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BK MIKRO9

1. 100 17 254 HERE 123 032 99 max stroke El o 1 N me a 9 Wm RO BK LO RO BK 8 RO BK x E E bai RO BK E a 19 E a a vt General tolerances ISO 2768 mK Fig 4 11 Mechanical Dimensions Scanner TK9LIN100 Option Compressed air connection Example TK9LIN50 General tolerances ISO 2768 mK I wo ch RO RO B Fig 4 12 Mechanical Dimensions Option compressed air connection Page 70 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 4 10 Accessories 4 10 1 Scanning wand set Scanner TK9LIN50 100 Scanning tip extension M3 M3 7 Xx 92 Adapter with point of fracture me in case of damage M2 M3 a y M3 Wand holder M2 5 M2 5 o dy a Rev 1 05 dated 3 5 2010 Technical Data Scanner tip brass L ur ee Scanner tip plastic M3 el date ar Ai sr Fig 4 13 Scanner Accessories Page 71 of 75 Installation Notes BA BK MIKROI 5 Installation Notes 5 1 Interference prevention All inputs are opto decoupled which provides maximum protection against interference voltage peaks that could occur from inductive sources Relay outputs are protected against inductive interference voltage peaks by using varistors Further interference suppression measures may be necessary depending on the type of load used If suppression measures are necessary to reduce
2. circ 484 032 44 a o 15 04 0 BK MIKRO BK MIKRO BK MIKRO BK MIKRO ess 82 5 max 127 26 5 21 5 Se max 145 General tolerances ISO 2768 mK Fig 4 5 Mechanical Dimensions Scanner TK91A Page 66 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKROI Technical Data 4 6 Scanner TK94A Housing Anodized aluminum Protection type IP 67 Scanning wand length 165 mm standard 1 2mm scanning wand exchangeable Scanning angle 300 max A Mechanical Dimensions I circ 139 032 024 4 Sa BK MIKRO BK MIKRO BK MIKRO BK MIKRO BK MIKRO Be er 92 5 max 134 max 150 26 5 General tolerances ISO 2768 mK Fig 4 6 Mechanical Dimensions Scanner TK94A Option air barrier light adapter General tolerances ISO 2768 mK 4 22 6 11 5 19 3 Fig 4 7 Mechanical Dimensions Option Air barrier light adapter Rev 1 05 dated 3 5 2010 Page 67 of 75 Technical Data BA BK MIKRO9 4 7 Scanner TK96A and TKI6RL Housing Stainless steel Protection type IP 67 Scanning wand length 100 mm standard 1 2 mm scanning wand exchangeable Scanning angle TK7A max 270 A TK7RL max 360 RL Co
3. BK MIKRO9 Control System for Tool Breakage and Object Monitoring with PROFIBUS Interface and USB Interface Operating Instructions Issue 1 05 3 5 2010 MSC Tuttlingen GmbH Rudolf Diesel Stra e 17 D 78532 Tuttlingen Tel 49 7461 925 200 Fax 49 7461 925 268 E Mail sales msc tuttlingen de www bk mikro com MICROCOMPUTERS SYSTEMS COMPONENTS TUTTLINGEN GMBH BA BK MIKROI General Notice General Notice Safety guidelines This document contains notices which you should observe to ensure your own personal safety as well as to protect the product and connected equipment These notices are highlighted in the manual by a warning triangle and are marked as follows according to the level of danger Danger Caution e bp Intended use i gt Rev 1 05 dated 3 5 2010 Immediate danger to life and limb of personnel and others Non compliance will cause death or serious crippling injury Hazardous situation to life and limb of personnel and others Non compliance may cause death or serious injury Potentially hazardous situation Non compliance may cause slight injury possible damage to property Notes on correct handling Non compliance may cause damage to the product and or to parts items in the vicinity Important information about the product the handling of the product or the part of the documentation onto which is supposed to be made especially attentive Environme
4. For further information s please use the help menu of the program The program is free to download at http www bk mikro com de Rev 1 05 dated 3 5 2010 Page 61 of 75 Technical Data BA BK MIKROI 4 1 Technical Data Control Unit Insulating material housing protection class II built in unit Protection type IP 20 24 VDC 220 SET Inputs Galvanically isolated Input current 5 mA approx Pulse duration 30 ms min Switched outputs 2 x 30 VDC 1 A max Operational life of relay 5x10 switching cycles depending on switching current Connections Plug in screw terminals for connecting power supply relay outputs control inputs Scanner small circular socket 8 pin Mini USB PROFIBUS Sub D socket 9 pin only BKM91 Premium Climatological conditions Classification 3K3 under EN 50178 Ambient temperature 0 C to 50 C Storage temperature 25 C to 80 C The voltage applied must meet the requirements for the safety low voltage SELV according to EN 60950 DC Power input LV Limited Voltage and LC Limited Current according to UL 508 Protection approved according to UL248 with a maximum of 4A should be used between the voltage supply and the BK MIKRO9 control unit Mechanical Dimensions Mechanical Dimensions are considered for all control units BK MIKRO9 14 85 113 6 gt 128 45 ca 108 General tolerances ISO 2768 mK
5. 0 Left 1 Right 3 00 mm Default Scanner 129 Dec 0 AutoDetect 1 TK8A 2 TK7A 3 TK8A Short Wand 4 TK9A 5 TK9A Fast long 6 TK94A RL 7 TK9LIN50 100 8 TK Reserved 1 9 TK Reserved 2 10 TK Reserved 3 128 User Scanner 1 129 User Scanner 2 P1 Low byte 160 255 0 01 mm unit Position 1 P1 High byte P2 Low byte 200 255 255 2 56 mm unit 0 01 mm unit 40 00 mm Default Position 2 P2 High byte 50 255 2 56 mm unit 130 00 mm Default lo jojojo y Return travel monitoring ojojojojo Boolean 0 Outputs do not change 1 H wand does not come back during return travel KO output will be active Power On Boolean 0 Wand will not travel after Power On 1 Wand will travel to stop position after Power On Output setting Boolean 0 Outputs will set at the object position 1 Outputs will set at the Home Position Output back setting Boolean 0 Outputs will set back at the next scanning 1 Outputs will set back with a fallen Start Signal HomePos offset 255 unit 0 Inactive 1 255 16 Reserved 17 Common options 255 Bool See appendix 18 Home position Offset 255 0 1 mm unit PB 0 01 mm unit USB 0 00 mm Default adopt scanner parameter Page 50 of 75 Rev 1 05 dated 3 5 2
6. Profibus Address fo Scanner TKSA v Crash Free Area 0 00 Homepos Offset Tool Change Time Position 1 Position 2 Limit Position Print Save Tool Settings Global Settings Output Settings Default Settings Setup Return Travel Monitoring 7 Inactive Active Rotation direction Counter Clockwise Clockwise M Counter Clear By Tesch Inactive Active Power On Move C Inactive Active m Profibus Data Format Little Endian C Big Endian Save As Page 46 of 75 Meng Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes Process data Output words 2 and 3 From PLC to BK MIKRO9 control unit Control word AW2 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Tolerance byte L Start LL Tesch L GoBack Go Position L __ __ __ Preposition __ __ __ _ Table active Tolerance byte Tolerance Specification of the angle in multiples of 0 1 degree 4 Value Degree mm 0 Param Accept value of parameter no 5 Tolerance range 1 0 1 2 0 2 3 0 3 255 25 5 Angle set value Length set value AW3 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Angle set value Angle set value Specification of the angle in multiples of 0 01 degree Value Degree J mm In the mode mm the tool size is spe
7. Teach or the position set using switches 1 off 2 off small Tron 2 off 1 off 2 on 3 0 1 on 2 on large 10 0 on switch position left off switch position right Desired position Scanner Scanning wand Stop position Fig 2 12 Range of tolerance SW1 switch The wand is between two objects With SW1 is activated the CW CCW scanning with Teach the wand travels first to left object and then to the right object When a start input is given both objects are scanned New Tool Settings With the RL function 128 different RL tool kits left and right tool are available The tool selection occurs from the selection inputs of the I O modules INS to IN8 About IN1 and IN2 can be determined the scanned tool IN2 IN Tool The right and the left tool are scanned The right tool is scanned The left tool is scanned The left and the right tool are scanned l lolo oj o At a Teach both tools must always be present SW2 Output State switch When set to Valid the outputs are momentary or only active as long as the Teach or Start signals are held high when the signal drops the output opens or closes depending on its setting When set to Static the outputs are latched and stay in that state until the next Teach or Start signal is given Page 22 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 3 2 3 1 Scanner Charact
8. The current position of the wand is monitored in doing so Outputs for warnings and errors ranges are then set or reset corresponding to the wand position It can be established from this monitoring e g whether a scanned product is the 1st 2nd or 3rd choice In the case of scanning on both sides objects or free spaces can be monitored in both directions with respect to the starting position 4 Rotation direction This parameter changes the scanning direction of the wand As soon as the parameter is changed the wand travels in the other way to the internal stop 5 Tolerance range This parameter sets the tolerance range With this information the tolerance range has not to be set in start cycle Tolerance range 0 in control word parameter value is used as tolerance range Rev 1 05 dated 3 5 2010 Page 53 of 75 Operating Modes BA BK MIKROI Scanner Settings of the scanner for further applications Scanning wand parameter Meaning TK_AutoDetect Activate of the automatically detection from the scanner wands Only for scanner wands TK9xxx Ist der Tastkopf TK91A angeschlossen wird Parametersatz 5 geladen TK8A Scanner wand TK8A standard needle 380mm DS TK7A RL Scanner wand TK7A RL standard needle 165mm TK8A Short Wand Scanner wand TK8A short needle 165mm low intensity TK91A610 Scanner wand TK91 optimised up to 610mm needle TK91A510 Scanner wand TK91A standard needle up to 610mm fast action tim
9. Control inputs Fig 2 2 The nominal tightening torque for the clamping screws of the terminal connectors should be 0 5 0 6 Nm or 4 4 5 3 pound inches lbf in BK MIKRO9 Control Unit Connection positions Page 11 of 75 System Components BA BK MIKRO9 24V power supply 24 VDC Input of 24 VDC supply voltage Reference potential of 24 VDC supply voltage GND PE 24 VDC Connection to earth potential Mains supply voltage 24 VDC NM 24 VDC supply for integrated DC DC transducer The voltage applied must meet the requirements for a safe extra low voltage SELV according to EN 60950 Attend to and polarity OUT relay outputs 1 Relay 1 OK Indication of a no fault message OK 2 terminals OUT1 0 k OUT2 k o 2 Relay 2 KO Indication of a fault message KO 2 terminals Default configuration of the control unit The terminals are dry relay contacts By internal parameters they may be configured via PC Software PROFIBUS or BK MIKRO9 expansion modules as either normally closed or normally open The contacts have been designed for 24 VDC and are protected by additional internal circuits against inductive switch off peaks of up to 19 W 2 ms Note Relay as normally closed contact active Open inactive closed Relay as normally open contact active closed inactive open When there is no power to the unit the contacts always will be open Ev
