0001761 Articulation supplement v2, English
Contents
1. ZED GLOBAL SYSTEM ARTICULATION SOFTWARE MODULE USER MANUAL SUPPLEMENT Ref ND0001760 Issue 2 00 Date 23 December 2010 ZED Tunnel Guidance Ltd Unit 1 Russell House Molesey Road Hersham Surrey KT12 3PJ UK Tel 44 0 1932 251440 Fax 44 0 1932 244971 Email sales zed tg co uk Website www zed tg co uk ZED Global System ARTICULATION MANUAL SUPPLEMENT ZED Tunnel Guidance Ltd 2010 The information in this document is confidential and the property of ZED Tunnel Guidance Ltd It is released on condition that it shall not be disclosed to a third party without the prior written consent of ZED Tunnel Guidance Ltd Page 2 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System Contents 1 INTRODUCTION 2 INSTALLATION 2 1 Activating Articulation Mode 3 CONFIGURATION 3 1 Articulation Extensometer Settings 3 2 Extensometer Data 3 4 1 PLC via EtherNet IP Link ZEDOUT 3 4 2 AB1734 POINT I O Module via EtherNet IP 3 4 3 RS232 Serial Link 3 5 ZEDIN Data Tag 4 OPERATION 4 1 Main View 4 1 1 Mini View Articulation 4 1 2 Mini View Articulation Position 4 1 3 Mini View Lead to Axis amp Lookup to Axis 4 1 4 Mini View Graphical Positions 4 2 Menu Pages 4 2 1 Present Position Menu 4 2 2 Articulation Position Menu 4 2 3 Predicted Position Menu 4 2 4 Machine Params Menu 5 TROUBLESHOOTING 5 1 PLC EtherNet IP Link APPENDIX A SETTING THE PDU IP ADDRESS2. Page 20 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 4 2 2 Articulation Position Menu 2E 2EDGlobal 2 8 7 This is the default DTA tab 13 32 34 Comms LI DTA Data 11 09 2006 D x Articulated The X and Y offset of the TBM centre from the DTA at the Position articulation plane This is the plane mid way between the front and rear shields Global Machine Global position of the articulation pivot point between the two shields Position specified in North East and Level Lead to Axis Lead angle to the DTA of the front shield Lookup to Axis Lookup angle to the DTA of the front shield 4 2 3 Predicted Position Menu 2 2EDGlobal 2 8 7 This is the default DTA ta able for ZEDDemo lol x 13 31 42 Comms D DTA Data 11 09 2006 ND0001760 Articulation Manual Supplement v2 0 English Page 21 ZED Global System ARTICULATION MANUAL SUPPLEMENT Predicted The X and Y offset of the TBM centre from the DTA at the prediction Position plane This plane is a distance of CUPD extensions ahead of the articulation point normally set to the plane of the cutter face Global Machine Global position of the predicted position in North East and Level Position Lead to Axis Lead angle to the DTA of the rear and front shield combined Lookup to Axis Lookup angle to the DTA of the rear and front shield combined 4 2 4 Machine Params Me
3. Undefined An unexpected error has occurred on this data value Please contact ZED Tunnel Guidance Page 16 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 4 OPERATION 4 1 Main View When running in articulated machine mode the main view is as shown below Z ZEDGIobal 2 8 7 This is the default DTA table for ZEDDemo gt Ioj x 13 37 18 Do comme LI DTA Data 11 09 2006 BE SET SEHR AM es BEE Present Position 60 A3 Predicted Position 6 Predicted Position Articulation Lead to Axis Articulation Position 25 19 Lookup to Axis 4 1 1 Mini View Articulation The articulation view displays the articulation extensometer values Articulation or articulation angles The incoming extensometer value is displayed for each ram along with the ram label The shaded area represents the current extension where no shading indicates 0 closed and fully shaded indicates max extension In this mode the horizontal and vertical articulation angle is shown ND0001760 Articulation Manual Supplement v2 0 English Page 17 ZED Global System ARTICULATION MANUAL SUPPLEMENT Articulation To change between the display modes the articulation mini view needs to be selected into the middle by clicking it As shown on the left a toggle mode button appears in the top left corner of the view By clicking this it s
4. ND0001760 Articulation Manual Supplement v2 0 English ARTICULATION MANUAL SUPPLEMENT o N Gi Page 3 ZED Global System ARTICULATION MANUAL SUPPLEMENT Page 4 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 1 INTRODUCTION Normally for a double shielded or articulated Tunnel Boring Machine TBM the Combined Target Unit is mounted within the front shield Occasionally this is not possible due to space restrictions and in this case these units have to be mounted in the rear shield In order to measure the cutter position it is then necessary to measure the relative displacement between front and rear shields and it is for this purpose that the Articulation Software Module is used The articulation module receives data from extensometers or linear transducers within the hydraulic rams which are mounted around the circumference of the TBM between the front and rear shields These can be read either directly from a PLC using EtherNet IP from an Allen Bradley 1734 Ethernet IP POINT I O module or via a serial RS232 link From these ram extensions the elongation and angular deviation between front and rear shields may be determined and used in calculating the TBM s position ND0001760 Articulation Manual Supplement v2 0 English Page 5 ZED Global System ARTICULATION MANUAL SUPPLEMENT Page 6 ND0001760 Articulation Manual Supplement v2 0 English ZED Global Sys
