NAV245 2D laser scanners

Transcription

1 OPERATING INSTRUCTIONS NAV245 2D laser scanners Mounting, electrical installation, commissioning

2 Described product Product family: NAV245 Manufacturer SICK AG Erwin-Sick-Str Waldkirch Germany Phone: Fax: info@sick.de Production location SICK AG Merkurring Hamburg Germany Legal information This work is protected by copyright. The associated rights are reserved by SICK AG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of copyright law. Any modification, expurgation or translation of this document is prohibited without the express written permission of SICK AG. The trademarks stated in this document are the property of their respective owner. SICK AG. All rights reserved. Original document This document is an original document of SICK AG. 2 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

3 CONTENTS Contents 1 About this document Purpose of this document Target group Information depth Symbols used Safety information Authorized personnel Intended use General safety notes and protective measures Electrical installation work Laser radiation from the laser positioning sensor Quick stop and quick restart Switching off the NAV Switching on the NAV245 again Protection of the environment Power consumption Disposal after final decommissioning Product description Scope of delivery Structure of the NAV Operating and status indicators Operator interface Status indicators Operating principle of the NAV Landmark detection operating mode Impact of objects on the measurement Sensing range of the NAV Beam diameter and measuring point distance Sensing range of the NAV Measuring mode Measurement accuracy Reflector detection How the NAV245 deals with source of error Contamination measurement Output of measured values /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 1

4 CONTENTS 3.8 Integrating the NAV245 into the control system of an automated guided vehicle Data interfaces Communicating data via telegrams Output of measured values of a second reflective pulse Relative positioning system and absolute positioning system Digital output Synchronizing the clock in the automated guided vehicle and the NAV Detection mode Digital switching outputs Project planning System requirements of the NAV Mounting requirements Distance between the NAV245 and the object/surface to be measured Beam diameter and measuring point distance Reflectors Heating Mounting Overview of the mounting steps Preparation for mounting Getting the components to be mounted ready Getting the accessories and material ready Getting the tools ready Selecting the mounting location Steps for mounting Direct mounting Mounting with mounting kit 1a Mounting with mounting kit 1b Mounting with mounting kit 2 and Dismantling the NAV Electrical installation Overview of the installation steps NAV245 connections Preparation for electrical installation Supply voltage Wire cross-section General requirements of the data interfaces Carrying out the electrical installation on the NAV Auxiliary means OPERATING INSTRUCTIONS NAV /ZN24/ SICK

5 CONTENTS Connecting to the auxiliary and Ethernet interface of the NAV Wiring the M12 round connector on the NAV Wiring inputs and outputs on the NAV Commissioning and configuration Overview of the commissioning steps SOPAS ET configuration software Installing SOPAS ET SOPAS ET default settings Establishing communication with the NAV Connecting data interfaces Configuring the Ethernet connection Initial commissioning NAV245 configuration Connecting and performing a test measurement Maintenance Maintenance during operation Cleaning the optical cover Replacing a NAV Troubleshooting Response to faults Monitoring error and fault signals Troubleshooting Detailed fault analysis SICK support Technical data NAV245 data sheet Dimensional drawings NAV245 dimensional drawing Mounting kit dimensional drawings Accessories Appendix Overview of the appendices Ordering information Consumables Glossary EU declaration of conformity /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 3

6 CONTENTS 4 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

7 ABOUT THIS DOCUMENT 1 1 About this document 1.1 Purpose of this document Please read this chapter carefully before you begin working with this documentation and the NAV245 laser positioning sensor. These operating instructions are intended to allow the technical personnel to perform assembly, electrical installation work, configuration, commissioning, and maintenance on the laser positioning system in the following variants: Important For simplicity in this document, the variants are referred to as the NAV245 for short, unless a clear distinction needs to be made. 1.2 Target group The target group for this document consists of people in the following roles: Activities Mounting, electrical installation, maintenance, replacement Commissioning, configuration Table 1: Target group Target group Qualified personnel, such as service technicians or industrial electricians Qualified personnel, such as technicians or engineers 1.3 Information depth These operating instructions contain the following information about the NAV245: Product description Mounting Electrical installation Commissioning and configuration Maintenance Troubleshooting Ordering information Conformity and approval In addition, online support on operating the user interface and configuring the NAV245 is included with the supplied SOPAS ET configuration software. Additional information on the NAV245 is available from the SICK AG Identification & Measuring Division and online at A detailed description of the different telegrams can be found in the document Telegram listing LMS1xx, part no.: with the accompanying Supplement telegram listing NAV245, part no.: , English versions /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 1

8 1 ABOUT THIS DOCUMENT 1.4 Symbols used Recommendation Important Explanation Recommendations are designed to assist you in the decision-making process with respect to the use of a certain function or a technical measure. Passages marked with Important inform you about special aspects of the device. Explanations convey background knowledge about technical concepts. Menu option This font indicates a term in the SOPAS ET user interface. Terminal output This font indicates messages that the NAV245 outputs via its interfaces. Take action This indicates that action needs to be taken. This symbol indicates an instruction which only contains one step, or steps in warnings where you do not have to adhere to a certain order. Instructions which have several steps that follow on from one another are numbered. This symbol includes a reference to additional documentation available. Software notes show where you can make the appropriate settings in the SOPAS ET configuration software. NOTE: A note refers to a potential risk of damage or functional impairment to the NAV245 or other devices. WARNING: A warning indicates a specific or potential hazard. It is designed to protect you against accidents. The safety mark next to the warning refers to the type of accident risk, e.g., electricityrelated. The warning level (DANGER, WARNING, CAUTION) refers to the severity of the danger. Carefully read and follow the warnings. 2 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