10. Fig 4 1 Mechanical Dimensions Control Unit BK MIRKO9 Page 62 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Technical Data 4 2 UO Expansion Module Dimensions WxHxD Inputs Galvanically isolated Input current 5 mA approx Pulse duration 30 ms min 2 High side switch with maximum output current 0 5 A Plug in screw terminals for connecting 10 Inputs 2 Outputs with power supply voltage Classification 3K3 under EN 50178 0 C to 50 C 25 C to 80 C The voltage applied must meet the requirements for the safety low voltage SELV according to EN 60950 DC Power input LV Limited Voltage and LC Limited Current according to UL 508 Protection approved according to UL248 with a maximum of 4A should be used between the voltage supply and the BK MIKRO9 control unit Mechanical Dimensions Ae K G L ve e 113 6 General tolerances ISO 2768 mK Fig 4 2 Mechanical Dimensions I O Expansion Module Rev 1 05 dated 3 5 2010 Page 63 of 75 Technical Data BA BK MIKRO9 4 3 Scanner TK7A and TK7RL Housing Anodized aluminum Protection type IP 67 Scanning wand length 250 mm standard 1 2 mm scanning wand exchangeable Scanning angle TK7A max 270 A TK7RL max 360 RL Control unit connection Small circular connector M12x1 8 pin Ambient temperature 0 C to 80 C Storage temperature 25 C to 85 C Scannin
11. Page 2 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Table of Figures Table of Figures Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig Fig 222222 2200 ODIA O N OI ADN sch ea lr ON a NVNUNNNYNNNNNYNNNNNNNNN TSS 3 Fig 2 20 Fig 2 21 Fig 2 22 Fig 2 23 Fig 2 24 Fig 2 25 Fig 2 26 Fig 3 1 Fig 3 2 Fig 3 3 Fig 3 4 Fig 3 Fig 3 Fig 3 Fig 3 Fig 4 Fig 4 Fig 4 3 Fig 4 4 Fig 4 5 Fig 4 6 Fig 4 7 Abb 4 8 Fig 4 9 Fig 4 10 Fig 4 11 Fig 4 12 Fig 4 13 Overview BK MIKRO9 Control Unit Front and rear side cccceceeeeeeeeeeeeeeeeeeeeeeseaeeneneeees 6 Overview BK MIKRO9 I O Expansion Module Front and rear side ooooooocccinocccnccncoccncnann ns 7 Overview Scanner TK7A TK7R Uas EE 8 Overview Scanner TB Attias acido dea anatatsi as 8 Overview Scanner NEE 9 BK MIKRO9 Control Unit Front side with connections 40rsnnsnsnennnnnnnnnnnnnnnnnnnnnnnn 11 BK MIKRO9 Control Unit Connection Dostons e 11 Light emitting AMOS isis il abia cda 13 PROFIBUS DP interf te 22 need 14 I O Expansion Module Connections nn 15 I O Expansion Module Connections positions ccccccceceeeceeeeeeeeeeaeeeeeeeseeeeeeeaeeseeeseneeees 15 I O Expansion Module Digital OUtOUtS 2 0 2 0 ccecececeeeeeeeeeeeeeee cents eeeaeeeeaeesee
12. WUKO RS Fig 2 3 Light emitting diodes LED Color Designation Function Status PWR Yellow Power Power supply 24 VDC On BUS Yellow BUS active USB active On Data transmission Flashing USB PROFIBUS Bus not active Out OK Green OK Scanning OK On KO Red KO Scanning KO On Rev 1 05 dated 3 5 2010 Page 13 of 75 System Components 2 1 4 PROFIBUS interface BA BK MIKROI The PROFIBUS interface is a floating RS 485 interface electrically insulated A standard 9 pin Sub D socket is used for the plug The pin assignment of the 9 pin Sub D socket corresponds to PROFIBUS standard Sub D socket 9 pin On oo 0000 00000 2N0R0 Pin Signal Function 1 N C not connected 2 N C not connected 3 RxD TxD P Data line B 4 RTS Request To Send 5 GND Data reference potential 6 5V 5 VDC 7 N C not connected 8 RxD TxD N Data line A 9 N C not connected USB connection Fig 2 4 PROFIBUS DP interface Connection to the PC is established via a USB plug located on the front side of the control unit A common USB cable mini B is used Scanner connection The scanner is connected to the 8 pole M12 circular plug in connector with the control cable in the control unit front Page 14 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 2 UO Expansion Module 2 2 1 Characteristic properties The BKM9I O expansion module is used if several inputs or
13. 028 Axis 3 mm Wand 1 2 mm BKM Air barrier adapter TKI1A 62 04 029 Axis 4 mm Wand 1 2 mm or 4 mm TK94A RL Please find the installation notes in the appropriate operation manual Art no 68 36 266 Page 36 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 6 Connection cable Control unit and scanner are connected with a 8 wire PUR cable e 8 pole molded plug on the side facing the control unit e 8 pole molded plug straight or angled facing the scanner e Length 5 m or 15 m extendable up to approx 25 m with extension cable e Suitable for daisy chain Note To increase cable life repeat movement should be kept to a minimum during operating cycles Rev 1 05 dated 3 5 2010 Page 37 of 75 Operating Modes BA BK MIKRO9 3 1 Operating Modes There are three operating modes for the BK MIKRO9 system According to system configuration the modes are available e Via PROFIBUS the system can be completely configured and operated e Digital I Os with external expansion for configuration and function selection up to 512 tools e Additionally a mini USB connection is available to configure and program the system without an external expansion Operating Mode PROFIBUS DP Address setting The PROFIBUS can be set via PC with the BK Config 9 program or with help of the BKM9I O extension module The BK MIKRO91 control unit is delivered with an address of 50 dec Setting of the PROFIBUS addre
14. 6 1 2 Overview I O Expansion Module 7 1 3 Overview Scanner Sii EE 8 2 System Components eiii a a H 10 2 1 Control Unit a A Aids 10 2 1 1 Characteristic properties ococccncinnnncinncccnnccnnnonnnn nan nanc cnn nn ranma 10 2 1 2 elle TR nn EE 11 2 1 3 LEDs to indicate status information nennen 1n 1n 1n 1n nennen nennen 13 2 1 4 PROFIBUS interface a ENEE ENNEN EE ee Eed ENEE EAR 14 2 1 5 Ee lee EE 14 2 1 6 Scanner e Ile ee EE 14 2 2 V O EXpansi n ModulO s crs a aa at aaa aia 15 2 2 1 Characteristic properties u 444uns00nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnen 15 2 2 2 CONNECHON termal Sii a A aiaia 16 2 2 3 Light emitting belle EH RE 18 2 2 4 ROAY WIN ai Oo Alsa ee EE 19 2 3 eler TT aa 23 2 3 1 Characteristic properties oarnein a eina ad eaaa da anada aa aTa tataie aa 23 2 3 2 Teea NAA and TKR E A A E AE T 25 2 3 3 ele TIET H WEE 26 2 3 4 Scanner TKI1 Ara ee Steeg 27 2 3 5 Balance weights for TROIR E 28 2 3 6 Scanner TK94A and TKQ4RL innarnn nunaa aa ie a a ea a i a 29 2 3 7 Scanner TK96A and Ten 31 2 3 8 Mounting bracket and holding arm for TkKOGATTKOGPn nennen 32 2 3 9 Scanner TKOLIN50 1 00 a r a a r aaa aa aa e ae eai eiei 33 2 4 Exchanging of the Scanning Wand 35 2 5 Age e EE 36 2 6 elle Te La 37 3 el Une HA ET 38 3 1 Operating Mode PPOEIDUIG DP 38 3 1 1 Address setting EE 38 3 1 2 ESE A OO 39 3 1 3 SCANNING in A NA 39 3 1 4 Activation of the tool table PC configuration
15. CW travel Stop Position Wand Monitoring range Begin of measuring range Object End of learned position measuring range Fig 3 2 Start cycle with CW travel Monitoring range learned defaulted position tolerance Vmax max speed of scanning wand Vs speed of scanning wand preset by Scanning intensity Page 40 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 3 1 4 Activation of the tool table PC configuration software BK MIKRO9 With the BK Config BKM9 program different attributes and functions can be programmed for different tool numbers Every tool has a number and is stored in the table With the USB interface the table can be loaded into the control unit Normally the table is activated via the I O from the expansion module This is also possible via PROFIBUS If the Table bit is set in the control word AW2 then the angle set value AW3 gets it s a definition from the tool number Table position stored in the controller The Start bit in the control word AW2 will then execute this function from the table With a Teach bit the function is also executed and the objects new position is learned The GoBack GoPos Preposition bits and the tolerance byte have no significance when the Table bit is active Using this method some functions can be used that are not possible using the Profibus e g CCW CW scanning Scanning in both directions only via PROFIBUS A n
16. arm Page 32 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 3 9 Scanner TK9LIN50 100 The LIN series is designed to verify longitudinal scanning functions where rotary scanning is unsuitable or impossible e g with cavities bore holes or limited space Any scanning range between stop position and maximum stroke can be checked Two types of scanners with different strokes are available e TK9LIN5O with 50 mm stroke e TK9LIN100 with 100 mm stroke In case of use the TK9LIN50 100 scanner is measured basically instead of grade the length and unit mm Note Your wand is a wearing part To avoid injury users should exercise caution while working in the area that the BK MIKRO wand travels Example TK9LIN50 max stroke E Scanning wand Rm mm tip exchangeable M3x6 RO BK RO BK RO BK RO BK in ous I Connector angled 8 pin _ Connection cable connector at the control unit end 8 pin Connection cable Sg straight connector at the scanner end 8 pin General tolerances connector atthe control unit end 8 pin ISO 2768 mK Ld Fig 2 24 Scanner TK9LIN50 Note When using the TK9LIN scanner all positions are indicated in mm The mm refers to the movement of the wand e g ObjectPos 23 75 mm Rev 1 05 dated 3 5 2010 Page 33 of 75 System Components BA BK MIKRO9 Option Compressed air balance The TK9LIN50 1
17. barrier light connection must be connected with a compressed air hose With overly aggressive coolant we recommend the air barrier adapter see chapter 2 5 E Hexagon socket set screw M5 Ba Compressed air connection Hexagon socket set screw M5 Fig 2 20 Option Air barrier light connection TK94A TK94RL Two compressed air connections for the TK94A RL are included and can be installed if required There are two M5 set screws that act as plugs for the compressed air connections You must remove the plug from the hole that you plan to install the compressed air connection into A pressure of 0 5 bars or 7 25 psi is recommended Page 30 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 3 7 Scanner TK96A and TK96RL We offer two types of scanners for the different applications The only difference between the two scanners is that the rotary movement of TK96A wand is limited by a screw inside the housing This screw is the mechanical backstop The TK96A RL scanner has a firmly fixed cable outlet for the connection to the control unit This firm cable is approx 200 mm long and can be connected onto every arbitrary control cable TK94A Scanner with mechanical backstop Scanner for scanning in one direction CW or CCW TK94RL Scanner without mechanical backstop Scanner for scanning in both directions CW CCW or CCW CW in special cases for scanning in one direction CW or CCW Note e Due to it