5. AE2 AE3 ABA SE2 SE3 SE4 TEI TE2 TE3 TE4 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT The photo above shows a AB1734 module with 4 extensometers installed In this case they are 4 cutterhead articulation extensometers Therefore using the table on the previous page they should be wired in the following order from left to right AE AE2 AE3 AE4 These values correspond to the four quadrants used on the Articulation setup menu page After the extensometers have been wired and calibrated the general operation should be checked to ensure that they have been installed in the correct order This is best done by placing the articulation into a known direction e g up and right and then checking that the calculated angles are as expected 3 4 3 RS232 Serial Link This mode is under development ND0001760 Articulation Manual Supplement v2 0 English Page 15 ZED Global System ARTICULATION MANUAL SUPPLEMENT 3 5 ZEDIN Data Tag The ZEDIN Data Tag is used to export guidance data from the ZED system to a PLC This feature is activated by importing a ZEDIN tag file obtained from ZED Tunnel Guidance This file specifies which data variables are to be exported and in which order they appear The tag needs to be created in the PLC as a User Defined Type UDT and its data members need to match the file order For each data value specified two DINTs need to be created i
6. EIP Error Table e The PLC did not recognize the service Ox4C Read tag it was asked to perform Unable to find an Ethernet IP target at the specified IP address Verify IP address and ensure it has been entered correctly 14 IP address found but network path doesn t complete Check the correct PLC type and slot number is configured in the menu 0 2 Unknown attribute specified Check that the ZEDOUT tag has been created in the PLC s data tag table 10001 Failed to send unconnected message Internal error 10002 Incorrect number of extensometer values returned from the PLC Check that the number of entries in the ZEDOUT data tag match the number of extensometers expected by the ZEDGlobal software This will result in a data format error on the extensometer values 10003 Incorrect data type Check that the PLC data tag has been created as a User Defined Type UDT For further advice or if the error is not listed in the table contact ZED Tunnel Guidance If there is nothing displayed in the comms window when the Ethernet IP device is selected then the network connection on the PDU is not working Ensure the IP addresses for the PLC and PDU are compatible See Appendix A below for information on how to change the PDU IP address ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT APPENDIX A SETTING THE PDU IP ADDRESS The IP ad
7. The ZEDIN Tag field will update to show the new file description ND0001760 Articulation Manual Supplement v2 0 English Page 11 ZED Global System ARTICULATION MANUAL SUPPLEMENT The default IP address for aPDU 1s 192 168 1 222 with a subnet mask of 255 255 255 0 It is important that the subnet portion of the IP address in this case 192 168 1 is the same on the PDU and the PLC it is trying to communicate to If the PDU IP address needs changing then please see Appendix A Setting the PDU IP Address ZEDOUT Data Tag The values in the PLC are extracted by reading the ZEDOUT tag in the PLC s Data Tag Table This tag needs to be created in the PLC as a User Defined Type UDT and its data members need to match the extensometer values expected by the ZEDGlobal system Each data member should be a DINT and the order shown in the table below should be maintained omitting any extensometers not present on the system Name BLE AE2 AE3 AE4 SE2 SE3 SEA TE2 TE3 TEA If the number of extensometer values transmitted to the ZEDGlobal system does not match the ZEDGlobal configuration the extensometer values will have a Data Format error indicated by the symbol Page 12 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 3 4 2 AB1734 POINT I O Module via EtherNet IP If no direct link to a PLC is available then the ram extensometers can be connected to an Allen Brad
