Instruction Manual reflectcontrol Compact RCC RCC RCC RCC RCC RCC

Transcription

1 Instruction Manual reflectcontrol Compact RCC1-15 RCC1-14 RCC11-21 RCC RCC13-15 RCC13-135

2 MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Königbacher Strasse Ortenburg, Germany Tel. +49 () 8542 / 168- Fax +49 ()8542 / info@micro-epsilon.de Certified according to DIN EN ISO 91: 28

3 Contents 1. Safety Symbols Used Warnings Notes about CE Marking Intended Use Intended Environment Protection of the Software Functional Principle, Technical Data Measuring Principle Design Requirements for the Target Application Examples Technical Data Delivery Scope of Delivery Storage Installation and Assembly Precautions RCC1-15, RCC1-14 Dimensions, Measurement Window RCC11-21, RCC Dimensions, Measurement Window RCC13-15 Dimensions, Measurement Window RCC Dimensions, Measurement Window Interfaces General Digital I/O Mains Power Supply Operation Positioning Target Shading Switching on and off Process Switching on Switching off Measurement Process Using the Software Liability for Material Defects Service, Repair Decommissioning, Disposal... 2

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5 Safety 1. Safety The operation of the system requires knowledge of the operating manual. 1.1 Symbols Used The following symbols are used in this operating manual: i CAUTION NOTICE Measurement Indicates a hazardous situation which results in minor or medium injuries if not avoided. Indicates a situation which can result in property damage if not avoided. Indicates a user action. Indicates a user tip. Indicates a piece of hardware or a button/menu item in the software. CAUTION NOTICE 1.2 Warnings Connect the power supply and the system in accordance with the safety regulations for electrical equipment. > > Risk of injury > > Damage to or destruction of the system and/or the controller Avoid impacts and shocks to the system. > > Damage to or destruction of the system Protect the cables against damage. > > Failure of the measuring device 1.3 Notes about CE Marking The following are applicable for the RCC1xx series: EU Directive 214/3/EU EU Directive 214/35/EU EU Directive 211/65/EU, "RoHS", Category 9 Products which carry the CE mark satisfy the requirements of the above mentioned EU Directives and the harmonized European standards (EN) listed therein. The EU declaration of conformity is available according to EU Directive, Annex II, for the responsible authorities at MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Königbacher Straße Ortenburg, Germany The measurement system is designed for use in industry and satisfies the requirements of the standards. Page 5

6 Safety 1.4 Intended Use The measurement system is designed for use in industry and laboratories. It is used for non-contacting surface inspection of highly reflecting materials, quality monitoring and dimensional inspection. The measurement system may only be operated within the limits specified in the technical data, see chapter Only use the measurement system in such a way that no persons are endangered or machines are damaged in the event of malfunctions or total failure of the measurement system. Additional precautions for safety and damage prevention must be taken for safety-related applications. 1.5 Intended Environment Area between camera and target must not be soiled (for example water, abrasion, dust etc.). Operating temperature: C Temperature fluctuations during operation without calibration: 2.5 C Humidity: 1 %... 8 % (non-condensing) Ambient pressure: Atmospheric pressure Storage temperature: C 1.6 Protection of the Software The following important information for the complete application software, based on reflectcontrol, must be observed. The modification of hardware or software components in the industrial PC of the reflectcontrol system is not permitted as a matter of principle. Exceptions must be approved in writing by Micro-Epsilon Messtechnik GmbH & Co. KG. The automatic start of software components which do not originate from Micro-Epsilon Messtechnik GmbH & Co. KG and which run in the background of the measurement is not permitted. The operating company must be aware that the system will be restricted while using virus scanners. The integration of systems from Micro-Epsilon Messtechnik GmbH & Co. KG in networks must only be performed by qualified personnel. In doing so, the system operator is responsible for the security in the network. Micro-Epsilon Messtechnik GmbH & Co. KG shall not accept any claims arising from non-observance of these safety instructions. Page 6

7 Functional Principle, Technical Data 2. Functional Principle, Technical Data 2.1 Measuring Principle The measurement system automatically inspects highly reflecting materials System with light source and camera(s) 2 Touch screen 3 Telescopic feet / height adjustment 4 Target 3 4 Abb. 1 Complete view of the measurement system reflectcontrol Compact uses the principle of phase measuring deflectometry to perform measurements on glossy surfaces. For the measurement, a sinusoidal pattern is displayed on the screen. Defects on the surface result in a different deflection of this pattern which is detected by a camera. The pattern is phase shifted and several images are taken. Curvature, intensity and amplitude are calculated on the basis of the data obtained algorithmically for the entire surface. The advantage of deflectometry - compared to scanning test methods is the availability of the local curvature, intensity and amplitude data for the entire area covered by the camera. 3D reconstruction of the area is realized by adding a 2nd camera which covers the same field from a different direction (stereo deflectometry). For the measurement principle, a sufficient reflectivity of the surface is required. Calibration is required for the 3D reconstruction. The positions of the cameras, the screen and the imaging characteristics of the cameras are determined here using a special calibration mirror. The 3D reconstruction provides a point cloud with X/Y/Z coordinates. 1 1 Surface with striped pattern Target support / centering not 2 included in the scope of delivery 2 Abb. 2 Analysis of a surface Page 7