18. broken wand will always trigger an OK signal Rev 1 05 dated 3 5 2010 Page 59 of 75 Operating Modes BA BK MIKRO9 3 2 4 Output of results e Fault message KO A fault message is immediately outputted upon detection The scanner travels back to the stop position e Good cycle message OK The good cycle message is outputted immediately after recognition on the object Results will be indicated once the wand reaches its stop position These are the standard settings With the aid of the BK Config PC program you can set further parameters for the outputs Parameters as Return travel monitoring and Time of the switching Object HomePosition can be set Page 60 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 3 3 Function Mini USB Configuration program for BK MIKRO9 It is possible to control and make parameter changes to the BK MIKRO9 control unit via USB interface of a host PC with the help of the configuration program System Setup BK MIKRO9 After starting the configuration program the start page will appear where various functions can be selected in the menu Up to 512 functional attributes like specified angle tolerance and dead stop power can be defined in the programming operation The present monitoring cycle status is displayed detail when in manual mode The wand can be operated or set manually gt Manual Mode A trace function for long term monitoring is available gt Trace
19. done using in a binary pattern this means that through activating and deactivating the different positions can be called up 55 Selection inputs Tool position S9 S8 S7 S6 S5 S4 S3 S2 S1 0 L L LI L L L L L L 23 L L IL IL H L H H H 176 L H ILIH H L L L L 511 H HIHIH H H H H H L A Low HA High Digital outputs Two additional configurable active digital outputs are available with the I O extension module Only this digital output is not available in connection with the BK MIKRO93 basic control unit for counter alarm 24V free 2 configurable output Output 1 or 2 Fig 2 7 1 0 Expansion Module Digital outputs The outputs are high side switches which means that they act like normal switches Either they actively switch 24V max 0 5 A on the output or the output is unused ES Reference potential of the outputs GND 24V power supply Rev 1 05 dated 3 5 2010 Page 17 of 75 System Components BA BK MIKROI 2 2 3 Light emitting diodes LEDs Four LEDs on the front panel provide information about the current status of the expansion module BK MIKRO9 Extended Function OK Settings Power nm KO Settings 0000 PXSS WFOK R KO Fig 2 8 UO Expansion Module Light emitting diodes LED Color Designation Function Status PWR Yellow Power Power supply 24 VDC On XF Yellow PROFIBUS add
20. interference these measures should be placed directly at the source of the interference Possible additional noise filters e RC combination included in the contactor suppliers product ranges e Varistors e Diodes Page 72 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Ordering Information 6 Ordering Information Control Unit Article No BK MIKRO9I O Expansion Module 63 04 247 TK7A with scanning wand 63 04 234 TK7RL with scanning wand 63 04 235 TK8A without scanning wand 63 04 237 Connection Lenath BK MIKROQ Control Unit Scanner eng Accessories and spare parts Article No Scanning wands TK7A TK7RL TK94A TK96RL TK96A TKYARL thickness 1 2 mm length 165 mm 62 04 022 thickness 1 2 mm length 250 mm 62 04 216 Scanning wands TK8A thickness 3 mm length 380 mm plate 80x15 Scanning wands TK91A thickness 4 mm length 380 mm plate 30x15 62 04 284 thickness 4 mm length 510 mm plate 120x15 62 04 279 thickness 4 mm length 610 mm plate 120x15 62 04 285 Scanning wands TK9LIN50 100 Scanning wand set 62 04 904 Adapter with point of fracture in case of damage M3 scanning tip extension M3 scanning tip brass scanning tip plastic M3 Balance weight set 2x 20 mm 1x Y 16 mm 62 04 282 Mounting bracket scanning wands Y 32 mm 61 07 082 Mounting bracket scanning wands 20 mm 61 07 165 Mounting bracket scanning wands 12 mm 61 04 302 Accessories fo
21. of the power supply Usually set parameter to 0 Default Setting outputs The outputs are switching if the wand hits the object or first if the wand occurs the HomePosition Resetting outputs The outputs can be reset either with the next scan or with the falling Start signal Parameter index Bit0 Scanning mode A or R L Bit 1 Scanner powerless Common Options BitO Scanning mode Inaktiv The scanner scans only in one direction an object Aktiv A function R L is generated for the tool table In this mode a table bit AW2 bit 7 must be active at TEACH or START At TEACH both positions will be stored in an tool table At START both tool will be scanned Bit1 Inaktiv Scanner controls the position normal operation Aktiv The scanner motor will be powerless The wand can be travel freely At power on this bit will be deleted and the scanner travels normal HomePosition The HomePosition of the wand before of the mechanical backstop can be adjusted between 0 1 and 25 5 The standard value of the particular scanner will be use if it is 0 e g 8 Rev 1 05 dated 3 5 2010 Page 55 of 75 Operating Modes BA BK MIKRO9 19 Time frame value This value determines when the bit time frame1 will be set before the bit collision free area 20 Collision free area Here the Collision free area of the wand is defined e g outside a tool magazine 21 Monitoring unit All objects and free spaces can be monitore
22. outputs are needed and or to configure control the control unit directly without using PROFIBUS or USB The module will be connected with the control unit via top hat rail connector It will supply power to the control unit which means no additional power supply is needed The module offers 10 additional inputs 2 digital outputs several trigger switches and 3 rotary switches Four LEDs are used for status error display IN4 INS ING INT j IN3 Out 1 IN2 Out 2 CX IN1 COM Fig 2 5 1 0 Expansion Module Connections Note These plugs may only be inserted or removed when the power supply has been disconnected Uncharacterized clamps must be blank Caution Note The nominal tightening torque for the clamping screws of the terminal connectors should be 0 5 0 6 Nm or 4 4 5 3 pound inches lbf in Outputs OUT Inputs 1 2 IN 1 3 KI Top hat rail connector E Coupling principle Beil Right or left Inputs Control Inputs IN INA4 7 COM 8 10 Fig 2 6 1 0 Expansion Module Connections positions Rev 1 05 dated 3 5 2010 Page 15 of 75 System Components BA BK MIKRO9 2 2 2 Connection terminals Control inputs The I O expansion module has a total of 10 additional digital inputs 9 inputs are used for selecting the function to be started The input 10 can be used to reset the outputs of the BK MIKRO9 control unit and the BK MIKRO9 expansion module The function
23. scanner can be selected with the configuration software or by using the rotary switch of the expansion module Parameter values and technical data are listed below Rev 1 05 dated 3 5 2010 Page 23 of 75 System Components BA BK MIKROI If a scanner does not match the control unit setting the scanner type needs to be altered in the control unit before connecting Movement can occur due to different resolution and gear ratios This may result in maximum overstepping and damage to the scanner Dibib Note Connecting a scanner which does not correspond to the settings of the control unit can damage the scanner Note Wrong scanner parameters lead to wrong measurement results Note At scanners with an internal stop it is possible if an angles is gt 270 that the internal stop will be travel and a wrong OK will be trigger That applies also with the TK9LIN50 and TK9LIN100 scanners if they travel in the full area Automatic recognition of the scanners The TK9 series scanner are recognized automatically with the TK Autodetect parameter setting Parameters 6 scanner no special adjustments are necessary via PROFIBUS the PC software or the expansion module if IK Autodetect is selected At delivery TK Autodetect is adjusted Page 24 of 75 Note The TK7A RL and TK8A scanners can not be recognized automatically If TK Autodetect is active and no TK9 series scanner of the is connected then the TK8
24. software BK MIKPDOO 41 3 1 5 Scanning in both directions only via PROEIDUIG cnn cc nana nnannncccnnncnns 41 3 1 6 REPEKENCE EE 42 3 1 7 Blue tun e nu e WEE 43 3 1 8 GSD TEE 45 3 1 9 PROFIBUS DP dee ee EE 45 3 1 1 PROFIBUS data fo Mataro ici iaa deba aa 46 3 2 Operating Mede Digitalil Or 42H eier lese pa hl 58 3 2 1 Switch mode monitoring scanning range with switch seitings 59 3 2 2 Control operation Object monitoring uurs4ssrsnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnn 59 3 2 3 Control operation Free space monitoring canaria nc cnn rn cnn 59 3 2 4 Output OF results iii aaa io tallo E iaa 60 3 3 Function MINFUSB EE 61 4 Technical Data add di 62 4 1 ControlUnitacina inca mr AAA ie SNS ei a de EE 62 4 2 VJ Expansion Module iz 44 23 2s egen AE animal 63 4 3 scanner TK7A and WR TEE 64 4 4 Scanner TL ABA EE E 65 Rev 1 05 dated 3 5 2010 Page 1 of 75 4 5 4 6 4 7 4 8 4 9 4 10 4 10 1 5 1 BA BK MIKROI aper LEE ee Eeer e geha et Ee tee 66 EINEN EE 67 Scanner TK96A and Kent 68 EINEN GE RO NEE 69 Scanner TKILIN TOO ici atadas 70 ACCESO EE 71 Scanning wand Sti cui stad eee diana dd eii 71 Installation Notes EE 72 Interference prevention 2004444004n40nnnnnnnnnnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnannnnnnnnnnnen 72 Ordering Information uessrssansnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnnnnnnnnannnnnnnnnnnnnnnannnnnnnnnnnnnnnnannnnnannnnnnnnn 73
25. tolerance for OK message Vmax max speed of scanner Vs speed of scanner preset by Scanning intensity toggle switch The tool number that you would like to check needs to be selected with the correct binary pattern then the start impulse is applied The wand will then begin the scanning process If the wand contacts the object at the learned position an OK message will be set If the wand is stopped before the monitoring range or exceeds the area then a KO message will be set The wand rotates at a higher speed and slows down to scan the monitoring range with reduced speed and strength Page 58 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 3 2 1 3 2 2 3 2 3 During the scanning process i e after a Start pulse the wand will initially travel at maximum speed to the start of a given monitoring range The motor will slow down to a preselected scanning speed in time before reaching the learned position or a preselected angle which is set by the rotary switches is reached The wand travels through the area to be monitored and the scanning occurs with the set intensity If the system detects that the scanner no longer moves or has exceeded the end of the monitoring range the direction of rotation immediately changes and the scanner will return at maximum speed to its stop position Depending on the result of scanning the corresponding relay will be activated and the corresponding LED will indicate