9 SAFETY INFORMATION 2 2 Safety information 2.1 Authorized personnel This chapter concerns your own safety and the safety of the system operator. Please read this chapter carefully before you begin working with the NAV245. The NAV245 laser positioning sensor must only be mounted, commissioned, and maintained by adequately qualified personnel. NOTE: Repair work on the NAV245 may only be performed by qualified and authorized service personnel from SICK AG. The following qualifications are necessary for the various tasks: 2.2 Intended use Activities Mounting and maintenance Electrical installation and replacement Commissioning, operation, and configuration Table 2: Authorized personnel Qualification Basic practical technical training Knowledge of the current safety regulations in the workplace Practical electrical training Knowledge of current electrical safety regulations Knowledge of the operation and control of the devices in their particular application (e.g., crane, mounting system) Knowledge of the operation and control of the devices in their particular application (e.g., crane, mounting system) Knowledge of the software and hardware environment in their particular application (e.g., crane, mounting system, forklift truck) Basic knowledge of the Windows operating system used Basic knowledge of data transmission NOTE: The NAV245 laser positioning sensor is intended for use in industrial environments. Radio interference may result when used in residential areas. The NAV245 is used to determine reflector landmarks. The NAV245 is attached to the automated guided vehicle and continuously measures the positions of identified reflectors as well as the surrounding contour. Depending on the selected operating mode, the NAV245 outputs the position of the reflectors as well as the distance, the angle, and the reflectance of the visible surrounding contour on the automated guided vehicle's computer. The vehicle computer can use this information to correct the course of the automated guided vehicle accordingly to keep it on track /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 3

10 2 SAFETY INFORMATION The NAV245 is a sensor designed for use in industrial environments and also for uses within the permitted ambient temperature range in outdoor areas (also see NAV245 data sheet on page 64). Important In the event of any other usage or modification to the NAV245, e.g., due to opening the housing during mounting and electrical installation, or to the SICK software, any claims against SICK AG under the warranty will be rendered void. 2.3 General safety notes and protective measures Electrical installation work NOTE: The NAV245 must only be operated in the permitted ambient temperature range (see NAV245 data sheet on page 64). WARNING: Safety notes Observe the following to ensure the safe use of the NAV245 as intended. The notes in these operating instructions (e.g., regarding the use, mounting, installation, or integration into the machine controller) must be observed. All official and statutory regulations governing operation of the NAV245 must be complied with. The national and international legal specifications apply to the installation and use of the laser positioning sensor, to its commissioning, and to recurring technical inspections, in particular: The accident prevention regulations and work safety regulations Any other relevant safety regulations The manufacturer and operator of the system in which the NAV245 is installed are responsible for coordinating and complying with all applicable safety specifications and regulations, in cooperation with the relevant authorities. Through checks must be carried out by qualified safety personnel or specially authorized and instructed personnel and must be documented such that they can be replicated and traced at any time. These operating instructions must be made available to the operator of the system in which the NAV245 is used. The system operator must be instructed by qualified safety personnel and must read the operating instructions. The NAV245 does not constitute personal protection equipment in accordance with the respective applicable safety standards for machines. NOTE: Only authorized personnel are allowed to perform electrical installation work. The power supply must be disconnected when attaching and detaching electrical connections. Select and implement wire cross-sections and their correct fuse protection in accordance with the applicable standards. An external fuse and an external switch to separate the supply voltage must be provided for the electrical connection.! Do not open the housing. Observe the current safety regulations when working on electrical systems. 4 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

11 SAFETY INFORMATION Laser radiation from the laser positioning sensor Important No maintenance is required to ensure compliance with laser class 1. Laser output aperture The laser output aperture is the window in the scanner head of the NAV245. Laser power WARNING: Laser radiation! The NAV245 is corresponds to laser class 1 (eye-safe) according to EN/IEC :2014. Identical laser class for issue EN/IEC :2007. Complies with 21 CFR and except for deviations pursuant to Laser Notice No. 50. The laser beam is not visible to the human eye. Improper use can lead to hazardous radiation exposure. Do not open the housing (opening the housing does not prevent the laser from switching on). Pay attention to the laser safety regulations as per IEC (2007) (valid version). The laser operates at a wavelength l = 905 nm (invisible infrared light). The radiation emitted in normal operation is harmless to human skin and eyes. Window of the optical cover Fig. 1: Laser output aperture /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 5

12 2 SAFETY INFORMATION 2.4 Quick stop and quick restart Switching off the NAV245 Switch off the power supply to the NAV245. The NAV245 retains parameters permanently stored in the internal memory. Measured values at the interface are lost Switching on the NAV245 again Switch on the power supply to the NAV Protection of the environment Power consumption The NAV245 restarts operation with the last saved parameters. The NAV245 has been designed to minimize its impact on the environment. It consumes only a minimum of energy. Always act in an environmentally responsible manner at work. For this reason, please note the following information regarding disposal. The NAV245 consumes a maximum of 20 W in operation. The NAV245 also consumes a maximum of 40 W cyclically for heating Disposal after final decommissioning Always dispose of unusable or irreparable devices in accordance with the applicable waste disposal regulations specific to your country. Dispose of all electronic assemblies as hazardous waste. The electronic assemblies are easy to dismantle. Important SICK AG does not currently take back devices that are unusable or irreparable. 6 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

13 PRODUCT DESCRIPTION 3 3 Product description 3.1 Scope of delivery This chapter provides information on the special properties of the NAV245 laser positioning sensor. It describes the construction and operating principle of the device, in particular the various operating modes. Always read this chapter before you mount, install and commission the device. The NAV245 delivery includes the following components: Piece Component 1 NAV245 laser positioning sensor Safety note with electrical connection 1 diagram for initial information 1 Lens cloth Table 3: Scope of delivery Sources for obtaining more information Additional information about the NAV245 and its optional accessories can be found in the following places: Product web page for the NAV245 ( Detailed technical specifications (online data sheet) Technical information (additional information, e.g., for telegrams for NAV245, part. no.: ) These operating instructions are available in German, English, and other languages if required. Dimensional drawing and 3D CAD dimension models in various electronic formats EU declaration of conformity Updates for the SOPAS configuration software: Support is also available from your sales partner: /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 7

