement will be applied to the elevation offset of the milling drum The steering offsets will remain as they were before the leapfrog This may result in the machine moving left or right when put into active control lt Auto St gt The difference in position between the active measurement and the new measurement will be applied to the steer offsets The elevation offsets will remain as they were before the leapfrog This may result in the machine moving up or down when put into active control Step Description lt Manual gt The elevation and steering offsets will remain as they were before the leapfrog This may result in the machine moving left or right and up or down when put into active control lt Back gt Takes the user back to the last screen and the leapfrog is not carried out System Operation PaveSmart 3D Milling TR 113 System Operation PaveSmart 3D Milling TR 114 9 3 Search Introduction The search function in Leica PaveSmart 3D is used to find a reflector when a TPS losses lock
10. Freewave Fischer 6m MCC1304 Coiled Cable MPC COM3 TCPS275 Cannon 6m MCC1303 Coiled Cable MPC1310 COM3 Freewave Fisher 6m MCC1201 Coiled Cable CAN 7P bayonet 6m Straight Cable 7pol bayonet 3m MSC1258 11m cable PowerBox to Ma Batt MYC1204 1 8m Y Cabel Fw TPS1200 Batt Cabeling Wirtgen Milling Machine 3D prepared a b c TCPS27S radio modems Art no 737909 PWM cable for serial connection to TCPS275S Art no 776874 Straight Cable 7pol Art no 726089 Alarm box Art no 734166 Coiled Cable CAN 7P Art no 667345 Dual axis slope sensor Art no 667344 Wirtgen DLS controller Wirtgen machine cable PWM sensor cable Art no 726320 Machine cross slope sensor MPC1310 Art no 776882 H cable Power CAN connection Art no 776873 m Cable to machine Art no 667345 System Installation and Components PaveSmart 3D Milling TR 139 System Installation and Components PaveSmart 3D Milling TR 140 Cabeling Wirtgen Milling Machine 3D Hang on a TCPS27S radio modems Art no 737909 PWM cable for serial connection to TCPS275S Art no 776874 Straight Cable 7pol Art no 726089 Alarm box Art no 734166 Dual axis slope sensor Art no 667344 Coiled Cable CAN 7P Art no 667345 Junction box Art no 726314 Cable Art no 732682 Wirtgen DLS controller PWM sensor cable Art no 726320 Machine cross slope sensor MPC1310
11. Manual for further details Step Description l From the SURVEY Set Up Reference Station menu Setting up the Measurement Sensors PaveSmart 3D Milling TR 61 Setting up the Measurement Sensors PaveSmart 3D Milling TR 62 Using the coordinates from the last used reference station Step Description 2 SURVEY Set Up Reference Station Select the point to be used as reference station K A point may already be stored in the active job either by manual entry by measuring or by transfer from LGO Select the required point with known WGS 84 coordinates CS gt If anew point is to be created with known coordinates open the choicelist for lt Point ID gt and NEW F2 Enter the new point number and the known WGS 84 coordinates of the point CS If an existing point is to be edited open the choicelist for lt Point ID gt and EDIT F3 The coordinates and the point number of the existing point can be edited K If a new point with unknown coordinates is to be used refer to paragraph Using the coordinates from the last used reference station 3 Check the antenna height 4 CONT F1 to access SURVEY Survey Job Name Step Description The receiver must have previously been used as reference station After turning off the reference station coordinates are stored in the System RAM They can be used again the next time the receiver is used as a reference station Th
12. Measurements 99 8 2 Recording and Managing Logfiles 104 9 System Operation 106 9 1 Software and Calculation Description 106 9 2 Leapfrogging Swapping Total Stations 109 9 3 Search 114 9 4 Check 115 10 Offsets 116 10 1 Offset Conventions 116 11 Maintenance Tasks 121 11 1 Weekly Maintenance Tasks 121 11 2 Disk Check on MPC1310 Machine Computer 122 12 DLS Controller and Mobamatic 128 12 1 Operating the DLS Controller 128 12 2 Operating the Mobamatic Controller 130 12 3 Error Messages Controller 133 13 System Installation and Components 135 13 1 General 135 13 2 Machine Preparation Tasks 136 13 3 Hardware Descriptions 137 13 4 Machine Personal Computer MPC1310 147 14 Glossary Leica PaveSmart 3D 149 Index 157 Table of Contents PaveSmart 3D Milling TR 5 How to Use this Manual PaveSmart 3D Milling TR 6 1 Applicability of this manual Introduction to Leica PaveSmart 3D How to Use this Manual This Technical Reference Manual is for Leica PaveSmart 3D for use to control milling machines Conventionally milling machines are controlled for elevation and steering by a wire rope or sonic sensor Sometimes by a laser The wire rope is connected with the side blade and performs like a ski Sonic and side blade will be used to mill a copy from the existing surface with a constant milling depth By changing depth and cross slope the surveyor has to assign this at the surface The ground operator can then c
13. Menu Machine Dimension Menu Machine Dimensions fe 5 Head Width 1 0 570 m Mast Left Mast Right Height 7 Height 4 2 000 m 2 000 m Distance 6 Distance 3 1 000 m 1 000 m Width 5 Width 2 0 215 m 0 215 m O Without Mast Slope Without Mast Slope E CONT SLOPE BACK gt 4 o e eo To measure the dimensions the machine should be leveled in both directions The drum dimension 1 is given from the machine data The mast heights 4 and 7 will be measured from the working height of the drum to the antenna or prism We recommend holding a 3 4 m batten under neath the drum Measure from the prism centre or from the bottom of the GPS antenna Machine Configuration PaveSmart 3D Milling TR 29 Machine Configuration PaveSmart 3D Milling TR 30 Step Description 7 The prism or antenna positions 2 3 5 6 must be plumbed down and measured with a tape or meter to the drum centre This will do for both direc tions and both masts We recommend using a TPS to do this 8 It is possible to work without a mast slope sensor That means that there is no compensation of the mast long and cross slope This means that the posi tion which is interpolated from the antenna or prism to the design is less exact If the surface has a slope of 3 the influence could be as much as 4mm 3 3 Purpose Production Tolerance Defining Prod
14. Milling TR 54 Method Known Back If the coordinates of the instrument station are known Known Backsight Point allows sight Point Description setting the position and orientation of the instrument by taking a single measurement to a known backsight point Access step by step Step Description l Check the settings for the Fixpoint job in the start screen 2 SETUP F3 from the MGuide start screen to access Station Setup 3 SETUP Station Setup lt Method Known BS Point gt 4 Is lt Station Coord Frm Fixpoint Job gt e If yes continue with step 5 e If no continue with step 6 5 CONT F1 to access SETUP Select Station CONT F1 to access SETUP Set Stn amp Ori Known BS Point Following survey best practice always check the orientation of the system by turning the instrument onto a reference object with a known orientation after performing the Known Backsight set up tS Refer to TPS1200 Technical Reference Manual chapter Setup Methods for more informa tion on instrument setup 6 3 Description Access SETUP Results XX Stn Coords page Calculation Results The results of the TPS set up are displayed after a Resection or Known Back sight Point calculation have been carried out Press CALC F5 in the SETUP Measure Target XX screen This button is only available after the minimum number of fixpoints are measured The calc Results screen consists of the
15. Multiquadratic The method by which the residuals of the control points will be distributed throughout the transformation area lt GeoidModel gt Output Name of geoid model used as defined in DET C SYS Step 2 Choose Parameters STORE F1 stores the coordinate system to the DB X and attaches it to the lt WGS84 Pts Job gt selected in DET C SYS Determine Coord System Begin replacing any coordinate system attached to this job lt WGS84 Pts Job gt becomes the active job 6 9 Downloading Files to from the Instrument in LGO Downloading files from The Data Exchange Manager component of LGO can be used for transferring files to from the sensor the Sensor to the hard disk of your PC Download using Serial communication Access Step by Step Step Description l Connect the MNS1200 to the serial port of your computer using the datatransfer cable S With MNS1200 instruments ensure that the serial cable is attached to a port which is not configured to any other interface such as Real Time or NMEA S To configure a port on the MNS1200 sensor refer to the MNS1200 Technical Reference Manual From the tools menu select the Data Exchange Manager PE eae In the left hand side of the tree view open f the COM port node to which your instrument is connected Select the file you want to transfer Files can only be copied from a directory in the Files directory o
16. Or ne Ay A w A c a Set Design values Pwirtgen WW INA i b Automatic mode on off 9 Jo c Set current working offset as Zero Press both l J keys simultaneously d d Raise lower cylinder machine Meaning of the func cm The unit for the numerical data in the displays is centimetre cm tonal lamps inch The unit for the numerical data in the displays is Inch inch A Lamp to indicate manual or automatic mode e Lamp on automatic mode e Lamp off manual mode e Lamp flashes external automatic locking valve control locked This lamp has only a meaning when operating the multiplex unities e Lamp on Multiplex operation with multiple evaluation e Lamp off Single evaluation of the middle sensor Meaning of the keys Y lt lt gt o a TIC UP DOWN keys Set Use these keys to set the rated value independent of connected sensor UP DOWN keys Cylinder In manual mode use these keys to shift the cylinders by hand Automatic Manual key Use this key to toggle between manual and automatic mode Setup key Use this key to call the user menu Use the Automatic Manual key to exit the Setup menu UP DOWN keys Calibrate When in manual mode and with a distance sensor connected use this key to set the actual va
17. PaveSmart 3D the machine will always be controlled to the active stringline selected in elevation and slope and always relative to the current working direction of the machine On occasion it may be necessary to control the machine at a constant additional offset to the design in order to match into existing features not detected when the design was made adjust small errors which may have be introduced due to imperceptible movements of TPS instruments alter the amount of milling depth and slope sensor fine calibration In Leica PaveSmart 3D it is possible to change the elevation steer and slope offsets relative to the selected reference line Elevation Offsets er Elevation offsets are entered in the Work Offsets Elevation dialog Work Elevation Offsets Feroer 06 26 2007 17 03 Corrections Information Stationing oe m Speed Cte Li mimin Working Slope Design Slope 0 Elevation Cutting Depth m 4 0 007 m HERE R STEER SLOPE RESET BACK ioe eS amO If a positive Cutting Depth is entered the machine will be controlled below the design and if a negative offset is entered the machine will be controlled higher than the design The Cutting Depth works similar to a Set value at the controller but the Cutting Depth is regarded at the milling height Changes made to Working Offsets are instantaneous Ensure the milling drum will not strike the ground Offsets PaveSmart 3D Milling T
18. Stn Coords Sigma Stn Code and Plot page The explanations for the softkeys given below are valid for the Stn Coord and Sigma page Refer to TPS1200 Technical Reference Manual chapter Creating a New Point for infor mation on the keys on the Stn Code page to chapter Plot Mode MapView Screen Area for information on the keys on the Plot page Nis ERs TN IRN Soares a SN SRC a ASNN erat Sse Saka RARATAN Shaan Sa gt Sa SK Rates D R AREAS a Suse Re NOS ASSET Ska Rasta gt TARA DAAN Saka RNN SAL RAYA Sika REAR MA ANL a Rea kin A j BS RASA AED ASAE VEE SL SLNN SET F1 To set data selected in lt Set gt to set new geometric ppm if lt Use Scale Yes gt and to store all setup data and exit the application program COORD F2 To view other coordinate types ROBST F3 or LSQRS F3 To display the results for the robust or the least squares calculation method INFO F4 To display additional information about the accuracy of the measured target points and to delete inconsistent measurements in the SETUP Additional Information screen Setting up the Measurement Sensors PaveSmart 3D Milling TR 55 Setting up the Measurement Sensors PaveSmart 3D Milling TR 56 SURVY F5 To access SETUP Measure Target XX and tomeasure more target points PAGE F6 To change to another page on this screen SHIFT ELL H F2 or SHIFT ORTH F2 Changes between the ellipsoidal and t
19. another page on this screen SHIFT CONF F2 To configure auto points and hidden point measurements Accesses SURVEY Configura tion Refer to the GPS1200 Technical Reference Manual NARA a Wy SE NY Setting up the Measurement Sensors PaveSmart 3D Milling TR 69 Setting up the Measurement Sensors PaveSmart 3D Milling TR 70 Acess Step by Step Field Option Description lt Point ID gt Userinput The identifier for manually occupied points The configured point ID template is used The ID can be changed e To start a new sequence of point ID s overtype the point ID lt Antenna Ht gt Userinput The default antenna height as defined in the active configu ration set is suggested lt 3D CQ gt Output The current 3D coordinate quality of the computed position Step Description 1 Position the GNSS GPS GLONASS antenna over the fixpoints to be used in the transformation OCCUPY F1 all fixpoints to be used in the transformation STOP F1 to end the point occupation Repeat the procedure for all fixpoints 6 7 Description Transformation Transformation param eters Determining a New Coordinate System Transformation GNSS GPS GLONASS measured points are always stored based on the global geocentric datum known as WGS 1984 Most surveys require coordinates in a local grid system for example based on a country s
20. is the element used in describing a machine s draft The longslope is set automatically by the change in height along a Stringline Cross Slope Creating Stringlines for production Cross Slope describes the height change on the cross section of a stringline between elements In Leica PaveSmart 3D a single stringline can be given an orthogonal cross slope by projecting a plane through the stringline at a given angle in the Work offsets slope offset dialog Cross Slope may also be defined in Leica PaveSmart 3D by selecting an additional stringline to calculate the cross slope The cross slope is then calculated by the height difference between the Reference StringLine and the Slope Stringline If using a slope line additional cross slope may be added or subtracted from the design in the Work offsets slope offset The working slope is defined by the design cross slope a single stringline always has 0 cross slope plus the working slope offset Positive cross slope is defined as a clockwise rotation about the axis of the stringline in the direction of travel Negative cross slope is defined as a anti clockwise rotation about the axis of the stringline in the direction of travel Depending on the milling drum used this will form a catch or spill curb When creating designs only one stringline can be selected at any given time All calculations are then relative to this stringline Multiple stinglines can be created ona single layer
21. step 1 In SURVEY Survey Begin select a job or create a new job 2 Select a typical configuration set with lt R Time Mode Rover gt 3 Select an antenna 4 CONT F1 to access SURVEY Survey Job Name S The arrow at the real time device and real time status icon flashes when real time messages are being received E Fixing ambiguity begins The current position status is indicated by the position status icon When working with code only corrections an ambiguity solution is not attempted S The position mode icon is the moving icon This indicates that the antenna can be moved around and that no static observations are being recorded Ocupy points In the SURVEY Survey Begin menu occupy all fixpoints to be used in the transformation It is recommended that a minimum of 3 fixpoints are occupied with coordinates in the local system to perform the transformation SURVEY The fields shown are those from a typical configuration set for real time rover operations Survey Job Name The screen described consists of the Survey page and the Map page The explanations for Survey page the softkeys given below are sali for the Survey page SSS OCUPY F1 To start recording positions The position mode icon changes to the static icon F1 changes to STOP STOP F1 To end recording of positions when enough data is collected STORE F1 To store the point information H PNT F5 WH To measure a hidden point XU NNT ANEA sL PAGE F6 To change to
