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Intelligent Sensors & Measuring Systems • Controlling • Monitoring

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Contents

1. Laser T log Port Adresses ota Angle I Const Intensity 0 ES Port display u I _ J CT Mode ideo Gain I El Measur e H MIN Intensity XE on 8 ment 101118481 Profibus OK Demarcation C P52 SA 16 window A B Zesssnnssonssnssnsssnnssnsssnsssnssnusssnssnsnsunsnnesssenssenusen LOAD SETTINGS d STORE CAL EXIT Adjust scanner parameters SAYE SETTINGS Adjust mode Load settings command Start record Save settings Shutter control Upper and lower shutter sliders are controls for the electronic shutter to prevent false reflections to enter the signal evaluation in the scanner head camera This shutter may be closed more or less when significant dis tortions from external light source as sunlight or other light sources appears Closing the shutter will but also create the problem that the scanners viewing range is decreased Therefore the use of the shutter sliders is problematic and the shutter sliders should not be moved away from the upper and lower ends unless MEL technical support give you clear advice to do so The result of changing shutter slider position must be checked out thoroughly to avoid any misinterpretation of improvement which may turn out as other problems have been masked out Scanner Parameter Adjustment All Parameter of the Laser Scanners were adjusted in the adjust mode in the application softw
2. cc 2 201011010 111110110 11111011 11111 n ng 23 Open and close the flap manually 223 1101110102111111111010 111111010110 11111110100 c TK v 24 Eye safety and Laser Protection class information cc c2 13111111 11 1 TT ng cv rrn 24 HOWTO DEIN EE 24 Calibration with Compare to Pole lt lt c 100110111010 111111101111 111111010 1n c ng v 25 EEE E 26 Example for Profibus test seouence Q00 1n TH ng n TK n TK n TK TK n n 28 Typical TS UU TMS LOG FI Eee ee ee ee ee 30 Bieles IR 41 Measurement Sequence u u un nn nennen enable een en 822 86 43 Version information Software version 1 8 2 22 September 2008 JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 2 of 43 Laser Measurement System Manual System description Mounting of the Laser Scanners In the existing grinding machine of Max B gl company two Laser Scanners of M2D 200 68 have been inte grated For protection against water and dust the Scanners are packed into a protection case with a pneu matic flap The Laser Scanners are mounted at the vertical arms fort he mechanic probes F a ET ca E Mounting of the electronic unit On the bridge close to the numerical and PLC control system the MEL i Control is mounted The extended Scanner ca
3. e ar Im h2 The level difference results from the difference of the distance signals h and h2 Mounting and cabling of thickness and differenatiation measurement Sensor 1 Electronics 1 Master Electronics 2 Digital Display Slave MODIG 106 sensor 2 Digital Display MODIG 106 The digital display MODIG 106 for displaying all important values indicators and units is optionally available at MEL The device is operated via 5 buttons at the front panel Dar PARA Pia Far M r JN L 5L MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49 89 319 20 23 www MELsensor de 5 1 Product Overview LASER Distance Sensors e Check of dimensions e Detection of position e Detection of material overlap e Control of presence and absence e Check of liquid level e Measuring of concentricity e Vibration analysis e Thickness measurement LASER Line Scanner e Measurement of surface profiles e Inline quality assurance e Position control of assembly machines e Angle measurement e Weldseam guidance and inspection Inductive Proximity Switch MI e For the use in annealing ovens painting plants etc e Inured to permanent temperatures up to 350 C Code Reader ES e Identification of product carriers in conveying systems e Heat resistant up to 400 C e Usable in heavily soiled areas Radio Remote Control STK e Wireless control for production line e Reduction of dow
4. Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 11 0f 43 Laser Measurement System Manual Storage and screen display of measurement values After start signal the next scann profile is captured On screen the progress from hook to hook can be seen without having false pictures displayed IS The checkbox adjust switches the permanent update function When the checkbox is activated the screen is permanently updated For normal operation the adjust checkbox must be unchecked MEL LASER Measuremant Yer 1 8 2 Licensed to WEIHAI HUADONG AUTOMATION CO LTD Scanner 2L Scanner2R Scanner 1 L Scanner 1 R ee 0 ma Jonn 0 000 IN_Y 8 1 92 8 224 E o M o nz Eemer IM ra K2 KI log Port Adresse IT Const Intensity KI C K2 400 LASER Intensity el J a fo Video Gain fT H MIN Intensity F keng C ISAS Demarcation E STORE CALIB For remote access VNC software has been installed The VNC Server should be used activated only for service task and been deactivated straight after finishing the service task The VNC service takes up a lot of system performance When left active in background measurement results could be faulty by doing so li TM Be GA si in D Determination of Y and Z Offset Values of the Laser Scanners The mechanical mounting position of the Laser Scanners has and offset in Y and Z relative to the tactil
5. The laser line is produced by a pulsed laser diode and line generating optics The diffuse reflected light from the target is projected onto a 2 dimensional CCDArray figure 1 The different contour height of the measured object produces deviation of the reflected laser line This deviation is corrected and linearized trigonometrically In addition to the distance infor mation Z axis the position of the measured point X axis at the laser line of the line scanner is shown Function principle Separate unit depending on type of scanner Scan range Objective Linear optic Linearization unit Compensates Optical distortion Scattered light effects rn pixel noise Real time speccles Image processing Remote scanner control Shutter speed External trigger Data output to PC for further processing Buffer Interfaces dep on type d SA card Ethernet i Control SCANNER Control Fig 2 Scanner construction The scanner features a very com pact construction since all the li nearization and distance measurements are already handled completely from integra ted hardware in the scanner it self A narrow band filter protects the sensor against external light influ ence up to 5000 Lux The optics are protected by an optionally available replaceable plastic window These plastic windows will repell welding plasma sparks In case of wear the pro tection window can b
6. note Stop gt lt Command data 84 09 00 10 00 00 20 00 00 00 84 07 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note R7 9 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 84 06 00 10 00 00 20 00 00 00 84 04 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note R4 6 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 84 03 00 10 00 00 20 00 00 00 84 01 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note R1 3 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 40 00 00 00 00 00 00 00 00 00 20 00 00 00 00 00 00 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note Auswertung gt lt Command datars232 00 aktiv 1 waittime 2000 note v gt lt Makro data 07 aktiv 1 waittime 100 note RS232 Reset gt lt Makro data 03 aktiv 1 waittime 100 note CalcMethode gt lt Makro data 08 aktiv 1 waittime 5000 note Start gt lt Makro data 09 aktiv 1 waittime 3000 note Stopp gt lt ProfiBusSlave gt lt ProfiBusMakro gt lt Makro data aa 11 22 33 44 55 66 77 88 aa 11 22 33 44 55 66 77 88 00 11 22 33 44 55 waittime 11 aktiv 1
7. note Makro1 gt lt Makro data 11 22 33 44 55 66 77 88 aa waittime 1100 aktiv 1 note Makro2 gt lt Makro data 22 33 44 55 66 77 88 aa bb waittime 11 aktiv 1 note Makro3 gt lt Makro data 33 44 55 66 77 88 aa bb cc waittime 11 aktiv 1 note Makro4 gt lt Makro data 44 55 66 77 88 aa bb cc dd waittime 11 aktiv 1 note Makro5 gt lt ProfiBusMakro gt lt Programm gt lt Settings autostart 1 logfensterscroll 1 rxzeit 1 updatezeit 10 fileloggen 0 logfilename profibuslog txt gt lt Programm gt lt ProfiBusSPSSimulator gt JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 29 of 43 Laser Measurement System Manual Typical result file Log File Results Date 10 22 06 Time 7 35 52 AM Version Ver 1 8 0 KontrollMesspunkte 1 1 a 400 000000 954 431990 197 883827 0 000000 0 000000 0 000000 0 000000 0 000000 1 1 2 a 400 000000 945 276290 226 127253 0 000000 0 000000 0 000000 0 000000 0 000000 1 1 3 a 400 000000 934 276290 239 509079 0 000000 0 000000 0 000000 0 000000 0 000000 1 1 4 a 400 000000 908 466290 227 069092 0 000000 0 000000 0 000000 0 000000 0 000000 1 1 6 a 400 000000 579 014542 208 932621 0 000000 0 000000 0 000000 0 000000 0 000000 1 1 7 a 400 000000 589 8891 54 236 599516 0 000000 0 000000 0 000000 0 000000 0 000000 1 1 8 a 400 000000 600 889154 249 234071 0 000000 0 000000 0 000000 0 0
8. show that everything is ok with the Laser Scanners Intensity 100 Intensity 0 Intensity 100 Intensity 0 When the bar graph readings are ei mn oe um me wm oe ae significantly lower than 100 the front windows shall be checked and probably cleaned When after cleaning on a bright object concrete surface no good reading can be achieved the intensity setting of the Laser shall be checked in the adjust mode When no Laser beam is visible with activated Lasers on the object the Scanner cables shall be checked Hold a piece of paper or your hand below the Laser never look directly into the laser beam When the laser beam has full intensity and starts to regulate to a lower level as soon as you place your hand underneath the scanner then the hardware function should be ok When no object is in range the laser turns on maximum intensity When an object comes into the vision range the intensity is lowered un til the camera has good intensity over the whole range As described above this feature can be used to verify Laser Scanner function very quickly Maintenance and servicing the Laser Scanners M2D Laser Scanners are virtually free of demand for service This means the Scanner itself does not re quire any maintenance or recalibration The Scanner is an optical device like a photo camera the optical system is sensitive against dust fingerprints dirt and specially water The protection case holds away any dir