26. 00 scanners have an optional compressed air balance connection It s possible for the rack and pinion area of the scanner to fill with liquids coolants over time The compressed air balance connection allows the liquid to drain from the scanner an prevents a possible vacuum from occurring ke Compressed air connection Hexagon socket set screw M5 Hexagon socket set screw M5 Fig 2 25 Option compressed air balance TK9LIN50 100 Two compressed air connections of the TK9LIN50 100 are included which can be installed if required In the two borings of the scanner hexagon socket set screw M5 are inside as a protection one of the screw must be removed before a compressed air connection can be install On the compressed air connection must be applied a compressed air hose whose end is open and stands at a protected place against liquids With this measure can be increased the service life of the wand under liquids The open end may not be connected on the compressed air its only for the pressure balance of the scanner Page 34 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 4 Exchanging of the Scanning Wand The wand can be easily removed from the wand holder by loosening the hexagon socket M3 Insert the new wand into the wand holder and tighten Notes for wand exchange Wands of solid material Art no 6204022 6204215 6204216 6204231 or similar These wands may be shortened or bent as r
27. 010 BA BK MIKRO9 Operating Modes 19 Time frame value 0 0 255 1ms unit Oms Default tool replacement area tool free space 20 Collision free area 0 0 255 1 mm unit PB 0 00 mm Default adopt 0 01 mm unit USB scanner parameter 21 Monitoring unit 0 0 1 Boolean 0 Grad 1 Millimeter 22 Distance 0 0 255 0 01mm unit 0 00mm Default Low byte 23 Distance 0 0 255 2 56mm unit High byte 24 Reference angle 0 0 255 0 019 unit 0 00 Default Low byte 25 Reference angle 0 0 255 2 56 unit High byte 26 Tool length 0 0 255 0 01mm unit 0 00mm Default Low byte 27 Tool length 0 0 255 2 56mm unit High byte 28 BKM variant Read_only Hex 10h Basic93 20h Premium91 21h Premium92 22h Premium911 28 BKM variant Read_only Hex 10h Basic 20h Premium 29 Date month Read_only Dec Date month 30 Date year Read_only Dec Date year 31 FW version Read_only Dec Software version Rev 1 05 dated 3 5 2010 Page 51 of 75 Operating Modes BA BK MIKRO9 Declarations concerning parameters The table shows the allocation of parameters 0 31 There are parameters that can be read as well as to Other parameter are read_only An attempt to write a read_only parameter causes an error message 0 Scanning intensity Scanning intensity determines the size of strength and rate during the learning cycle and or within the tolerance range of
28. 4 Time optimized scanning Time framel nc cnnrn cnn 44 Dista citaron tadas 56 Start cycle with scanning in both directions ooonnnccincicnnncnnnnonncccnnnrcnn nara nccrnrccnnrrnnr rn 58 Mechanical Dimensions Control Unit BK MIO 62 Mechanical Dimensions I O Expansion Module 63 Mechanical Dimensions Scanner TKAZA TTKORL nr rnnanncnnnnc 64 Mechanical Dimensions Scanner TK8A oncccnnccnnonoconccnnnncccnnncc narran cc 65 Mechanical Dimensions Scanner TK91A oncccincccnonccnnnonnnnnccnancn nn rana 66 Mechanical Dimensions Scanner TK94A occcnicccnnnccnnnccnnancccnonnnn nana 67 Mechanical Dimensions Option Air barrier light adapter ccccceeseeeeeeeceeeeeeeteeeeneeeeeaees 67 Mechanische Abmessungen Tastkopf TKYAA enssnsnsseennsnennannnnnnnnnnnnnnnnnnnnnnnnn nn 68 Mechanical Dimensions Scanner TKOL IN 69 Mechanical Dimensions Option compressed air Conpectlon 69 Mechanical Dimensions Scanner TKOL IN 00 70 Mechanical Dimensions Option compressed air Conpectlon 70 Scanner AC eS OT OS eege aleta 71 Rev 1 05 dated 3 5 2010 Page 3 of 75 Table of Figures BA BK MIKRO9 Purpose These operating instructions are part of the documentation of the BK MIKRO9 They provide service personnel and system advisors with the information required to install commission operate and maintain the system BK MIKRO9 Copyright MSC Tuttlingen GmbH 78532 Tuttlingen 2010 These oper
29. 75 Operating Modes BA BK MIKRO9 3 1 6 Reference travel Using the Reference travel function the scanning wand can be assigned a new HomePosition by specifying the angle of an object In doing so the complete measuring system is reconfigured so that the position of the object precisely matches the specified position This function is usually used if the parameters of a measuring system have changed e g after replacement of a scanning head Sequence If the Go Back and Teach bits are set at the same time the scanning wand starts the scanning process The object found is then scanned three times in order to improve the accuracy of the measurement A new rest position zero position is calculated afterwards so that an object is now located exactly in the specified position as in the old system e g before scanning head replacement Page 42 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 3 1 7 Time optimized scanning The scanning time of the wand can be optimized during the outward as well as the return journey This will result in idle time savings of the tool e Outward journey with help of the command Preposition e Return journey with parameter collision free area CollFrArea and the bit collision free area CollFrArea with parameter time frame value CollChgTime and the bit time range CollChgArea Outward journey The command Preposition moves the wand to the close proximit
30. 8 mK Fig 2 14 Scanner TK8A Page 26 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 3 4 Scanner TK91A e Scanning wands are available in lengths up to 610 mm This allows for greater distances between the scanner and tools or objects that it is checking e Scanning plate on the scanning wand This makes it possible to use the scanner directly in the tool magazine to make positive contact with the tool s tip The TK91A scanner has a mechanical backstop that limits the rotary movement of the wand Using the TK91A scanner with a different control unit than the BK MIKRO9 may damage the scanner and control unit Note The wand is a wearing part To avoid injury users should exercise caution while working in the area that the BK MIKRO wand travels Example TK91A with 3 balance weights PEE l Scanning plate Scanning wand wg 120x15 500 V2A max length 610 mm BK MIKRO BK MIKRO Wand holder BK MIKRO Housing ____ BK MIKRO Connector angled 8 pin ee Se Connection sie connector at the control unit end 8 pin Connection cable Be straight connector at the scanner end 8 pin General tolerances connector at the control unit end 8 pin ISO 2768 mK Fig 2 15 Scanner TK91A with 3 balance weights Rev 1 05 dated 3 5 2010 Page 27 of 75 System Components BA BK MIKRO9 2 3 5 Balance weights for TK91A A balancing
31. A scanner will be automatically set i e only the TK7A RL scanner must be set via PROFIBUS PC software or the expansion module Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 3 2 Scanner TK7A and TK7RL We offer two types of scanners for the different applications The only difference between the two scanners is that the rotary movement of TK7A wand is limited by a screw inside the housing This screw is the mechanical backstop TK7A Scanner with mechanical backstop Scanner for scanning in one direction clockwise or counter clockwise TK7RL Scanner without mechanical backstop Scanner for scanning in both directions CW CCW or CCW CW in special cases for scanning in one direction CW or CCW Note e Due to its small diameter the wand is easily overlooked e Your wand is a wearing part Each contact with a rotating object will cause wear on the wand That can break the wand and the wand must be changed For rotation tools an especially hardened HSS steel wand is available To avoid injury users should exercise caution while working in the area that the BK MIKRO wand travels Di Protective cap Scanning wand standard length 165 mm RO BK Wand holder RO BK RO BK Housing Fr 8 BK Connector L angled 8 pin en Connection cable connector at the control unit end 8 pin m Connection cable straight connector at the scanner end 8 pin Genera
32. K94A Scanner with mechanical backstop Scanner for scanning in one direction CW or CCW TK94RL Scanner without mechanical backstop Scanner for scanning in both directions CW CCW or CCW CW in special cases for scanning in one direction CW or CCW Note be changed e Due to its small diameter the wand is easily overlooked e Your wand is a wearing part Each contact with a rotating object will cause wear on the wand That can break the wand and the wand must For rotation tools an especially hardened HSS steel wand is available To avoid injury users should exercise caution while working in the area that the BK MIKRO wand travels Protective cap Scanning wand standard length 165 mm Wand holder Housing Connector angled 8 pin BOSS Connection cable connector at the control unit end 8 pin General tolerances ISO 2768 mK Note Rev 1 05 dated 3 5 2010 5 BK MIKRO BK MIKRO BK MIKRO BK MIKRO BK MIKRO aa en Connection cable wa straight connector at the scanner end 8 pin connector at the control unit end 8 pin Fig 2 19 Scanner TK94A TK94RL To prevent possible injury the wand is supplied with a protective cap Page 29 of 75 System Components BA BK MIKRO9 Option Air barrier light connection To protect the s TK94A RL scanners better against coolant and swarf we recommend the use of the air barrier light connection The air
33. W2 Bit 0 15 Control word AW3 Bit 0 15 Angle set value BK MIKRO9 gt PLC 3 data words input 2 bytes each Input words Function EW1 Bit 0 15 Parameter identification EW2 Bit 0 15 Status word EW3 Bit 0 15 Angle Data from PLC to BK MIKRO9 control unit will be transmitted via control words of the PROFIBUS process channel Data from BK MIKROS9 control unit to PLC will be transmitted via status words Data transmission runs cyclically Page 45 of 75 Operating Modes 3 1 10 PROFIBUS data format BA BK MIKRO9 Various PLC s interpret the byte sequence of the output and input words differently because of this The bits 7 0 and 15 8 may get mixed up Like in the example below the data is preset and transferred in the Little Endian format Littlie Endian AW2 15 14 13 12 11 10 9 8 7 6 4 3 2 1 0 Tolerance Table PrePos GoPos GoBack TEACH START Big Endian AW 2 15 14 13 12 11 10 9 8 7 6 5 4 2 1 0 Table PrePos GoPos GoBack TEACH START Tolerance The particular byte sequence can be altered with help of the BK Config BKM9 PC program Using this settings messages can be sent and received in either the Little Endian or the Big Endian format JBK MIKRO 9 Settings example CDX iol x FSW Version
34. ating instructions are available as article no 68 36 263 Subject to change without notice Page 4 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Characteristics 1 Characteristics BK MIKRO 9 is a control system suitable for tool as well as for object and free space monitoring applications The complete BK MIKRO9 system comprises e a control unit 1 O expansion module option e a sensor scanner e a connection cable e various optional accessories BK MIKROS9 can be used universally for different types of monitoring by the integration of multifarious functions e Operation with PROFIBUS connection Monitoring occurs with parameter specification angle tolerance etc of the PROFIBUS Master SPS PLC With this mode of operation the full scope of device function is available e Operation with digital I Os Setting parameters with help of a PC Parameters of the tool object data are created on a PC transferred to the control unit via USB and digitally controlled SPS in the application In connection with the extension module up to 512 objects tools can be learned and checked via selection inputs With this mode of operation the full scope of function is available as well e Operation with digital I Os Setting parameters via toggle switches For easy setup without using the PC software all of the important functions can be set using the dip switches on the extension module The selection of up to 512 possible objects too