22. step by step 1 To perform a transformation in LGO open the Tool Datum Map tool In order to determine transformation parameters two sets of coordinates must be selected These two coordinate sets are always stored in the Projects directory Upon starting Datum Map the Selection View lists all available Projects in an upper and a lower Explorer View System A the upper view represents the points to be transformed System B the lower view represents the control or pass points into which System A is to be transformed Step Description To select two sets of coordinates e From the upper View select a Project as the system A This will contain the WGS 84 coordinates e From the lower View select a Project as the system B This will contain the local coordinates tr 6724 00 Em menas VEDE pye CMO SEE 2 The transformation type is displayed in the status bar between the upper and the lower window The default transformation type is the last used Configure the transformation type and parameters Refer to the LGO help files for more information on transformation types Setting up the Measurement Sensors PaveSmart 3D Milling TR 85 Setting up the Measurement Sensors PaveSmart 3D Milling TR 86 Step Description 3 The Match tab at the bottom of the view will be active once the two coordinate sets have been selected Click on this tab to continue er The Match View enables y
23. the transformation is to be applied It is not good practice to survey or convert coordinates outside of the area covered by the control points as extrapolation errors may be introduced Milling must not be carried out outside the area enclosed by the control points F ROA i j a Reference Line b Control points in Local and WGS coor dinate system with good distribution c Control points in Local and WGS coor dinate systems with unable distribu tion Setting up the Measurement Sensors PaveSmart 3D Milling TR 75 Setting up the Measurement Sensors PaveSmart 3D Milling TR 76 6 8 Description er Manually entering local coordinates Uploading local coordi nates from LGO Determine a New Coor dinate system Access step by step Determining a New Coordinate System Transformation Onboard the MNS1200 Sensor Before a transformation can take place onboard the MNS1200 sensor it is necessary to have both the local coordinate system information and the corresponding WGS 84 coordinates on the sensor MNS sensor must have the survey option enabled If a limited number of reference points are being used local coordinates should be manually entered onto the sensor before carrying out the transformation Care should be taken not to introduce transcription errors when entering the fixpoint coor dinates manually Refer to GPS1200 Technical Reference Manual for more information
24. 3 Version 2 0 English when it has to be Introduction PaveSmart 3D Milling TR 2 Introduction Purchase er Product identification Symbols Trademarks Congratulations on your purchase of the Leica PaveSmart 3D Machine Control System Leica PaveSmart 3D is an ideal tool for increasing productivity in milling applications To use the product in a permitted manner please refer to the detailed safety directions in the User Manual The type and serial number of your product are indicated on the label on the base of the product Enter the model and serial number in your manual and always refer to this information when you need to contact your agency or Leica Geosystems authorized service workshop Type MPC1310 Machine Computer SerialNo 2 ae Type MSS1201 Dual Axis Slope Sensor SerialNo 2 Type TCPS27S Ruggedised Radio Modem SerialNo 2 Type TCPS27S Ruggedised Radio Modem SerialNo 2 The symbols used in this manual have the following meanings Type Description S Important paragraphs which must be adhered to in practice as they enable the product to be used in a technically correct and efficient manner e Windows is a registered trademark of Microsoft Corporation e Wirtgen is a registered trademark of Wirtgen Group Germany All other trademarks are the property of their respective owners Table of Contents In this manual Chapter Page 1
25. Art no 776882 m H cable Power CAN connection Art no 776873 Cabeling PWM MOBA matic Hang on 3D a TCPS27S radio modems Art no 737909 b PWM cable for serial connection to TCPS275S Art no 776874 c Straight Cable 7pol Art no 726089 d Alarm box Art no 734166 e Dual axis slope sensor Art no 667344 f Cable slope sensor to junction box Art no 667345 g Junction box Art no 726314 h Cable Art no 731977 i MOBAmatic Controller Art no 726312 j Coiled cable PWM Art no 726320 k MPC1310 Art no 776882 Wiring on Machine connector pies H cable Power CAN connection mm o Vave UP y Art no 776873 I m Cable to machine Art no 667345 n Slope sensor PWM Art no pa aE rn Oa Wah TEE E tis uin Ie act hn 726313 oly R of L connectable System Installation and Components PaveSmart 3D Milling TR 141 System Installation and Components PaveSmart 3D Milling TR 142 Cabeling CAN MOBA matic Junctionbox 3D TCPS27S radio modems Art no 737909 b PWM cable for serial connection to TCPS275S Art no 776874 c Straight Cable 7pol Art no 726089 d Alarm box Art no 734166 e MOBAmatic Controller Art no 732659 f Cable 10pol Art no 732676 g Junction box Left Art no 766976 h Cable Art no 732675 i Coiled Cable CAN 7P Art no 667345 j Dual axis slope sensor Art no 667344 k Y Cable for Dual a
26. How to Use this Manual 6 2 Projects 10 2 1 The Projects Dialog 10 2 2 Recommendations and Rules for Designs 14 2 3 Rules for Defining Projects 16 2 4 Converting Data With the Design to Field Tool 18 3 Machine Configuration 23 3 1 Machine Profiles 23 3 2 Measuring the Machine Dimensions 27 3 3 Defining Production Tolerances and Stop Rules 31 3 4 Tuning the Machine 36 4 Radio Modem Configuration 39 5 Defining Measurement Sensors 41 5 1 Sensor Arrangement 4l 5 2 Sending a Start Tracking Command 44 5 3 Checking the Data Flow 46 5 4 Adding Serial Interfaces COM Ports 48 Table of Contents PaveSmart 3D Milling TR 3 Table of Contents PaveSmart 3D Milling TR 4 6 Setting up the Measurement Sensors 49 6 1 Instrument TPS Setup 50 6 2 Setting the Instrument TPS Orientation 52 6 3 Calculation Results 55 6 4 GNSS GPS GLONASS Solution 58 6 5 Real Time Reference Operations 59 6 6 Real Time Rover Operations 66 6 7 Determining a New Coordinate System Transformation 71 6 8 Determining a New Coordinate System Transformation Onboard the MNS1200 Sensor 76 6 9 Downloading Files to from the Instrument in LGO 83 6 10 Determining a New Coordinate System Transformation in LGO 85 6 11 Uploading a Trafoset to a GNSS GPS GLONASS Sensor with PaveSmart 3D 88 6 12 Preparing the GNSS GPS GLONASS Rover on the Machine for Milling 93 Setting the Operators Preferences 95 Quality Control 99 8 1 Taking and Recording As Built
27. If a large number of coordinates are being used to perform the transformation they may be uploaded directly from LGO Refer to GPS1200 Technical Reference Manual and LGO help files for more information Step Description l Select lt Method Normal gt 2 CONT F1 to access DET C SYS Step 1 Choose Transform Type QIN BA x i aes hy EES Se aoe ts A ARNE RASSY Serer EEE Sn L2 Re OREN REA Smits Ss SAG HQ tansa Wage Ser MABEHASAQ CONT F1 To confirm the selections and to continue No Ga N SSE withthe subsequent screen Description of Fields Field Option Description lt Transfrm Userinput A unique name for the transformation The name may be up Name gt to 16 characters in length and may include spaces If a coor dinate system is being updated then its name is displayed lt Transfrm Onestep The type of transformation to be used when determining a Name gt Twostep or coordinate system Available when determining a new coor Classic 3D dinate system Available when updating a coordinate system Output The transformation type shown is the same as the transfor mation used in the existing system lt Height Orthometric The height mode to be used in the determination of a coor Mode gt or Ellipsoidal dinate system Output Next Step CONT F1 continues to DET C SYS Step 2 Choose Parameters Setting up the Measurement Sensors PaveSmart 3D
28. Milling TR 77 Setting up the Measurement Sensors PaveSmart 3D Milling TR 78 Next Step DET C SYS Step 3 Match Points n The geoid model to be used in the transformation Geoid models from MANAGE Geoid Models can be selected CONT F1 continues to DET C SYS Step 3 Match Points n not required for One Step transformations This screen provides a list of points chosen from lt WGS84 Pts Job gt and lt Local Pts Job gt The number of control points matched between both Jobs is indicated in the title for example DET C SYS Step 3 Match Points 4 Unless there is no pair of matching points in the list all softkeys are available a ee wne CALC F1 a Ra L To confirm the selections compute the transfor SSeS Soc SS mation and continue with the subsequent AERAN RA Ss Nana Ss screen SOS aR Ba NEW F2 To match a new pair of points This pair is added to the list A new point can be manually occupied EDIT F3 To edit the highlighted pair of matched points DEL F4 Si To delete the highlighted pair of matched points EE ESE WS from the list MATCH F5 To change the type of match for a highlighted pair of matched points Refer to Description of columns AUTO F6 To scan both jobs for points that have the same point ID Points with matching point ID s are added to the list Description of columns er Next step Column Description WGS84 Pts The point ID of the point
29. R 117 Offsets PaveSmart 3D Milling TR 118 Steering Offsets Steer offsets are entered in the Work Offsets Elevation Offsets Steer Offsets dialog If a positive offset is entered the steering value will be indicated to the right of the design and if a negative offset is entered to the left of the design A reference at the machine can be chosen for Left Right or centre The indication is along this parallel line to the reference line Work Elevation Offsets Steer Offsets kollfj_dal 08 09 2007 09 08 Corrections Information Stationing ft Speed mimin Working Slope 0 Design Slope 0 Offset Reference ci og mBo HERE ELEVATION SLOPE RESET BACK ees we fy tT e eo The steering value is just a indication An automatic steering is not implimented at the current milling machines Cross Slope offsets Cross Slope offsets are entered in the Work Offsets Elevation Offsets Slope Offsets dialog If a positive cross slope offset is entered a clockwise rotation will be applied If a negative cross slope offset is entered an anti clockwise rotation will be applied Regularly the cross slope is given from the design but in the case of a cross slope deviation of the machine slope the offset can be used instead of a sensor calibration The Cross Slope offset values may be adjusted with the arrow buttons or with the number pad by clicking inside the field Work Elevation Offsets Slope Offset
30. RFSET DAT gt in the DBX folder of the USB storage device Setting up the Measurement Sensors PaveSmart 3D Milling TR 89 Setting up the Measurement Sensors PaveSmart 3D Milling TR 90 cE e If you don t have a Leica Coordinate System available but all the transformation param eters it s possible to create a new Coordinate System by entering all the parameters Please refer to the LGO help function e Anew Coordinate System can also be calculated in LGO from previous GNSS GPS GLONASS measurements taken on site Please refer to 6 10 Determining a New Coor dinate System Transformation in LGO e It s very important to check with an RX1200 terminal on the MNS1200 sensor if the correct Coordinate System is selected Furthermore it s recommended to verify your Coordinate System on the job site by measuring some control points before commencing milling Uploading the Trafoset Open the following dialog Menu Projects Exchange with PaveSmart 3D Sensor Upload fe z Transfer Object Type Transformation Set j Object TRFSET DAT 3j Sensor 4 GNSS P 31 CONT BACK i om re The lt Transfer Object Type Transformation Set gt is set by default and can t be changed In lt Object gt the Transformation Set lt TRFSET DAT gt is shown It has to be selected so the background colour is displayed in black Setting up the Measurement Sensors PaveSmart 3D Milling TR 91 Setting up the Measurement Sensor
31. System Summary page Store F1 To store the coordinate system to the DB X and return to GPS1200 Main Menu PAGE F6 To change to another page on this screen NSRSSR NRE NSS OS SO Description of Fields Field Option Description lt Name gt User The name of the coordinate system can be changed The input name may be up to 16 characters in length and may include spaces Setting up the Measurement Sensors PaveSmart 3D Milling TR 81 Setting up the Measurement Sensors PaveSmart 3D Milling TR 82 Next Step DET C SYS Step 5 Store CordSystem Coord System page Next Step Field Option Description lt Transfrm Output The type of transformation used as defined in DET C SYS Type gt Step 1 Choose Transform Type lt MatchedPts gt Output Number of matched points as defined in DET C SYS Step 3 Match Points n lt Easting gt Output Largest Easting residual from the transformation calculation lt Northing gt Output Largest Northing residual from the transformation calculation lt Height gt Output Largest Height residual from the transformation calculation PAGE F6 changes to the Coord System page Refer to paragraph DET C SYS Step 5 Store CordSystem Coord System page For lt Transfrm Type Onestep gt Description of fields Field Option Description lt Residuals gt None 1 DistanceXX or
32. System Installation and Components PaveSmart 3D Milling TR 146 GNSS GPS GLONASS Further Reading Wiring Diagrams The GNSS option uses the MNS1230 machine navi gation sensor GPS and GLONASS with power protection and milconnectors For further information refer to the MNS1200 User Manual Art no 748105 Antenna Art no 753221 The MNA1202 GG antenna mounted on the mast Sateline radio modem GNSS GPS GLONASS Assist option works with the Satelline radio modem FreeWave radios or other 3rd party products may be used as an alternative Cabling Art no 667399 Antenna spiral cable 6m Art no 744686 or Radio modem cable 6m 639968 For further details on each component listed below refer to the specific component manual mentioned in each section For system wiring diagrams refer to the Leica PaveSmart 3D User Manual 13 4 Machine Personal Computer MPC1310 MPC1310 LAN connector Ventilation cap USB A Host connector COM 1 port Keyboard connector 2A fuse for outgoing power USB B Device connector COM 2 port COM 3 CAN 1 port COM 4 CAN 2 port k Power connector 1 Power key USB USB connection Leica Geosystems USB storage device or standard USB keyboards recommended only ce Never remove the USB storage device until file read write copy opera tions are completed as this may cause file loss or corruption System Installation and Components PaveSmart 3D M
33. TORE F1 stores the new point and all associated information and returns to SURVEY Set Up Reference Station The properties stored with the point are e Class NAV e Sub class GPS Code Only e Source Survey Static e Instrument source GPS 6 SURVEY Set Up Reference Station The coordinates of the new point are displayed Check the antenna height 7 CONT F1 to access SURVEY Survey Job Name The appearance and functionality of the screen is identical for all real time reference config uration sets Display masks cannot be used for real time reference configuration sets OU MA Bardot Re g a RS N SAGARA oa S Soa S ss INL SS AAA WY WE A STOP F1 To end the point occupation store the point NoN MASDAN and to return to GPS1200 Main Menu Description of flelds Field Option Description lt Point ID gt Output The identifier for the reference station point lt Antenna Ht gt Output The antenna height as entered in SURVEY Set Up Refer ence Station is displayed lt Time atPoint gt Output The time from when the point is occupied until point occupa tion is stopped lt GDOP gt Output The current GDOP of the computed position Next step STOP F1 to end the point occupation store the point and to return to GPS1200 Main Menu Setting up the Measurement Sensors PaveSmart 3D Milling TR 65 Setting up the Measurement Sensors PaveS