9. 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 2 b 4800 000000 936 739163 236 656392 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 3 b 4800 000000 925 739163 250 08281 1 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 4 b 4800 000000 899 929163 237 451385 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 6 b 4800 000000 571 033365 216 151575 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 7 b 4800 000000 581 602619 243 928394 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 8 b 4800 000000 592 602619 256 726149 0 000000 0 000000 0 000000 0 000000 0 000000 1 24 9 b 4800 000000 618 412619 243 128067 0 000000 0 000000 0 000000 0 000000 0 000000 1 25 1 a 5600 000000 940 688768 202 121588 0 000000 0 000000 0 000000 0 000000 0 000000 1 29 2 a 5600 000000 931 472291 230 309816 0 000000 0 000000 0 000000 0 000000 0 000000 1 29 3 a 5600 000000 920 472291 243 511164 0 000000 0 000000 0 000000 0 000000 0 000000 1 25 4 a 5600 000000 894 662291 231 039610 0 000000 0 000000 0 000000 0 000000 0 000000 1 25 6 a 5600 000000 565 057188 212 403282 0 000000 0 000000 0 000000 0 000000 0 000000 1 25 7 a 5600 000000 576 008383 240 1 35936 0 000000 0 000000 0 000000 0 000000 0 000000 1 25 8 a 5600 000000 587 008383 253 003669 0 000000 0 000000 0 000000 0 000000 0 000000 1 25 9 a 5600 000000 612 818383 239 20 73 70 0 000000 0 000000 0 000000 0 000000 0 000000 1 2 1 a 5600 000000 948 672779 208 802151 0 000000 0 000000 0 000000 0 000000 0 0
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11. 000131 685 81 1 162 234 438770 7 2 a 1625 000131 5941 722920 226 901348 7 2 b 1625 000131 942 109716 226 779766 Z 3 a 1625 000131 929 808603 240 329307 7 3 b 1625 000131 930 204961 240 216075 4 a 1625 000131 905 222822 227 989512 7 4 b 1625 000131 905 612539 227 871954 Z 5 a 1625 000131 840 998789 229 927207 Z 5 b 1625 000131 841 395439 229 813819 Z 6 a 1625 000131 575 434629 209 749200 7 6 b 1625 000131 575 812138 209 669649 7 1 a 1625 000131 586 421240 237 445157 7 7 0 1625 000131 586 805195 237 364209 Z 8 a 1625 000131 596 643955 250 193633 7 8 b 1625 000131 597 020888 250 104786 7 9 a 1625 000131 623 638076 236 335889 7 9 b 1625 000 131 624 028232 236 250332 10 1 a 2275 000517 949 319648 199 198516 page 37 of 43 10 2 a 2275 00051 7 940 037910 227 413604 10 2 b 2275 000517 940 430175 227 279707 10 3 a 2275 000517 928 128613 240 845362 10 3 b 2275 000517 928 523466 240 714278 10 4 a 2275 000517 903 534668 228 499698 10 4 b 2275 000517 903 924336 228 369092 10 5 a 2275 00051 7 839 319062 230 429375 10 5 b 2275 000517 839 714521 230 311670 10 6 a 2275 000517 573 65166 210 243467 10 6 b 2275 000517 574 150742 210 137754 10 7 a 2275 00051 7 584 745879 237 939971 10 7 b 2275 000517 585 153877 237 832852 10 8 a 2275 00051 7 594 973466 250 689004 10 8 b 2275 000517 595 359570 250 584913 10 9 a 2275 00051 7 621 950195 236 833047 10 9 b 2275 000517 622 340537 236 723702 13 1 a 2925 001299 947 656084 199
12. 04 07 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L7 9 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 06 00 10 00 00 20 00 00 00 04 04 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L4 6 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 03 00 10 00 00 20 00 00 00 04 01 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L1 3 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command datars232 00 aktiv 1 waittime 5000 note STOP Change Side gt lt Command data 84 1e 00 10 00 00 20 00 00 00 84 1c 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note R28 30 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 84 1b 00 10 00 00 20 00 00 00 84 19 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note R25 27 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 84 18 00 10 00 00 20 00 00 00 84 16 00 01 00 0
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14. 497138 238 074590 28 10 b 6175 004803 673 90451 1 237 948096 28 2 a 6175 004803 929 623789 230 508956 28 2 b 6175 004803 930 015507 230 349366 28 3 a 6175 004803 917 715820 243 859483 28 3 b 6175 004803 918 130634 243 772295 28 4 a 61 75 004803 893 402216 231 581416 28 4 b 61 75 004803 893 792031 231 424756 28 5 a 61 7Z5 004803 828 905673 233 519258 28 5 b 6175 004803 829 321396 233 355752 28 6 a 6175 004803 563 497578 213 277618 28 6 b 6175 004803 563 904423 213 148975 28 7 a 61 75 004803 574 470195 240 975166 28 7 b 6175 004803 574 884697 240 846290 28 8 a 61 75 004803 584 706621 253 720782 28 8 b 6175 004803 585 113877 253 554864 28 9 a 6175 004803 611 818252 239 870186 28 9 b 61 75 004803 612 208261 239 73831 1 3 1 a 324 999522 935 087747 205 748360 3 1 0 324 999522 934 707943 205 601329 10 a 324 999522 669 31 1800 238 974258 3 10 0 324 999522 668 919525 238 839620 3 2 a 324 999522 925 484046 233 901114 3 2 0 324 999522 925 102230 233 753975 3 3 a 324 999522 913 897406 247 305166 3 3 b 324 999522 913 519036 247 191436 3 4 a 324 999522 888 589505 234 633379 3 4 0 324 999522 888 201 751 234 486329 3 5 4 324 999522 825 087542 235 910957 3 5 0 324 999522 824 707552 235 797950 3 6 324 999522 559 311693 213 136163 3 6 0 324 999522 558 919378 212 994258 a 324 999522 570 053968 240 936680 3 7 0 324 999522 569 644935 240 797510 3 8 a 324 999522 580 521 742 253 861797 3 8 b 324
15. 5 a 1625 001083 828 396488 236 692276 9 5 b 1625 001083 828 033900 236 627022 9 6 a 1625 001083 562 820970 213 945040 9 6 b 1625 001083 562 437806 213 868331 9 7 a 1625 001083 573 529798 241 747510 9 7 b 1625 001083 573 164251 241 670684 9 8 a 1625 001083 584 030482 254 671084 9 8 b 1625 001083 583 647279 254 604747 9 9 a 1625 001083 610 329066 241 010088 9 9 b 1625 001083 609 939681 240 935879 12 1 a 2275 001470 940 085597 206 967950 12 1 b 2275 001470 939 701956 206 877969 12 10 a 2275 001470 674 522474 240 196758 12 10 b 2275 001470 674 120404 240 099180 12 2 a 2275 001470 930 469886 235 121241 12 2 b 2275 001470 930 101077 235 031221 12 3 a 2275 001470 918 892396 248 498760 12 3 b 2275 001470 918 51 1361 248 428770 12 4 a 2275 001470 893 657513 235 860616 12 4 b 2275 001470 893 267142 235 764444 12 5 a 2275 001470 830 081995 237 136993 12 5 b 2275 001470 829 701048 237 036104 12 6 a 2275 001470 564 522689 214 421 133 12 6 b 2275 001470 564 120824 214 273555 12 7 a 2275 001470 575 246478 242 221475 12 7 b 2275 001470 574 853646 242 075655 12 8 a 2275 001470 585 732718 255 117715 Laser Measurement System 12 8 b 2275 001470 585 330326 255 01 3663 12 9 a 2275 001470 612 016771 241 484131 12 9 b 2275 001470 611 627347 241 343916 15 1 a 2925 001329 941 740589 207 277471 15 1 b 2925 001329 941 362454 207 200684 15 10 a 2925 001329 676 173577 240 500567 15 10 b 2925 0013
16. 675 000000000000 895 000000000000 13 70000 0000000 1 10338 426757812500 11769 382812500 000 Koordinaten 1 325 000373969267 752 549927850407 0 000550 1 19495 0 000000000000e 00 1 490116119385e 08 0 000000000000e 00 1 1 1 0 210000 0 MZ001 2 325 000389202796 0 000072155001 0 000550119439 0 000000000000e 00 0 00000000 0000e 00 0 000000000000e 00 0 0 1 0 000000 0 3 325 000404430582 752 550072147038 0 000550 1 19375 0 000000000000e 00 1 490116119385e 08 0 000000000000e 00 1 1 1 0 210000 0 MZ001 4 975 001153776756 752 549783547090 0 000650359354 0 000000000000e 00 1 4901 16119385e 08 1 519626234052e 07 1 1 1 0 210000 0 MZ001 5 975 001169004071 0 000216453068 0 000650359290 0 000000000000e 00 0 00000000 0000e 00 0 000000000000e 00 0 0 1 0 000000 0 6 975 001184238071 752 550216450355 0 000650359234 0 000000000000e 00 1 4901 16119385e 08 1 54138809931 1e 07 1 1 1 0 210000 0 MZ001 7 1625 001013185754 752 549441917492 0 000749306266 0 000000000000e 00 6 329047853230e 07 6 165552397245e 07 1 1 1 0 210000 0 MZ001 8 1625 00194880821 7 0 000360757821 0 000750599144 0 000000000000e 00 0 00000000 0000e 00 0 000000000000e 00 0 0 1 0 000000 0 9 1625 001965603958 752 550558083851 0 000750601283 0 000000000000e 00 6 329047853230e 07 6 154738792200e 07 1 1 1 0 210000 0 MZ001 10 2275 001399742904 752 550216443712 0 0001 51007287 0 000000000000e 00 6 327293439377e 07 6 154738792200e 07 1 1 1 0 210000 0
17. 89 319 20 23 www MELsensor de 6 beam from mirroring surfaces with scratches e multiple reflections at edges e dark coloured objects which do not reflect enough light e extreme variation of the sur face finish e no object within the measu Sensor Measured object LL Scan data Z X X Intensity I X kg i Area to suppress Fig 4 ring range e interrupted laser beam and shadows e partly transparent surfaces si milar to glass or synthetic ma terial e for each measurement point the corresponding intensity has to be evaluated in addition to the dis tance information X Z in order to obtain valid measurements Application Notes Measurement setup e The resolution degrades with increasing distance between object and scanner especially with large scan ranges e Best results are achieved when the scanner beam is focused rectangular to the objects sur face Measurements with angu lar deviation of up to 60 are pos sible e In order to avoid radio interfe rence or noise the scanner should be electrically isolated from the mounting surface e Scanners with detached sensor head are perfectly matched to their individual electronic box and should not be interchan ged or mixed up e The interface wire should not be exchanged by a longer or shorter one Scanner Configuration Adjustment of shutter speed The shutter speed is regulated depending on the brightness of th