14 3 PRODUCT DESCRIPTION 3.2 Structure of the NAV245 LEDs and 7-segment display NAV245 System plug with PG connector M12 round connector Fig. 2: View of the NAV245 8 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

15 PRODUCT DESCRIPTION Operating and status indicators Operator interface Status indicators The laser positioning sensor is fully automatic in normal operation and requires no operator intervention. The SOPAS ET configuration software supplied makes interactive configuration possible. For this, the software runs on a PC which is connected to one of the interfaces with the NAV245. Use the graphic scan view in SOPAS ET to verify the generated measured values and the measuring range online. Please note that the field evaluation monitor cannot display the data in real time and therefore not all measured values are visualized. The LEDs and 7-segment display signal the operational status of the NAV245. Fig. 3: Status indicators Important As well as the standard indicators described below, the indicator functions of the LEDs and the 7-segment display can be configured in SOPAS ET for the NAV245. Project tree, NAV245, Parameters, Network/Interfaces/IOs, Indicator /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 9

16 3 PRODUCT DESCRIPTION LEDs Indicator OK STOP Possible cause NAV245 in operation, no evaluation cases report an event Red: Motor failure, configuration error Off: OK, measurement Optical cover is dirty Q1 Q2 Switching output is on Not assigned Table 4: Meaning of the LEDs 7-segment display Indicator Possible cause Remedy - No error Device is in measuring mode : IDLE mode, outputs are in OFF state, laser is switched off. Table 5: Indicators in the 7-segment display No fault. If the criteria for IDLE mode are withdrawn, operational readiness is restored. _ Motor starts No fault. - No error Indicator in service level: Number of visible reflectors e NAV245 is defective Send the NAV245 to the manufacturer for repair. 10 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

17 PRODUCT DESCRIPTION Operating principle of the NAV245 The NAV245 has an opto-electronic laser scanner that uses laser beams to scan the outline of its surroundings on a plane without contact. The NAV245 measures its surroundings in two-dimensional polar coordinates. If a measuring beam strikes an object, the position of that object is determined in terms of distance, direction, and remission. Fig. 4: Measurement principle of the NAV245 The NAV245 calculates the distance from the object using the elapsed time that the light requires between sending and receiving the reflection in the sensor. The scanning sector is 270. The scanner head rotates with a frequency of 25 Hz. A laser pulse and thus a distance measurement is triggered continuously after each angle increment of /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 11

18 3 PRODUCT DESCRIPTION Landmark detection operating mode The NAV245 has integrated application software which detects reflectors continuously. The relative position can be displayed on the connected vehicle computer using the detected reflectors. Reflectors x = 2500 y = 2500 α =45 x = 1000 y = 2500 α = 70 Landmark detection (reflector position display) Fig. 5: Principle of operation of the NAV245 In addition to landmark detection, the NAV245 can also display the measured surrounding contour on the connected vehicle computer (mixed mode). 12 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

19 PRODUCT DESCRIPTION Impact of objects on the measurement Most surfaces produce a diffuse reflection of the laser beam in all directions. The structure and color of the surface determine how well the laser beam is reflected. Bright surfaces reflect the laser beam better than dark surfaces and can be detected by the NAV245 over greater distances. Brilliant white plaster reflects approx. 100 % of the light, while black foam rubber reflects approx. 2.4 %. On very rough surfaces, part of the energy is lost due to shadowing. The sensing range of the NAV245 is therefore reduced. Fig. 6: Diffuse reflection of objects The angle of reflection corresponds to the angle of incidence. If the laser beam hits a surface at right angles, the energy is optimally reflected (left). If the laser beam hits a surface at an oblique angle, energy, and range are lost accordingly (right). Fig. 7: Targeted reflection of reflectors The beam is not reflected diffusely in all directions; instead it is reflected in a targeted way. Thus a large part of the emitted energy can be received by the NAV245. The NAV245 utilizes this in order to be able to measure the positions of the reflectors extremely precisely /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 13

20 3 PRODUCT DESCRIPTION Possible sources of error Sensing range of the NAV245 Fig. 8: Possible sources of error when measuring The laser beam is almost completely deflected on reflective surfaces (fig. 9, left). This means that an object hit by the deflected beam may be detected instead of the reflective surface. Objects that are smaller than the diameter of the laser beam (fig. 9, right) cannot reflect the laser light's full energy. The energy of the non-reflected part of the laser light is lost. This means the range is less than would theoretically be possible due to the reflective property of the object's surface. The sensing range of the NAV245 depends on the remission of the object to be detected. The better a surface reflects the beams it is hit by, the greater the range of the NAV245 is. Material Remission Black car paint, matte 5 % Black photo mounting board, matte 10 % Gray concrete 18 % White cardboard 90 % White plaster 100 % Reflective tape 3000 % Table 6: Typical remissions 14 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

21 PRODUCT DESCRIPTION Beam diameter and measuring point distance As the distance from the NAV245 increases, its laser beam expands. As a result, the beam diameter increases on the surface of the object. The range-dependent beam diameter corresponds to the distance (mm) rad + 8 mm. As the distance from the NAV245 increases, the individual measuring points also grow further apart from one another. The graph in fig. 10 shows the beam diameter and the measuring point distance depending on the distance from the NAV Beam diameter Size [mm] angular resolution Measuring point distance Distance [m] Beam diameter Fig. 9: Beam diameter and measuring point distance at 0 to 50 m For an object to be detected reliably, it must be completely hit by the beam once. If it is only partially hit, less energy will be reflected from the object than is required in some cases (see Possible sources of error when measuring, page 14) /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 15