34. The Spare sensor at COM4 can be chosen also if no TPS is connected Selecting the Sensor Arrangement It is essential that the correct sensor arrangement is defined before paving commences The Sensor Arrangement dialog is available in Menu Sensors Arrange or via the short cut Work Sensors Arrange If using a One TPS solution select the lt Secondary Sensor gt to lt None gt The orientation of the machine will be calculated parallel to the design The secondary communication port is not used in this application Menu Sensor Sensor Arrangement fe r Sensor Arrangement Primary TPS COM k f Secondary O TPS E None COM2 ly Spare Sensor COMS3 ry Leapfrog Parameters Leapfrog Tolerance 0 197 ft o Take over from shortest measuring distance CONT eack i 4 O 8 o If using a Two TPS solution select the lt Secondary Sensor as the lt TPS gt If using the GNSS GPS GLONASS assist solution select the lt Secondary Sensor as the lt GNSS gt The GNSS sensor is automatically allocated to the secondary communication port Defining Measurement Sensors PaveSmart 3D Milling TR 43 Defining Measurement Sensors PaveSmart 3D Milling TR 44 5 2 Sendinga start tracking command Sending a Start Tracking Command After defining the sensor arrangement the TPS and GNSS GPS GLONASS sensors are ready to send 3D Position data to Leica PaveSmart 3D All sensors which have been c
35. This may be useful if the line of sight to the reflector is temporarily obstructed during the course of milling From the Work Sensor dialog select the sensor which is to search for the prism and press the search button The search button is deactivated while the system is in control and if no sensor has been selected A command is sent to the TPS to perform a search based on the settings in the MGuide appli cation For more information refer to the MGuide User Manual cS The search function is not required with a GNSS GPS GLONASS sensor 9 4 Check Introduction Observing survey best practice is the key to maximum milling accuracy with Leica PaveSmart 3D Poorly positioned or orientated instruments may have a serious effect on milling quality The Check procedure should be carried out regularly ideally during breaks in milling operations for example while waiting for trucks to ensure no undetected movement of the total stations has occurred which may be due to excessive vibrations bad sub ground of the tripod high wind temperature cycling effects etc This is also very important when the instrument has been standing for a long time gt 2 hr at the same setup For more information on performing check measurements refer to the Leica PaveSmart 3D User Manual System Operation PaveSmart 3D Milling TR 115 PaveSmart 3D Milling TR 116 Offsets 10 Offsets 10 1 Offset Conventions Introduction When using Leica
36. Warning System Installation and Components General Unauthorized modification of machines by mounting the 3D Control System may alter the function and safety of the machine Always follow the instructions of the machine manufacturer If no appropriate instruction is available ask the machine manufacturer for instructions before mounting the 3D Control System Even though the hardware components are designed for rough conditions the components have to be treated and transported in a careful manner Therefore always use the desig nated packaging for transport and study the relevant documentation for cleaning and main tenance work The installed components on the machine comprise a Machine Computer with attached Radio Modem s to communicate with the Total Station s Dual Slope Sensor mast with attached prism or optional GNSS GPS GLONASS Sensor As well as the installed components on the machine TPS s with radio modem s need to be set up In case of a Hybrid GNSS GPS GLONASS TPS System a combination of this two different measurement techniques is needed System Installation and Components PaveSmart 3D Milling TR 135 System Installation and Components PaveSmart 3D Milling TR 136 13 2 General System Instal lationSteps Machine Preparation Tasks Check the Leica compatible machine controller software DLS 207 3 or higher and Mobamatic V 3 28 Check the power availability independent from the engine M
37. a DBX Road job format System1200 There may be multiple stringlines on multiple layers The Leica PaveSmart 3D Job contains the current StringLine in a DBX Road job format System1200 For an easier handling in Leica PaveSmart 3D there are several restrictions to a Leica PaveSmart 3D StringLine job A Leica PaveSmart 3D layer is the same as a System1200 DBX Layer In Leica PaveSmart 3D one Layer represents one curb amp gutter object In a Leica PaveSmart 3D Layer we always need a Reference Line selected from the stringlines contained in the layer The current selected Layer defines with its Reference Line to which object the relative position of the machine is calculated to A slope line may also be selected to calculate cross slope A Leica PaveSmart 3D object is a single 3D Stringline The Reference Line is the line which the machine drives along in position and in height The long slope and cross slope of the machine is calculated to the Reference Line If there is no default Reference Line in a StringLine Job it must be selected before paving commences Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 155 Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 156 SlopeLine DXF file DXF Layer not the same as a DBX layer Entity The SlopeLine is used for the height calculation and regulation of the cross slope If there is no default SlopeLine in a StringLine Job the machine operator has to choose it bef
38. activated or deactivated by selecting the appropriate check box vating stop rules Be The measurement timeout Stop rules can not be deactivated S It is recommended that no milling operations should be undertaken without all of the Lock and Stop Rules turned on Machine Configuration PaveSmart 3D Milling TR 35 Machine Configuration PaveSmart 3D Milling TR 36 3 4 General Tuning the Machine The hydraulic behaviour of every machine is different due to the type of the machine the machines hydraulics or the tolerances required etc Although the biggest influence comes from the different sensors because of this every machine needs a different tuning if the sensors are changed For this different tuning settings like sensitivity and dead band are stored in the controller With the identification of the sensor the controller automatically chooses the proper tuning set For special solutions Leica PaveSmart 3D has additional tuning features Especially for milling applications with GNSS GPS GLONASS sensors the tuning is necessary because the controller has no distinction between TPS and GNSS e With standard milling machines using TPS there is no need to use this feature e The tuning has to be done by Leica support The tuning parameters dialog Menu Machine Tune Elevation can be changed while the machine is in control and moving Because there is no automatic steering at standard milling machines the tuni
39. and all stringlines on one layer will be displayed in the graphic The active stringline is then graphi cally selected in the Work design dialog Multiple layers can be imported into Leica PaveSmart 3D but only one layer can be displayed at a time Projects PaveSmart 3D Milling TR 13 Projects PaveSmart 3D Milling TR 14 2 2 Introduction CAD Layers Recommendations and Rules for Designs Leica PaveSmart 3D works with DBX data DBX is a Leica proprietary file format that is based on LandXML A number of CAD software packages support the DBX file format and PaveSmart 3D designs can be created directly within these packages It is also possible using Leica Geomatics Office LGO or Leica SiteSmart Translator late 2006 onwards to convert DXF or other supported CAD format files into the DBX format Independent of the data source or the method used to convert the data into the DBX format there are several important aspects to be aware of in the design creation to assure good production results The following recommendations are not restrictions by the soft ware but more by the machine geometry and behaviour or the general production workflow and machine Refer to the LGO User Manual for further details of data file formats supported CAD design layers with multiple stringlines are handled in Leica Geo Office and Leica PaveSmart 3D the same as they are in conventional CAD packages In Leica PaveSmart 3D only one
40. ce open the lt Coordinate System gt window Coordinate Systems lt Import Coordinate System gt by right clicking on the Coordinate Systems folder Coordinate System Management Contents C Coordinate Systeme R New 3 Transformations ike Oe ol ae Import Coordinate System ri i i 4 Ellipsoids Save As 3 Projections Print CtrHP State Plane Zones ging CtrrtF i J Geoids CSCS Models Once the Coordinate System is in LGO it has to be renamed to lt MA_COORD gt The correct name is very important for the whole successful transfer process to the GNSS GPS GLONASS sensor Name Last Modified Transformation Transformation Resid Kein 01 13 2006 15 44 25 09 09 2005 11 09 03 z z a TSite 06 21 2007 16 57 34 TSite Onestep No dis wes 1984 09 09 2005 11 09 03 g 2 After renaming the Coordinate System it is sent to the USB storage device by right clicking on the name Name ___Last Modified Transformation Transformation Residuals Local Ellip Projection 01 13 2006 15 44 25 4 g z New TSite wes 1984 inestep No distrib Import Coordinate System Modify Delete DEL Save As Print Ctrl P Find Ctr HF Send To HardDisk gt CF Card gt 1200 GPS Properties Alt Enter Ee a ASPENA ae R t E UIE Finally you have the file lt T
41. cess taskmar exe winlogon exe Processes 20 cru Usage 5 Commit Charge 174376K 239580 4 Start the Windows Explorer Programs Startup ba plc B taskmor 47 Notepad gt Onscreen Keyboard I Leica PaveSmart 3D gt Help and Support F Snagit 6 gt Maintenance Tasks PaveSmart 3D Milling TR 123 Maintenance Tasks PaveSmart 3D Milling TR 124 Prepare Check Disk Select the drive c File Edit View Favorites Tools Help Qe O B P n E rowers i gt X Address me c Folders x E Desktop Documents and Sel E 3 My Documents Program Files a My Music winoows B My Pictures BOOTEX E My Computer EinroeteEcT E TERNAL C a ntidr E THOMAS D R E WeRUNTIME G Control Panel Shared Documents Administrator s Documents Lo My Network Places Recycle Bin Open File Properties Fj Edit view Favorites Tools Help JO search gt Folders is Ez x Greate Shortcut Delete Reni Documents and Set Program Files winpows la BooTex intoetect E ntldr WERUNTIME My Computer INTERNAL C THOMAS D G Control Panel Shared Documents E O Administrator s Documents a My Network Places Recycle Bin Select Tools and press Check Now INTERNAL C Properties Maintenance Tasks PaveSmart 3D Milling TR 125 Maintenance Tasks Pa
42. chine Type gt is selected by default depending on the Profile you have chosen to copy previously Machine Configuration PaveSmart 3D Milling TR 25 Machine Configuration PaveSmart 3D Milling TR 26 In lt Machine Model all of the supported models of the selected manufacturer are avail able The lt Controller gt depends on the Machine Model and can be selected in the last field e The new machine has to be set up in the same way as a new installation is carried out All the machine relevant settings are stored in the Profile so after a Profile change all machine specific settings are re activated An easy switch of the PaveSmart 3D system between different machines is possible e Depending on the Machine Type the user interface of PaveSmart 3D changes slightly as not every function is useful for all the different machines 3 2 General er Mast and slope sensor position Measuring the Machine Dimensions The Machine Dimension procedure is the process of linking all of the measuring components into one system to control the machine including the milling drum Sensor Masts and Slope Sensor A change of the machine dimensions is needed whenever the relative position changes between the drum and the machine masts This includes moving the mast up down or moving the mast positions If the position of the slope sensor changes the sensor needs a new calibration It is recommended this procedure is repeated befo
43. d as reference station Available when the receiver has previously been used as reference station and if no point in the active job has the same point ID as the one last used as reference station HERE F4 To use the coordinates of the current naviga tion position as reference station coordinates SHIFT ELL H F2 or SHIFT ORTH F2 To change between the ellipsoidal and theo rthometric height Available for local coordi nates Field Option Description lt Point ID gt Choicelist The point selected as reference station Opening the choicelist opens SURVEY Data Job Name which is similar to MANAGE Data Job Name Enter GNSS GPS GLONASS base station coordinates Using a known point stored in the active job Field Option Description lt Antenna Ht gt User input The default antenna height as defined in the active config uration set is suggested Changing the antenna height here does not update the default antenna height as defined in the active configuration set The changed antenna height is used until the application program is exited The reference station coordinates can be entered in four different ways IF the coordinates of the reference station are known are those from the last used reference station are those of the current navigation position using a known point stored in the active job CS Refer to Leica GPS1200 Technical Reference
44. d ensure that it is communication with Leica PaveSmart 3D and they are in the MGuide lt Tracking gt Screen 2 Before swapping a TPS the machine must be stationary and out of active control If the machine is moving the spare instrument will not be able to lock onto the prism and erroneous measurements may result 3 Enter the lt Work Sensors Leapfrog gt dialog The leapfrog will automatically take place and the spare TPS will turn to the Primary or Secondary prism depending on the settings in the lt Leapfrog parameters The TPS which has just been swapped will start tracking automatically 4 A calculation between the coordinates of the old sensor measurement and the new sensor measurement is carried out If the deviation is less than the specified in the lt Leapfrog parameters gt Leica PaveSmart 3D will prompt the user to select a method for dealing with the deviations between the two measurments Auto 3D is the recommended method to prevent steps appearing in the finished product System Operation PaveSmart 3D Milling TR 111 System Operation PaveSmart 3D Milling TR 112 Step Description Work Sensor TPS Leapfrog Software_Room fi ra TPS Leapfrog Diff in Prism Position XY 3 05 Machine steers right Diff in Prism Elevation Machine moves up Position Info To prevent risk of steps in the surface Choose Auto 3D Auto 3D Auto St ACK eo lt
45. e e Setting to zero Press the enter or UP DOWN keys until SEt is displayed and then 0 0 Is and Design values are set to zero DLS Controller and Mobamatic PaveSmart 3D Milling TR 131 DLS Controller and Mobamatic PaveSmart 3D Milling TR 132 Slope sensors 1 Set screed drum to initial position Preset project data to about j 1 5x the thickness of layer depending on the type of machine used 2 Manually preset Design values With 3D sensor connected the SP control parameter must manu ally be set to Hd Without 3D sensor it is automatically set to Hand The UP DOWN keys changes the Design values 3 Automatically preset Design value With 3D sensor connected the SP control parameter must manu ally be set to A The steering automatically adjusts to any changes in Design value cE To make the distinction the Design value flashes on the control display The Design value cannot be chaged with the arrow keys 12 3 Error Messages Controller Error messages Error message Error diagnoses Controller line out Countermeasures no SEn Controller does not recognize any sensor Line out blocked in automatic mode e Connect sensor e Check and replace connecting cable e Replace sensor e Connect mast sensor machine computer e Update controller SW Err 3d Tracking does not work error message on machine computer Line out blocked in automatic mode e Correct machine comp