8 Functional Principle, Technical Data 2.2 Design The compact system contains all the necessary components for the measurement in one case. 2D version RCC1-15 / RCC1-14 / RCC11-21 RCC Defect detection 3D version RCC13-15 / RCC Defect detection 3D point cloud A touch screen is available for the operation. The feet of the device can be adjusted for height. The device can be shaded on all four sides to prevent external light influences. 2.3 Requirements for the Target The prerequisite for deflectometry is that the striped pattern can be recorded by the camera via the target. Flat and reflecting surfaces are optimal. In the case of curved surfaces, concave curvature is preferable as the beams will be bundled for the camera. Convex curved targets (beams are scattered) may have to be examined from multiple measurement positions. 2.4 Application Examples Consumer goods industry: inspection of reflecting surfaces in the visible area Inspection of touch screens of smart phones and tablets Defect detection on motor vehicle attachment parts and interior parts Measurement of telescopic mirrors and lenses Page 8

9 Functional Principle, Technical Data 2.5 Technical Data Type RCC Measurement field mm 114 x x x x x x 125 Lateral resolution µm Height resolution nm Planarity measurement error 1 µm Number of cameras Light source Industrial PC LCD, 17 TFT (> 35 cd/m²) Panel PC 17 inch / i5 / 8 GB RAM / Windows 7 Ultimate 64-bit Image 2D measurement approx. 1 second acquisition 3D measurement approx. 2 seconds Data calculation approx seconds for 2D result images including defect detection approx. 2 seconds for an entire surface 3D construction Target reference position mm 3 mm underneath the case bottom edge of the measurement system Power supply Fuse 1 23 V AC, 5/6 Hz Glass tube microfuse 4 A, slow-blow, 5 x 2 mm Weight kg <17 Dimensions mm 452 x 452 x 382 (WxDxH) Operating temperature C Storage temperature C Temperature fluctuation Humidity Ambient pressure ±2.5 C (during operation without calibration) 1%... 8% (non-condensing) Atmospheric pressure 1) In the entire measurement volume, measured on Zerodur flat mirror, aluminum coated, 1/2 lambda surface accuracy. The peak-to-valley value according to VDI2634 is applicable for measurement volume depth of 4 mm, -3 mm to +1 mm in relation to the reference plane. Page 9

10 Delivery 3. Delivery 3.1 Scope of Delivery 1 measurement system including PC and camera(s) 1 IEC power cable 1 operating manual 1 calibration mirror for the 3D models Remove the components of the measuring system from the packaging carefully and ensure furthermore that the goods are forwarded in such a way that no damage will occur. Check the delivery for completeness and shipping damage immediately after unpacking. In case of damage or missing parts, please contact the manufacturer or supplier immediately. 3.2 Storage Storage temperature: Humidity: 1 %... 8 % (non-condensing) 4. Installation and Assembly 4.1 Precautions No sharp or heavy objects should be allowed to affect the cable sheath Always avoid cable kinks. Check the plug connections for firm seating. The measurement system is an optical system for measuring in the μm range. Ensure careful handling during assembly and operation. i Page 1

11 Installation and Assembly 4.2 RCC1-15, RCC1-14 Dimensions, Measurement Window A B Dimension RCC1-15 RCC1-14 A B C I H G F Measurement field D E F G H C D E I A Abb. 3 RCC1-15, RCC1-14 measurement system dimensions drawing Dimensions in mm, not to scale Page 11

12 Installation and Assembly 4.3 RCC11-21, RCC Dimensions, Measurement Window L K I H G A F B Measurement field C D E Dimension RCC11-21 RCC A B C D E F G H I K L A Abb. 4 RCC11-21, RCC measurement system dimensions drawing Dimensions in mm, not to scale Page 12

13 Installation and Assembly 4.4 RCC13-15 Dimensions, Measurement Window A (15) Measurement fields 3D-Area 2D-Area Abb. 5 RCC13-15 measurement system dimensions drawing Dimensions in mm, not to scale Page 13

14 Installation and Assembly 4.5 RCC Dimensions, Measurement Window (135) Measurement fields A D-Area 3D-Area Abb. 6 RCC13-15, RCC measurement system dimensions drawing Dimensions in mm, not to scale Page 14

15 Installation and Assembly 4.6 Interfaces General The measurement system has the following interfaces: Ethernet, 1/1/1 Mbps, RJ45 connector Digital I/O, e.g. for triggering 2 USB ports, e.g. for mouse, keyboard VGA for external operating monitor, resolution up to 192 x 12, 6 Hz, 154 MHz pixel clock rate Digital I/O 2 USB 2. 3 VGA 4 Ethernet 5 IEC plug connector, fuse, on/ off switch Digital I/O This interface is reserved for any external triggering Mains Power Supply The is supplied with mains voltage of V AC. The system is fused with a type 4 A, slow-blow glass tube fuse. Page 15