8. The scale in the bottom right indicates what each tick mark on the cross represents in this case 10mm In this example you can see that the present position is to the right and below the DTA However the rear shield is angled in such a way that the articulated position is above and to the left of the DTA The articulation of the front shield then takes the predicted position slightly to the left and above the DTA If the machine was on the DTA and at the same angle all three circles would be concentric about the middle of the cross 4 2 Menu Pages When running in articulated mode some of the menu pages change their behaviour slightly 4 2 1 Present Position Menu ZE ZEDGIobal 2 8 7 This is the default DTA table for ZEDDemo Ag EEE EEE 13 31 04 Comms DTA Data 11 09 2006 ES SERS 5 SREY Present Position x x Present Position 60m 43 mm Northing Easting Level Global Machine Position 815 304 m 843 644 m 73 766 m Lead to Axis 11 mmm Lookup to Axis 10 mmm Present Position The X and Y offset of the TBM centre from the DTA at the present position plane This is the plane of the front screen in the target unit Global Machine Global position of the TBM centre at the present position plane in Position North East and Level Lead to Axis Lead angle to the DTA of the rear shield where the target is mounted Lookup to Axis Lookup angle to the DTA of the rear shield where the target is mounted
9. possible to cycle between the available mode ZEDGlobal will remember the last selected mode 4 1 2 Mini View Articulation Position Articulation Position 25 This view shows the position of the articulation pivot point relative to the DTA 19 4 1 3 Mini View Lead to Axis amp Lookup to Axis Lead to Axis afa In an articulated machine each shield has a different lead and lookup to the DTA depending on the articulation Using these two values a combined lead and lookup to the DTA can be calculated This combined value is the one displayed by these mini views The diagram below illustrates these three sets of values Note The drawing of the front and rear shield only indicates that articulation mode is active and is not an indication of the current attitude of the machine Lookup to Axis lt Page 18 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT DIA Read Shield Angle Front Shield Angle DTA Combined Shield Angle ND0001760 Articulation Manual Supplement v2 0 English Page 19 ZED Global System ARTICULATION MANUAL SUPPLEMENT 4 1 4 Mini View Graphical Positions This view shows the present position blue articulated position yellow and predicted position green relative to the DTA The DTA is the centre of the cross and the view is drawn from the rear of the machine looking forwards in direction of advance
10. the bottom X axis The Gain value specifies the distance that each volt corresponds to This will set the slope of the graph The two values below show what the current voltage is and what distance this equates to using the current zero and gain parameters These values are also shown on the graph as a green cross The maximum extension distance on the Y axis needs to be set for each extensometer type using the Ram Setup menu pages see Section 3 1 for details on the Articulation Setup Extensometer Calibration mr 2 036 ARI 1 X 600 Y 600 ET Gain ui AR2 3 X 600 Y 600 MEN cola AR3 7 X 600 Y 600 value ale AR4 10 X 600 Y 600 The example above shows how adjusting the zero value affects the graph The best method of calibrating the extensometers is to fully retract the ram and then enter the voltage value shown as the zero offset Then position the ram to a known distance e g 1000mm and adjust the gain until the distance value reads the correct distance For cutterhead articulation rams it may be difficult to stroke the rams in this way In this case we recommend setting all rams to their middle positions and adjusting the zero and gain values such that the graph is balanced about the current middle position The extensometer outputs need to be wired into the appropriate IO module The table below details the order in which they should be wired going from left to right in the module BLE
11. dress of the PDU needs to have the same subnet as the PLC it 1s trying to talk to Normally the subnet mask is 255 255 255 0 which means the first three numbers of the IP address needs to be the same For example if the PLC s address is 192 168 0 60 then the PDU needs to have an IP address of 192 168 0 xxx where xxx is a unique number on the local network The default IP address for a PDU 1s 192 168 1 222 To set the IP address you will need a USB keyboard plugged into the USB port on the side of the PDU top connector l Close ZEDGlobal 2 Run Explorer from the start menu To do this move the mouse cursor down to the bottom of the screen to reveal the taskbar Press the Start menu button which should contain the explorer item 3 Open Control Panel from within My Computer 4 Open Network Connections 5 Select Local Area Connection Now open Properties from the File menu 6 Select Internet Protocol TCP IP and press the Properties button 7 Select Use the Following IP Address option if not already selected 8 Enter your IP address 9 Enter your subnet mask 10 Press OK 11 Press Close on the network connections dialog 12 Run ZEDGlobal ND0001760 Articulation Manual Supplement v2 0 English Page 25