18. LASER Scanner General description LASER Scanner M2D LASER Scanner M2DW Evaluation Electronic i Control Blue Box ISA Card LASER Scanner M2 iLAN LASER Scanner M2W iLAN Other products Distributors 13 15 17 18 19 25 27 28 ASS MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49 89 319 20 23 www MELsensor de SC Functional Description The Scanner M2D provides the 2 dimensional measuring of pro file heights The measured ob jects may consist of various ma terials A laser line is projected onto the target and the distance to several points of the object is measured by triangulation The height Z axis by distance X axis is measured The result is the 2 dimensional contour of the object Zt Profile Bin X Start Scanrange Scanrange Z axis Object Fig 1 Typical applications e Precise guidance of handling robots assembly of window panes positioning of car bodies gap adjustment in automotive welding seam tracking quality assurance Measurement for automatic as sembly notch gap egde width and depth of fissures 3D shapes and profiles fissured profiles Object detection discrimination sorting go no go recognition completeness collision detection mobile gap measurement e Welding seam control automatic welding robot guidance Method of measurement The Line scanner M2D is working according to the triangulation method
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20. active the laser light will be shining Have the concrete panel or a test fixture under the lasers so that the software will show a profile Check the position of scanner 1 and adjust mechanical position of the test fixture or machine axis so that scanner 1 has an ideal profile The test fixture should be positioned in a way that later scanner 2 can reach the same position as scanner 1 Also the test fixture should be positioned horizontally and stable so that it will not move by hazard On the test fixture make a marking where the laser beam of scanner 1 hits the target Note the machine axis position precisely Remove scanner 1 from the test area so that scanner 2 can go there without collision Now change machine position for scanner 2 so that scanner 2 will see the same object at the same previously marked position as scanner 1 before The software tool needs to be left unchanged to give a clear indication of machine position GG Note the precise position of scanner 2 over the test fixture Now the Numerical control PC can calculate the offsets in Y and Z Manual ESE EES EE 8 M6 E E ees Pee hi co cac eyes bi c TEEN eee EI e E ee ee ee i m E m m ELLEELLE e 8 ME E RE f Pees ees eee ees eee eee eee between scanners and machine axis encoders gathered in the steps before t When Ausrichten is finished exit the software Test fixture The adjustment of the axis is b
21. scanner rejecting dust and water sparkles from the scanners front Picture at the right side view on scanners front with flap open The front plate has two windows allowing the laser projector sending the laser profile line to the measured surface and the camera window The pressure control screws allow adjusting the amount of air streaming through the front plate Adjustment has been made for 4 atmospheres This is considered the minimum pressure for opening and closing the flap safely During the final adjustments the pressure may be raised to 6 atmospheres if needed In order to minimize the danger of collision with parts of the mechanical drive systems the filter and pressure regulators should be mounted on top of the Laser Scanners protection cases JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 5 of 43 Laser Measurement System Manual Pressure control and filter The Scanner connection cables are mounted firmly at the Scanner head In the power chain of the machine and in the vertical axis the Scanner cables are moved frequently Therefore the cable is in segments 2 8 m segments in the power chain and a 4 m extension cable have been mounted at the end of the power chain on the vertical axis The Scanner head connection cable is mounted above the protection case at the vertical arms Command cable for pneumatic flap M
22. the right and left vertical arms of the mechanical probes The mounting position height of the Laser Scanners has been selected so that the position of the mechani cal probes is visible in the upper half of the of the Laser Scanners vision range With other words the position of the mechanical probes can be measured with the Laser Scanners without changing the height of the verti cal arms The Laser Scanners must be moved of course sideways For calibration a control measurement for both scanners is made registering offset in the x and y axis to the probes The offset remains constant when the position of the probes and the scanners is not changed The offset value is different for both scanners The mounting position of the scanners does not allow that the both axis can move without the possibility of a collision The software end switches which limit the axis movement sideways must be set accordingly to prevent collision when the scanners are in working position and protec tion flap open Protecting enclosure The two Laser Scanners are mounted in protecting cases with a pneumatic flap Inside of the protecting case are a magnetic valve and a pneumatic cylinder The machine supplies compressed air with 6 atmospheres The flap is opened with command 24 V from the PLC to the magnetic valve When the flap opens an air stream is created from the plate with holes underneath the scanners front The air forms a pressure cushion under the
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24. 0 0 Fax 49 89 319 20 23 www MELsensor de 26 How to find us Motorway A9 exit Eching direction Ortsmitte first street turn right into Paul K smaier Stra e turn left into F rholzener Stra e turn left into Breslauer Stra e last building on the left N rnberg A Berlin Deggendorf 166 km i 565 km Z Passau Stuttgart 240 km Eching b ZA axe K OT MEL MIKROELEKTRONIK GmbH Ne Breslauer Str 2 ee indau 220 km D 85386 Eching Schweiz m Tel 49 89 327150 0 Pa ei Fax 49 89 319 20 23 N sS ee EEN E ES ER P Ee www MELsensor de Patenkirchen Austria 165 km Distribution partners in Europe and world wide Austria Intermadox GmbH Italy Leane International Roder Sensormatic Australia Applied Measurement Belgium Sensortech Tecnosens Canada Multiprox NV A Tech Netherlands Denmark AE Sensors BV China EIE Proces Suzhou SV Technology Co LTD Norway England Primatech Japan Sensors UK Sankyo International Corp Sweden Finland AB Liros Korea Murrelektronik OY Micro Tech Switzerland France Bachofen AG Malaysia Bullier Automation Info Trax Spain Hungary Sensing Russia Ukraine Sargent ASMess South Africa ASS Tech USA Centella Frontline Management H G Associates Jack Colgan Precision Measurement Stress Analysis Services error and technical modification reserved ASS MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49 89 319 20 23 www MELsenso
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48. 43 Laser Measurement System Manual i Control connections Fe Profibus DP a Keyboard Paralell port i Ch e a if mmn i iE USB Ethernet Ol Ve VGA Display OC JO Confr ol Floppy Disk Intelligent Sensor Interface HD Act N d e PB Data Sensor Power O ee e del 24VDC 24 V DC supply and interface connector Power i ignal level N Fur iction j Signal Sic Remarks OV V upply voltage 0V EE Digital input 1 24 V high active Start Stop ch 1 B 1 2 ANA out 4 ANA out 3 ANA out 2 6 ANA out 1 Analog GND 8 9 DA Strobe 1 DA Strobe 2 11 DIG out 1 DIG out 2 DIG out 3 DIG out 4 The digital inputs receive the Start Stop Signal from the fast digital outputs of the PLC when the NC de tects that position has been reached The D Sub 15 connector is mounted firmly The i Control unit has no power switch For disconnecting power remove the power supply from the AC line when the unit shall be switched off JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 21 of 43 Laser Measurement System Manual Profibus interface Byte Direction of data t ng Machine data SPS gt M gt gt A ann Ir pe Name Er ee Tee CT ment eraged Bt ee E Ces ment LASER SS on LU Du Safety switch off Laser uE IM 40 128
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51. 602686 13 1 b 2925 001299 948 050722 199 479297 13 10 a 2925 001299 682 103115 235 424805 13 10 b 2925 001299 682 497187 235 336856 13 2 a 2925 001299 938 344824 227 818389 13 2 b 2925 001299 938 770673 227 693467 13 3 a 2925 001299 926 464629 241 249053 13 3 b 2925 001299 926 859599 241 128145 13 4 a 2925 001299 901 845683 228 903282 13 4 b 2925 001299 902 235673 228 784258 13 5 a 2925 001299 837 655234 230 832295 13 5 b 2925 001299 838 049922 230 719415 13 6 a 2925 001299 572 103466 210 633038 13 6 b 2925 001299 572 497441 210 553047 13 7 a 2925 001299 583 09288 1 238 329346 13 7 b 2925 001299 583 482334 238 248028 13 8 a 2925 001299 593 312988 251 089571 13 8 b 2925 001299 593 707314 250 994961 13 9 a 2925 001299 620 261494 237 225225 13 9 b 2925 001299 620 651562 237 139278 16 1 a 3575 002078 945 988896 200 022999 16 1 b 3575 002078 946 381845 199 910733 16 10 a 3575 002078 680 446084 235 841836 16 10 6 3575 002078 680 836181 235 769913 16 2 a 35795 002078 936 704765 228 238448 16 2 b 3575 002078 937 096562 228 126758 16 3 a 3575 002078 924 97617 241 675840 16 3 b 3575 002078 925 190898 241 569190 16 4 a 3575 002078 900 156474 229 323379 16 4 b 3575 002078 900 546435 229 216485 16 5 a 3575 002078 835 987636 231 257823 16 5 b 3575 002078 836 381484 231 159268 JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc 16 7 b 3575 002