22 3 PRODUCT DESCRIPTION Sensing range of the NAV245 The sensing range of the NAV245 depends on the remission of the object to be detected. The better a surface reflects the beams it is hit by, the greater the range of the NAV245 is. NAV245 sensing range Remission of the target Distance of the target [m] Minimum remission [%] Fig. 10: NAV245: Figure 10 Sensing range depending on the remission of the target The graph in Fig. NAV245: Figure 10 Sensing range depending on the remission of the target shows the relationship between remission and detectability for the NAV245. Sensing range NAV245 Remission of the target Distance of the target [m] Minimum remission [%] Fig. 11: NAV245 sensing range depending on the remission of the target The NAV245 can detect objects with a remission of 3 % or more up to a distance of 10 m. Up to a distance of 20 m, the NAV245 can only reliably detect objects with a remission greater than 13 %. The NAV245 detects a remission of 3 % or more up to a distance of 16 m. Important The graphs in Figure 10 and Figure 11 only apply when no filters have been configured. 16 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

23 PRODUCT DESCRIPTION Measuring mode In the measuring mode operating mode, the NAV245 generates an image of its current reflector surroundings within one rotation of the scanner head. A maximum of 60 reflectors are displayed (factory setting: 40). You can configure the number at will. The output reflectors take into account the reflectors which are positioned the closest to one another in order to limit the output size Measurement accuracy Fig. 12: Landmark detection x = 1000 y = 2500 α = 70 In live mode, the automated guided vehicle's computer imports the landmarks (reflectors) determined by the NAV245 and calculates its current position based on this. As a result, deviations in the position determined using the odometry data (encoder) are usually corrected. Landmarks in a limited radius of action of the NAV245 are measured more accurately and thus improve the result of determining a position (see NAV245 data sheet on page 64). Recommendation Fix the reflectors to docking stations (e.g., pallet transfer points) and, when cornering, fix them within the defined, restricted radius of action of the NAV245 or on the route /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 17

24 3 PRODUCT DESCRIPTION 3.6 Reflector detection r min r max Fig. 13: Restricted radius of action Reducing the radius of action You can configure the minimum and maximum radius using a software telegram from the vehicle computer. The example in fig. 15 shows a defined, restricted radius of action with the parameters rmin = 500 mm and rmax = 15,000 mm in which the NAV245 detects five reflectors within a 270 scanning area. Suppressing sectors (sector muting) In certain applications, it may be necessary to suppress individual angle segments (sectors) within the 270 scanning area of the NAV245, e.g., if individual reflectors are partially hidden by a raised load and therefore the middle of the reflectors cannot be determined accurately. This can lead to reduced accuracy when determining the position. The limits of the suppressed sectors are output in a mathematically positive direction as angles in mdeg. Up to four sectors are possible. 18 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

25 PRODUCT DESCRIPTION 3 S 1 S 2 0 S 3 S 4 Fig. 14: Example for defining suppressed sectors How the NAV245 deals with source of error Covered reflectors When cornering or in narrow aisles, two reflectors positioned behind one another from the point of view of the NAV245 always fully or partially cover one another. It is then no longer possible to determine the positions of these reflectors clearly. The NAV245 detects this type of situation and automatically suppresses the use of the reflectors covering one another depending on the configured detection strategy. A covered reflector appears when the angle between two reflectors from the point of view of the NAV245 is smaller than the current beam diameter at this position. In this case, the reflector arrangement must be chosen in such a way that at least three additional reflectors are in the field of view of the NAV245. Reflector 1 Reflector 2 Fig. 15: Covering two reflectors /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 19

26 3 PRODUCT DESCRIPTION Incorrect reflection Incorrect reflections may arise due to highly reflective objects. Highly reflective objects include windows, stainless-steel casings, or metal pipes. The incorrect reflections occur when the measuring beam of the NAV245 meets these objects vertically. 300 mm 300 mm Fig. 16: Minimum distance between reflectors and other reflective surfaces To prevent these incorrect reflections from being interpreted as reflectors, please ensure that the fitted reflectors are always at least 300 mm away from these objects. If it is not possible to comply with the minimum distance for certain objects, then you must cover these objects with a material with low reflective properties. 20 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

27 PRODUCT DESCRIPTION Contamination measurement The NAV245 has an optical cover to protect it. This optical cover can get dirty. Contamination reduces the energy emitted and received by the laser beam. As a result, scanned objects appear to have a lower remission than they actually have and, with a certain level of contamination, it will no longer be possible to perform measurements. For this reason, the contamination is measured constantly during operation. When a certain level of contamination is reached, a contamination warning is output initially. If the contamination becomes stronger, then a contamination error is output and the NAV245 deactivates measuring mode. Depending on the application in which the NAV245 is used, you can choose from different contamination measurement strategies. Project tree, NAV245, Parameters, Contamination measurement. Inactive Contamination measurement is not carried out. High availability Contamination warnings and contamination errors are only output when the front screen is uniformly contaminated. Available Contamination warnings and contamination errors are only output when the optical cover is partially contaminated. Sensitive Contamination warnings and contamination errors are even output for isolated areas of contamination. Recommendation The cleaner the application environment is, the lower you can set the contamination measurement sensitivity. The more accurate the measurement result must be, the higher you must set the contamination measurement sensitivity. Contamination warnings and contamination errors are displayed on the LEDs of the NAV245. They can also be read out using telegrams. A detailed description of the different telegrams can be found in the document Telegram listing LMS1xx, part no.: with the accompanying Supplement telegram listing NAV245, part no.: , English versions. A contamination error is also reported on a digital or external output if this has been configured for the function Contamination /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 21