12. ley 1734 Ethernet IP POINT I O module The supported types of extensometer outputs are 0 10VDC or 4 20mA This mode is selected on the Ethernet Setup menu page as shown below 15 45 57 Comms DTA Data 23 12 2010 4510 VDE SS DE Ethernet Setup PLC Type AB1734 POINT IO IP Address _10 _9 _8 _56 ZEDBasic 3 1 6 By selecting AB1734 POINT IO as the PLC type and specifying the IP address of the module it is possible to read the extensometer output It is necessary to calibrate the conversion of the incoming voltage to an extension distance This is done using the Extensometer Calibration dialog accessed by pressing the settings button Extensometer Calibration AR 3 600 Y 600 AR3 7 X 600 Y 600 ARA 10 x 600 Y 600 This dialog allows the calibration of all extensometers types A symbol for each type CutterHead Shove Tail skin and Boom of extensometer installed will be shown By clicking the symbol the corresponding group of extensometers are shown By clicking the individual extensometer labels the settings for each one can be viewed and edited ND0001760 Articulation Manual Supplement v2 0 English Page 13 ZED Global System ARTICULATION MANUAL SUPPLEMENT Page 14 The two editable fields are Zero and Gain The Zero value specifies at which voltage the extensometer is reading Omm This zero offset will move the start of the graph along
13. n the tag The first DINT is for the data value and the second is for any errors associated with this value The first DINT in the tag should be called HEAD and the last should be TAIL These values will increase everytime new data is written to the tag and the tag data should only be used if the head value equals the tail value The table below shows an example ZEDIN tag for two values called XS and YS HEAD DINT Used for ensuring all data is synchronised XS_ Value DINT Value of XS in mm or centi feet depending on system setup The table below shows the possible errors which can be associated with a value Somewhere in the guidance system there is a communication problem and the data from that unit is not available Therefore the guidance data can not be calculated There is a light error on the target or total station EDM The guidance calculations can not be completed This data value has exceeded its allowable range or a value required to calculate this value has exceeded its range and this value was not calculated broken it can t get the data it needs Data Format Some data that the system is expecting is arriving in the wrong format This could be to do with reading the ZEDOUT tag from the PLC or if the PDU has been incorrectly configured for the current target unit 7 Data Value Not Found The piece of data specified in the ZEDIN tag file could not be found in the system Please contact ZED Tunnel Guidance
14. nu ZED ZEDGIobal 2 8 7 This is the default DTA table for ZEDDemo Mf EEE 13 33 38 Comms ota Data 11 09 2006 OS ASE gt SY Machine Params Prediction Distance mm Zero Drive 894 696 Im Ss mm Target Co ordinates mm mm mm X Target Offset hole Lead Steps degrees As shown above the prediction distance is a calculated value in an articulated system It is the sum of the current values of TUPD and CUPD and will vary as the articulation rams change Page 22 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 5 TROUBLESHOOTING 5 1 PLC EtherNet IP Link The Comms Viewer menu page can be used to help find any problems associated with the EtherNet IP link ioj x 22 2EDGlobal 2 7 7 This is the default DTA table for ZEDDemo _ 13 46 02 LI Comms DTA Data 27 04 2006 Toggle the device until it reads Ethernet IP If the system is working properly many values should be scrolling down the screen Each line should start with A0 02 followed by the extensometer values If a line starts with EIP Error followed by a number as shown below then look up that number in the EIP error table ZED ZEDGlobal 2 7 7 for ZEDDemo 14 02 53 LJ Comms LI DTA Data 27 04 2006 ND0001760 Articulation Manual Supplement v2 0 English Page 23 ZED Global System ARTICULATION MANUAL SUPPLEMENT Page 24