46. e independent calibration value to the machine slope sensor Stationing shows current Stationing or Chainage in m or ft Opposite Stationing shows the inverted Stationing or Chainage the difference to the end in m or ft Speed indicates current Speed of the machine in m min or ft min Design display shows the whole project and the current machine position System Operation PaveSmart 3D Milling TR 107 System Operation PaveSmart 3D Milling TR 108 SENSORS a h open the Sensor dialog to manage the TPS and GNSS GPS GLONASS sensors i Zi open the Offset dialog to set the working offsets relative to the stringline MENU j open the Menu dialog to configure the Leica PaveSmart 3D software TUNING D open the Tuning dialog to set the hydraulics parameters for the machine EXIT I press and hold for more than 1 second to stop Active Control and in a second step to close the software and shut down the MPC1310 Do not power off the MPC1310 by holding down the Power Key Always shut down the MPC1310 by using the Exit button to ensure all important project data are saved 9 2 Purpose Adjusting the working Offsets Leapfrogging Swapping Total Stations Leapfrogging refers to the method of swapping measurement from a machine prism froma TPS primary in active control to the spare TPS This is usually required when the machine has reached a predetermined distance away from the total station
47. eck the Free Wave radio settings open the Free Wave configuration tool in Menu Tools Fwave Conf Choose the port number your radio modem is attached to and press Read From Radio The configuration tool will displays the currently stored settings Refer to the Free Wave Radio Manual chapter Quick Start on a Point to Point Network 5 a1 Definition of the Meas urement Sensors Definition of the serial COM ports Defining Measurement Sensors Sensor Arrangement The Leica PaveSmart 3D Curb amp Gutter application can be used with two different sensor combinations The appropriate sensor combination will depend on the application the system is being used for A sensor combination is possible in the case for a parallel running as build check and leapfrogs TPS Solution Is the standard solution for exact 3D milling Depending on the instrument distance a milling accuracy of 1 2 mm is possible The limitation is given from the measurement distance and from frequently occurring leapfrogs This can slow down the milling process The solution is useful for accurate design milling A secondary TPS can be used for as build checks and take over control after the distance is exceeded GNSS GPS GLONASS Solution Ideal for design milling with decreased tolerances K This option is not appropriate if the GNSS availability is not guaranteed such as in urban canyons heavily built up areas heavily vegetated areas or where milli
48. ed Further Reading Refer to Leica GPS1200 Technical Reference Manual for further details 6 5 Real Time Reference Operations Description To enable differential positioning a GNSS GPS GLONASS base station must first be estab lished Requirements e A typical configuration set for real time reference operations e Areal time interface configured correctly e The real time device must be attached to the receiver and working properly Station Access step by step Step Description 1 In the SURVEY application on Survey Begin screen select an existing job if an appropriate one exists or create a new job Select a typical configuration set with lt R Time Mode Reference gt Select an antenna CONT F1 to access SURVEY Set Up Reference Station Setting up the Measurement Sensors PaveSmart 3D Milling TR 59 Setting up the Measurement Sensors PaveSmart 3D Milling TR 60 SURVEY Set up Reference Station The settings on this screen set the reference station and its coordinates arn S Se Doe SNe QOS QS NER ASSN Ss BASS A RADA ARMA AER RON amp R x CONT F1 To accept changes and access the subsequent screen The chosen settings become active COORD F2 To view other coordinate types Local coordi natesare available when a local coordinate system is active LAST F3 To use the same coordinates as when the receiver was last use
49. ed is 1 arc second For further information refer to the TPS1200 User Manual Art no 737451 737455 737463 CF Card Art no 733256 CF Card storage device to up and download data to and from the Total Station Power Cable Art no 734697 Power cable to connect the Total Station with a GEB171 Long Life Battery Battery Art no 727367 GEB171 External universal battery NIMH 12V 9Ah rechargeable Battery Charger Art no 733271 Universal charger for external and internal batteries For further information refer to the GKL221 User Manual Tripod Art no 667301 Tripods for the TPS1200 total stations Tribrach Art no 667304 GDF121 Pro Tribrach for TPS1200 total stations TCPS27S Radio Modems Art no 737909 TCPS275S radio modems with robust connectors are used on the machine and communicate with the TPS1200 radio handle mounted onto the instrument For further information refer to the TCP27S User Manual FreeWave Radio Modems Art no 8214737 FreeWave radio modems can be used as an alternative to the TCP27 and Radio handle for communication between the MPC1310 and the measurement sensors Freewave radios require either removable Flex ible Antenna Art no 8218706 or permanently mounted Whip Antenna Art no 8205634 Reflector Prism Art no 756637 MPR122 360 Reflector PRO System Installation and Components PaveSmart 3D Milling TR 145
50. ed on the machine In addition to the components mounted on the machine two TPS instru ments are required and or a GNSS GPS GLONASS reference station if using the GNSS assist option without an available correction signal Details on each component are listed below Refer to component specific manuals for further details The MPC1310 is a ruggedised computer with Windows XP Embedded touchscreen milspec connectors for power CAN four serial RS232 and USB interfaces Bracket to mount Machine Computer for easy installation and removal at the end of the day a power supply for office prepara tion a carry case and a USB CF Card adapter are all supplied as part of the MPC1310 package For further information refer to the MPC1310 user manual System Installation and Components PaveSmart 3D Milling TR 137 System Installation and Components PaveSmart 3D Milling TR 138 USB Data Stick Art no 777172 USB Data Storage device for exchanging Projects Jobs Logfiles etc between office and machine s Cabling Art Art Art Art Art Art Art Art Art Art no no no no no no no no no no 767518 776873 776874 776875 776877 777179 667345 726089 762356 746616 MSC1328 Kabel MPC1310 PWRBox no PWR 7m MYC1304 H Cable MPC1310 CAN to Alarmbox 35cm MCC1301 Coiled Cable MPC1310 COM1 amp 2 to TCPS27S Cannon 6m MCC1302 Coiled Cable MPC1310 COM1 amp 2 to
51. eeeeeeeeeeees 58 C H CAD aches eieleteleleledalelelelaleivlelelelileeed cul aaa aaa Hai HardWare ainn rrr cerr a terertr 137 Calculation Results ceeeeeecceeeeeeeeeeeeeeeeeeeeaaeeeeeeeeeeeeeaes 55 K MOCK 4 sececvieterieiedl anaa aa aa a 115 i COM POF S nassisti ictinatiatn nian E E a r ad CONFIQUATION ook eeeeeeeceeeeeeeteetttcteeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 23 Known Backsight POIN ssssssstsissssersrsssstnrtrrtstennetr tennt gt l Control POINTS aeccncrrirrriiri irri riran ran ONAA ON 75 L Coordinate c aiiisiieediesiiees ti enatenesesmnsensennennatanudaieds 71 O Leapfrog fest dina craslnclecadnsdavadlsntd dined 109 110 111 COEG ONT sia fsketalahes ithe ctietdi eee eoslieliadicacbieeereeeeentie K OE WEG ccs hese heehee 19 72 76 83 85 Cross SIOPC es sects teeereeeteeeeeeeneeseeeetens 13 120 Local coordinates o e eeeecececessssesetststeesceceesesesesesetseececeeaes 76 D Logfiles occ eeeecccec ccc eeeeeeeeeeeeeeeaaeeeeeeeeeeeesaaaaeeeeees 104 105 Data TOW zienien aiaa ia 46 long SIOPC soseesstesssteessstesssteeesntessneesnntessnecenateesaecenaaes I Date And Time eeceeeeeeeeeaeeeteeeeeeeeeeeeeeaaaeeeeeeeeeeeaas 97 DEX at nna ie wants A ae TEE 18 21 22 Design to Field ccceeeeeeeeceeeeeeeeeeeeeeeeeeeeaaaenees 18 19 DFA eee ere eer er eee ere ere cre er mee ort ane nee men 20 DXR eek es i eee ie ee ae 21 Index PaveSmart 3D Milling TR 157 Index PaveSmart 3D Milling TR 158 M Machine C
52. eo Office software package select lt Design to Field gt from the lt Tools gt menu Projects PaveSmart 3D Milling TR 19 Projects PaveSmart 3D Milling TR 20 Selecting the Import Type Choosing the DFX Elements er ee Deanas EzE ne een a Select lt Import Type Road Data gt This is the only lt import type gt supported by Leica PaveSmart 3D If you work with DXF data then choose lt Importer DXF Importer road gt If working with an alternative file type select the appropriate importer Manage In the Manage dialog additional import formats can be added Import doae Confirms the selections and continues After selecting the DXF file to be imported a list of the layers containing polylines is displayed Take care to select the correct Units usually either Metric Metres or English US Feet before importing data Leica PaveSmart 3D requires 3D polylines to enable elevation control Converting the DXF DXF Converter Wizard x DXF elements Select elements to import Select the layers to import DXF File Linear Units POLYLINES i US Foot X DESIGN DESIGN_ANNOTATION DESIGN_PERIMETER REPORT_REGIONS SECTIONAL_AREAS Line ID prefix Line_ lt Back Cancel lt Select the layers to import gt to the Leica PaveSmart 3D software A layer will be created in the DBX job with the same name as the dxf layer and will contain all of the p
53. estep Characteristics Description Principle Transforms coordinates directly from WGS 1984 to local grid and vice versa without knowledge about the local ellipsoid or the map projection Procedure 1 The WGS 1984 coordinates are projected onto a temporary Trans verse Mercator projection The central meridian of this projection passes through the centre of gravity of the common control points 2 The results of 1 are preliminary grid coordinates for the WGS 1984 points 3 These preliminary grid coordinates are matched with the local grid control points in order to compute the Easting and Northing shifts the rotation and the scale factor between these two sets of points This is known as a classic 2D transformation 4 The height transformation is a single dimension height approxima tion Positions and The position and height transformations are separated Heights Use When measurements are to be forced to tie in with local existing control For example A site where the coordinates of the control points are based on a purely local grid The coordinate values within this grid are totally arbitrary and are in no way connected with any ellipsoid or map projection Characteristics Description Requirements The position is known in WGS 1984 and in the local system for at least one point Three or more points are recommended in order to obtain redundancy Additional height information for one point enable
54. f either the PC Card or Internal memory device isso pio a psa mo WENN Ainaa In the right hand side tree view of the Data Exchange Manager open the Files folder of the My Computer location and select the sub directory where the files will be transferred to Setting up the Measurement Sensors PaveSmart 3D Milling TR 83 Setting up the Measurement Sensors PaveSmart 3D Milling TR 84 Step Description 5 Drag and Drop Copy and Paste the file to the selected sub directory on your hard disk er The same procedure is used for copying file back onto the sensor er Select the file with coordinate details of the WGS 84 control points and copy it to the projects folder on the hard drive of the computer The LGO software can now be used to perform a transformation on the GNSS GPS GLONASS data If the local fixpoints coordinate file has not been created in LGO then another project must be created containing details of the local coordinate system This is carried out by e Connecting the TPS instrument and downloading the details from the TPS e Transferring data from the memory card held in the TPS via a memory card port e By importing an ASCII file into a new job in LGO For more details refer to the TPS1200 User Manual and the LGO help files 6 10 Determining a New Coordinate System Transformation in LGO Performing a transfor mation in LGO Access
55. fferent sensors The appropriate sensor will depend on the application the system is being used for Asensor combination is possible in the case for a parallel running as build check and leapfrogs TPS solution e Is the standard solution for precise 3D milling Depending on the instrument distance a milling accuracy of 1 2 mm is possible The limitation is given from the measurement distance and from frequently occurring leapfrogs This can slow down the milling process e The solution is useful for accurate design milling e Asecondary TPS can be used for as build checks and take over control after the distance is exceeded GNSS GPS GLONASS Ideal for design milling with decreased tolerances solution e This option is not appropriate if the GNSS availability is not guaranteed such as in urban canyons heavily built up areas heavily vegetated areas or where milling needs to be placed near or under existing structures e A TPS can lock on to use for as build checks right away behind the machine Therewith the absolute height of the milled surface can be monitored Setting up the Measurement Sensors PaveSmart 3D Milling TR 49 Setting up the Measurement Sensors PaveSmart 3D Milling TR 50 6 1 Overview S Description Instrument TPS Setup The overall accuracy of milling using Leica PaveSmart 3D is greatly influenced by the instru ment set up procedure The procedure uses a known fixed points reference poi
56. for example 100 m 300 or an obstacle blocks the line of sight to the prism A Leapfrog is a fully automatic process but the user may choose to adjust the Working Offsets to accommodate any change in Deviations due to inbuilt errors in the Fixpoint Refer ence Point network or where instruments have been allowed to stand for a long period of time at one location and the quality of the TPS setup and orientation has deteriorated due to factor such as vibration high wind thermal expansion contraction effects etc In Leica PaveSmart 3D the Work Sensors Leapfrog is able to automatically adjusts the Working Offsets to produce new Deviations which are inside the deadband of the machine This will prevent steps in the surface of the material when the machine moves again The user can choose to override this feature and make manual adjustments to the Working Offsets if desired The maximum operating distance between instrument and machine will vary according to e Temperature e Humidity e Weather Conditions e Air Quality Leica Geosystems recommends a maximum distance from instrument to machine of 200 m 600 however this is often not achievable due to the above influences It is the customer s responsibility to ensure that construction tolerances and required surface smoothness are being achieved and to regulate the maximum measurement distance accordingly System Operation PaveSmart 3D Milling TR 109 System Operation
57. ght Steer 0 060 to 0 060 m E Elevation 0 010 to 0 010 m ao eq s ope 01 tof 01 No of Rule breaks before the Machine Stops DEFAULT BACK L a eo S All Stop Rules depend on accurate instrument setup and orientation and react to an apparent error condition instantly They should not be switched on until the machine is inside the project area and within the lt Production Tolerance gt for example on or around zero deviations Also the lt No of Rule breaks before Machine Stops gt should usually be set to 10 to prevent for example an erroneous measurement from a total station or GNSS causing an unwanted 3D ERROR Travel Speed Locks Measurement Timeouts lt Travel Speed Locks gt are used to freeze the hydraulic cylinders while the machine is stationary This is to prevent small fluctuations in the hydraulics due to measurement noise while the machine is not moving The Travel Speed Locks send an Actual value the current Set value This results in no move ment in the hydraulics The machine will not move up or down The speed at which this rule is activated is set in the lt Menu Machine Locks and Stops gt dialog lt No of Rule breaks before Machine Stops gt sets the number of continuous meas urements which must break this rule before the machine will stop default 10 The default Travel Speed Lock is set to 0 3 m min 0 5 ft min Menu Machine Locks and Stops fe P Travel Speed Loc
58. hange the height and cross slope on the controller manually Milling with laser makes sense to design a surface with a constant slope To mill a design for roads and surfaces with changing slopes the rational method is 3D With Leica s PaveSmart 3D control system the machine is controlled from a design on the PC One Leica Geosystems robotic total station TPS or GNSS GPS GLONASS sensor meas ures the position of a prism or an antenna at a rate of 10 20 Hz These measurements are transmitted by radio to the Leica Machine Computer MPC1310 mounted on the machine A high accuracy machine mounted slope sensor provides additional information and cross slope cross fall of the machine s milling drum From this pool of position height and slope information Leica PaveSmart 3D continuously calculates the current or Actual position elevation and slope of the drum and the heading or direction of travel of the machine These Actual position elevation and slope values are compared to the computed 3D Design model of the project The results of this Design vs Actual comparison are called Correc tions These represent the amount of Correction in position elevation and slope required to bring the machine ongrade Leica PaveSmart 3D transmits these Corrections to the machine controller which regulates the hydraulics in a similar way to controlling the machine with conventional sensors Contents of this manual Path Screen Fields and option