35. chieved and how strong the wand swings Page 52 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 2 Out2 Using these parameters the relay output 1 relay output 2 can be defined as to how they should behave in the active condition After switch on the control unit these outputs are always either in the set state normally closed or normally open even before a scanning cycle has occurred 3 Monitoring Using this parameter either object or free space monitoring can be specified Object monitoring When an object is scanned the OK output is active if the presence of the object is detected in the specified range The KO output is active if the object is not present Free space monitoring checks if the specified area can be exceeded without hit to a barrier The ranges are specified using either the angle and tolerance definitions or using the P1 and P2 position parameters If the angle is defined as 0 then P1 and P2 are used as the tolerance range Tolerance range is used as the tolerance range if 0 is input for the tolerance here The wand will travel to a specified position GO Position for the positioning run This is specified by the object position Go Back the wand travels in a specified direction until it encounters an obstacle normally this is the internal end stop The HomePosition is defined and set at this position Touch the wand presses for so long against an object until the check is stopped
36. cified in mm 0 0 1 0 01 2 0 02 3 0 03 65535 655 35 Angle min 8 320 hex 00000011 0010 0000 Angle max 300 7530 hex 01110101 0011 0000 Angle specification Angle specification Indicates the angle in multiples of 0 01 degree 9 Value Degree 0 0 1 0 01 2 0 02 3 0 03 65535 655 35 Min Angle 8 320 hex 0000 0011 0010 0000 Max Angle 300 7530 hex u 0111 0101 0011 0000 Rev 1 05 dated 3 5 2010 Page 47 0f 75 Operating Modes BA BK MIKRO9 Status words Input words 2 and 3 From BK MIKRO9 control unit to PLC Status word EW2 145 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 L Wand in stop position N E Scanning active NE 2a OR L KO L Scanning area not reached L Time frame CollChgArea L Collision free area CollFrArea L Error Cable break L Error Scanner L Error Control unit L Error Wand L Error Angle set value L Error Control word L Error Parameter Angle Length EW3 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 EH Angle Angle Specification of the angle in multiples of 0 01 degree Value Degree mm In the mode mm the tool size is specified in mm 0 0 1 0 01 2 0 02 3 0 03 65535 655 35 Page 48 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes Parameter The transmission of the parameters also run cyclically via the process channel of th
37. d in two different ways in degree units all information is in degrees TI in millimeter units all information is in millimeters mm Note In order to use the millimeter mode the following three parameters must be configured as a reference for the millimeter conversion Distance Reference angle and Tool length 22 23 Distance This parameter corresponds to the distance between the scanner axis and the tool which the scanner wand would contacted at 90 Tool length Object r A 90 Scanning wand Distance Reference angle Scanning wand HomePosition Scanner axis Fig 3 7 Distance Note In order to use the millimeter mode the following three parameters must be configured as reference for millimeter conversion Distance Reference angle and Tool length Note This function is not possible with TK9LIN50 100 scanner Page 56 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 24 25 Reference angle This parameter corresponds to the angle between the tool and the rest position at the 90 position of the tool to the wand Note In order to use the millimeter mode the following three parameters must be configured as reference for millimeter conversion Distance Reference angle and Tool length 26 27 Tool length This parameter corresponds to the tool length at the 90 position of the tool to the wand Note In order to use the millimeter mo
38. de the following three parameters must be configured as reference for millimeter conversion Distance Reference angle and Tool length Rev 1 05 dated 3 5 2010 Page 57 of 75 Operating Modes BA BK MIKRO9 3 2 Operating Mode Digital UO The wand moves to home position when the control unit is turned on This means the wand rotates to the left or right until it reaches the internal backstop depending on the preset parameters Thats why there is to provide that the wand can move freely into home position without previous stop at an object or tool Teach cycle When a pulse to the Teach input is turned on the wand will begin with the scanning cycle The wand rotates until it contacts on an object or tool This position will be stored in the control units internal data base The number of the tool is defined by the selected teach input The default values for tolerance and scanning intensity can be adjusted using the configuration software or with the DIP switches Whether the wand has not contacted any object during the Teach cycle it moves to the angle which is above of the Teach position and Tolerance parameter returns and sets the KO message Start cycle with CW travel using teach mode using switch mode Stop Position Stop position Vmax Wand eg Wand Monitoring Monitoring range range learned position Fig 3 8 Start cycle with scanning in both directions Monitoring range Range of
39. e PROFIBUS From PLC to BK MIKRO9 control unit Parameter identification AW1 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 lL Read Parameter byte Kane Parameter value Parameter number fi He ae Write Parameter byte 0 255 0 31 A Resetting the outputs OK KO From BK MIKRO9 control unit to PLC Parameter identification EW1 l L Parameter updated L Parameter value Parameter number we Error during writing 0 255 0 31 Beete Error during reading Rev 1 05 dated 3 5 2010 Page 49 of 75 Operating Modes Parameter list BA BK MIKROI Number Name Default Min Format Description 0 Scanning intensity 0 Dec 0 Low 1 High 2 Intermediate level 1 3 Intermediate level 2 4 Intermediate level 3 5 Intermediate level 4 6 Intermediate level 5 7 Intermediate level 6 Special functions Out 0000 001 255 See declaration of the parameters Out2 Relay output 1 Boolean 0 InActive normally open 1 Active normally closed Monitoring 1 Dec 0 Free space 1 Object 2 GoPos 3 GoBack 4 TK91A610 5 TK91A510 6 Object both sides 7 Free space both sides 8 TKI6A RL 9 TK91A732 128 User Tastkopf 1 129 User Tastkopf 2 Rotation direction Tolerance range 300 255 Bool 0 1 mm unit PB 0 01 mm unit USB
40. e moved Scanning position Scanning position largest tool smallest tool Tool magazine Collision free area HomePosition Fig 3 5 Time optimized scanning Collision free area e Idle times in the system such as moving the wand toward the tool magazine can be avoided The parameter Time frame value determines the required time for this procedure The bit time frame s set before the bit collision free area which is determined in the parameter time frame value Thus e g moving towards the tool magazine can be initiated already when the wand has not arrived yet in the collision free area By the time the tool magazine actually moves the wand will have reached the collision free area already A Scanning positio Changing area e PORAS smallest tool Scanning position largest tool Tool magazine Collision free area NY gt Wand Scanner HomePosition Fig 3 6 Time optimized scanning Time frame Page 44 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKROI 3 1 8 Rev 1 05 dated 3 5 2010 Operating Modes GSD File The appropriate GSD file for BK MIKRO9 is named MSCTO5CF gsd and can be downloaded at http www bk mikro com or http www techna tool com PROFIBUS DP Protocol Configuration PLC gt BK MIKROQY 3 data words output 2 bytes each Output words Function AW1 Bit 0 15 Parameter identification A
41. e saving optimised for 510mm needle e TK94A RL Scanner wand TK94A RL standard needle 165mm fe TK9LIN Scanner wand TK9LIN e TK96A RL Scanner wand TK96A RL standard needle 100mm e TK91A732 Scanner wand TK91 optimised up to 732mm needle 128 USER_0_NotDef Special detected parameter for one scanner wand Loadable in the menu File Scanner If this programmable appear instead of NotDef the assigned scanner wand name 129 USER_1_NotDef Special detected parameter for one scanning wand Loadable in the menu File Scanner If this programmable appear instead of NotDef the assigned scanner wand name Note In case of a change of the scanner parameters the system must be restarted the new wand parameters will be are taken over Page 54 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 7 18 9 10 11 12 13 14 17 18 Operating Modes Position 1 P1 Low byte P1 High byte and Position 2 P2 Low byte P2 High byte Using these parameters the angle set value can be preset by P1 and P2 These values are used as range set value as soon as angle set value 0 Return travel monitoring Using this parameter the OK output can be activated in case of non attaining the stop position If return travel monitoring is not active this information can also be interrogated in bit Wand in stop position via PROFIBUS Power On Using this parameter it can be prevented that the wand starts moving immediately after switch on
42. eetaeeeeaeeseneeees 17 1 O Expansion Module Light emitting dodes tees eeeeeeseeeeeteaeeetaeeseeeeens 18 I O Expansion Module Rotary switch canon nnnnn cnn rca ran rana 19 I O Expansion Module Toggle switches 0 cccecsceceeeeeeeeeeeeeeeeeeeeesaaeeeeneeseeeeeseaeeeseaeeeeeeeee 20 Definition of the rotation direction urs440s4snannnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 21 Range of e EE Te 22 Scanner Le TRB eek deg GE Ee 25 Scanner KB Avion eee 26 Scanner TK91A with 3 balance weights oooooccnnocinncccnncccnnononnnccncancccnornn nara cnn rca 27 Dimensions in mm with 3 balance weight 28 Dimensions in mm with 2 different balance welgbts nar ccnncnnn 28 Dimensions in mm with 3 different balance welgbts nana cc nn 28 Scanner TK9O4Ad TKA RE een inte 29 Option Air barrier light connection TK94A TK94BL oooicccnncccnnccococccononinonanananana narran cnn 30 Scanner TKIGA KOO R burger iesen aaa ida 31 Scanner IK96AY TKOGRES coord tie 32 Dimensions Mounting Bracket Holding arm u 444sernnnennennnnnnnennnnnnnennnnnnnennnnnnnennnnnenn 32 Scanner KOLN E Or Rn ernennen 33 Option compressed air balance TOL INGOImO0 naar cnn cnn narran 34 Scanner TK91A blind DIUG tica iia da 35 FUNGCHOM SCQUONCE EE 39 Start cycle with CW travel nissan eii tots A0 Scanning CW COW EE 41 Time optimized scanning Preposigon cn nana 43 Time optimized scanning Collision free are 4