52. 900 000000 926 456628 234 539996 0 000000 0 000000 0 000000 0 000000 0 000000 1 6 3 b 900 000000 915 456628 247 607581 0 000000 0 000000 0 000000 0 000000 0 000000 1 6 4 b 900 000000 889 646628 235 110691 0 000000 0 000000 0 000000 0 000000 0 000000 1 6 6 6 900 000000 560 736750 213 408685 0 000000 0 000000 0 000000 0 000000 0 000000 1 6 7 b 900 000000 571 319597 241 209235 0 000000 0 000000 0 000000 0 000000 0 000000 1 6 8 b 900 000000 582 319597 254 188791 0 000000 0 000000 0 000000 0 000000 0 000000 1 6 9 b 900 000000 608 129597 240 497277 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 1 a 1700 000000 950 920697 199 266071 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 2 a 1700 000000 941 768576 227 443505 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 3 a 1700 000000 930 768576 240 484356 0 000000 0 000000 0 000000 0 000000 0 000000 1 IVE MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de 1 1 1 1 HB ConcreteGrinding SVC E doc page 30 of 43 Laser Measurement System Manual 4 a 1700 000000 904 958576 228 137157 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 6 a 1700 000000 575 537050 209 728456 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 a 1 00 000000 586 444471 237 415786 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 8 a 1 700 000000 597 444471 250 205938 0 000000 0 000000 0 000000 0 000000 0 000000 1 7 9 a 1 700 000000 623 254471 236 318637 0 000000 0
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54. 999522 580 129427 253 735508 3 9 a 324 999522 606 951693 240 206260 3 9 b 324 999522 606 562474 240 064610 6 1 a 975 000302 936 754984 206 095215 6 1 0 975 000302 936 379867 205 991788 6 10 a 975 000302 671 108138 239 359834 6 10 b 975 000302 670 728050 239 235176 6 2 a 975 000302 927 133294 234 251055 6 2 b 975 000302 926 771224 234 145098 6 3 a 975 000302 915 563939 247 674971 Manual JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de 6 3 b 975 000302 915 189066 247 571788 6 4 2a 975 000302 890 280267 234 987657 6 4 b 975 000302 889 890697 234 880870 6 5 a 975 000302 826 754740 236 260655 6 5 0 975 000302 826 379730 236 170625 6 6 a 975 000302 561 109202 213 531 719 6 6 b 975 000302 560 729085 213 409190 6 7 a 975 000302 571 823099 241 332149 6 7 b 975 000302 571 457425 241 209825 6 8 a 975 000302 582 318431 254 262579 6 8 b 975 000302 581 938870 254 046534 6 9 a 975 000302 608 640570 240 596622 6 9 b 975 000302 608 250326 240 477247 9 1 a 1625 001083 938 398138 206 511622 9 1 0 1625 001083 938 035228 206 447979 9 10 a 1625 001083 672 820159 239 764961 9 10 b 1625 001083 672 437327 239 692745 9 2 a 1625 001083 928 808968 234 666641 9 2 b 1625 001083 928 431566 234 602500 9 3 a 1625 001083 917 206849 248 098204 9 3 b 1625 001083 916 843919 248 020713 9 4 a 1625 001083 891 969915 235 402237 9 4 b 1625 001083 891 579368 235 338077 9
55. Control after finishing the measurement In order to minimize the amount of data to be transmitted only an average value for the measurement win dow coordinates is transferred to the i Contol The i Control receives from two fast digital outputs at the PLC start stop the signals for the two channels when to start and stop the measurement The i Control performs the measurement and writes the results to the shared folder Transfer on the internal disk drive At the end of the measurement cycle the i Control sends a message done fertig to the PLC The PLC then triggers the NC to get read the file from the internal drive In order to allow access the folder is shared without password requirement Description of measurement cycle and data evaluation Each time when the start position of the measurement window is reached the NC triggers the fast digital out puts of the PLC The i Control reacts upon this signal and stores the profiles of the measurement window The profile points calculated from this profile were written to file at the end of the measurement cycle During the phase of active measurement they were held in RAM MEL sends on the Profibus busy until the evaluation routine is active and data is written into a file in the folder Transfer When the file is saved the signal done fertig is set active see description of Profibus in terface on page 20 JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0
56. LASER Scanner for profile measurement T o e N D gt T DN 2 s Intelligent Sensors Jett MIKROELEKTRONIK GMBH U Length measurement E Width measurement Measurement of length of fast moving targets with Precise detection of target width trigger signal I Position measurement l Profile measurement Positioning of targets on one another 1 e before wel Profile controlling and position sensing ding A Groove measurement D Door gap measurement For groove measurement 2 ore more points are mea sured at the same time f Measuring the width of the gap as well as the distance of the door to the frame Welding seam inspection at tailored blanks After welding scan line is used crosswise to welding seam for inspection With enforced speed of transportation scan line is used transversal to seam Values are transmitted via RS232 Values outside of range will generate an alarm signal min 0 1 mm 35 Years of Experience in Test amp Measurement First developments of measure ment and control systems starting in 1969 First projects were computerized controls for electron beam welding machines peri pheral components for machine attached computers like opto couplers AD converters high voltage controllers deflection units or missile controllers In 1972 the first optical measure ment system for the detection of the eye movement was developed T
57. M1 More details can be found in the i Operation of i Control with keyboard monitor and mouse at the bridge 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 18 of 43 Laser Measurement System Manual 230 V AC power for i Control Monitor Separation point I Control 24 Volt 1 5 A Power Power Supply Replacement Cable at the verti cal arms connector Binder round 12p both sides Scanner 1 Scanner 2 ne KH Profibus DP StartStop Digital in plug Scanner cable Binder 12 p male get Data over Ethernet TCP IP Protect case Pressure valve Pneumatic cylinder Protection flap female plugs Round 3p M12 Protect case 2 Pressure valve Pneumatic cylinder Protection flap SPS Control of pressure valves 24V Profibus control Interface for i Control Valve control for pneumatic flap JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 19 of 43 Laser Measurement System Manual Cables and pipes Length MEL Nr SES ER EE EE DEE Valve command cableflapl 220m M12 Openleadls TI Valve command cable flap2 220m M2 TOpernleadds Ir Ethernet cable 2m_ RJ 45 Rab E Ethernet connection is made with an Ethernet Switch and Standard Ethernet cables ll T4 C
58. Start data evaluation Begin evaluation int a ae 2 ooknr i TT Coordinates Avg value Start Stop o o y Byte Nr 3 4 5 2 3 Byte height mm 100 LI Byte Nr 6 7 8 3 Byte Travel to side y mm 100 Byte Nr 510 2 Byte te ravel Travel along x x H9 D Machine data IB Byte 11 Infobyte 2 d r ep eer ment en ment ment ER LASER SSES on d off_ GE switch off Laser 2 HEI KE A NEU NewpBB Eemere new Pie NEU 6 EVAL Start data evaluation l0 noadlon ____ 1 begin evaluation Auswerung _ 7 L L fo E Byen hoon tk Goerges Mvg value Sat Soe o Byte Nr 13 14 15 Z 3 Byte Hegih _ __ mm 100 Byte Nr 161718 Y__ Byte__ Travelto side y__ mm O Byte Nr 19 S 2 Byte Travel Travel along x x m9 Byte N 21 24 Paten 14 e Fe Plate Nr File name en pos Meaning a LS CT En EE EEE me Bit Nr Sigal LL E E 2 Heartbeat Heartbeat signal 0 10 Changes 1x ee a ene cauaton done Daan F s ready Iren 5 Profle 7 t Profle recognion OK Seanner seas object Seen Eeer Scaner ses obea 7s Reserved DD Ce 2 231 Reewed Ill this is also the sideways travel for changing from side A to side B The Laser Scanner mounting zero reference point is saved in the ini File ascii text readable in clear text with any text editor The values can be changed when necessary Th
59. Woodworking and metal industry thickness measurement of plates and bands e Products of extrusion lines and calenders e Materials like floorings roofing sealings etc e Textiles e Control of material doubling to avoid tool or machine damage and so on The mounting of the sensors depends on the surrounding conditions Normally there are two synchronized sensors which are directed at the upper and the lower side of the measuring object double sided measuring method The thickness can also be measured with a one sided sensor system one ore more sensors are measuring onto one side the reference distance will be the fixed underlayment of the object The material thickness results from the difference of reference and object distance Double sided measuring method Two sensors measure on the upper and the lower side of the object The material thickness results from the addition of the measuring signals Application Detection of metal sheet doubling Multiple measuring systems The signals of up to 4 thickness measuring systems can be simultaneously evaluated with a MEL i Control e g thickness measurement of profile plates ASS MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49 89 319 20 23 www MELsensor de Thickness Measurement with LASER Sensors A special application of the thickness measurement is the differentiation measurement With this method differences in height can be detected Sensor 1 Sensor 2
60. an off hold your hand or a piece of paper un der the Laser Scanner to see the reflected light JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 24 of 43 Laser Measurement System Manual Calibration with compare to PL0 file For the reference measurement the best concrete element is chosen 10 02 de At first the measurement is carried out with the tactile sensors ME The measurement result values are written into a PLO File E Const Intensity Cam The PL_ 0 file is transferred to the shared folder LASER mens f Transfer on the internal disk of the iControl VdsoBan m j MIN Intensity r 2 Normal measurement is taken from the best concrete eleme Demarcation a The Laser Scanners record the profile The values are saved to a result file comment field 3 click calibration The calibration routine prompts for selection of the PL_O file a I CALIBRATE Look m Trar sfer del al als L00211027 L L002110 7a PL0 STORE CALIB File name Loo 1 27a FL Files of type PL amp Fies PLO D Cancel IT Open as read only File name L286331 153 MEL Files of type MEL Files MEL sl Cancel Open as read only 2 When the MEL file has loaded the calibration algorithm calculates the offset values of the Laser Scanners relative to the tactile sensors The offset values are saved to the pre set