28 3 PRODUCT DESCRIPTION 3.7 Output of measured values Fig. 17: View of scanning angle In addition to landmark detection, the NAV245 can also display the measured surrounding contour on the connected host (mixed mode). The measured values can be transferred to a connected computer system and evaluated there ( Communicating data via telegrams on page 23). The host can compute the position of the automated guided vehicle using these measured values. Navigation by means of the measured surrounding contour is useful at locations where no reflectors can be fixed, such as in the cargo area of a truck. The NAV245 outputs the following measured values on its data interface: Profile of the field of view in two-dimensional polar coordinates Content of a rotation (270 ), e.g., starting angle of the scan, increment, time stamp for the start of the scan, number of measured values, value and direction of the measured distance, remission value of the measured object. Important It is only possible to output all measured values of a 270 scan in real-time using the Ethernet interface. 3.8 Integrating the NAV245 into the control system of an automated guided vehicle Recommendation Integrating a NAV245 into the control system of an automated guided vehicle requires indepth programming knowledge in the area of vehicle control. You also need knowledge on exchanging data between a laser positioning sensor like the NAV245 and the vehicle computer. SICK AG offers in-depth training on request Data interfaces The NAV245 has a serial host interface and an Ethernet interface. You can configure the NAV245 via these interfaces with the help of SOPAS ET. The NAV245 also communicates with the automated guided vehicle's computer via its interfaces. 22 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

29 PRODUCT DESCRIPTION Communicating data via telegrams The NAV245 sends telegrams over the interfaces described above to communicate with a connected vehicle computer. The following functions can be carried out with telegrams: Setting parameters via the automated guided vehicle's computer to configure the NAV245 Retrieving parameters and status protocols via the automated guided vehicle's computer Requesting landmark positions (incl. the contour measured value if necessary) via the automated guided vehicle's computer, subsequent answer from the NAV245 Request Landmark positions Fig. 18: Landmark position request The telegrams each comprise a frame (see section Frame and coding for the telegrams on page 23) and the data. Frame and coding for the telegrams Reply Landmark positions Frame Telegram Frame Designation STX Data (see Telegram listing NAV245, part no.: ) ETX Length (byte) 1 50 kb 1 Description Start of text character ASCII-coded. This length depends on the previous send telegram. End of text character Table 7: Frame for the telegrams with ASCII coding A detailed description of the different telegrams can be found in Telegram listing NAV245, part no.: /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 23

30 3 PRODUCT DESCRIPTION Output of measured values of a second reflective pulse The NAV245 also measures a potential second reflective pulse and sends this measured value in a measured value telegram. A second reflective pulse occurs, for example, when the NAV245 next hits a raindrop. This reflects part of the energy (first reflective pulse). The other part of the beam continues and is then reflected by an actual object (second reflective pulse). Send pulse t Reflective pulse 1 2 Fig. 19: Principle of operation for measuring the second reflective pulse Important After the first reflective pulse, you must wait a certain period of time before you can measure with full accuracy again. This depends on the target that the first reflective pulse reflected. An application in the connected host can therefore observe the second reflective pulse for the measurement or ignore the first reflective pulse, for example. This can lead to better results in poor weather (rain/snow), for example, or it can even facilitate special applications, such as measuring through a pane (e.g., in an ATEX environment). 24 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

31 PRODUCT DESCRIPTION 3 Measuring through a pane When measuring through a pane, one unique factor to remember is that different light reflections can occur, either from aspects directly on the pane (e.g., from contamination or scratches) or from reflections on the pane (i.e., caused by objects behind or next to the NAV245). Reflections of objects on the pane must be shadowed. 2nd reflective pulse (object) 1st reflective pulse (pane) Shadowed reflective pulse (reflected object) Shadowing Fig. 20: Shadowing reflections /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 25

32 3 PRODUCT DESCRIPTION Relative positioning system and absolute positioning system The automated guided vehicle uses two positioning systems for lane control a relative positioning system and an absolute positioning system. The relative positioning system obtains its data from the odometry (incremental encoder). The odometry provides new data with a high update rate. The vehicle computer can calculate the position of the vehicle from this data. However, the relative position calculation is prone to errors. The error develops as more and more distance is covered. The NAV245 positioning sensor provides relative landmark coordinates (reflectors). Using these relative landmark coordinates, the vehicle computer can determine the automated guided vehicle's position with its own algorithms and minimize errors from the odometry. Fig. Integrating the NAV245 into a navigation system shows a diagram explaining how the NAV245 is integrated into a complete navigation system: Fig. 21: Integrating the NAV245 into a navigation system 26 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

33 PRODUCT DESCRIPTION Digital output The NAV245 has a digital output which is used to synchronize the internal clock of the NAV245 and the vehicle computer. Depending on the synchronization method, the output provides a 10 or 20 ms pulse ( Synchronizing the clock in the automated guided vehicle and the NAV245 on page 27). The pulse is output depending on the synchronization method. The default value is Active High.. 5/20 ms Fig. 22: Synchronization pulse The polarity of the digital output can be reversed. The setting should be set to Active High and it should be triggered on the rising edge Synchronizing the clock in the automated guided vehicle and the NAV245 For precise control, you must synchronize the timings of the landmark data from the NAV245 and the calculations in the vehicle computer as accurately as possible. The measurement data from the NAV245 is provided with the time stamp of the NAV245. The internal time stamp in the NAV245 is a 32-bit counter which increases in increments of 1 every 1 μs. The NAV245 has two options available for synchronizing the internal time of the NAV245 with the system time of the vehicle computer. 1 Via telegram The vehicle computer retrieves the internal time of the NAV245 using a telegram. The NAV245 writes its internal time in a telegram and sends this to the vehicle computer. 2 Via telegrams and adjustment via the digital output of the NAV245 (Output 1 or 2: Reading timer) The vehicle computer retrieves the internal time of the NAV245 using a telegram. The hardware output provides a pulse of at least 20 ms once the internal time stamp is written in the telegram. If the telegram is then received by the vehicle computer, this can add the delta between the pulse and receipt to the time entered in the telegram. As a result, the automated guided vehicle can determine the actual time in the NAV /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 27