59. have not shifted excessively Repeat Machine Dimension procedure Maintenance Tasks PaveSmart 3D Milling TR 121 Maintenance Tasks PaveSmart 3D Milling TR 122 11 2 Introduction Shut down PaveSmart 3D Disk Check on MPC1310 Machine Computer This is a short description on how to check the disk of an MPC1310 machine computer The procedure can be very helpful if you get messages about corrupted files on your MPC1310 PaveSmart is in the Autostart folder and will therefore always start automatically If there are corrupted files on the MPC1310 PaveSmart can t start up completely and there will always be a system crash To prevent from a crash the operator needs to shut down PaveSmart 3D before it can read the corrupted files Programs fan Startup Documents gt d explorer Settings i 4 Notepad Search gt Onscreen Keyboard an Leica PaveSmart 3D gt Help and Support Shut Down In the Processes tab you have to end LMA_Boot exe LMA_Control exe and LMA_Terminal exe This has to be done very fast as PaveSmart tries to start up in the mean time Windows Explorer windows Task Manager FA fe x Ele Options View Help Applications Processes Performance Networking csrss exe Explorer EXE LM amp _Control exe LMA_Terminal exe Isass exe SCardSvr exe services exe smss exe spoolsv exe svchost exe svchost exe svchost exe svchost exe svchost exe System System Idle Pro
60. he ortho metric height SHIFT OTHER F5 Available if two solutions were calculated Changes between these solutions Ca Refer to TPS1200 Technical Reference Manual chapter Least Square and Robust Calcula tion for more information on calculation results Power Search Instru After the Setup procedure is complete the Power Search Window screen is opened ments NS S Sa SS NA CONT F1 IIIS oe Ra GP To accept changes and return to MGuide Main RASSEN S Menu SNA ER anata NEW F2 To define your working area and pointing two corners of the desired search window CENTR F4 To centre the PowerSearch window to current position of the telescope SHOW F5 SR To position the telescope to corners of Search NSE SAA ASE AAA ARV window PAGE F6 To change the ATR search window Additional Reading Refer to Leica TPS1200 Technical Reference Manual chapter Setup for more information Setting up the Measurement Sensors PaveSmart 3D Milling TR 57 Setting up the Measurement Sensors PaveSmart 3D Milling TR 58 6 4 GNSS GPS GLONASS Solution Overview If using a GNSS system a GNSS reference station is also required to enable differential posi tioning coordinates to be computed Prior to milling the GNSS coordinate system and the local TPS coordinate system must be linked to ensure the orientation is calculated correctly If this is not carried out correctly the machine may not track as expect
61. illing TR 147 System Installation and Components PaveSmart 3D Milling TR 148 er COM 1 2 3 4 CAN 1 2 POWER Power key A caution KEYBOARD Do not attach any USB device which needs additional driver installation as this may cause configuration corruption or installation problems Serial Ports for Radio Modem connection to Total Station and connection to GNSS sensor Power output voltage regulated 13 6 V CAN bus connection Power in 10 36 volt DC reverse polarity protected To turn On and Off the Machine Computer Never turn Off the Machine Computer without shutting down all running applications This could result in unexpected data loss Precautions Black screen must be displayed after pressing the Shutdown button in Leica PaveSmart 3D software before switching the power off to the MPC1310 Permits connection of external keyboards with compatible LEMO connec tors Contact Leica Geosystems for further information 14 System1200 RoadRunner RoadRunner Project Fixpoint job Glossary Leica PaveSmart 3D System1200 includes the current Leica TPS GNSS GPS GLONASS and office software products Leica PaveSmart 3D is closely integrated with System1200 For example the data structure and files DBX is same format and the user interface looks similar As there are these dependencies Leica PaveSmart 3D uses the same terms as in System1200 where possible RoadRunner is an application program fo
62. in the design the greater the processing power required to run the system A balance must be found between the number of segments required to define the design and the processing power it will take The recommendations detailed below must be followed when creating designs Without following these rules Leica Geosystems cannot guarantee good quality milling performance Leica PaveSmart 3D is capable of using designs in a 3 dimensional format which may contain e Straights e Arcs e Clothoids entry and exit as well as partial e Cubic parabolas e Full Partial Bloss curves parabola of degree five Using these shapes only a small number of segments are required to define any 3 dimen sional shapes Number of Segments Not all CAD packages are capable of producing curved 3 dimensional polylines To overcome this curved line segment are broken up into a number of individual straight line segments The closer these straight segments are together the more accurate the original design data is approximated e When approximating curved 3 dimensional line segments the angle change between two connected line segments must never be greater than 1 degree e When defining a straight line it is not necessary to add more points in the middle of a line a Reference line b Line segments c Angle change lt 1 Ln VILLE 97 The number of segments contained within a single stringline must not exceed 2000 indi vidual elements
63. ins the entire system documentation in electronic format The user manuals are also available in printed form Leica PaveSmart 3D is divided into three operator levels accessed via two software paths The Work dialog displays all of the information required for daily production and is designed for use by the machine operator There is unrestricted access for all users in the Work dialogs Upon making a change to any field within the work dialog the result is effective immediately This is why there is no lt CONT gt or confirmation buttons are present in the Work dialogs The Menu dialog is where all system configuration and data preparation is carried out The Menu dialog is divided into two access levels The first level contains the configuration dialogs access via the password 007 All configuration tasks must be carried out before production commences The second access level in the Menu dialog is the service level and is intended for service personal to install the system and for rapid trouble shooting if any problems arise How to Use this Manual PaveSmart 3D Milling TR 9 Projects PaveSmart 3D Milling TR 10 2 Projects 2 1 The Projects Dialog Introduction Project preparation steps The Projects dialog contains all the information necessary to manage and create the data required to operate Leica PaveSmart 3D Refer to the Leica PaveSmart 3D user manual Quick Start chapter for details on creating a new project
64. ion Helmert set up by resection Helmert e Local Resection set up by local resection Each setup method has specific requirements for input data and each setup method requires a different number of target points For Leica PaveSmart 3D we recommend using e Resection with a minimum of 2 preferably 3 fixed points or e Known Backsight Point The Tiepoint Check function in Leica PaveSmart 3D will use the first point of a Resection or the orientation point from a Known BS Point setup by default Other points may be selected in the lt CONF gt settings in MGuide The Tiepoint Check function will only work automatically if you are using either Resection or Known Backsight Point method Refer to MGuide 1200 User Manual chapter Tie point check for more information on tie point check Setting up the Measurement Sensors PaveSmart 3D Milling TR 51 Setting up the Measurement Sensors PaveSmart 3D Milling TR 52 6 2 Station Setup Description Method Resection Description Setting the Instrument TPS Orientation Press SETUP F3 in the MGuide Start screen The Fixpoint job is automatically set to the file selected in the start screen Choose the method for the instrument setup and press F1 CONT For the Tiepoint check function to work correctly the lt Fixpoint Job gt name must be set in the lt Start gt screen If setting up the TPS by Resection the station coordinates of the TPS and the orien
65. ir individual needs Below is a description of the most common parameters which may be changed Setting general Menu Preferences General feica Application starts with Brightness o 255 g Confirm all actions Use User Level Config Reset User Level CONT DEFAULT BACK Od AAS eo lt Application Starts with gt Selects the application Leica PaveSmart 3D will start in The Work dialog default Main dialog Projects dialog or the Job dialog can be selected Setting the Operators Preferences PaveSmart 3D Milling TR 95 Setting the Operators Preferences PaveSmart 3D Milling TR 96 lt Brightness gt Choose a value in between 2 dullest and 255 brightest lt Confirm all actions gt If not activated all changes are immediately rejected when pressing DEFAULT or RESET If activated an additional message box will ask if you are sure you want to reject any changes made after pressing DEFAULT or RESET lt Use User Level Config gt Leica PaveSmart 3D is divided into three access levels e Level 1 Operator level This allows for all daily operations to be carried required for production All configuration and Service tools are deactivated to the user e Level 2 Configuration level This allows configuration of the system Access to this user level is required to adjust the tuning set the stop rules and change the user preferences The Config user level is deactivated by selecting not to use the lt Use User Le
66. is means that even if the Compact Flash card that previously contained the reference station coordinates is formatted the last used coordinates can still be used From the SURVEY Set Up Reference Station menu LAST F3 Step Description The point ID and coordinates of the last used reference station are displayed in grid When no local coordinate system is active WGS 1984 coordinates are displayed Check the antenna height CONT F1 to access SURVEY Survey Job Name Using the coordinates Description From the SURVEY Set Up Reference Station menu HERE F4 to access SURVEY New Reference Point of the current naviga PESP tion position 1 2 3 SURVEY New Reference Point Coords page The current navigation position in grid is displayed When no local coordinate system is active WGS 1984 coordinates are displayed Type in a point ID for this new point COORD F2 views other coordinate types Local coordinates are available when a local coordinate system is active SHIFT ELL H F2 and SHIFT ORTH F2 Available for local geodetic coordinates Changes between the ellipsoidal and the orthometric height PAGE F6 changes to the Code page Setting up the Measurement Sensors PaveSmart 3D Milling TR 63 Setting up the Measurement Sensors PaveSmart 3D Milling TR 64 SURVEY Survey Job Name Step Description 5 S
67. is not taken into consideration If a slope line is selected the elevation deviation is calculated relative to the slope calcu lated from the slope line Quality Control PaveSmart 3D Milling TR 99 Quality Control PaveSmart 3D Milling TR 100 S S Viewing As built results Any Slope offsets entered into the lt Work Offsets Slope Offsets gt dialog are not taken into consideration when performing as built checks Refer to the MGuide User Manual for your instrument type for detailed instructions on making as built measurements The as built results are seen in the as built logfile in the Menu Projects As Built dialog The coordinates of the as built point and the offsets to the design are also displayed in the Work Design dialog immediately after being recorded The results are also displayed on the TPS screen used to make the lt control gt measurement Menu Projects AsBuilt Check ASCII fe 3 Work Design Two_PointsMatts_Cigar 07 25 2006 08 25 Tos 000 106 000 100 050 100 000 100 050 T 400 000 105 000 100 050 T 105 000 105 000 100 050 E 103 198 m N 101 068 m H 100 051 m Hz 0 016 m Vt 0 001 m DPos 0 016 m 110 000 105 000 100 050 Hro 100 000 100 050 Quality Control PaveSmart 3D Milling TR 101 Quality Control PaveSmart 3D Milling TR 102 As Built Control A comma separated As Built log fi
68. k Use Travel Speed Locks Minimum Speed for Active Control No of Rule breaks before the Machine hydraulics lock 1 f Timeout Lock all Cylinders If no valid measurements are received from the TPS s GNSS GPS GLONASS or slope sensor after a predefined period then Leica PaveSmart 3D freezes the elevation send an Actual value the current Set value The lt Time out Lock all Cylinders gt default value is 2 seconds Machine Configuration PaveSmart 3D Milling TR 33 Machine Configuration PaveSmart 3D Milling TR 34 Machine controller communication timeout Timeout Stop Machine If no valid measurements are received for a longer period of time a 3D Error message is sent to the machine controller This will put the machine controller and Leica PaveSmart 3D out of control and into standby The lt Time out Stop Machine gt default value is 5 seconds For causes and remedies of timeouts refer to the Troubleshooting Chart Measurement Time outs Time out Lock all Time out 3D cylinders 2 J Xj gt Error message 2 J A z CONT DEFAULT BACK L O 8 X eo The machine controller communication timeout ensures that in the event of communica tions failure between MPC and Controller for example CANBus fault the machine should stop Leica PaveSmart 3D indicates no deviation values and the D icon The machine controller will indicate No Sensor Activating amp deacti Stop rules can be
69. layer is visible at a time The operator can only select a single Stringline from this layer for calculation and machine control All Stringlines that are in relation to each other should be on one layer Gap If there is a gap in a CAD StringLine line it may be converted as two separate StringLines If this occurs it is only possible to select one stringline or the other For production this means that the machine cannot mill the whole length continuously Therefore a very small gap in the stringline file can lead to a large gap in production at least the length of the milling drum Due to this stringlines must be checked in the CAD software for gaps before and after they are converted Leica PaveSmart 3D will attempt to automatically fill very small gaps if present however we recommend inspecting and Joining stringlines at design time to prevent unwanted stop pages in production Projects PaveSmart 3D Milling TR 15 Projects PaveSmart 3D Milling TR 16 2 3 Rules for Defining Projects Overview Leica PaveSmart 3D requires accurate design data to be able to control the machines move Angle change between segments ments The machine is only capable of following the information contained within the design data therefore the quality of the final product is directly influenced by the quality of the data used The control process is also influenced by the design data The greater the number of segments contained with
70. le able to be imported into Excel or CAD systems for 3D Measurements Log plotting of as built results is recorded Data recorded in this file includes Hes Field Description Date and Time Date and Time of measurement Pt Point number dH Height deviation from Design value not including Working Offsets dA Position deviation from Current RefLine not including Working Offsets Prof no Selected Reference line Ch Stationing Chainage XYZ As built Control point coordinates ReflHt Reflector prism height used to take measurement Description of cor The diagrams below detail the arrow conventions used in the as built lt control gt function in rection and deviation Leica PaveSmart 3D and MGuide conventions UP and Down arrow a Design b Positive Offset from design or Negative Correction i Down arrow diesplayed in correction dialog and in the as build file a Negative Offset from design or Positive Correction T Up arrow diesplayed in correction dialog and in the as build file Additional Data Vali Leica s RoadRunner Application for TPS1200 instruments can also be used for data valida dation options tion RoadRunner supports the same DBX file format as Leica PaveSmart 3D and has addi tional road stakeout functionality cE Refer to the RoadRunner Technical Reference Manual for more information Quality Control PaveSmart 3D Milling TR 103 Quality Control PaveSmart 3D Milling TR 104 8