61. anner 1 and Scanner 2 are exactly in the same line Check which scanner must be probably shifted to the other screw holes to make the position of laser lines exactly the same The laser lines must not be rotated they shall form a unique straight line If necessary change position of one of the axis t When this is ok note the machine axis encoder values IS When done exit the software tool adjust exe Manual EN Exploring Mel File Edit View Go Favorites Tools Help a Fa Back Foward Up Cut Copy Paste Address C Program Files MEL Undo x Delete Folders A Desktop BR Mu Computer il 3 Floppy A New volume IC i My Documents New Folder Program Files Accessories D Common Files DirectX C Internet Explorer Mel E Scans C Scans Online Services Plus Tight NC Uninstall Information Windows Media Player Recycled Lebel he Ee 10 objects A 34MB Disk free E My Computer BEE mlldemdp M Trage SNAPSHOT LA EfiHrienier L mi obin Laser Lines shall be in line JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 7 of 43 Laser Measurement System Machine Axis Adjustment Y Z X I launch the Ausrichten exe software tool When the software Ausrichten exe is
62. are For this purpose the remote software VNC should grant access over the Ethernet network to the i Control unit or in other case keyboard mouse and monitor shall be connected at the i Control on the bridge The Password for VNC access is vaksic You can change this password As well as with VNC or in local operation all parameters relevant for use of the software can be set in the ad just mode user interface 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 17 of 43 Laser Measurement System Manual GG When set up is finished exit the VNC software Leaving the VNC software on the iControl active in back ground may seriously degrade the function of the recognition software If you quitthe VNC link at the remote PC Client everything will be fine but never keep an active communication while the machine is in op eration The same applies to the adjust mode checkbox Do not forget to de activate adjust mode before starting nor mal operation Automatic Laser Intensity Control In Auto Mode the i Control and Laser Scanner System determines the necessary shutter time and Laser In tensity automatic Adding video gain shortens the shutter time but increases noise Adjust mode at the bridge For maintenance a monitor keyboard and mouse may be connected USB mouse can be connected to the USB connector best use Logitech or use a serial mouse at CO
63. asurement Range 200 00 mm Scanner Distance ocann Range Measurement Range 200 00 mm Scanner Distance _ Port 2 Adress __ _ 0 2 ee Port 1 Adress Mode Mode Z c EPP C PS C ISAS ISAIB EFF PS C ISAS I5A16 Store Yalues EXIT 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 16 of 43 Laser Measurement System Manual Application Software The user interface adjust mode is active in background all the times When the system is operated without a monitor the screen display is not deactivated For service purpose the screen display is thus available all the times The communication with the PLC system is shown with yellow LED panels stating which messages are sent over the Profibus interface Upper Shutter Screen display in adjust mode Plate Number Profile display Intensity display purple Profile asuremant Yer 1 8 2 Licensed to WEIHAI HUADONG AUTOMATION CO er2L Scanner R 2R Scanner 1 Scanner 1 R Hook T Number Li Online display Blue 2 Profile l Coordinates X Y Z Intensity 0 Intensity Intensity Intensity 0 IN_x 0 000 ee Port IN_Y 18 192 8 224 as o mm Sg vn Wm E MS MAT Ju In m SE K2 Ki Start Stop Signal Address
64. ation has loaded and exit the main application For a moment we will start other software tools to support mechanical adjustment procedure Step 2 launch adjustexe from the directory C Program Files MEL Adjust exe is a software tool for Angle measurement When you launch the software tool the lasers will be on and create a visible red line on the underground Activate the checkbox Show Values at the lower right side of the screen screenshot at the right side The Show Values function displays the grey angle display in the two scanner windows Additionally temperature and other scanner values are displayed in this software tool The main benefit is the precise angle measurement For best precision the underground must be flat and aligned horizontally Use the same principle to adjust the underground for this alignment step as for alignment of the protecting enclosure see step 1 GG Now the Scanner mounting angle of rotation of x axis should be checked and adjusted Best adjustment for both scanners is 0 Height adjustment Z The adjust exe tool also reads the height Z of both scanners Check that both scanners are mounted in the same height and check the reading of the Numerical control PC for the axis position in Z when the Scanner readings are brought to the same height position Laser line adjustment X Offset Now the mechanical adjustment of the laser lines can be made so that the two projected laser lines of Sc
65. b 3575 002109 588 670843 255 719834 18 9 a 3575 002109 615 395697 242 121280 18 9 b 3575 002109 615 004964 242 050967 21 1 a 4225 002889 945 104046 208 127696 21 1 0 4225 002889 944 719115 208 050459 21 10 a 4225 002889 679 563587 241 387901 21 10 b 4225 002889 679 159193 241 279483 21 2 a 4225 002889 935 491576 236 283467 21 2 b 4225 002889 935 1 14867 236 202881 21 3 a 4225 002889 923 912679 249 716153 21 3 b 4225 002889 923 528421 249 602832 page 39 of 43 21 4 a 4225 002889 898 724183 237 018594 21 4 b 4225 002889 898 334437 236 937256 21 5 a 4225 002889 835 103060 238 300254 21 5 b 4225 002889 834 71 7630 238 211045 21 6 a 4225 002889 569 564564 215 570147 21 6 b 4225 002889 569 160511 215 460782 21 7 a 4225 002889 580 306419 243 3 70245 21 7 0 4225 002889 579 885394 243 261866 21 8 a 4225 002889 590 773714 256 297334 21 8 b 4225 002889 590 369027 256 223301 21 9 a 4225 002889 61 7 084242 242 633145 21 9 b 4225 002889 616 694251 242 528926 24 1 a 4875 003669 946 807122 208 590850 24 1 0 4875 003669 946 405628 208 48457 1 24 10 a 4875 003669 681 294183 241 863936 24 10 0 4875 003669 680 881458 241 740215 24 2 a 4875 003669 937 195335 236 743731 24 2 0 4875 003669 936 795033 236 638877 24 3 a 4875 003669 925 616097 250 169893 24 3 0 4875 003669 925 213909 250 043790 24 4 a 4875 003669 900 412484 237 483995 24 4 0 4875 003669 900 022513 237 373389 24 5 a 4875
66. bles and control cables for the pneumatic flaps are connected through the energy chains of the motor units with the i Control The photos below show the mounting at the bridge JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 3 of 43 Laser Measurement System Manual Picture of the machine Ethernet connection EEE ZS eo a ee Keyboard Power supply 24V TW al a m Ee eee TEE i Control Intelligent Sensor Interface ce Mounting of i Control The i Control is mounted directly at the rear metallic wall of the cabinet This way of mounting makes sure that the iControl can dissipate the heat directly to the metallic wall When the i Control is mounted differently make sure that it is mounted on a metallic surface for good cooling MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 28 HB ConcreteGrinding SVC E doc page 4 of 43 Laser Measurement System Manual System components The Laser Measurement System consists of the following components MEL i Control Sensor Controller and Data Processing Unit 2 Laser Scanner in protection case with pneumatic flap Scanner connection cables Measurement Software VNC Server for remote access Windows 98SE Operating System Power Supply 24 V 1 5A DC O O O OOO Mechanical structure of the System The Laser Scanners are mounted into a protection case with pneumatic flaps at
67. c 011221011 111111 TT ng 11 Storage and screen display of measurement values S100 2111101 1111 TT nh 12 Determination of Y and Z Offset Values of the Laser ScannerS nennen 12 Determination of the precise measurement position of the X AXIS uuuensennennennnnnnennnnnnnnnnnennnnnennnnnnnnnn nennen nnennnnnennnn nenn 12 Definition of profile points NEE 14 DEHRILON OL prole eil LE 15 Software COMMOUNANON ee UE 16 eelere Eet 17 Screen display in adjust mode 0 1122200011011 010 21111111000 11111 n ng ng ng ren 17 SVMS EE 17 Scanner Parameter Adjus rmern 1 111 2211011101110 21111111110 n n TT RERE Ra 17 teure Laser Mens ICON dl 18 Adjust mode at the GO ur ae ee ee ee ee 18 Cables and pipes EE 20 Cable connection to digital inputs Start Gtop n TT v 20 Control signal for protection ap 20 FG CAO NMS NOI EE 21 24 V DC supply and interface connector Power 21 FOILS II ELTA Seen te en ae ee ee Eee 22 Maintenance of the Laser Scanne rS c c0 221111011010 n ng TK rrn 23 Checking Laser Seanner F Nneli ne reellen 23 Maintenance and servicing the Laser Scann rS 000112 11111010 1 n1 ng n ng n n 23 Cleaning the protective windows of the Laser Scann rS 00010 2 1111111 ng n 23 Adjustment of air pressure for the front flap oDeninQ