34 3 PRODUCT DESCRIPTION The NAV245 reads the time stamp Sync pulse to vehicle computer Time of the answer Time stamp request Answers with time stamp The vehicle computer compensates for the time stamp transfer time with the sync pulse Fig. 23: Visualization of the hardware-supported synchronization via synchronization on the start-ofscan index 3 (Output 1 or 2: Sync index) The scanner outputs a signal depending on the position of the scanner head. This pulse is output at the time of the first measuring point (-45 ) and it corresponds to the startof-scan time stamp in the measurement data. The length of the pulse is approx. 5 ms. Important Result Port Program the vehicle computer so that it responds to the falling edge of the output pulse. The NAV245 features a Result Port, a simplified telegramme with its own port. The Result Port supplies CoLa dialect scan data and landmark data. You can configure the Result Port via SOPAS GUI, or alternatively, via CoLa telegrammes. 28 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

35 PRODUCT DESCRIPTION Detection mode Various filter settings can be adjusted with the detection mode. It is possible to limit the detection zone or to change the sensitivity. The detection mode evaluates the measurement data of the surrounding contour according to individual landmarks with the help of algorithms and therefore improves the evaluation of the measured values. If properties are determined which could influence the measurement accuracy, the affected landmarks are filtered out. You can set the sensitivity using the parameter NLMDDetectionMode. Parameter Accuracy (default setting) Standard Availability Meaning Only landmarks with a verified high level of accuracy. PartlyCovered filter threshold is 200 mm. More landmarks are available but potentially with a larger measurement error. PartlyCovered filter threshold is 500 mm. ReflectiveAlignment filter is deactivated. No landmark filtering at surrounding contour. PartlyCovered filter is deactivated. ReflectiveAlignment filter is deactivated. You can set the detection mode via SOPAS landmark configuration: Fig. 24: Setting detection mode /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 29

36 3 PRODUCT DESCRIPTION 3.9 Digital switching outputs 3.10 Project planning The NAV245 has three digital switching outputs. The outputs can be used as digital switching outputs to ground, as floating outputs, or as resistance-monitored outputs (see section Wiring inputs and outputs on the NAV245 on page 54). For each output, configure whether it should be switched via SOPAS ET telegrams or whether it should be used to signalize device readiness. Project tree, NAV..., Parameters, Network/Interfaces/IOs, Digital outputs System requirements of the NAV245 The user will require the following to commission and operate the NAV245: Supply voltage of 24 V DC ± 15 %, created according to IEC (VDE 0100, Part 410), minimum power output 40 W; 60 W when used for heating. Standard Intel Pentium PC or compatible, minimum Pentium III 500 MHz. RAM: at least 256 MB, 512 MB recommended Operating system: MS Windows 2000, XP, VISTA, or 7 Monitor: at least 256 colors, 65,536 recommended Screen resolution: at least Hard drive: at least 220 MB free disk space available Data interface: RS-232 or Ethernet (see section General requirements of the data interfaces on page 51); if necessary, use an RS-232 converter if the PC interface and the NAV245 interface do not correspond Mounting requirements The NAV245 must be mounted securely. Different mounting kits with suitable mounting material are available for the NAV245 to ensure secure mounting. You can use these to align the NAV245 in the X and Y axes. Also see Accessories, page OPERATING INSTRUCTIONS NAV /ZN24/ SICK

37 PRODUCT DESCRIPTION Distance between the NAV245 and the object/surface to be measured The measuring range of the NAV245 starts 0.5 m in front of the lens (light emission window). With recessed installation of the NAV245, it is important to consider how the laser beam expands as the distance increases in order to avoid incorrect measurements. If the device is mounted in an unfavorable position, depending on the distance, this could therefore mean that objects in the scanning area are detected constantly as they are hit by the laser beam. Expanded laser beam Safety supplement 5 mm/m Optical axis Continuous detection from 15 m Fig. 25: Beam expansion and safety supplement The optical axis is located around 198 mm above the lower edge of the housing when the NAV245 is mounted vertically. This is used as a reference plane for the distance that must be maintained from the wall. The range-dependent beam expansion can be calculated using this formula: Beam diameter = (distance (mm) 15.0 mrad) + 8 mm The table below provides a few values as examples: Distance [m] Beam diameter [mm] Table 8: Beam diameter at different distances from the NAV245 When assessing whether the laser beam can meet an object, the distance from the half beam diameter to the optical axis is used. Important Recommendation A safety supplement of 5 mm per meter is used above and below (see Fig. Beam expansion and safety supplement ) You can use a value of 25 mm per meter to make it easier to calculate the sum from the beam expansion and the safety supplement /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 31

38 3 PRODUCT DESCRIPTION Beam diameter and measuring point distance As the distance from the NAV245 increases, the laser beam of the NAV245 expands. As a result, the diameter of the measuring point increases on the surface of the object. The range-dependent diameter of the measuring point corresponds to the distance (mm) rad + 8 mm. Expanded laser beam Beam diameter on the optical cover = 8 mm Optical axis Fig. 26: Beam expansion Similarly, as the distance from the NAV245 increases, the individual measuring points also grow further apart from one another. The range-dependent distance between the measuring points corresponds to the tangent of the angular resolution distance. Measuring point Scan with 0.25 angular resolution Fig. 27: Schematic diagram of the measuring point distance The graph in Fig. Beam diameter and measuring point distance at 0 to 50 m shows the beam diameter and the measuring point distance depending on the distance to the NAV OPERATING INSTRUCTIONS NAV /ZN24/ SICK