16 Operation 5. Operation 5.1 Positioning Target The surface of the target must be in the depth of field range of the lenses both for the defect detection as well as for the 3D reconstruction. The tolerances for the vertical positioning are approx. 4 mm (-3 mm to +1 mm). Ideally, the target surface is 3 mm underneath the bottom edge of the measurement system. The dimensions of the measurement fields that the target must be located within can be found in the dimensions drawings, see chapter 4.2. ff. F 3 Target +1-3 Abb. 7 Vertical and horizontal measurement fields for the target surface Measurement field Locking bolt The measurement system 2 Telescopic foot can be raised vertically using the telescopic feet. 3 Lock nut for adjustment foot, A/F 13 The maximum height offset is 2 mm with increments 4 Adjustment foot, non-slip of 4 mm. For this, pull out the locking bolt and move the telescopic foot. The telescopic feet have anti-twist protection, the locking bolt thus locks automatically when the next level is reached. 4 Abb. 8 Height adjustment with telescopic and adjustment foot Position the measurement system so that it is level. Compensate for unevenness using the four adjustment feet. A height offset of approx. 58 mm can be compensated for using the adjustment feet. Air bubble central in the red tolerance range of the level: measurement system exactly aligned horizontally. Air bubble out of center in the red tolerance range of the level: adjust the horizontal alignment of the measurement system using the adjustment feet. Abb. 9 Alignment of the measurement system using circular bullseye level Page 16

17 Operation 5.2 Shading Lateral scattered light on the target can cause measurement inaccuracies. Avoid scattered light, e.g. bright daylight, on the target. i Shade the measurement environment with the four roller blinds if required. For this, pull out the locking bolt and keep it pulled out. Pull out the roller blind on the bottom of the case using the grip bar. 1 Locking bolt 2 Roller blind grip bar 1 2 Abb. 1 Shading of the measurement environment using roller blinds 5.3 Switching on and off Process Switching on The system is switched on using the mains power switch, see chapter The PC starts the boot process. This is completed when the measurement program starts. Abb. 11 Start screen after switching on the mains power The system is now operational. Page 17

18 Operation Switching off The measurement program must be ended in order to shut down the system correctly. The PC is shut down and switched off automatically. Switch off the main power switch to disconnect the system from the power supply. 5.4 Measurement Process Let the measurement equipment warm up for approx. 15 minutes, 6 minutes for high-precision measurements, before you perform any measurement or calibration. This prevents measurement inaccuracies. The following table shows the most important steps of a measurement process: Step 1 Position target Chapter 5.1 Step 2 Step 3 Basic settings, e.g. camera, striped pattern Image acquisition Step 4 2D data processing 3D data processing Result images: base intensity, amplitude, curvature 3D view Step 5 Parametrization Defect detection Step 6 Save results Abb. 12 Measurement process steps, software blocks Place the target in the object plane for the measurement. Then, the camera (exposure time), the striped pattern and the number of images can be parametrized. Depending on the selected number of images, the image acquisition takes approx. 1 second. The result images of the deflectometry are available after the data processing in 2D mode. A processing time of 1-2 seconds can be expected here. Then the defects found are shown in the result images. Page 18

19 Using the Software 6. Using the Software Menu bar 7 Information, error line 2 Light source, camera, operating mode basic 8 Start measurement using software command settings 3 Show or hide parameter column 9 Parameters for 3D evaluation 4 Result view selection 1 Parameters for defect detection 5 Toolbar 11 Parameters for 2D evaluation 6 Enable or disable extended view for the information line Page 19

20 Liability for Material Defects 7. Liability for Material Defects All components of the device have been checked and tested for functionality at the factory. However, should defects occur despite our careful quality control, MICRO-EPSILON or your dealer must be notified immediately. The warranty period for material defects is 12 months from delivery. Within this period, defective parts except wear parts will be repaired or replaced at no charge, if the device is sent to MICRO-EPSILON with shipping costs prepaid. Any damage which can be attributed to improper handling or violent action or to repairs or modifications by third parties is not covered by the liability for material defects. MICRO-EPSILON is exclusively responsible for repairs. No other claims may be made. Claims arising from the purchase contract are not affected by this. MICRO-EPSILON particularly shall not be liable for any consequential damage. We reserve the right to make design changes in the interest of further development. 8. Service, Repair For any defect on the system: If possible, save the current system settings in a parameter set to be able to reload the settings into the system after the repair. In the case of faults whose causes are not clearly recognizable, please always send the complete measurement system to: MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Königbacher Str Ortenburg, Germany Tel. +49 () 8542 / 168- Fax +49 ()8542 / info@micro-epsilon.de 9. Decommissioning, Disposal Remove the electrical connection cables on the measurement system. Incorrect disposal may pose risks to the environment. Dispose of the device, its components and the accessories and packaging materials in accordance with the relevant country-specific waste handing and disposal regulations of the application area. Page 2

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22 MICRO-EPSILON MESSTECHNIK GmbH & Co. KG Königbacher Str. 15 D Ortenburg / Germany Tel. +49 () 8542 / 168- Fax +49 () 8542 / info@micro-epsilon.de X A1186HDR MICRO-EPSILON MESSTECHNIK *X A1*