43. en when using relay as normally closed they are open like the active status when the power supply is not connected Page 12 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components IN control inputs Reference potential for control inputs and selection input Teach control input An input level of 24 VDC relative to COM terminal will trigger a Teach The position stored during the Teach will remain stored even after the unit has been switched off Start control input An input level of 24 VDC relative to COM terminal will trigger a Start cycle the real scanning process Stop control input An input level of 24 VDC relative to COM terminal will trigger a Stop an operation will be disconnected The inputs can be connected with positive or negative logic Positive logic COM input must be put on GND The particular input IN 1 3 will be set on 24 V high by switching As low condition the input will be wired on GND or left open Negative logic COM input must be put on 24 V The particular input IN 1 3 will be set on O V high with switching Considered low condition the input will be connected to 24 V or left open 2 1 3 LEDs to indicate status information Four light emitting diodes LEDs on the front panel of the BK MIKRO9 control board are used to indicate status information BUS active OK Power es KO 0000 PBOK
44. equired Wands of hollow material Art no 6204260 6204266 6204270 or similar Wands may be shortened as required Bending is not recommended To prevent crushing the wand must not be hollow in the section of the scanners positioning screw Wands may be shortened as required Bending is not recommended The blind plug must be put into the end of the wand that prevents a crimped wand Fig 2 26 Scanner TK91A blind plug Note If a hollow wand needs shortening the provided blind plug or the pole for the balance weight set must be removed before after this it must be put into the open end again Rev 1 05 dated 3 5 2010 Page 35 of 75 System Components BA BK MIKRO9 2 5 Air Barrier Adapter The air barrier adapter has been mainly designed for using the BK MIKRO scanner in harsh and aggressive environments The adapter keeps liquids and splints away from important seals with a air barrier adapter This leads to an increased scanner life cycle Note Some compositions of coolants or emulsions may harm the seals if they have an unfavorable PH value The gear mechanism can be damaged and internal electronics may be destroyed if liquids enter the scanner housing Different air barrier adapters are available for select scanners and scanning wands Accessories and Spare Parts For Scanner Article no BKM Air barrier adapter TK7A RL 62 04 027 Axis 3 mm Wand 3 mm TK8A Le DRM Air barrier adapter 62 04
45. eristic properties The scanner housing is cylindrical and smooth which permits easy installation e g by using the mounting bracket The scanner is designed for easy access for servicing and changing of the wand Aligning the scanner is easy and requires no additional instruments or aids The scanner listed blow can be connected to the BK MIKRO9 control unit Following chart shows the main features Type Axis Unit High Scanning wand Plate Time of 180 Repeat accuracy 9 2 mm length max rotation max mm approx sec TK7A RL 3mm 20 mm 79mm 250 mm No 0 4s 1 2 TK8A 3mm 20 mm 79mm 380 mm Yes 1 35 0 15 TK91A 4 mm 32 mm 107 5 mm 610 mm Yes 1 85 0 05 TK94A RL 4 mm 32 mm 117 5 mm 250 mm No 0 25 s 1 2 TK96A RL 3 mm 12 mm 90 5 mm 100 mm No 0 25 s 1 2 Hub length max Time of 1 hub Repeat accuracy approx sec max mm TK9LIN50O 32 mm 103 5 mm 50 mm 1 48 0 05 TK9LIN100 32 mm 103 5mm 100 mm 1 85 0 05 Type description A gt Scanner with wand holder backstop no external dead stop for home positioning necessary RL gt Scanner capable of right left run with external backstop or controlling of two tools simultaneously A customized set of the motor parameters may be necessary for demands that differ from the denoted wand lengths or scanning times in the chart above Please contact the producer if the values listed above are exceeded The
46. es Settings at delivery All switches are on the right side Only with the scanner setting unequal 0 all switches are active There s a the higher priority as the saved parameters in the control unit Page 20 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components Right Left switch Rotation direction of the scanning wand i e direction in which the wand moves from the rest position Right Rotation clockwise Rear view of the cable connection side on the scanning head in the direction of the axis of rotation Fig 2 11 Definition of the rotation direction Object Free space monitoring switch OK message for presence object monitoring or object not present free space monitoring in the scanning range N C N O contact switch Functionality of the 4 outputs see section Digital outputs Scanning intensity switch Adjusts the speed and force of the scanning wand within the scanning range For the Teach and the Start cycle where an OK message should be received this is Switch position Scanning Intensity Impact force small a large Note If this switch is in the small position the reduced impact force helps to protect the wand against wear Rev 1 05 dated 3 5 2010 Page 21 of 75 System Components BA BK MIKRO9 Tolerance range switch Tolerance range for OK message in relation to the target position i e the position taught by
47. ew stop position between two objects tools can be allocated the wand by a freely definable angle set value with the function Go position No objects tools can be within the movement area of the wand during this process After the wand has reached it s new stop position the two objects can be charged and sampled The scanning direction can be defined by the angle set value Function When the bits Go position and Start or Go position and Teach are set simultaneously the wand will begin with the scanning cycle The wand moves back to the stored new stop position after the scanning cycle An OK or KO message will be transmitted to the machine control system simultaneously The direction of rotation is defined with the angle set value If the angle is larger than the stop position the wand will move away from the zero position If the angle is smaller than the stop position the wand will move towards the zero position The wand can be moved back to the zero position by setting the bit Go Back Requirement the two objects need to be removed before New stop position GoPos Object 1 Object 2 Scanning direction if 4 4 Scanning direction if angle set value gt stop position 5 angle set value lt stop position E bai EA Want _______ Zero position internal mechanical stop Scanner Fig 3 3 Scanning CW CCW Note This function is not possible with TK9LIN50 100 scanner Rev 1 05 dated 3 5 2010 Page 41 of
48. g cycles gt 5 million at minimum scanning intensity Mechanical Dimensions k circ 150 020 91 2 e 0 10 RO BK RO BK RO BK RO BK 59 max 98 42 5 max 114 26 5 General tolerances ISO 2768 mK Fig 4 3 Mechanical Dimensions Scanner TK7A TK7RL Page 64 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKROI Technical Data 4 4 Scanner TK8A Protection type IP 67 Scanning wand length 380 mm with plate 80 mm x 15 mm 284 mm with plate 65 mm x 15 mm wand exchangeable 300 max with backstop Mechanical Dimensions circ 264 360 820 a El p ts ol mm mm RO BK RO BK RO BK RO BK Rm mm 110 59 max 98 max 114 26 5 i 42 5 General tolerances ISO 2768 mK Fig 4 4 Mechanical Dimensions Scanner TK8A Rev 1 05 dated 3 5 2010 Page 65 of 75 Technical Data BA BK MIKROI 4 5 Scanner TK91A Protection type IP 67 Scanning wand length Up to 610 mm max with plate 120 mm x 15 mm Scanning angle 300 max A Control unit connection Small circular connector M12x1 8 pin Ambient temperature 0 C to 80 C Storage temperature 25 C to 85 C Scanning cycles gt 5 million at minimum scanning intensity Mechanical Dimensions For example TK91A with 510 mm scanning wand length and 3 balance weights
49. insulating housing On the top and bottom side the control unit is fitted with plug in screw terminals to connect all machine inputs and outputs supply voltage and the scanner The scanner will be connected via a 8 wire cable to the scanner socket of the control unit The BK MIKRO9 control unit build in device for switch cabinets is designed for supply voltage 24VDC Other supply voltages can damage the device Page 10 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 2 1 2 Connection terminals System Components BK MIKRO91 Premium BK MIKRO92 Premium BK MIKRO93 Basic Power supply 24 VDC Grounding PE 24 VDC GND Power supply 24 VDC Grounding PE 24 VDC GND Power supply 24 VDC Grounding PE 24 VDC GND Mini USB Mini USB Mini USB Scanner Scanner Scanner LEDs LEDs LEDs Profibus DP Relay Outputs ER Relay Outputs rer Relay Outputs Fer OUT1 o k OUT1 o k OUT1 0 k OUT2 k o OUT2 k o OUT2 k o Inputs Inputs Inputs COM COM COM IN1 IN IN IN2 IN2 IN2 IN3 IN3 IN3 Fig 2 1 BK MIKRO9 Control Unit Front side with connections Note These plugs may only be inserted or removed when the power supply has been disconnected Caution These blocks are keyed so that they cannot be accidentally plugged into Note Caution gt P the wrong socket Power supply OUT Relay outputs Rev 1 05 dated 3 5 2010
50. kstop B TK8A Short Wand Scanner TK8A with short wand Scanner with backstop 6 TK94A RL Scanner TK94A RL Scanner with and without backstop The illustration shows the factory settings Invalid switch settings P1 P2 Error cause red LED on the control unit to light Rev 1 05 dated 3 5 2010 Page 19 of 75 System Components Setting the profibus address via P1 and P2 BA BK MIKRO9 With the scanner selection 0 via P1 and P2 the profibus address can be set in connection with the BK MIKRO91 control unit The internally memorized address in the control unit is not regarded Settings via P1 and P2 are hexadecimal With P1 the rather significant bits are set and with P2 the less significant are set Example Address 50dec 32hex gt P1 3 P2 2 Toggle switches The following functions can be set using the rows of eight toggle switches on the front panel of the control unit Counter clockwise travel Free space monitoring Relay N C High scanning intensity Large range of tolerance R L function active Output State Valid Note Tl I e D gt R Clockwise travel O Object monitoring y er Relay N O MM Low scanning intensity 4 Es Lowrange of tolerance 2 SW1 R L function deactive SW2 Output State Static Fig 2 10 I O Expansion Module Toggle switch