39 PRODUCT DESCRIPTION 3 Important The beam diameter is always bigger than the measuring point distance. This ensures a scanning process without interruptions. 800 Beam diameter Size [mm] angular resolution Measuring point distance Beam diameter Distance [m] Fig. 28: Beam diameter and measuring point distance at 0 to 50 m Reflectors Important The NAV245 is able to detect reflectors and determine their position. To do this, it must distinguish between the reflectors and other reflective surfaces. The parameters apply for the reflective tape (part no ), which can be obtained as an accessory from SICK AG by quoting REF-DG. Reflective tapes from other brands may not be detected correctly by the NAV245 or the working area may be restricted. The reflector marks are designed as cylindrical reflectors. Cylindrical reflector marks can be detected from any angle. Reflector height The height and vertical position of the reflectors is to be selected such that the measuring beam hits the reflectors even if the floor is uneven. The maximum sensing range of the NAV245 is 30 m on reflectors. Depending on the ground conditions and the resulting measurement distance, the minimum height of the reflectors can be derived from this. The measuring beam of the NAV245 expands by around 15 mm per meter of measuring distance (see Distance between the NAV245 and the object/surface to be measured on page 31). Any tilting of the automated guided vehicle caused by uneven ground must be addressed accordingly (incl. safety supplement). The recommended reflector heights are 500 mm for a measuring distance of up to 30 m and 750 mm for a measuring distance up to 46 m /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 33

40 3 PRODUCT DESCRIPTION Reflector width and reflector diameter The minimum width for flat reflectors is 100 mm. The maximum usable width for reflectors is 250 mm. The recommended diameter of cylindrical reflectors is 80 mm. If the diameters of the reflectors differ, it can lead to deviating measurement characteristics. Recommendation Use cylindrical reflectors as the measurement accuracy is higher than for flat reflectors (see NAV245 data sheet, page 64). Detection angle for flat reflectors To detect a reflector, the measuring beam transmitted by the scanner head of the NAV245 must be reflected back to the scanner head. If the measuring beam hits the reflector vertically (detection angle = 0 ), a flat reflector acts like a mirror. The special diamond-grade reflective tape reflects the measuring beam but then also reflects it back to the scanner head if it hits the tape at other detection angles. The detection angle does not depend on the measuring distance. The reflective properties of the DG reflective tape do not depend on the alignment. Reflector reference points To determine the coordinates of a reflector clearly with the NAV245, the reflector surface must be reduced to a reference point: With reflector strips, the reference point is located at the point of intersection between the vertical center line of the cylinder and the scan plane, which is generally halfway up the reflector. With cylindrical reflectors, the reference point is located at the point of intersection between the vertical center axis of the cylinder and the scan plane, which is generally halfway up the reflector. 34 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

41 PRODUCT DESCRIPTION Heating A separate power source is required for heating in the NAV245 (supply voltage 24 V DC, power output min. 40 W (cyclical)). Heating begins when the internal temperature drops below 10 C. It then continues for at least three seconds. If the temperature continues to fluctuate around the 10 C mark, then the heating often runs for a shorter time. Important If the temperature is over 0 C in the NAV245 during commissioning, the device activates. If the temperature is below 0 C in the NAV245 during commissioning, the device must first be heated before it activates. If the temperature in the device drops below 0 C during operation, the device continues to run, but sends a telegram indicating that the minimum operating temperature has been breached. The minimum operating temperature of 30 C (outdoor temperature) is guaranteed for a wind speed of 0 m/s. Experience has shown that operation is possible at wind speeds up to 0.5 m/s. At higher wind speeds the heat is transferred from the scanner too quickly /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 35

42 4 ALIGNMENT OF THE SCAN LEVEL 4 Alignment of the scan level 4.1 Introduction and Preparation To get the maximum detection range of the NAV245 onto reflectors it is recommende to perform a horizontal levelling of the scanner on the vehicle. It is recommend to install the scanner by the mouting sets 1b,2 and 3 or by the mounting sets 1a, 2 und 3 which is described in details in the operational manual of the NAV245. Fig. 29: NAV245 with mounting sets 1a, 2 and 3 This document shows the preparation and the procedure. Further information about the NAV245 is avaiable in the operational manual of NAV245 with the order number _BANAV245ene_ pdf 36 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

43 ALIGNMENT OF THE SCAN LEVEL Preparation For the alignment a flat and even ground floor e.g. in the service area is required. In this area there must be 3 target board in the 0, 90 und 180 positions fixed installed, referred to the coordinate system of the scanner. The allowed tolerance is +/- 10 Abb. 30: topview (left), sideview (right) The horizontal centre of the target boards must be installed in the same height h as the scan level of the scanner, for the orientation there is a mark at housing window (rear side of the NAV245) in the shape of a rhomb. Abb. 31: correct level of target boards The alignmend could be simplified by a temporay replacement of the NAV245 by a laser level e.g. BOSCH self-levelling cross-line Laser GLL /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 37

44 4 ALIGNMENT OF THE SCAN LEVEL The size of the target boards are depending on the distance and are listed in the table: Distance to board Tolerance of distance (1) Height of target (2) Height of scan (3) Width of target Abb. 32: target boards for distances from 1,25 to 15m (4) Refl 1 left (5) Refl 2 bottom left (6) Refl 2 top left (7) Refl 3 left [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] (1) Height of target Board top left R1 top left R2 top left R3 top left Board top right (2) Height of scan level o Board centre-left Board centre-right o Y=0 Board bottom left R1 links unten R2 bottom left R3 bottom left Board bottom right X=0 (4) X R1 left (5) X R2 bottom left (6) X R2 top left (7) X R3 left (3) Width of target Abb. 33: correct mounting of target boards For the reflector material we recommend the foil of 3M with the width of 55m, which is available as a roll (width 50 mm / length 25 m). The SICK order number is Abb. 34: suitable reflector material 38 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

