Laser Projection Sensor User's manual.

Transcription

1 LPS Laser Projection Sensor User's manual CERSA-MCI CERSA-MCI 53, parc Expobat CABRIES FRANCE tel: +33 (0) fax: +33 (0) web:

2 2 Part I: Introduction Part I: Introduction The LPS-H (Laser Projection Sensor High speed) is specially built for tube, cable, wires. It measures the diameter at very high speed on 1 or 3 axes (depending of the version). Its measurement principle is based on the laser projection (shadow). This method is position and vibration independent. With 3 axes, it covers well enough the periphery of the cable to follow accurately the high frequency dimension changes in line and to quantify them, leading to a new approach of defect detection. It cumulates in one single instrument the diameter, the ovality measurement, the lump and neck detection as well as event management and recording. The LPS-H instrument uses the latest technology to give the maximum performance. Main Advantages Accurate and fast diameter measurement. Lump & Neck detection. Ovality measurement. Vibration measurement independent. Real time tolerances checking. Cable position measurement. Spool length and speed computing. Compact and hardened industrial instrument. Local display of measures and parameters. CERSA-MCI develops and produces also complementary high performance measurement instruments for wire industry and optical fiber production. LPS 's manual

3 3 Part II: Specifications Part II: Specifications 1 General specifications HIGH SPEED DIAMETER MEASUREMENT Model : LPS005 Laser beam w idth : Range : Uncertainty / Repeatability: LPS020 LPS m m 25.0 m m m m m m m m m m ±7µm ±20µm ±80µm Remarks: Includes slow ambient temperature fluctuation w ithin 1040 c. Includes cable moves w ithin the measurement area 1 or 3 (both versions are available) 20 khz (no averaging required) Number of axes : Internal measurement frequency : LUMP & NECK DOWN DETECTION The detection principle is based on the high speed diameter measurement (diameter tracking) w ithout additional hardw are. Model : LPS005 LPS020 LPS080 Minimum detectable diameter change : Number of axis : 14µm 40µm 160µm Similar to the number of axis of the high speed diameter measurement. 20 khz (no averaging required) max: 50µs Detection frequency : Dating uncertainty : X & Y POSITION MEASUREMENT Model : LPS005 LPS020 Range : LPS080 ±3.5 mm ±12.5 mm maximum maximum Uncertainty / Repeatability: ±0.05mm ±0.20mm Remark: for 1 axis version, X position is unavailable, only Y position is measured BNC OUTPUTS Quantity : 1 (for diameter control) Type Voltage Range : ±4V Voltage (Av) or current (Aa) type must be specified at order. Updating frequency 500Hz ±50.0 mm maximum ±0.80mm Current 0-20mA or 4-20mA DIGITAL OUTPUTS (Open collectors) For alarms, tolerances...( configurable) Quantity : 2 (or 1 if length reset input is used) DIGITAL INPUTS For length counting and length reset. Quantity : 2 RS232 COMMUNICATION Used to connect the instrument to CIM softw are Baudrate : configurable (38400 to ) Maximum cable length : 35 meters (certified only w ith cables supplied by CERSA) ENVIRONMENTAL CONDITIONS:

4 4 Part II: Specifications Air flow of 5 to 20 litres per minute required to clean the optics and cool dow n the electronic. Ambient w orking temperature : Maximal w orking internal temperature : Storage temperature : LPS 's manual c 55 c 0-60 c

5 5 Part II: Specifications 2 Mechanical design LPS005-1-H (one axis version):

6 6 Part II: Specifications LPS005-3-H (three axes version): LPS 's manual

7 7 Part III: CIM software Part III: CIM software C.I.M. software (CERSA Instruments Manager) is a PC environment to manage all CERSA-MCI instruments. It provides a complete set of comprehensive tools to improve and master the production process as well as all features to certify the whole production specifications. Refer to CIM manual for further details. 1 Production environment Main features in production : Monitoring the process in real time. Data logging and export (database). Product definition and configuration. Production reports. Instruments configuration and maintenance.

8 8 Part IV: Measures and principle Part IV: Measures and principle 1 Generalities 1.1 Available measures Here below is the list of measures transferred from the instrument to CIM. Measure Actual delta length Actual max length Actual min length Diameter Diameter A1 Diameter A2 Diameter A3 Non Circ. Speed mmin Speed ms Temp. X position Y position unit Description access level Value of the lump and neck maximum delta length parameter supervisor taken into by the instrument according to the production speed. Value of the lump and neck maximum length parameter supervisor taken into by the instrument according to the production speed. Value of the lump and neck minimum length parameter taken supervisor into by the instrument according to the production speed. Value of the outer diameter. Value of the outer diameter. Measured by axis 1. Value of the outer diameter. Measured by axis 2. Value of the outer diameter. Measured by axis 3. Value of the outer non-circularity. [m/min] Value of the production speed. [m/s] Value of the production speed. [ C] Value of internal temperature of the instrument. Should not supervisor exceed 55. Value of the X position for the measured object. Value of the Y position for the measured object. Remark: A non-measured value is forced to zero, except for X & Y positions which are force to -5.00mm The outer non circularity is estimated thanks to the 3 axes diameters measurement LPS 's manual