71. lue simultaneously pressing both keys causes zero position In automatic mode a rated value actual value reading correction can be carried out i e while shifting the actual value for example to the physically actual value the rated value is corrected accordingly DLS Controller and Mobamatic PaveSmart 3D Milling TR 129 DLS Controller and Mobamatic PaveSmart 3D Milling TR 130 12 2 Operating the Mobamatic Controller MOBA matic Controller a Set to zero and set design values Raise lower cylinder b Switch profile reference string ground c Automatic on off d Sensor alignment Set current working position to Zero by pressing for 1 second Basic settings Basic settings are always to be made in manual mode vA ar Functions lamp off Grade sensors E 1 Set screed drum to initial position Preset project data to about 1 5x the thickness of layer depending on the type of machine a used E 2 Sonic Ski Sensor T Align the sensor With the Sonic Ski sensor the string ground scan is set by simultaneously pressing the UP DOWN keys es Bd String a se Ground 3 3D sensor MPC has been started and the mast sensor has been connected to enable the selection of 3dSEn control s lt Press enter key Al The UP DOWN keys changes the Design values 4 Height setting e Is value setting Press the enter or UP DOWN keys until SEt is displayed The Is value is set as Design valu
72. mart 3D Milling TR 66 6 6 Real Time Rover Operations Recording points to be The system is now ready to record WGS 84 coordinates of the local fixed points to be used used in the trans in the transformation formation This process will link the local TPS coordinate system with the GNSS GPS GLONASS coor dinate system cS e Ensure that the same fixpoints used in the local coordinate system are occupied during the GNSS measurement procedure e Ensure that the fixpoints recorded in both the local coordinate system and the WGS84 coordinate system are distributed around the extents of the working area If they are not incorrect orientation may result and the milling machine may not steer as desired Requirements e A typical configuration set for real time rover operations e Areal time interface configured correctly e The real time device must be attached to the receiver and working properly Refer to the GPS1200 Technical Reference Manual Diagram of distribu tion required and possible errors a Reference Line b Control points in Local and WGS coor dinate system with good distribution c Control points in Local and WGS coor dinate systems with unable distribu tion Setting up the Measurement Sensors PaveSmart 3D Milling TR 67 Setting up the Measurement Sensors PaveSmart 3D Milling TR 68 Real time Rover op Step Description erations Access step by
73. n the System1200 definition a DBX Road Job consists of several StringLines One of them may be defined as the Refer ence Line the others are only used for height information The different StringLines in one StringLine Job may have different functions and are then named with a different term During definition of a stringline alignments and cross sections are used Alignments are defined by geometric elements for example straights and arcs and the cross sections by vertices Furthermore one defines at which chainage a certain cross section is used By doing this the vertices are connected to create a series of lines representing the three dimensional design of the road Stringline representa tion of a road design In Leica PaveSmart 3D such lines defining the design are called stringlines Stringlines are the base elements used for machine control calculations Stringlines have a project unique name by which they are identified and selected Whenever a new design is typed in or imported from a design package these stringlines are generated automatically in the back ground Cross section A cross section may be derived from the stringline model by slicing a group of stringlines with a vertical plane orthogonal to the centre line i i VTN Stringline representa tion of a road design Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 153 Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 154 Long slope Cros
74. ng needs to be placed near or under existing structures A TPS can lock on to use for as build checks right away behind the machine Therewith the absolute height of the milled surface can be monitored It is essential that the correct sensor combination be defined before milling commences TPS and GNSS GPS GLONASS sensors communicate with the MPC1310 via radios TCPS275S or FreeWave or cable MNS1200 After defining the point to point communication each radio pair or the MNS must be set to operate on a separate communication channels Refer to chapter 4 Radio Modem Configuration for setting radio pair frequencies Defining Measurement Sensors PaveSmart 3D Milling TR 41 Defining Measurement Sensors PaveSmart 3D Milling TR 42 After Leica PaveSmart 3D is installed on the MPC1310 four Communication or COM ports 1 2 3 and 4 are available The COM port combination can be altered in Menu Sensors Arrange dialog or via the short cut Work Sensors Arrange dialog Menu Sensor Sensor Arrangement fe gt Sensor Arrangement Spare Sensor a p f Leapfrog Parameters Leapfrog Tolerance 0 060 m O Take over from shortest measuring distance e If using a TPS solution connect and select the lt Primary Sensor gt at COM1 and the second as lt Spare Sensor gt at COM2 e If using the GNSS solution connect and select the MNS1200 as lt Primary Sensor gt at COM1 and the TPS as lt Spare Sensor gt at COM2
75. ng for steering is not relevant The tuning parameters dialog Menu Machine Tune Elevation or Tune steer can be changed while the machine is in control and moving The tuning process is a key procedure for a good quality concrete milling Tuning the Elevation The tuning affects a change at the measured deviation to get a faster or slower reaction at the hydraulic This option is additional to the machine tuning at the controller Wirtgen DLS and Mobamatic controller have defined values form Leica PaveSmart 3D By using these controllers it is not normally necessary to tune additionally with PaveSmart 3D heica LEFT ry 50 00010 A 50 00010 cm 100 0 50 00010cm 50 00010cm g g g b O Link Elevation DEFAULT BACK L amp AZ eo Tuning is an iterative and intuitive process which must be repeated until a desirable hydraulic performance is achieved Initially start the tuning procedure with the default tuning settings from the configuration created during the installation Work Tuning Tuning Elevation 50 00010cm 50 00010cm Machine Configuration PaveSmart 3D Milling TR 37 Machine Configuration PaveSmart 3D Milling TR 38 If the machine is reacting much too fast or too slow and an extremely undesirable behaviour is seen roughly tune the machine using the Link Elevation tick box When this button is selected the tuning parameters for all of the ranges will change simultaneously
76. nment and a long section vertical alignment is needed Horizontal Alignment The horizontal alignment is a design of the horizontal geometry of a road Leica PaveSmart 3D supports the following elements in the horizontal component of align ments e Straights e Arcs e Clothoids entry and exit as well as partial e Multipoints all elements that cannot be described by one of the previous types are represented by discrete points along the curve For example a line parallel to a clothoid Vertical Alignment The vertical alignment is a design of the vertical geometry of a road Leica PaveSmart 3D supports the following elements in the vertical component of align ments e Straights e Arcs e Quadratic parabolas e Multipoints all elements that cannot be described by one of the previous types are represented by discrete points along the curve a elevation Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 151 Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 152 Chainage Stationing or The cumulative distance along the centre line in general but not always starting at zero Station Stringlines In conventional milling work the stringline is physically staked out with pins Between this pins a chord or a string is mounted where the machine drives along In Leica PaveSmart 3D a StringLine is a part of a StringLine Job I
77. nts file to establish the position and orientation of each TPS relative to the design local coordinate system It is important that this information is accurate as this will influence the set up quality of the TPS s and in turn the overall milling quality The TPS s must be setup in a stable location and leveled Refer to TPS1200 User Manual chapter Instrument Setup for more information on instru ment setup z The instrument should be protected from direct sunlight in order to avoid thermal v warming Additional information is provided in the TPS1200 Technical Reference Manual and MGuide User Manual When using Leica PaveSmart 3D the MGuide application onboard system 1200 TPS s will begin automatically in the lt Start gt dialog This dialog displays general information required to carry out the Setup procedure The lt Fixpoint Job gt selected must contain the coordinates of the fixed points which are to be used to set up the instruments The lt Reflector gt type can also be selected in this menu or by pressing F9 with the standard Hot Key definition The instruments can now be set up and orientated using the SETUP application F3 on the instrument Various methods are available e Set Azimuth set up by azimuth e Known BS Point set up by a known backsight point Recommended Methods er e Ori amp Ht Transfr set up by orientation and height transfer e Resection set up by resection e Resect
78. official mapping datum or an arbitrary grid system used in a particular area such as a construction site To convert the WGS 1984 coordinates into local coordinates a coordinate system needs to be created Part of the coordinate system is the transformation used to convert coordinates from the WGS 1984 datum to the local datum This can be carried out on board the MNS1200 sensor with a Survey Licence or in Leica Geo Office LGO A transformation is the process of converting coordinates from one geodetic datum to another Requirements e Transformation parameters e In some cases a local ellipsoid e In some cases a map projection e In some cases a geoid model A transformation consists of a number of shifts rotations and scale factors depending on the type of transformation used Not all of these parameters are always required These parameters may already be known or may need to be computed Three different transformations are provided onboard the MNS sensor e Classic 3D also called Helmert transformation e Onestep e Twostep Further methods are also available in LGO Setting up the Measurement Sensors PaveSmart 3D Milling TR 71 Setting up the Measurement Sensors PaveSmart 3D Milling TR 72 S The details of a Onestep transformation is provided in this manual For more information about other transformation types refer to GPS1200 Technical Refer ence Manual and LGO help files Transformation On
79. og file is to be generated tick the appropriate checkbox To View the logfile press the lt v gt button Measurements of each of the sensors are continuously recorded if selected Menu Projects Log File Settings fe x Primary Sensor Log all Data Name TPS1 200 _COM5B loc Pv Secondary Log all Data uu Name TPS1200_COM6 loc M Sensor Spare Sensor Log all Data Name TPS1200 COM1 loc Pv Slope Sensor Log all Data Name DS_ DualSlopeLeft Pv CAN Log all Data Name GT Gomaco log Pv Machine track Log all Data Name Machine Itrk sg CONT BACK gt O eo Recording and All logfiles are saved in the C Program Files Leica Geosystems Leica PaveSmart 3D Exporting Logfiles Projects directory of the MPC1310 Quality Control PaveSmart 3D Milling TR 105 System Operation PaveSmart 3D Milling TR 106 9 9 1 Work dialog System Operation Software and Calculation Description a fan R s 205 583 18 917 ll Nfa 673 The Software is divided into two different areas All production tasks are carried out in the Work dialog 14 45 Values Information d Cross Slope Position 3D Height Stationing se 0 0 Set 0 010 ft aay Opposite Stationing rh W 3483 4 ft La Act 0 1 0 015 ft Act 0 000 ft AUTO AUTO Eu Work TS3_Straights_CSlope 06 19 2007 Speed 0 0 ftfmin Milling Height 3274 272 ft Design Height 3275 133 f
80. olylines that correspond to that layer The majority of DXF files do not contain information regarding the linear units of the file the user must select the unit in lt DXF File Linear Units gt Lines imported from the DXF file do not have identifiers During the import the lines are numbered sequentially starting with the number 1 and incrementing each line by 1 In addi tion a prefix may be added to each line number in lt Line ID prefix gt Projects PaveSmart 3D Milling TR 21 Projects PaveSmart 3D Milling TR 22 Checking the Design graphically Work Design Graphics kollfj_dal 08 08 2007 15 08 I s gt O _ _ eo In the Design to Field Viewer all the data can be checked before exporting Single layers can be selected to be viewed or exported New layers can also be created and lines can be moved from one layer to another Export When all of the layer information is ready press the Export button and enter a folder and file name for the DBX to be saved to To import the DBX to Leica PaveSmart 3D the DBX files must be stored on the DBX folder on the USB flashdrive Machine Configuration 3 1 Machine Profiles Introduction PaveSmart 3D is designed to be used on a variety of different construction machines from different manufacturers and different models with different machine controllers To define all of these machines a lt Machine Profiles gt function i
81. omputer cee 137 Machine Dimension cccccceecceece eee sseeeeeeeeeseueeeneeeeees 27 Machine dimension cecececeecceeecceeeeeeeeeeeeeeeeeeueeeneeeeees 28 Machine DIMENSIONS siorr ioietan aa iaa 27 Maintenance saaana e 121 Mast POSIMOM serieren gencdeee ann cdee ann caecantands 27 Measurement SENSOMS ar aa aaa aa aaraa 49 Measurement TIM OUtS oo cece ceecceeseeceeeeseeeeeeeueeeueeeeees 33 MINST 200 22tidctscctioatctncecentodedodsdodsenibode aede AN 76 MPGI 335 On iamaniere 137 147 0 OARE EE A E ath aah ata S A v lt 116 118 119 P Preferences o ceccccccccccecccessecssesseeeeucseeesueusuueeaeeaeeeaeeaaeeas 95 Production Tolerance c cecccecccceseeseeecseeeeeeeeeeeaeeeees 31 33 ProjJEGES aene e a Aa eA aa RREA 10 11 R RAGIO MOG OM enra a a a a a 39 Real time Reference ssssssssesserssrssrerierisrirrerierrssrrrrens 59 Real time ROVE orrian aaraa Nna a 66 RESO GEOR ai aeaa ae AN 51 52 53 Residuals m a RARR R RAAR RAR 80 ROVER arainn a aa a ann aa aTa a a aea A a a ea EA 68 S Search u cceseecseeeeeeeee ees Sensor arrangement Serial Interfaces Slope sensor position Station Setup serres STOP TUES sacactesceceeserestes Stringline ssesssesseeesen T olerances osson Total Station s e e ET TPS Solution Tracking uhkina Transformation Travel Speed Locks TURING ae dvi etieed WGS BA aaaea Total Quality Management Ou
82. or Log Data Secondary Sensor Spare Sensor 342 72 Log Data Spare Sensor Orientation 350 9 335 63 NO Name 334 91 NO Name 334 94 NO Name deg Leica ft 332 14 ft TPS1200_COM5 log ft 332 16 ft TPS1200_COM6 log ft 332 17 ft TPS1200_COM1 log SLOPE MOLD TPS LOC CANOUT BACK t eo Other details available include Displays the current slope sensor measurements Displays the current drum correction TPS LOC E Displays each of the TPS location set up coordinates Displays the CAN messages being sent to the machine controller Defining Measurement Sensors PaveSmart 3D Milling TR 47 Defining Measurement Sensors PaveSmart 3D Milling TR 48 5 4 Adding Serial Interfaces COM Ports Definition of the Serial The Default Communication port numbers are 1 2 3 and 4 which correspond to the COM ports settings on the MPC1310 These four ports cannot be altered If the software is installed on a laptop or a PC for a training or a demonstration purposes additional Communication ports can be defined or deleted in the Menu Sensors Interface dialog Select lt ADD gt and follow the instructions to add an additional serial port Menu Sensor Interface f gt All Channels COM1 115200 g COM 115200 4 COM 115200 COMA 115200 CONT ADD EDIT DELETE BACK gt gt t O 8 eo 6 Setting up the Measurement Sensors General PaveSmart 3D can be used with two di