45 ALIGNMENT OF THE SCAN LEVEL Alignment of the NAV245 by SOPAS The alignment procedure will be intialized by SOPAS. The menu Alignment Scan level will be available after the Log-In as Authorized client and the passwort Client Abb. 35: menu Abb. 36: start to Alignment Scan level By clicking on Start the seach and verify procedure will be started, which will check if the 3 required target boards are at the correct height, distance and direction. Remark : If the view to the target boards will be covered during the adjustment procedure, the display returns temporary back to the search mode /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 39

46 4 ALIGNMENT OF THE SCAN LEVEL 4.4 Search and check for the target boards The following image shows the search side page. The three required target boards are symbolized as a graphics. The colour of the graphics are presenting their actual status. A graphic with a green background indi-cate the detection of target board without problems A graphic with a yellow background indicates that the status of the target board in the expected direction is unknown. Abb. 37: recognised target boards A graphic with a red background indicate that a possible target board has been detected with an error that a target board is missing in the expected directiont. Beside the symbolising graphics oft he target boards the value of the refering target board are presented. The value Availability is rating the qualty of the detection. Is the percentage of the quality is above 80, then the quality is sufficient for the usage as a target board for the alignment of the scanner. In the center of the page the value of the Sampling progress is presented, which indicates the progress ot the search and queck procedure. Abb. 38: values of target boards 40 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

47 ALIGNMENT OF THE SCAN LEVEL Alignment of the NAV245 If all 3 target board are identified correctly then the visualization is changing to the alignment page. On this page the actual alignment of the scanner will measured and presented. The correct alignment for the rolling and the pitch angle is succeded if this image will be presented: Abb. 39: Alignment page To define the rolling angle and the pitch angle two symbols are presented. Pitch angle θ of the unit Rolling-angle Φ of the unit Abb. 40: definition of the roll- and pitch angle /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 41

48 4 ALIGNMENT OF THE SCAN LEVEL Alignment of the rolling angle The first step: the optimization of the alignment will be done by adjusting of the rolling angle (graphic on the right side). Therefore the hexagon socket screws #1 and #2 have to be loosened, the scanner carefully turned and finally the screws have to be fixed hand-tight again. Hexagonal socket screws, left and right for the adjustment and fixation Abb. 41: adjusting of the rolling angle NAV245 The alignment is optimal and done, if the bar in the center of the right graphic stays green. Abb. 42: optimal adjustment of the roll angle 42 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

49 ALIGNMENT OF THE SCAN LEVEL Alignment of the pitch angle As a second step the pitch angle (graphik on the left side) has to be optimised. As a preparation the hexagon socket screws 1 and 3 has to loosened to be used as a turning axis. After loosening the screws 2 and 4 the scanner has to be turned carefully. and fixed by tightening the screws again. Finally also the hexagon socket screws 1 and 3 have to be fixed hand-tight. Fig. 43: adjusting of the pitch angle NAV245 During the adjustement the main focus is on the left side for the best possible pitch angle. Abb. 44: optimal adjustment of the pitch angle /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 43

50 5 MOUNTING 5 Mounting NOTE: Do not open the NAV245 housing. If opened, any warranty claims against SICK AG are void. 5.1 Overview of the mounting steps 5.2 Preparation for mounting Select a mounting location for the NAV245 Mount and adjust the NAV Getting the components to be mounted ready One NAV245 (weight approx. 1.1 kg) Getting the accessories and material ready Mounting kit(s) with mounting material (not included with delivery) or Getting the tools ready Alternatively, if a mounting bracket is provided by the user: Stable mounting device that provides adjustable alignment of the NAV245 on the Xand Y axis 4 M5 screws for the NAV245, screw length dependent on the thickness of the mounting bracket used 4 M5 screws for mounting the SICK mounting bracket on the support, screw length dependent on the thickness of the support Tool 44 OPERATING INSTRUCTIONS NAV /ZN24/ SICK

51 MOUNTING Selecting the mounting location 5.3 Steps for mounting NOTE: Mount the NAV245 in such a way that it is not exposed to direct sunlight (if necessary, install roofing). This prevents an impermissible temperature increase inside the sensor. Avoid installation where the laser would be directed at glass or stainless-steel surfaces. NOTE: Please noted the following points in particular during mounting: Mount the NAV245 so that it is protected from moisture, dirt, and damage. Ensure that the entire field of view of the NAV245 is not restricted. Mount the laser positioning sensor so that the status indicators can be clearly seen. Always mount the NAV245 so that there is still enough space for mounting and dismantling the system connector. Avoid excessive shock and vibration loading on the laser positioning sensor. On systems that experience heavy vibration, prevent the fixing screws from accidentally coming loose using screw-locking devices (see section 9.1 NAV245 data sheet on page 70). Regularly check the tightness of the fixing screws. Pay attention to the maximum torque of 5.9 Nm for the NAV245 M5 fixing screws. Possible ways of mounting the NAV245: Direct mounting without mounting kit Mounting with mounting kit 1a or 1b Mounting with mounting kit 2 (only in combination with mounting kit 1a or 1b) /ZN24/ SICK OPERATING INSTRUCTIONS NAV245 45

52 5 MOUNTING Direct mounting The NAV245 has four M5 8 threaded holes on the rear. They can be used to mount the NAV245 directly on the intended mounting surface. To prevent possible oscillations, the reference plane located on the rear can be used at a third support point if necessary (1). M5 8 Fig. 45: Direct mounting Important Please observe the dimensional drawings during mounting (see NAV245 dimensional drawing, page 66) Mounting with mounting kit 1a You can use mounting kit 1 to mount the NAV245 on a mounting surface (wall, machine). The mounting kit is available as mounting kit 1a without a protective device for the optical cover and as mounting kit 1b with a protective device for the optical cover. Fixing screws Mounting kit 1a Fixing screws M5 8 threaded holes Fig. 46: Mounting with mounting kit 1a 46 OPERATING INSTRUCTIONS NAV /ZN24/ SICK