15. ont shield Present Position Point Articulation point JE ET En En reL 4 E Er EgtEpt E Page 10 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 3 2 Extensometer Data Extensometer data can be read by the system in various ways Currently the values can be extracted directly from the TBM PLC or an Allen Bradley 1734 POINT IO module via an EtherNet IP link 3 4 1 PLC via EtherNet IP Link ZEDOUT For the system to extract values from a PLC various values need to be configured This is done in the EtherNet IP menu page ZED 2EDGlobal 2 9 1 This is the default DTA table for ZEDDemo ANSIA YO 14 54 50 Comms DTA Data 07 09 2006 EtherNet IP Setup PLC Type IP Address 192 168 1 206 Data Format PLC Slot Ca ZEDIN Tag ControlLogix CompactLogix Specifies the type of PLC the system is connected to IP Address This is the IP Address of the PLC PLC Slot For some PLCs the number of the slot in which the PLC is mounted in the chassis needs to be entered ZEDIN Tag None Descriptive name Shows the descriptive name of the current ZEDIN tag file A value of None means that this data export facility to the PLC is currently disabled Apply New ZEDIN tag Button This is used to import a new ZEDIN tag file from an attached device If a ZEDIN tag file is found in the root folder of the attached device it is imported and applied
16. ooking in the direction of advance AE1 AE2 AE3 AE4 Articulation Extensometer value being received by the system Min Extension The value entered here determines the Minimum Extension value the system will allow as a valid value Max Extension The value entered here determines the Maximum Extension value the system will allow as a valid value Target Unit to Pivot Distance The value entered here is the distance from the plane of the Target Unit Front Screen to the articulation pivot plane when the extensometers are at zero TUPD The value displayed here is the value entered at TUPD 0 with the addition of the extensometer component values CUPD 0 CUtter to Pivot Distance The value entered here is the distance from the articulation pivot plane to the desired predicted position of the cutter when the extensometers are at zero 1 e closed CUPD The value displayed here is the value entered at CUPD 0 with the addition of the extensometer component values Determines how extensometer values are brought into the system ND0001760 Articulation Manual Supplement v2 0 English Page 9 ZED Global System ARTICULATION MANUAL SUPPLEMENT Below are diagrammatic plan views of an articulated TBM in the closed position and in the open or articulated position Pitch circle diameter CUPD 0 TUPD 0 for articualtion rams TUPD TUPD 0 E CUPD CUPD d E Predicted Position Point Axis of rear shield Axis of fr
17. tem ARTICULATION MANUAL SUPPLEMENT 2 INSTALLATION For articulation support the Articulation and Head Ext software modules need to be installed Depending on how the extensometer values are being read either the Ethernet IP or Serial module is also required These are installed on the System Install menu page shown below ZE 2EDGlobal 2 7 7 This is the default DTA table for ZEDDemo 210 x comms DDTa Data 27 04 2006 WE Ethemet IP le 1ee 71 i Urves i i Articulation m De gt W c Select the Articulation Head Ext and in this case Ethernet IP if not already installed modules by clicking them Now enter the keycode provided by ZED Tunnel Guidance for these modules Then press the unlock button to install the modules There should now be green ticks next to newly installed modules as shown below At this point the software should be shutdown and restart This is the default DTA table for ZEDDemo O x 2 2EDGlobal 2 7 7 09 38 17 Comms LI DTA Data 27 04 2006 22 o EEE Gites A stat He ad E Ai stow IR Tai Ski l Doom E I Vino De di a I ND0001760 Articulation Manual Supplement v2 0 English Page 7 ZED Global System ARTICULATION MANUAL SUPPLEMENT 2 1 Activating Articulation Mode Once the necessary articulation modules have been installed it is possible to change
18. the machine type to Articulated This is done on the System Connections menu page as shown below ED ZEDGIobal 2 7 7 This is the default DTA table for ZEDDemo 09 44 08 Comms Data 27 04 2006 System Connections Operational Mode Machine Type Articulated Target Type Advanced Laser Reference Station Mode Page 8 ND0001760 Articulation Manual Supplement v2 0 English ZED Global System ARTICULATION MANUAL SUPPLEMENT 3 CONFIGURATION 3 1 Articulation Extensometer Settings The Articulation Setup menu page is used to define the positions of the Extensometers as well as some limit settings ED ZEDGIlobal 2 8 7 This is the default DTA table for ZEDDemo 13 30 11 Comms 11 09 2006 Articulation Setup AR4 oe ARI z Min Extension mm x min x nus Max Extension mm TUPD 0 7000 mm AEA mm ABI mm Sn om TUPD mm ma eee CUPD 0 mm x mm x mm ce 5 m i 5 Y s0 mm Y 600 mm AES 149 0 mm AE mm Interface PLC EIP R1 AR2 AR3 AR4 Articulation Extension Ram Label Normally the number of the ram containing or nearest the Extensometer A X This is the X position referenced from centre of each articulation Extensometer Right is positive and Left is negative as viewed Y This is the Y position referenced from centre of each articulation Extensometer Up is positive and Down is negative as viewed from the rear of the machine looking in the direction of advance Bo from the rear of the machine l
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