83. or delete an existing project Projects PaveSmart 3D Milling TR 11 Projects PaveSmart 3D Milling TR 12 er Stringlines Long Slope mainfall If the Project is deleted the folder will be completely removed from the MPC1310 hard drive Leica Geosystems recommends that the project defined at installation by the Leica support engineer be used to create for example copy to a new project name any subse quent projects for the specific machine it was installed on This project will contain the machine dimensions and all settings The main element used in Leica PaveSmart 3D projects is a Stringline A stringline is defined as a System 1200 road DBX Job Refer to chapter 2 4 Converting Data With the Design to Field Tool for details on converting data to the DBX format A stringline contains all of the design information necessary to control the machine It must be in a 3 dimensional format and may contain Straights Arcs Clothoids entry and exit as well as partial Cubic parabolas Full Partial Bloss curves parabola of degree five Multipoints are all elements that cannot be described by one of the previous types and are represented by discrete points along the curve For example a line parallel to a clot hoid The long slope describes a height change on the long section of a stringline The long slope is the angle between a horizontal line and the stringline This is also referred to as mainfall and
84. ore he starts paving It is possible to work without slopelines and use manually selected cross slopes Without a SlopeLine supplied in the design only manual slope setting and adjust ment is possible via the Slope Offset dialog A DXF file is the most common way to exchange CAD data It is based on the AutoCAD soft ware although is supported by almost all CAD systems The file contains different layers not the same as DBX layers In one layer are different entities The DXF format is graphical for example points lines shapes and stores no additional information for example no stationing no cross slope for a single line unit information A DMF layer includes all the objects related to one topic for example houses roads electrical wires gas pipelines The objects are formed by entities An entity is a geometrical object in a DXF file Common entities are e Point e Line e Polyline e Block amp 3Dface Index Numerics F 3D slope CaliDration woo eeeeseseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 28 EPEC WAVE cccttenccnmsumidccanecensmunitcconettearuibbeyvervusrtiutueyas 40 A G AIISMMMOME orirun nananana aa aaa aaia 130 GNSS GPS GLONASS naassen 58 59 61 66 93 146 AS BUIIt essiri auaa Aa AAAA a 99 100 102 GNSS GPS GLONASS Assist cceccceeceeceeeeeeeeeeeeeeees 4l Automatic mode cccceccccecceeeeceeceseeceseecancetaneecaneeeanes 128 GNSS GPS GLONASS Solution ccccceecceee
85. orrectly configured will appear in the Work Sensors dialog labelled as e TPS P 1 or GPS S 1 Primary Sensor e TPS Sp 2 Spare Sensor If all of the sensors do not appear check the radios are correctly connected to the MPC1310 and the Sensors the Sensors are switched on and in MGuide TPS only and the sensor arrangement have been configured correctly Work Sensor SimlateoneLine A He 960 000 N 1050 000 H 1000 000 TPS P 41 41 31 m TPaiSS THL 29 m 07 28 2006 08 39 Information Stationing 0 39 3 m Speed 3 0 m min Working Slope 0 0 Design Slope 0 0 TPS P 41 O TPS S 51 oe i LEAP ARRANGE To send a Start Tracking command highlight the desired sensor by pressing the circle next to the sensor name and press the Start button When the lt START gt button is pressed in the Work dialog a start tracking command is sent to the primary or spare sensors gt j Start button E You can stop tracking by pressing the stop button Defining Measurement Sensors PaveSmart 3D Milling TR 45 Defining Measurement Sensors PaveSmart 3D Milling TR 46 5 3 Purpose Checking the Data Flow The lt Menu Tools Data Flow dialog is used predominantly for trouble shooting support purposes Measurements from each of the sensors are displayed in real time Menu Tools Data Flow 3D Position Primary Sensor 338 19 Log Data Primary Sensor Secondary 342 72 Sens
86. ou to select the common points of system A and system B which are used to determine the transformation parameters After selecting the Match icon a screen will appear with the System A WGS 84 coordi nates on the left hand side and System B Local coordinates on the right hand side Match the corresponding data points by se lecting the two points and pressing the left hand mouse button A drop down screen will then appear Press Match Repeat this process until all corresponding data points are matched Tab to the Results page at the bottom of the window and view the residuals These should all be under 25 mm If they are not the measurement process should be repeated Step Description 5 Save the transformation parameters Enter a file name for the transformation and save it onto the hard drive 6 In the manage dialog copy the transformation file DAT back onto the sensor Setting up the Measurement Sensors PaveSmart 3D Milling TR 87 Setting up the Measurement Sensors PaveSmart 3D Milling TR 88 6 11 Existing Trafoset Preparing the Trafoset in LGO Uploading a Trafoset to a GNSS GPS GLONASS Sensor with PaveSmart 3D For construction projects a lot of surveying work is done in advance It s quite likely that for this tasks a GNSS GPS GLONASS sensor was used and therefore a Coordinate System or Trafoset already exists In LGO Leica Geo Offi
87. ount Mast s with the Prism s or GNSS GPS GLONASS Antenna ensure both bayonet and locking collar on the prism are being used Mount Dual Slope Sensor Use the machine manufacturer supplied slope sensor mounting bracket wher ever possible Mount Radio Modems for TPS GNSS GPS GLONASS Mount Machine Computer MPC1310 Setup Total Stations with a GNSS GPS GLONASS Combination also the Reference and Rover Receiver Test radio communications between all devices Test Slope Sensor communications Test Installation and Leica to machine communications In the dataflow Check amp Adjust instruments refer to instrument User Manual Tune the machine hydraulics in both elevation and steer Refer to the Leica PaveSmart 3D User Manual for a detailed cabling description 13 3 General information System Hardware er Machine Computer Hardware Descriptions All hardware components used in Leica PaveSmart 3D have been designed for rough condi tions To ensure longevity of the components they must be treated and transported correctly Always use the designated packaging for transport and study all relevant docu mentation for cleaning and maintenance procedures The installed components on the machine comprise a Machine Computer with attached radio modem s to communicate with the Total Station s dual slope sensor and optional GNSS GPS GLONASS rover and GNSS antenna One or two prism antenna masts are mount
88. r GPS1200 and TPS1200 for staking out and checking all types of alignments highways railways pipelines canals airport runways earthworks etc RoadRunner also includes support software that converts data from many design packages prepares the data and uploads data to GPS1200 and TPS1200 A project consists of different kinds of jobs that belong together By selecting a project automatically all referenced jobs are selected as well A project can reference e one fixpoint job e one measurement job e one road job e one DTM job As jobs are just referenced by a project they can be used in more than one RoadRunner project as well as in other applications For example the same collection of control points may be used in two different projects Leica PaveSmart 3D uses the same DBX format as a RoadRunner Road job The fixpoint job holds all control point information needed in the field Control points are for example points with known coordinates used for a TPS set up or points used to deter mine a GNSS GPS GLONASS coordinate system The fixpoint job is a source of information Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 149 Glossary Leica PaveSmart 3D PaveSmart 3D Milling TR 150 Road job Alignment All road design information either typed in manually or exported from a design package is stored in the road job The alignment defines the geometry of a road Therefore a plan view horizontal alig
89. r commitment to total customer satisfaction 5 s ot N Leica Geosystems AG Heerbrugg Switzerland has been ro E certified as being equipped with a quality system which meets w5 QO IVI the International Standards of Quality Management and Quality m Systems ISO standard 9001 and Environmental Management S Systems ISO standard 14001 7 N Ask your local Leica Geosystems dealer for more information about our TQM program Printed in Switzerland 2009 Leica Geosystems AG Heerbrugg Switzerland Leica Geosystems AG Heinrich Wild Strasse CH 9435 Heerbrugg e Switzerland when it has to be right etca Phone 41 71 727 31 31 www leica geosystems com Geosystems
90. re each new project is commenced and when a milling drum is changed The mast position is important for a stable performance To minimise the effects from abrupt machine driving starts and stops to the 3D elevation it is best to mount the masts vertical to the drum centre no more than 20 cm in front or behind the centre In the horizontal direction the masts should not be mounted more than 20 cm from the drum edge The best option for the placement of the masts is to have one mast on each side of the machine This will enable you to choose the best side for TPS or GPS Machine Configuration PaveSmart 3D Milling TR 27 Machine Configuration PaveSmart 3D Milling TR 28 er Machine dimension and 3D slope calibration Step by Step The 3D slope sensor can be mounted anywhere on the machine frame because the drum is constantly connected to the frame Step Description Se Leica PaveSmart 3D must be running and the sensors must have radio commu nication with the MPC1310 Before setting up the machine dimensions the frame must be leveled with an accurate spirit level Start the engine and level the machine with manual hydraulic control Additionally level the cross slope in parallel with the machine slope sensor Menu Sensor Slope press the Zero button to set both slope directions to 0 00 In some cases a slope can be typed in and stored with Set Step Description
91. s Index ee Available documen tation The Leica PaveSmart 3D Technical Reference Manual has been designed to match the layout of the Software The individual chapters are based on the options available within the soft ware and have been arranged to mimic the workflow setup of a new project and installation Work Offset Steer describes the working sequence From the Work dialog select Offset and then select Steer Leica PaveSmart 3D paths always start either in the Work dialog or in the Menu dialog Work Elevation Offsets Steer Offsets describes the name of the screen Fields displayed on the screen are described such as lt Speed gt or lt Speed ft min if ft min is the selected speed unit The index is at the end of the manual Keys fields and options on the screens which are considered as self explanatory are not explained Name of documentation Description Leica PaveSmart 3D User All instructions required in order to operate the system to Manual a basic level are contained in this User Manual It provides an overview of the system together with technical data and safety directions Leica PaveSmart 3D Technical Overall comprehensive guide to the system functions Reference Manual for Milling Included are detailed descriptions of special system settings Machines and functions intended for technical specialists TPS1200 User Manual Contains important safety directions as well as in
92. s PaveSmart 3D Milling TR 92 On the right side in lt Sensor gt the currently connected sensors are listed You have to tick the GNSS GPS GLONASS sensor on which you want to upload the Transformation Set CONT The Transformation Set is uploaded automatically by PaveSmart 3D On the GNSS GPS GLONASS sensor the uploaded Transformation Set with the name lt MA_COORD gt is set as the currently used transformation No further settings have to be made on the GNSS sensor ae It s very important to check with an RX1200 terminal on the MNS1200 sensor if the correct Coordinate System is selected Furthermore it s recommended to verify your Coordinate System on the Job site by measuring some control points before commencing milling 6 12 Preparing the GNSS GPS GLONASS Rover on the Machine for Milling Mounting the GGNSS Once the transformation parameters have been established the GNSS GPS GLONASS can GPS GLONASS onthe be mounted onto the milling machine milling machine 1 The antenna must be mounted on the left or right Mast position and connected to the antenna cable 2 The MNS1200 sensor must be mounted on the milling machine and all cables connected See diagram in chapter 13 System Installation and Components 3 Connect the RX1200 terminal and ensure the correct transformation is selected Step Description 1 In SURVEY Survey Begin select the job containing the transformation parame ters for the site
93. s chosen from lt WGS84 Pts Job gt Local Pts The point ID of the points chosen from lt Local Pts Job gt Match The type of match to be made between the points This information is used in the transformation calculation Position amp Height Position only Height only or None e For lt Transfrm Type Onestep gt or lt Transfrm Type Twostep gt possible options are P amp H P only H only or None e For lt Transfrm Type Classic 3D gt possible options are P amp H or None None removes matched common points from the transformation calculation but does not delete them from the list This can be used to try and improve the residuals that are obtained when calculating the transformation when the point that is the problem is not known For more information on matching points refer to GPS1200 User Manual CALC F1 computes the transformation and continues to DET C SYS Step 4 Check Resid uals Refer to paragraph DET C SYS Step 4 Check Residuals Setting up the Measurement Sensors PaveSmart 3D Milling TR 79 Setting up the Measurement Sensors PaveSmart 3D Milling TR 80 DET CSYS Step 4 Check Residuals Description of columns Displays a list of the matched points used in the transformation calculation and their asso ciated residuals ele Hye ENS 75 SSNS RA Sa S SNE CONT F1 To accept the residuals and to continue with the subsequent screen RESLT F3 To
94. s slope The long slope describes a height change on the long section of a stringline The long slope is the angle between a horizontal line and the stringline This is also called mainfall and is the element describing draft a Long slope Cross Slope describes the height change on the cross section of a stringline between elements In PaveSmart 3D a single stringline can be given a cross slope by projecting a plane through the stringline at a given angle Positive cross slope is defined as a clockwise rotation about the axis of the stringline in the direction of travel Negative cross slope is defined as a anti clockwise rotation about the axis of the stringline in the direction of travel Depending on the milling drum used this will form a catch or spill curb a Cross slope between two stringlines b Stringlines Leica PaveSmart 3D Leica PaveSmart 3D Project Leica PaveSmart 3D Job Leica PaveSmart 3D Layer Leica PaveSmart 3D Object Reference Line Center Line in RoadRu nner System1200 Leica PaveSmart 3D terms are the same as System1200 where possible Some terms have a slightly different meaning and have been described as such Others terms come from Leica Machine Guidance System LMGS or from the different applications A Leica PaveSmart 3D Project contains all of the Stringline data needed to carry out produc tion in
95. s the transforma tion of heights Parameters of the local geoid model This is not compulsory No parameters of the local ellipsoid No parameters of the local map projection Area Limited to 10 x 10 km because no projection scale factor is applied and a standard Transverse Mercator projection is used to compute the preliminary WGS 1984 grid coordinates For areas without large height differences Points and trans formation parameters The transformation parameters determined depend on the number of available points with position information One point Classic 2D with shift in X and Y Two points Classic 2D with shift in X and Y rotation about Z and scale More than two points Classic 2D with shift in X and Y rotation about Z scale and residuals Setting up the Measurement Sensors PaveSmart 3D Milling TR 73 Setting up the Measurement Sensors PaveSmart 3D Milling TR 74 Characteristics Description Points and height transfor mation The type of height transformation performed depends on the number of available points with height information No point No height transformation One point Heights are shifted to fit to the height control point Two points Average height shift between the two height control points Three points Tilted plane through the three height control points to approximate the local heights More than three points Best fitting average plane Ad