51. l tolerances connector at the control unit end 8 pin ISO 2768 mK Fig 2 13 Scanner TK7A TK7RL Note To prevent possible injury the wand is supplied with a protective cap Rev 1 05 dated 3 5 2010 Page 25 of 75 System Components BA BK MIKRO9 2 3 3 Scanner TK8A The TK8A scanner offers two special features e Scanning wands are available in lengths up to 380 mm This allows for greater distances between the scanner and tools or objects that it is checking e Scanning plate on the scanning wand This makes it possible to use the scanner directly in the tool magazine to make positive contact with the tool s tip The TK8A scanner has a mechanical backstop that limits the rotary movement of the wand Using the TK8A scanner with a different control unit than the BK MIKRO9 may damage the scanner and control unit Note Wrong scanner parameters lead to incorrect measurement results Note The wand is a wearing part To avoid injury users should exercise caution while working in the area that the BK MIKRO wand travels Az canning wan ko BK Scanning plate jength 284 380 mm 80x15 380 V2A Wand holder RO BK Housing po BK em a Connector mmm angled 8 pin Wf f Connection cable se connector at the control unit end 8 pin Connection cable ef straight connector at the scanner end 8 pin connector at the control unit end 8 pin General tolerances La ISO 276
52. ls from using the SPS as well Principle of operation The scanner wand controls in a specified area the object positions or angles in the machine A micro computer based control unit triggers the wand movement by an external signal or signal from PROFIBUS Master PLC The result of measurement will be checked with the stored value in the control unit before certain via TEACH or different parameters and triggers an OK or KO message according to the result This message will be outputted to the relays contact digital I Os or the PROIBUS As required can activate every deviation an immediate machine stop Through that are avoided consequential damages of the machine and parts The galvanically isolated inputs and outputs guarantee a high degree of operational safety and protection against interferences Further features e Scanning in clockwise CW or counter clockwise CCW direction e 8 steps for scanning intensity e Output relay contacts selectable as normally open or normally closed e Ranges of tolerance for OK message adjustable e Scanning results indicated by two LEDs OK and KO on the control unit e Detection of cable breaks e Configuration software for program setting and tool data e Various movement functions of the scanning wand e Use of various scanners for different applications Rev 1 05 dated 3 5 2010 Page 5 of 75 Characteristics BA BK MIKRO9 1 1 Overview Control Units BK MIKRO9 Device type Fr
53. nection cable Scanner TK7A TK7RL without cable Wand length 165 mm wm RO BR RO BK RO BK RO BK wm Straight connector 8 pin 5 m Angled connector 8 pin 5 m Straight connector 8 pin 15 m Angled connector 8 pin 15 m Fig 1 3 Overview Scanner TK7A TK7RL BK MIKRO 8 Device type Scanner Connection cable Scanner TK8A incl wand holder without wand without cable Wand length 380 mm mm RO BK RO BK RO BK RO BK mm Straight connector 8 pin 5 m Angled connector 8 pin 5 m Straight connector 8 pin 15 m Angled connector 8 pin 15 m Page 8 of 75 Fig 1 4 Overview Scanner TK8A Rev 1 05 dated 3 5 2010 BA BK MIKROI Characteristics BK MIKRO9 Device type Scanner Connection cable Scanner TK91A incl wand holder without wand without cable Wand length 610 mm Straight connector 8 pin 5 m Angled connector 8 pin 5 m Straight connector 8 pin 15 m Angled connector 8 pin 15 m Scanner TK94A TK94RL without cable Wand length 165 mm Straight connector 8 pin 5 m Angled connector 8 pin 5 m Straight connector 8 pin 15 m Angled connector 8 pin 15 m Scanner TK9LIN50 100 with
54. ntal protection Non compliance may have an impact on the environment The products of MSC Tuttlingen GmbH may only be used for the applications described in the technical documents and only in connection with devices or components from other manufacturers which have been approved or recommended by us Start up must not take place until it is established that the machine which is to accommodate this component conforms to the guideline 98 37 EC This product can only function correctly and safely if it is transported stored set up and installed correctly and operated and maintained as recommended General Notice BA BK MIKROI Qualification of personnel Only qualified personnel may carry out the following activities on the products installation commissioning operation maintenance Qualified persons in accordance with the safety guidelines are defined as persons who are authorized to commission to ground and to tag circuits equipment and systems in accordance with established safety practices and standards Disclaimer of liability We have checked the contents of this document for agreement with the hardware and software described Since deviations cannot be precluded entirely we cannot guarantee full agreement However the data in this manual are reviewed regularly and any necessary corrections included in subsequent editions Suggestions for improvement are welcomed EMC directive 2004 108 EC The following applies to this
55. ntrol unit connection Fixed cable 200 mm with Small circular connector M12x1 8 pin Ambient temperature 0 C to 65 C Storage temperature 25 C to 80 C Scanning cycles gt 5 million at minimum scanning intensity Mechanical Dimensions i 92 912 15 y O A A SN Q Ge o O g e 00 x N m iz o ky bg x 3 E LA o ER N be O N General tolerances ISO 2768 mK Abb 4 8 Mechanische Abmessungen Tastkopf TK94A Page 68 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKROI Technical Data 4 8 Scanner TK9LIN50 Scanning angle 50 mm max stroke Mechanical Dimensions I 50 A 154 nn 73 L 932 49 _ max stroke 5 AS EE N E Q mm RO BK RO BK oT o RO BK o x LO RO BK P z mm E Y General tolerances ISO 2768 mK Fig 4 9 Mechanical Dimensions Scanner TK9LIN50 Option compressed air connection FRA e AC Lei General tolerances ISO 2768 mK I RO B RO B Fig 4 10 Mechanical Dimensions Option compressed air connection Rev 1 05 dated 3 5 2010 Page 69 of 75 Technical Data BA BK MIKRO9 4 9 Scanner TK9LIN100 Scanning angle 100 mm max stroke Mechanical Dimensions
56. numbers selected via the inputs are from 0 to 511 These control inputs cannot be used with the BK MIKRO93 basic control unit and can be connected using either positive or negative logic Positive logic COM input must be put on GND The particular input IN 1 3 will be set on 24 V high by switching As low condition the input will be wired on GND or left open Negative logic COM input must be put on 24 V The particular input IN 1 3 will be set on O V high with switching Considered low condition the input will be connected to 24 V or left open Unnecessary selection inputs may remain open A signal must be applied for at least 40 ms to be effective Reference potential of inputs IN 1 3 Connect positive logic with GND Connect negative logic with 24 V 2 Selection input 1 IN2 INI Selection input 2 COM Selection input 3 Selection input 4 IN7 Selection input 5 IN6 nalen INS Selection input 6 Ne Selection input 7 Reference potential of control inputs 8 10 This inputs may remain open if 8 10 are not used Positive logic GND IN10 Negative logic 24 V IN9 Selection input 8 INS Selection input 9 COM Reset input of outputs Outputs e g OK KO can be reset with this input Page 16 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components Through the 9 selection inputs 512 different tool positions can be saved and monitored The selection of the tool positions is
57. ont and rear side Connections BK MIKRO91 Premium with Profibus interface Dimensions 22 6 mm x 99 mm x 113 6 mm PROFIBUS interface Mini USB Digital inputs Relay outputs Scanner connection 3 connection terminals Opening for top hat rail connector BK MIKRO92 Premium without Profibus interface Dimensions 22 6 mm x 99 mm x 113 6 mm Mini USB Digital inputs Relay outputs Scanner connection 3 connection terminals Opening for top hat rail connector BK MIKRO93 Basic without Profibus interface Dimensions 22 6 mm x 99 mm x 113 6 mm Mini USB Digital inputs Relay outputs Scanner connection 3 connection terminals Opening for top hat rail connector Page 6 of 75 Fig 1 1 Overview BK MIKRO9 Control Unit Front and rear side Rev 1 05 dated 3 5 2010 BA BK MIKROI 1 2 Overview UO Expansion Module Characteristics BK MIKRO9 Device type Front and rear side Connections switches BK MIKRO9I O Expansion Module Digital I Os Toggle switches Rotary switch 4 connection terminals Top hat rail connector Dimensions 22 6 mm x 99 mm x 113 6 mm Rev 1 05 dated 3 5 2010 Fig 1 2 Overview BK MIKRO9 UO Expansion Module Front and rear side Page 7 of 75 Characteristics BA BK MIKRO9 1 3 Overview Scanners BK MIKRO 7 Device type Scanner Con
58. out cable max stroke Cl Wm mm RO BK RO BK RO BK RO BK a Maximum stroke of 50 100 mm Straight connector 8 pin 5 m Angled connector 8 pin 5 m Straight connector 8 pin 15 m Angled connector 8 pin 15 m Scanner TK96A TKI6RL with fixed cable of 210 mm BK MIKRO Wand length 100 mm Straight connector 8 pin 5 m Angled connector 8 pin 5 m Straight connector 8 pin 15 m Angled connector 8 pin 15 m Rev 1 05 dated 3 5 2010 Fig 1 5 Overview Scanner TKO Page 9 of 75 System Components BA BK MIKRO9 2 System Components 2 1 Control Unit Three versions of control units are offered e BK MIKRO91 Premium with PROFIBUS interface all functions e BK MIKRO92 Premium without PROFIBUS interface all functions e BK MIKRO93 Basic without PROFIBUS interface reduced function range for simple handling Functionality overview PROFIB Number of R BKM91 x Toggle Rotary switches 512 All Premium 2 Outputs 10 Inputs Il BKM93 Basic BKM92 Toggle Rotary switches 512 A Premium 2 Outputs 10 Inputs Ge Toggle Rotary switches Only CheckObj Intensity 1 Output and FreeSpace Return travel Outputs No area adjustments Parameter reduction 2 1 1 Characteristic properties The BK MIKRO9 system control unit is housed in an protection class Il
59. product of MSC Tuttlingen GmbH BK MIKRO9 complies with the requirements of the EMC directive 2004 108 EC on basis of the standards following in chapter Technical Data The EC declarations of conformity and the related documentation will be maintained at the following address for inspection by the responsible officials in accordance with article 10 1 of the above stated EC directive MSC Tuttlingen GmbH Rudolf Diesel StraBe 17 78532 Tuttlingen Germany Areas of use Products of MSC Tuttlingen GmbH meet the applicable harmonized European standards for the respective area of applications Warranty For the devices of MSC Tuttlingen GmbH the agreements determined in the General Terms and Conditions AGB are valid Fitting conditions The fitting conditions and safety notes in the submitted document must be adhered to when commissioning and operating the products Trade names and or trademarks All hardware and software names are trade names and or trademarks of the respective manufacturer Copyright Every user documentation is intended for the operator and the operator s personnel only The transmission and reproduction of this document and the exploitation and communication of its contents are not allowed without express authority Offenders will be liable for damages Il Rev 1 05 dated 3 5 2010 BA BK MIKROI Contents Contents 1 Gharacteristics 4 2 22ER AA 5 1 1 Overview Control UNIS maehae nn a A gn
60. r mounting bracket amp 12 mm knuckle joint holding arm 61 04 303 BKM air barrier adapter 62 04 029 Operating Instructions BK MIKRO9 68 36 262 Basic system 63 04 242 62 04 279 62 04 251 63 04 245 Rev 1 05 dated 3 5 2010 Page 73 of 75 Ordering Information BA BK MIKRO9 Page 74 of 75 Rev 1 05 dated 3 5 2010