68. e chan ged quickly There are no mo ving parts in the scanner which makes it completely free of maintenance Data output There are several data processing unit of the M2 Series e ISA PC board e MEL Blue Box V2 for Ethernet Interface e i Control with integrated PC 104 RS 232 CAN Bus Profibus DP Ethernet EPP parallel Port 4 Analog output 0 10V digital output digital input A comprehensive description of the i Controls can be found in the i control manual For more sophisticated applica tions industrial type PCs can be ordered Measuring method The object is scanned by the fanshaped light beam of the laser For each light beam the points on the object are calculated from the scanner The coordinates of these points are linearized and then transferred as 2 by 2 values The real profile of the surface can be achieved as a repre Standard Scanrange m IN Measuring range Z Be 4095 10V Begin scanrange X M i 0 10 End Scanrange X oV View limited Te Scanrange BS v d ch d 0V 0 OV Scanrange Measuring range Z 4095 10V 4095 0 10V lov Scanrange X Fig 3 sentation of Z X The distances of the measurement points on the X axis are not constant and increa se with the distance to the sensor Errors may occur due to e direct reflection of the Laser ASS MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49
69. e data transport of the reference position information for the measurement occurs be fore the measurement takes place in the gaps between the hooks or before the first hook The start of measurement is triggered through the NC accessing the fast digital outputs of the PLC MEL writes the measured data to file and confirms after end of measurement cycle data is ready Byte 1 bit Nr 4 1 When the evaluation is active Bit 3 is been set to 1 Sending data is done in 1 package of data for each side Bit 8 of the first Byte tells which side sends data The coordinates of the measurement area are stored by MEL The cross side movement is calculated from this Plate number Rail number File number For this information 4 Bytes are reserved I the Profibus address is 5 The Profibus address can not be changed by the user JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 22 of 43 Laser Measurement System Manual Maintenance of the Laser Scanners Checking Laser Scanner Function The measurement software Scanner 2L Scanner 2 R Scanner 1L Scanner1R provides a display of the Scann profiles including information of Y and Z and intensity of each pixel Additional information on the Scanners vision quality is given by the blue bar graph meters showing total intensity reading of the Scanners Clearly visible profiles and intensity reading of close to 100
70. e reflected signal The diffuse reflection of the objects surface is influencing the shutter speed Sur faces with more diffuse reflections will yield brighter profiles thus cau sing shorter shutter times Darker surfaces result in longer shutter ti mes accordingly Due to an automatic Gain Control of the Video signal the shutter speed can be reduced hence cau sing of some extra noise Depending on the reflections of the surface shutter speeds between 1 47 000 sec and 1 225 sec are typical Z 1st half frame 2nd half frame X full frame X Fig 5 With the supplied configuration software shutter speed and video gain control can be adjusted see software description External Synchronisation In order to synchronize the measu rement exactly with a running pro cess it is possible to trigger the scanner externaly The maximum scan rate is 100 halfscans sec The measurement object is scan ned 100 times sec If the object is not moving or moving very slowly then 2 consecutive measurements can be integrated to one measure ment which will result in 2 times the resolution in X direction fig 5 Security advices When setting up the Scanner it is important that the Caution sign will be visible very well Fig 6 The power of the Laserbeam is so low that damage to the human eye ist prevented by the wink reflex of the eyelid It is harmless t
71. e sen Sors Determination of the precise measurement position of the X Axis The position of measurement in the direction of movement x axis is defined by the NC ini file The start signal is send over the fast digital outputs of the PLC to the digital inputs of i Control The i Control finally saves the profiles and evaluates the profile points according to definition on page 14 The delay between reaching the starting coordinate the trigger impulse at the outputs of the PLC the reac tion time of i Control and the position where the Laser Scanners have made their measurement cannot be calculated precisely The delays depend on internal cycle times of the NC the PLC and last not least the re action time of i Control Therefore a simple method for determination of the measurement location has been designed On the last hook a ramp with 10 slope is placed The last profile remains in the screen display The height of the pictured ramp in display can be evaluated in order to know the position of the last measurement 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 12 of 43 Laser Measurement System Manual Path of the Laser Scanners 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 13 of 43 Laser Measurement System Manual Definition of profile points 1 L
72. ed in the Win98ENG folder Base5 cab In most cases Windows will ask for the Windows CD Then navigate with TAB and cursor keys to the Win98ENG folder and press ENTER OK Windows will then load the necessary files from the Win98ENG folder WindSeng File Edt View Go Favorites Help gt 4 Bajs x Cut Copy Paste Undo Delete Based cab _Win98eng Mee al Baseb cab Cataloga cab CHI99 cab Modified E 4 24 99 6 22 AM size 1 760KB Dossetup bin Diserll cah Driverl amp cab Drivea cab Erwerld cab Drwerlb cab Drwverib cab Driver d ce Erverld cab Drwerl3 cab Dinverzlcah Extractexe ha ME B Mu Computer JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 26 of 43 Laser Measurement System Manual Recommended Spare parts Pan PatNr Vendor Function SKK_450 10m SKK_450 8m SKK_450 4m Floppy disk drive 562 014 Floppy disk drive for iControl Compact Flash disk 562 013 Compact flash disk for iControl Pressure reductor Keep compressed air clean and at correct and air filter pressure for flap and air purge Pneumatic cylinder po Festo LI O Replacement system WF570 200 MEL iControl with 2 Scanners complete set up with Wal ef software including protecting enclosure with pneumatic flaps no scanner extension cables Power supply 24V 1 5A 550 121 Power supply for iControl Scanner head WF570 000HR MEL Scann
73. eft hook L1 iD e Right hook Left and right hooks are symmetrical 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 14 of 43 Laser Measurement System Manual Definition of profile points 2 The profile points are calculated from the junction of straights over the surface tangent approximation line The parallel straight to the straight through P4 gives the point P1 accordingly also the profile points P9 P6 were found Z Axis dimensions in mm P1 Parallel to P2 P4 28 Y Axis 129 A Definition of the measurement segments A and B relative to the travel path One hook is shown direction of travel JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 15 of 43 Laser Measurement System Manual Software Configuration Tool Functions of Config exe The MEL Scanner Configuration Tool is used to make the basic adjustments of Scanner parameters Port Mode Port Address Scann range Measurement range o Standoff distance Adjustment with the Scanner Configuration Tool is only necessary the very first time All other adjustments were made in the user interface provided by the application software 00060 gt Scanner Configuration Tool Oy x Scanner 1 Data Scanner Data cann Range Me
74. er head special model for concrete For replacement grinding application mounting at cover pos M2DF 200 68 100R sible communicate the serial number of the ex changed head to MEL with the order ready for mounting of scanner head M2 Ethernet Switch 10 100 Cisco Linksys Ethernet Switch 10 100 Mbit 5 port with power DLink supply for service purpose Netgear or TP Link JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 27 of 43 Laser Measurement System Manual Example for Profibus test sequence lt xml version 1 0 encoding utf 8 gt lt ProfiBusSPSSimulator name ProfiBusSPSSimulatorName gt lt ProfiBusSlave gt lt Settings name Slave1 adresse 5 recvioggen 1 sendloggen 1 autostart 0 gt lt Command data 00 00 00 00 00 00 00 00 00 00 20 00 00 00 00 00 00 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note new concrete element gt lt Command data 04 1e 00 10 00 00 20 00 00 00 04 1c 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L28 30 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 1b 00 10 00 00 20 00 00 00 04 19 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L25 27 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datar
75. est done with a test fixture providing a sharp edge This allows better identification the position of the axis as a shallow edge The test fixture also should have a defined height This allows a quick visual control of the scanners viewing range Picture at the right side Drawing of test fixture The angle should be 110 this will allow to check the mounting position of the scanner and the scanners angle measurement ability The other dimensions could be changed The total height should be not higher than the scanners viewing range In best case the height is 70 100 mm The surface of the test fixture should be flat and painted with light grey colour like the car paint spray colour primer available in pit stops This surface will give good profile reading with the laser scanners dimensions in mm JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 8 of 43 Laser Measurement System Manual 2260 gd E E EE O00 Drawing of protection case position of Laser beam out position and vision range of Laser Scanner left side 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 9 of 43 Laser Measurement System gt CH CH l i T Drawing of protection case position of Lase