96. s used Select a Profile Open the following dialog Menu Machine Profile Menu Machine Type fe gt Machine Profiles Machine M facti Curb And Gutter Default 3j achine Manufacturer Gomaco Milling Default g Machine Type CurbAndGutter Machine Model GT3600 G21 Controller CONT COPY DELETE BACK o eo Machine Configuration PaveSmart 3D Milling TR 23 Machine Configuration PaveSmart 3D Milling TR 24 On the left side of the screen the available Profiles are listed The currently selected Profile is shown with a black background colour It can be changed by selecting a different machine type On the right side the detailed information from the highlighted Profile is listed sa confirm the selected Profile PaveSmart 3D now automatically restarts to set the new Profile delete the highlighted Profile COPY E create a new Profile by copying the highlighted Profile and changing the required settings See the following dialog Create a new Profile Create a new Profile Open the following dialog Menu Machine Profile Copy Menu Machine Type Copy fei New Profile Name Machine Manufacturer Candven 20008 CP ES Machine Type Milling l jv Machine Model Controller MobaMatic ly sack 4 om eo Enter a lt New Profile Name gt which will show up in the selection list Select a lt Machine Manufacturer gt The lt Ma
97. structions for setting up the TPS1200 product and operating it How to Use this Manual PaveSmart 3D Milling TR 7 How to Use this Manual PaveSmart 3D Milling TR 8 Name of documentation Description MNS1200 User Manual Contains important safety directions as well as instructions for setting up the MNS1200 product and operating it TPS1200 Technical Refer ence Manual Contains detailed technical instructions for setting up the TPS1200 product and operating it MNS1200 Technical Ref erence Manual Contains detailed technical instructions for setting up the MNS1200 product and operating it MGuide User Manual Contains instructions for setting up the MGuide onboard application for TPS1200 and operating it TCPS27 User Manual Contains important safety directions as well as technical instructions for setting up the TCPS27 product and oper ating it optional FreeWave Radio Manual Contains important safety directions as well as technical instructions for setting up the FreeWave radio modems and operating them optional MPC1310 User Manual Contains important safety directions as well as a general description of technical processes and instructions for using and operating the MPC1310 All documents must be read before commencing working on the machine Format of the docu mentation Software Architecture The Leica PaveSmart 3D CD conta
98. t Layer Offset 0 877 ft Slope Offset 5 0 The Work dialog screen shows all the information needed while the machine is in operation a b C d e f g Dash board Error messages the specific icon flashes yellow if a warning is detected or flashes red if an error occurres By pressing on the specific button additional information and troubleshooting tips will be displayed 1 MPC1310 messages 2 Communication messages 3 Sensor messages 4 Machine messages 5 Software messages Corrections indicates the required corrections for the elevation and cross slope of the milling head and the position of the milling head For example if the height correction shows 0 010 in m or ft the machine has to lower the milling head by 0 010 in m or ft The values and settings are exactly the same as those displayed on the machine controller and can be changed manually on the controller or automatically through PaveSmart 3D Information provides information about the work progress e Stationing is calculated at the reference line e Opposite Stationing is calculated from the project data end e Speed is the actual machine calculated from the measurement data e Milling Height is the actual drum height at the ground at the bottom of the drum e Design Height is the project height at the actual drum centre position e Layer offset is the cutting depth e Slope offset is the offset between design slope or th
99. tation of the system are determined by measuring angles or angles and distances to known target points The instrument may be set up on an unknown point A least squares or robust calculation is used to determine the system orientation when performing a resection Resection step by step The following table explains the most common settings Step Description l Check settings for the Fixpoint job in the start screen 2 SETUP F3 from MGuide start screen to access Station Setup 3 SETUP Station Setup Choose a method lt Method Resection gt Type in a station ID and the instrument height 4 CONT F1 to access SETUP Measure Target XX 5 SETUP Measure Target XX Choose a target type in a reflector height and choose reflector type with the F9 key Aim the TPS at the reflector 6 ALL F1 7 Repeat steps 5 and 6 until all target points are measured A minimum of 3 fixpoints should be used to introduce redundancy into the calculation 8 CALC F5 to access SETUP Results XX 9 SETUP Results XX Stn Coords page lt Set gt select the information to be set in the system 10 SET F1 to store the selected setup data and exit the application program S Refer to TPS1200 Technical Reference Manual chapter Setup Methods for more informa tion on instrument setup Setting up the Measurement Sensors PaveSmart 3D Milling TR 53 Setting up the Measurement Sensors PaveSmart 3D
100. uction Tolerances and Stop Rules Leica PaveSmart 3D has integrated safety features designed to send a 3D ERROR to the controller if a system measurement or tolerance error is detected These are defined when setting up the Project All Tolerance and Stop rule settings are set in the Configuration level of Leica PaveSmart 3D and should be turned on when milling The Production Tolerance function allows the user to define a set of rules to send a 3D ERROR message to the hydraulic controller if it is too far away from the reference line if the deviations are outside the predefined tolerances These rules when switched on can prevent incorrect milling if for example the operator forgets to switch on Automatic control for on the machine s control console auto steer is not implemented in V1 10 Separate tolerances are available for the steering elevation and slope controls When the detected deviation exceeds the value set in the dialog 3D ERROR will be indicated at the controller and the D at the PaveSmart 3D screen The steering option is not availeble at milling machines at the moment lt No of Rule breaks before 3D ERROR sent gt sets the number of continuous meas urements which must break this rule before the machine will stop default 10 Machine Configuration PaveSmart 3D Milling TR 31 Machine Configuration PaveSmart 3D Milling TR 32 Menu Machine Production Tolerance fe z O UseSteerRules Left Ri
101. ud rate 115kbit s 115kbit s Transceiver mode Remote Base Link number 0 0 Further information refer to the TCPS27 User manual To check the TCPS27 radio settings open the TCPS configuration tool in Menu Tools Tcps Conf Choose the port number your radio modem is attached to and press Connect Disconnect and reconnect the radio as prompted from the port The configuration tool displays the currently stored settings To change the TCPS configuration repeat the procedure detailed in chapter Checking TCPS radio modem settings Set all values back to the factory settings by pressing lt Default gt Change the appropriate parameter and press lt Save gt Repeat the procedure to check the new parameters have been stored Suggested parameters e Baud rate 115200 baud e Link number 1 15 do not use 0 e TCPS27S Remote link information on machine radio e Radio Handle Base Radio Modem Configuration PaveSmart 3D Milling TR 39 Radio Modem Configuration PaveSmart 3D Milling TR 40 Free Wave radios applicable in U S A Checking Free Wave radio modem settings Storing new Free Wave radio modem settings Free Wave Radios may be used as an alternative to TCPS27 radios in the USA and have a maximum transmitted output of 500 mW I series The radios are delivered as pairs and must be set up in Point to Point Network configuration Each pair of radio must have unique matching parameters To ch
102. uter error message e Start tracking Measured value overrun on controller display Line out blocked in automatic mode e Define layer e Check position TCA SLo out Pot out LAS out 23 out Measured value of active sensor outside permissable measuring area Line out blocked in automatic mode e Check sensor align ment resp position e Replace sensor Measured value of active sensor outside of the set controller window Line out blocked in automatic mode e Check sensor align ment resp position e Set up sensor again DLS Controller and Mobamatic PaveSmart 3D Milling TR 133 DLS Controller and Mobamatic PaveSmart 3D Milling TR 134 Error message Error diagnoses Controller line out Countermeasures Son dEF Slo DEF Controller recognizes faulty sensor Line out blocked in automatic mode e Check and replace connecting cable e Replace sensor Err 2 Battery buffered memory looses data Line out blocked in automatic mode e Acknowledge error message with any key e Reset work position zero point and Design value Err 3 Err 4 Err 5 Data loss of saved parameters in battery independent memory Line out blocked in automatic mode e Acknowledge error message with any key The machine parameters are set to default values e Reset work position zero point and Design value 13 13 1 A
103. vantage Errors in height do not propagate into errors in position since the height and position transformations are separated The height points and position points do not have to be the same points No parameters of the local ellipsoid and map projection is required Parameters may be computed with a minimum of points Care should be taken when computing parameters using just one or two local points as the parameters calculated are valid in the vicinity of the points used for the transformation Disadvantage Restriction in the area over which the transformation can be applied This is mainly due to the fact that there is no provision for scale factor in the projection The accuracy in height depends on the undulation of the geoid The bigger the geoid variations the less accurate the results are Requirements to deter mine a transformation Requirements forcon trol points Diagram of control point distribution To determine a transformation it is necessary to have common control points whose posi tions are known in both WGS 1984 coordinates and local coordinates The more points that are common between datums the more accurately the transformation parameters can be calculated Depending on the type of transformation used details about the map projection the local ellipsoid and a local geoidal model program may also be needed The control points used for the transformation should surround the area for which
104. veSmart 3D Milling TR 126 Set the two ticks as shown below and press Start Check Disk INTERNAL C 2 xi Check disk options IV Automatically Fix file system errors IV Scan for and attempt recovery of bad sectors mes Confirm the message by clicking Yes Checking Disk INTERNAL C i s The disk check could not be performed because the disk check utility needs exclusive JW access to some Windows files on the disk These files can be accessed only by restarting Windows Do you want to schedule this disk check to occur the next time you restart the computer Lem Restart MPC1310 The disk check can only take place during a start up of the MPC1310 machine computer Therefore you have to restart your computer before the procedure can be finished As soon as the computer starts up again you will see a blue screen with some percentage numbers counting up This may take a few minutes Further Steps During the disk check some files on your drive c may be deleted automatically if they are corrupted If this happens one or more of the following steps may be necessairy e Upload the PaveSmart design project again e Delete projects you don t need anymore e Reinstall PaveSmart 3D Maintenance Tasks PaveSmart 3D Milling TR 127 DLS Controller and Mobamatic PaveSmart 3D Milling TR 128 12 DLS Controller and Mobamatic 12 1 Operating the DLS Controller Function keys a b
105. vel Config gt All configuration tasks will be accessible in the operator level The configuration level password is 007 e Level 3 Service level This is intended for service personal to install the system and for rapid trouble shooting if any problems arise Enter the current Date Menu Preferences Date and Time and time zone Menu Preferences Date and Time Rica Date e coo Time OS O08 Bg The Day Month Year and current time can be set in the Menu Preferences Date and Time dialog Changing the date and time settings in Leica PaveSmart 3D also changes the windows date and time settings All logfiles are timestamped relative to this clock Setting the Operators Preferences PaveSmart 3D Milling TR 97 Setting the Operators Preferences PaveSmart 3D Milling TR 98 Choosing the appro Menu Preferences Units fei priate Units Type Distance US Feet ft ly Angles 360 dec deg Slope Percent spo US feet min ft min ry TT Stationing 1234456 7 ry CONT DEFAULT BACK j J c O 8 sA eo The Menu Preferences Units dialog allows the unit settings to be customised to your needs The unit options are e lt Distance gt US Feet ft default International Feet fi Meter m e lt Angles gt 360 dec deg default 400 gon gon e lt Slope gt Percent 360 dec deg default 400 gon gon e lt Speed gt US Feet min ft min default Meter min m min
106. view results of the transformation Accesses DET C SYS TransformationResults Waa MORE F5 WEA LARA To display information about height residuals Column Description WGS84 Pts The point ID of the points chosen from lt WGS84 Pts Job gt East The Easting residual If positions were not used in the transformation calcu lation then will be displayed North The Northing residual If positions were not used in the transformation calcu lation then will be displayed Height The Height residual If heights were not used in the transformation calcula tion then will be displayed Indicates residuals that exceed the residual limit defined in DET C SYS Configuration Residuals page Indicates the largest residual in East North and Height Next Step IF the residuals are THEN ESC returns to DET C SYS Step 3 Match Points n Matched points can be edited deleted or temporarily removed from the list and the transformation recalculated CONT F1 continues to DET C SYS Step 5 Store Coord System unacceptable acceptable This screen consists of the Summary page and the Coord System page The Coord System page contains different fields depending on what transformation type was chosen in DET C SYS Step 1 Choose Transform Type The explanations for the softkeys given below are valid for all pages ae SS SSS DET C SYS Step 5 Store Coord
107. xis slope sensor Art no 722428 I MPC1310 Art no 776882 m H cable Power CAN connection Art no 776873 n Cable to machine Art no 667345 o Junction box Right Art no 766977 p Slope sensor CAN Art no 732660 q Coiled cable Art no 667345 a3 Cabeling one TPS and GPS Satel a b c d e f g h i j MPC1310 Art no 776882 TCPS27S radio modems Art no 737909 PWM cable for serial connection to TCPS275 Art no 776874 PWM cable for serial connection COM3 to TCPS27S Art no 776877 Straight Cable 7pol Art no 726089 Alarm box Art no 734166 Cable MPC1310 to PowerBox Art no 767518 Cable PowerBox to machine battery Art no 762356 SATELLine or Freewave radio PowerBox GNSS sensor Art no 761677 H cable Power CAN connection machine specific Cable to machine usually supplied by machine manufacturer as part of 3D Kit m GNSS antenna Art no 753221 n Antenna cable Art no 632372 System Installation and Components PaveSmart 3D Milling TR 143 System Installation and Components PaveSmart 3D Milling TR 144 Total Station s The system supports TPS1200 Total Stations with the OnBoard software application MGuide The radio modem is integrated into the handle of the instrument Only fully robotic ATR equipped instru ments can be used with PaveSmart 3D i e TCP TCA TCRP verions angular accuracy recommend

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