61. ress PROFIBUS address Out Rotary switch UO Expansion module active SOK Green OK settings Signal for right switch settings On SKO Red KO settings Signal for wrong switch On Page 18 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 System Components 2 2 4 Rotary switch The SCANNER rotary switch is used for selecting the scanning head A selection between 1 and 10 can be made Position 15 is reserved for automatic scanner detection Position 0 means that the PROFIBUS address can be set via P1 and P2 If the scanner switch is not set at O then the P1 and P2 rotary switches are used to manually set the position or area that is going to be checked for an object or for free space monitoring These switches set the position via angle that the wand needs to travel to P1 and how far it travels to P2 before it outputs an OK or KO signal These switches do not need to be used if you are teaching the objects position The smaller P1 P2 value determines the start of the monitoring area and the bigger value of P1 P2 indicates the end of the monitoring area The settings are possible in steps of 24 0 from 0 0 to 360 09 SCANNER 0 o NVA 7 N NS g 8 8 Fig 2 9 1 0 Expansion Module Rotary switch Selection of the scanners O PROFIBUS setting P1 and P2 display the PROFIBUS address Toggle switch are inactive 1 TK8A Scanner TK8A Scanner with backstop 2 TK7A Scanner TK7A Scanner with bac
62. s small diameter the wand is easily overlooked e Your wand is a wearing part Each contact with a rotating object will cause wear on the wand That can break the wand and the wand must be changed e For rotation tools an especially hardened HSS steel wand is available To avoid injury users should exercise caution while working in the area that the BK MIKRO wand travels E 7 El Protective cap Scanning wand 93 mm standard length 100 mm Wand holder E Housin yY laser marked m Connection cable straight connector at the control unit end 8 pin N General tolerances ISO 2768 mK Fig 2 21 Scanner TK96A TK96RL Note To prevent possible injury the wand is supplied with a protective cap Rev 1 05 dated 3 5 2010 Page 31 of 75 System Components BA BK MIKRO9 2 3 8 Mounting bracket and holding arm for TK96A TK96RL The scanner can be fixed and attached simply with aid of the mounting bracket The scanner is stuck by the hexagon socket set screw into the mounting bracket and then can be fixed with the drilling Fig 2 22 Scanner TK96A TK96RL As accessories we still offer a holding arm and a knuckle joint Instead of fixing the mounting bracket in the machine directly the scanner can be attached also with the aid of the knuckle joint and the holding arm see figure D n u 10 gt Fig 2 23 Dimensions Mounting Bracket Holding
63. ss via P1 and P2 With scanner selection 0 via P1 and P2 the profibus address can be set in connection with the BK MIKROQ1 control unit The internally memorized address in the control unit is not regarded Settings via P1 and P2 are hexadecimal With P1 the rather significant bits are set and with P2 the less significant are set Example Address 50 dec 32 hex gt P1 3 P2 2 Baud rates Supported baud rates 9 6 kbaud 19 2 kbaud 45 45 kbaud 93 75 kbaud 187 5 kbaud 500 kbaud 1 5 MBaud 3 MBaud 6 MBaud 12 MBaud The baud rate is identified automatically Page 38 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKRO9 Operating Modes 3 1 2 General function sequence Commands and parameter data to the BK MIKRO91 control unit are sent and received by the PLC Step 1 Machine Control unit tool control Start or Teach BK MIRKO 9 Angle range Tool data base 4 N Measured angle Scanner O K or K O Step 2 Fig 3 1 Function sequence The scanner moves CW or CCW according to settings to the zero position internal backstop during power up of the control unit ZeroPosition During switch on the wand in free movement must reached the ZeroPosition without a previous stop caused through an object or tool For this operation it is necessary that the internal backstop can be reached without obstacle between wand and zero posi
64. start cycle There are 8 steps of setting 1 Special functions The 8 bit data word of this parameter get partitioned in a 4 bit sub address and a 4 bit data word 15 14 13 12 11 10 9 8 Sub Address Data Sub Address Data 0000 Out 1 0000 inactiv 0001 activ 0001 Scanning Mode downtime characteristics 0000 normal 0001 Vibration tolerant 0010 Fast 0010 PrePosition Speed 0000 standart fast large ringing 0001 very slow at slowlyest low ringing 0010 slow Out1 With this parameter can define the active status of the relay output 1 After switch on the outputs the adjusted status Open or Close is set without a scanning before Scanning Mode Normal The scanning wand must be stopped to finish the measurement Vibration Tolerant If vibrations are behaviour in the machine it requires a longer time that BK MiKRO diagnosed the stop of the scanning wand In this mode small actions are tolerated The result of measurement will be non essential affected Fast In this mode the measurement will be stopped after arriving the object With this fast mode it is possible to recognize if the object is in the specified tolerance Due to the reduced measuring time the result of measurement will be more inaccurate PrePosition Speed The speed of the Preposition can be changed PrePosition verandert werden This has an influence how fast the position of the PrePos will be a
65. the result at the control unit Switch mode monitoring scanning range with switch settings Requirement Rotary switches 0 lt P1 lt P2 lt 270 Rotary switch P1 and P2 settings will define the scanning range In this mode of operation the BK MIKRO is capable of monitoring tools with different diameters object monitoring as well as for ejection monitoring free space monitoring The two rotary switches are used to define a scanning range which is monitored during each cycle P1 defines the starting angle and P2 defines the ending angle of a scanning range During the object monitoring an OK will be transmitted if the wand contacts an object within the scanning range Control operation Object monitoring Using Object monitoring the control unit will change into an OK signal i e it will issue a good message if during the scanning cycle the operation sequence described below is followed e The scanner leaves its stop position e The angle preset via rotary switch P1 has been exceeded e The angle preset via rotary switch P2 has not been reached Control operation Free space monitoring The operation of Free space monitoring differs from object monitoring mode in that within its monitoring range no object must be detected Its OK state is characterized by e The scanner leaves its stop position e The angle preset via rotary switch P2 has been exceeded Caution When performing Free space monitoring a
66. tion e g object or tool 3 1 3 Scanning in one direction Angle set value via data base In order to check a tool e g drill the control unit receives a target angle from the machine control system via PROFIBUS This value has been calculated according to the tool length which is filed in the tool data base Then the measurement can begin by setting the start bit If the wand contacts an object within the correct measurement range an OK message will be transmitted via PROFIBUS The digital output for OK message is also switched to high or low level After a Teach Start the wand goes automatically back into the HomePosition Rev 1 05 dated 3 5 2010 Page 39 of 75 Operating Modes BA BK MIKRO9 Angle set value via Teach If a tool needs to be checked that doesn t have a value in the data base entry then it is necessary to perform a Teach procedure The angle set value has to be larger than the angle being taught The angle set value serves only as an end limit for the angle range during this cycle If the wand contacts an object within the angle range then an OK message will be triggered and the measured angle will be transmitted via PROFIBUS to the machine control system This angle can be filed in the tool data base to the corresponding tool To check the tool the stored angle value with tolerance is transmitted to the control unit Then the measurement sequence can begin by setting the bit start Start cycle with
67. weight may be necessary for long scanning wands that do not travel horizontally The more balanced the wand is the better the scanning result will be A balance weight set Art no 62 04 282 with one small and two large weights are available for balancing Use of the balance weights for wands of different lengths Wand length 380 mm 2 Balance weights 1 x small 1 x large Wand length 510 mm 3 Balance weights 1 x small 2 x large Wand length 610 mm 3 Balance weights 1 x small 2 x large Note The measuring results may vary if the wand is not traveling in a horizontal plane and balancing weights are not used The Function of the BKM9 system in extreme installment positions and with long wands without balance weight can not be guaranteed r 500 60 D Fig 2 16 Dimensions in mm with 3 balance weights 370 44 Fig 2 17 Dimensions in mm with 2 different balance weights 600 75 15 Fig 2 18 Dimensions in mm with 3 different balance weights Note A distance of 15 mm between wand holder and balance weights is necessary for a wand length of 610 mm Page 28 of 75 Rev 1 05 dated 3 5 2010 BA BK MIKROI 2 3 6 Scanner TK94A and TK94RL System Components We offer two types of scanners for the different applications The only difference between the two scanners is that the rotary movement of TK94A wand is limited by a screw inside the housing This screw is the mechanical backstop T
68. y of the object to be monitored before the actual scanning procedure starts and while the tool can still be positioned If the tool is in the scanning position the wand travel only a short way and through this it requires a less time Example the wand is prepositioned by the command Preposition while the tool moves out of the tool magazine This means that the wand moves up to 10 before the specified angle and waits at this position Now the Start command initiates the scanning procedure once the tool is correctly positioned The advantage is the reduced travel distance of only 10 to the tool The command Start can be initiated even if the wand has not completely executed the Preposition command Note Always send a Zero between commands Preposition and Start Scanning position Tool Preposition 1 azine Wand moves g with up to the specified angle S bd Z Wand Scanner HomePosition Fig 3 4 Time optimized scanning Preposition Rev 1 05 dated 3 5 2010 Page 43 of 75 Operating Modes BA BK MIKRO9 Return travel The tool can be moved before the wand reaches its home position e The parameter Collision free area defines an area where e g the largest tool not reaches so that no collision is possible with the wand With the Collision free area bit is specified that the wand is in the collision free area As soon as this bit is set e g the tool magazine can b

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