76. he flap should close automatically when you release the flap and no flap open command is sent When no pressure is there you can close the flap by hand The cylinder could lock up with the mover arm so best press gently against the mover arm when closing manually To avoid damage do not apply force Press here Eye safety and Laser Protection class information The Laser Scanners send out Laser light at a wavelength of 675 nm highly visible red The Laser diodes are set at the factory to send no more than 1 mW at the outlet of the Laser beam This is according to pro tection class 2 M The Laser light is widened up for projection of a laser line Therefore in a short distance the Laser power drops to a very low value The Laser power is measured and documented during manufacturing process A ae Warning panels at the machine Left side warning at the entrance of the cabin right side warnings at the Scanner heads Caution authorised Laser Radiation personel only The Laser beam is widened up this causes the Laser power to drop fast over distance from the Laser out let When looking from a greater distance by hazard into the Laser beam no damage to the eye will occur yet you should never look directly into the Laser at will For safety the Lasers were switched on and off over the Profibus How to behave Never watch into the Laser beam at will When you want to check function of the Laser switching on
77. his system was able to detect rapid eye movements exactly The contactless system could also control X Y mirrors for the gene ration of stabilized pictures of the retina With a resolution in the um range and the capture of move ments of up to 250 Hz this was quite a sophisticated technology Beginning in 1975 electronic was developed for stratospheric reseach missiles Many missiles have been operated with the directional control UNISTAB which had been developed by Mr Langer In 1985 the MEL GmbH was founded with the purpose of development and manufacturing of Sensors First pilot projects were optical pre crash sensors for cars optical 2D scanners for security systems The optical triangulation distance sensors became a standard product as well as in 1994 the scanner for 2D and 3D measure ments The MEL GmbH iis still a development company for customer specific solutions and is well known for its high tech products throughout the auto motive industry 2D Laser scanners are used for quality assurance of mechanical parts or for gap finding or seam control with welding robots The MEL Radio controlled systems are used for the fast identification of malfunctions and the management of maintenance and repairs in complex production lines The MEL Ident systems control automatic paint shop systems in order to enable a 100 opera tional readiness ITable of contents Applications Overview
78. il the end of the panel is reached then the machine stops PLC change side position IVE MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 41 of 43 Laser Measurement System Manual XConfig ini Settings SchwelleMin 1200 SchwelleMax 1950 Min_X 0 Max_X 4095 HwAnfangBereich 3 HwEndeBereich 80 SchwelleMin_ 1L 0 SchwelleMax_ 1L 4095 Min X 1L 0 Max X 1L 4095 SchwelleMin_1R 0 SchwelleMax_1R 4095 Min_X_1R 0 Max_X_1R 4095 SchwelleMin_2L 0 SchwelleMax_2L 4095 Min X_2L 0 Max X 2L 4095 SchwelleMin_2R 0 SchwelleMax_2R 4095 Min_X_2R 0 Max_X_2R 4095 Calibration delta_X_2 L 0 delta_Y_2_L 0 58414200000027 delta_Z 2 L 0 0296190000000821 delta X 2 R 0 delta Y 2 R 0 100112999999965 delta Z 2 R 0 195791999999954 delta X 1 L 0 delta Y 1 L 0 778260000000275 delta Z 1 L 0 411393000000119 delta X 1 R 0 delta_Y_1_R 1 1568030000002 delta_Z_ 1_R 0 731586000000024 delta_NP_L 0 0879779999999073 delta_NP_R 0 174084000000108 Measurement distance Z P2 P1 28 distance Y P2 P3 11 distance Y P2 P4 36 81 offset_K1_P3 0 2 offset_K1_P8 0 2 offset_K2 P3 0 1 offset_K2 P8 0 1 P3_P8_pixel radius 10 P3_P8_appx degree 6 P3_P8_radius 9 IVE MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 42 0f 43 Laser Measurement System Manual Measurement Sequence Step Nr Ope
79. iod is 24 months Warranty voids with unauthorized repairs or alterations improper usage In case of a malfuction ple ase send the unit properly packed to MEL Mikroelektronik GmbH Breslauer Str 2 85386 Eching Germany or call us or send a fax Tel 49 89 327 150 0 Fax 49 89 319 20 23 Internet www MELsensor de E Mail info MELsensor de MEL is not liable for any damages resulting the usage of its products This data may be changed without notice IMEC MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49 89 319 20 23 www MELsensor de 8 Other MEL products LASER Distance Sensors e Check of dimensions e Detection of position e Detection of material overlap Control of presence and absence Check of liquid level Measuring of concentricity Vibration analysis e Thickness measurement Radio Remote Control STK and STK Il e Wireless control of all functional actuating elements to the PLC e Reduction of down time e When starting up or in case of breakdown the switching functions are sent by radio from a small portable transmitter to the PLC Inductive Proximity Switch MI e For the use in annealing ovens painting plants etc e Inured to permanent temperatures up to 350 C Code Reader ES e Identification of product carriers in conveying systems e High temperature resistance up to 400 C e Usuable in heavily soiled areas ASS MIKROELEKTRONIK GmbH Tel 49 89 32715
80. n time e Hand held transmitter A global distribution network ensures the permanent availability of MEL sensors and spare parts You will find all distributors on our website www MELsensor com MIET MIKROELEKTRONIK GMBH Breslauer Str 2 Tel 49 89 327150 0 Fax 49 89 3192023 E Mail info MELsensor de www MELsensor de
81. nting makes sure that the laser lines come out at the same position BG d HH Je D gt The protecting enclosure has 8 mounting holes with thread M6 The additional mounting holes allow shifting one of the two scanners to match the position of the laser lines exactly See also following page The following chapter describes the adjustment procedure required to define the offset values between scanner measurement and machine E position tactile measurement JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 6 of 43 Laser Measurement System Adjustment procedure of Laser Scanner heads Angle adjustment Step1 position the motor axes of left and right side at the same x position Mount Scanner 1 unit with protecting enclosure Mount Scanner 2 unit with protecting enclosure Open the protecting flaps Provide a flat panel under the Laser Scanners so that the laser lines will be visible when the lasers are switched on Check the mechanical adjustment of the protecting enclosure with a balance as shown in the small picture at the right side This is the adjustment of the Scanner mounting angle rotation at the y Axis The protection enclosure should be adjusted at 0 t Connect Laser Scanner to i Control GG Power up 24V When the start exe software launches automatically wait until the software applic
82. o view in to the diffuse reflected laser line Interfaces Digital Outputs The scanner can output the digital profile data via the integrated Ethernet Interface Detailled infor mation about interfaces and soft ware control can be found in the respective hardware and softwa re manuals Signal Inputs The following functions can be ad justed via Ethernet Interface e Time of exposure e Video Gain e Trigger input e Trigger with rising edge A single measurement ca be trig gered with the trigger input During measurements no new triggers will be accepted Synchronization of two Scanners Option 1 alternating mode Option 2 sync mode o MEL Option 1 Option 2 Fig 7 Sync inaccuracy 15 sec Master slave mode can be defined via jumpers onthe ISA board via external wires with the Blue Box The desired option can be selected IMEI MIKROELEKTRONIK GmbH Tel 49 89 327150 0 Fax 49 89 319 20 23 www MELsensor de T in the respective program There is no trigger mode possible in the sync master slave mode Data Link e with i Control Fig 9 Remote control of running software applications display of results and status signals is possible via the serial RS 232 interface Remote Emulation Fig 10 Conversion of the analog signals into digital signals analog i Control 0 10V Fig 11 e with the Blue Box V2 The ethernet cable is connected either through an adap
83. ompressed air pipe Il ll 6 bar flap protection gas Festo clutch 6 bar flap protection gas Festo clutch Binder 12 p m Binder Round connector male 12 pin Binder 12 p w Binder female cable connector 12 pin Binder 8pm Binder Round connector male 8 pin Binder 8pw Binder female cable connector 8 pin Cable connection to digital inputs Start Stop digital inputs Start Stop channel 1 Start Stop channel 2 are located at the D Sub 15 power connector of the i Control See following page Signal Level Remarks o Digital input 1 Start 24 V Stop 0V Load resistor 1 5 kQ to ground Ground Ground Digital input 2 Start 24 V Stop 0V Load resistor 1 5 kQ to ground 24V Supply for digital outputs Feed for outputs of the NC control unit Shield Shield Control signal for protection flap The protection enclosure opens the flap when 24 V are applied to the 4 pin M12 connector on top of the enclosure Connecting cable SKK_502 open ends Binder connector 713 99 0430 04 Function 24V open flap OV close flap The 2m connection cable SKK_502 is shipped with the unit The specified Binder connector is a angular plastic M12 connector The connections are made at the pins 1 and 2 the polarity of 24 V and ground of the switching signal has no meaning for the function IVE MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 20 of
84. ounting the Laser Scanners in relation to the mechanical probes The Laser Scanners have been mounted as close as possible to the mechanical probes In order to allow the use of both measurement systems independently from each other or in combination the scanners have been mounted so that the position of the probe is in the vision range of the scanners The protection flap can be opened without affecting the measurement capability of the mechanical probes For a comparative measurement only the difference in position of the probes must be considered The difference in position from centre of axis of the Laser Scanner to the mounting plate is 36 7 mm This must be added to the distance of the mechanical probe to the edge of the vertical arms The better way is to measure the distance with the procedure given further below I JM Ha zo bref un A reference measurement needs to be performed in order to determine the offsets in x y and z When this measurement with the tactile probes Renishaw has bee done the offset values are stored in the NC ini file E eu N m f WW hae l E F Before doing this the Laser Scanner heads shall be adjusted mechanically using the following procedure The two Scanner heads are mounted differently inside of the protection housings Scanner 1 is mounted in normal position Scanner 2 is mounted at the side of the printed cover This way of mou
85. r beam out position and vision range of Laser Scanner right side N 72 0 200 0 1 51 MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 10 of 43 Laser Measurement System Manual Electrical structure of the System The two Laser Scanners are connected with a special cable to the i Control unit The interface to the PLC isa Profibus connection the i Control unit is a Profibus slave and the Profibus address is firmly set to 5 The nu merical control system receives data with a file transfer over the Ethernet network Sensor iControl control Ee data storage Screen Display Picture above schematic signal path Description of system function The numerical control system creates a measurement routine for the concrete elements The Laser measurement system receives from the PLC system the information on concrete element number plate number number of hooks the coordinates of the measurement window A measurement window for the D bel and measurement window B The numerical control system has no Profibus connection therefore the numerical control system NC sends its data to the PLC system and the PLC system sends it over the Profibus to the i Control This may be changed in future machines without changing the interface to iControl The plate number is equal the file name which will be written to the result file on the internal drive of the i
86. r de Laser Measurement System Manual IMUEIL MIKROELEKTRONIK GMBH intelligent sensors amp measuring systems Measurement System for Concrete elements with M2D Laser Scanner SVC User Manual Version 1 8 2 Editor Reinhard Kutzner Software Denis Vaksic MEL Mikroelektronik GmbH Breslauer Str 2 85386 Eching Germany Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de April 2009 JL MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 1 of 43 Laser Measurement System Manual Contents Bed Eu 1 EEN 2 Dy SHS MY SS de e EE 3 Mounting of the Laser Scanners 3 Oaar a 1010 R daada A usr n a i Eroan a arni ie 3 Mounting ofthe electronic UNE zes ea ee ea ee endende 3 DYS ICH COMPONENT See ee 5 Mechanical structure of the SYSTEM Q00 0n eriein n TK TT TK nen 5 Protecting Bee E E 5 Mounting the Laser Scanners in relation to the mechanical porobes 32 11113 111111133 111111 nvv rey 6 Adjustment procedure of Laser Scanner heads c c0 01 SH 1 ng TT TT vn 7 ANGE AA Ne TI ee ee ee eee ee eee eee eee ore 7 ae EEEE dn 7 Laser line adjustment A OSEI anne er ee 7 Machine Axis Adjustment Y ZI an a a a Le 8 E TE 8 Electrical Structure ofihe System a ea a Lu 11 Description of system FUNCTION c0 HH n TH n Hi c KT TK TT ng 11 Description of measurement cycle and data evaluation
87. ration el Bring Scanners into start position at end of concrete panel CNC does this Open pneumatic flaps L PLC sends signal ae movement CNC does this Send new plate command and plate number KB lt a Send measurement sector data PLC sends this Number of hook Side A B Rail L R Normal Control meas Angle Normal Laser On Coordinates z y x average of start and stop position coordi cates mm 6 mm 8 Sopmovemeni O H fepeat measurement sequence until end of panel reached _ Start measurement PL Stop measurement Pe repeat steps 4 5 6 until end of panel reached TL MU LC Stop Stop movement CNC Change to other side CNC Change movement direction Restart movement repeat measurement sequence until end of panel reached JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 43 of 43 LASER Sensors Thickness Measurement V DS V gt gt ep LA Cc e m V 4 s Intelligent Sensors MIKROELEKTRONIK GMBH Thickness Measurement with LASER Sensors The integration of MEL thickness measuring systems in production lines allows a contact free and continuous control of material thickness Deviations from the reference value will be transmitted to the control circuit the reject rate will be minimized MEL thickness measuring systems are used in many fields of application e
88. s232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 18 00 10 00 00 20 00 00 00 04 16 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L22 24 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 15 00 10 00 00 20 00 00 00 04 13 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L19 21 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 12 00 10 00 00 20 00 00 00 04 10 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L16 18 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 Of 00 10 00 00 20 00 00 00 04 Od 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L13 15 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 0c 00 10 00 00 20 00 00 00 04 0a 00 01 00 00 20 00 00 00 11 11 11 11 aktiv 1 waittime 2000 note L10 12 gt lt Command datars232 01 aktiv 1 waittime 100 note Start gt lt Command datars232 00 aktiv 1 waittime 100 note Stop gt lt Command data 04 09 00 10 00 00 20 00 00 00
89. t from the Scanners front windows Only for the time of measure ment the front flaps shall be opened Cleaning the protective windows of the Laser Scanners The integrated front windows are specially coated optical filters These optical glasses are very sensitive Do not clean them with normal cleaning chemicals or solvents Use instead pure Alcohol 15 30 or benzene and clean soft cloth Do not touch Scanner front windows with your fingers these causes finger prints will disturb the optical pickup process Please be careful when opening the protection flap manually Adjustment of air pressure for the front flap opening The Air filter pressure gauge adjusts the pressure with the blue knob on top To change setting pull the knob up Now the knob can be turned easily When the setting is made push the knob down to lock it Once a week the filter shall be cleaned with the water removal screw at bottom Open and close screw The flap starts to move when the pressure is higher than 2 8 atmospheres The good value has later been found during installation with close to 4 atmospheres JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 23 of 43 Laser Measurement System Manual Open and close the flap manually The flap can be opened and closed by hand The flap can be OPENGL even against the pressure of the pneumatic cylinder When the prssure is on t
90. ter or th rough a fixed wire Data from mul tiple scanners can be grouped th rough a commercial switch and forwarded to a PC VUB BlueBox Ethernet EPP Parallel Port PC Software Following modules are supplied with the M2D LASER Scanner standard software package e Windows software to read data and to control the sensor e DLLs for Win 95 98 2000 NT XP DLL functions read data routines sensor configuration filtering of measurement data visualization routines for cotinuous mode Several sources are availble to support development They are available for the following environ ments DOS Turbo Pascal Delphi Borland or Microsoft C LabView Kylix Linux Special Software Tools DLL Test Software Configuration Tool ScanRecorder Diagnose Tool Demo Software M2D Show M2D Vision Documentation for each of these tools is available on request Customized programs on re quest M2D W Scanner cooled by air water The M2D W scanners with con nectors for air water cooling have been developed f r usage in hot environments up to 500 C for ex ample with welding robots and ex truding machines Protective Scanner Heat shield Fig 13 The protection window can be re placed after removal of the heat protection Applications Welding Welding seam control Rolling mills Marine Fig 14 Welding Robot Laser Bug Warranty The warranty per
91. values of the MEL measurement software and saved permanently in the Xconfig ini File The STORE CALIB button then is greyed out These entries in the Xconfig file are like the following delta X 2 L 0 delta_Y 2 L 0 58414200000027 delta_Z 2 L 0 0296190000000821 see the example of Xconfig ini file on the last pages The calibration must be made just once after performing the calibration the store calib button is deacti vated This is to prevent unwanted change of calibration settings Of course the correction values can be deleted altered or overwritten in the ini File JCT MIKROELEKTRONIK GmbH Tel 49 89 327 150 0 Fax 49 89 319 20 23 www MELsensor de HB ConcreteGrinding SVC E doc page 25 of 43 Laser Measurement System Manual File system e New volume IL File Edit View Go Favortes Help ocd bea 2 Back Forward Up Cut Copy Paste Undo Address ES CH T u Mu Documents Scandisk lag Program Files 2 Setuplog txt i s Recycled B Setupsig tst aE windSeng Suhdlog dat Windows Spaten 1 sk vo ume Autoexec bat Videorom bin C S Bootlog pry Bootlog bet mi Command com Winggeng Config sys File Folder D etlog txt Madified Orvepace bin 3 30 09 8 33 AM Frunlog txt lo ays Medos Medos sys Netlog txt EY My Computer The software is located in the folder MEL inside the Program files folder C Program Files MEL Drivers for USB devices are locat

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