9 9 Part IV: Measures and principle 1.2 Events It is a particular phenomenon that is detected by the instrument. Events are detected in real time, dated (3ms accuracy) and located (product length). Each event is also characterized by its extremum value. Here below is an example of high speed diameter fluctuation which exceeds the tolerances. Here below is the list of events transferred from the instrument to CIM: Event unit Description Diameter Lump & Neck L&N length Holes Status Diameter event is generated in case of out of tolerance Lump&Neck event is generated in case of out of tolerance [m] In the case of detection of small necks sequence. Lump and neck event is generated in case of out of tolerances. Hole event is generated in case of multiple wires detection. Measured diameter is then the overall diameter. General status of the instrument. access level 1.3 Real time scopes Because the measurement frequency of the instrument is very high, it is impossible to transfer all measures in real time to the computer through RS232. The instrument stores the main measures continuously in internal buffers of 500 points each. This function is called Real Time Scope. Those buffers can be watched through CIM. Only few buffers per seconds can be watched, because of communication constraints. The sampling period of each buffer can be modified, depending on the time scale you want to analyse. Those tools are very useful for process analysis to qualify the stability, the regulation performance, and display some particular effects. The F.F.T. processing shows specific oscillations. We recommend strongly to the process engineer to use those tools for understanding and improvement of the manufacturing process.

10 10 Part IV: Measures and principle 2 High speed Diameter 2.1 Optical principle and structure An object, placed in a plane beam of collimated light, interrupts the path of the light and produces a shadow on the CCD sensor, associated to diffraction and reflection phenomenon. Based on the shadow image, each individual CCD board computes the real time signal at a data rate of 20 khz. This high speed and accurate measurement give the capability to track in real time the product shape. By the way, it provides a very liable "Lump and Neck" detection function. This tracking function is also very useful for shape control, like envelop measurement for twisted cables. This measurement system can be provided with 1 or 3 axes (60 between each). LPS 's manual

11 11 Part IV: Measures and principle 2.2 Projection scope This scope shows 1 signal: CCD projection: Light energy vs pixel. It shows the signal acquired by the CCD. This scope is used for maintenance purpose to check at the signal quality. Without wire inside the instrument : 2.3 Real time diameter scope This scope shows 1 signal: Real time diameter projection axis 1, 2, 3 : Diameter vs time. It shows real time diameter fluctuations for each axis. This scope is interesting for process study and analysis. It can show high speed phenomenon, such as spinning or diameter oscillations. The following parameter can be adjusted: Sampling period [ms]: Represents the duration between 2 storages inside the buffer. It is used to adapt the time scale. Minimum value: 0.050ms.

12 12 Part IV: Measures and principle 3 Position Cable position is measured by the CCD boards. The cable must be placed in the center of the instrument, especially in the middle of each laser beam. Position must be controlled by the to insure a correct measurement. Position can be seen under CIM software. In case of 1 axis version, the position is measured in only one dimension. In case of 3 axes version, the position is measured in two dimensions. LPS 's manual

13 13 Part V: Connexions and Interfaces Part V: Connexions and Interfaces 1 Rear panel OK = Smooth blink ALARM = Fast blink NOT USED SUB-D 9 CONNECTOR DIGITAL I/O CONNECTOR BNC output AIR connector 2 SUB-D 9 connector This connector integrates: power supply serial link (RS232) Pulse input for length counting

14 14 Part V: Connexions and Interfaces DB9 Pins nb. 1 IN/OUT Signal IN Pulse input for length counting 6 Negative supply 2 7 do NOT connect IN Positive supply RS232 gnd OUT RS232 TX IN RS232 RX Do NOT connect 5 Do NOT connect 2.1 External power supply and cable The power supply inputs are floating. Max input voltage: 36V Min input voltage: 18V Reverse voltage protected Supply current: 24V LPS 's manual

15 15 Part V: Connexions and Interfaces The instrument comes with its CERSA MCI s power supply and cable. This power supply provides +24V volts rectified and filtered DC voltage with a power of 15W isolated from ground. A short-circuit protection is included. Input voltage : from 100V to 240V AC, 50 to 60 Hz. 2.2 Serial link Communication cable should be shielded. Communication settings: baudrate: bauds (configurable through CIM software) data bits: 8 parity: even stop bit: 1

16 16 Part V: Connexions and Interfaces 2.3 Length counting use Opto-isolated input referenced to the negative supply (reverse voltage tolerant) Minimum voltage to ensure a high level input : 7,2V Maximum voltage to ensure a low level input : 2V sunk current : 7,2V. Input impedance : 1200 ohms If you connect the length counting signal and the reset signal, the instrument will compute the speed and length with the same reference as your production system. It allows the instrument to locate accurately all events in the spool. It can help you to determine the portion of product to reject. The length counting interface has to be configured under CIM software (Parameters manager / Digital interface) with the following parameters: Pulses number: The number of pulses for 1 meter length. Slip factor: in case of the real speed and the measured speed are not perfectly correlated, you can adjust this factor. This multiplication factor is applied to the measured speed. Default value: pins digital I/O connector IN/OUT connector is a circular HIROSE HR10 series 6 pins. 2 floating Inputs / outputs. The direction of each I/O (input OR output) is individually configurable through the CIM sofware. The instrument comes with a 5m cable, with compatible connector. Corresponding Pin color on CERSA Numbe cable r Description 1 White Not connected 2 Brown Not connected 3 Green digital I/O Yellow digital I/O 1-5 Grey digital I/O Pink digital I/O 2 - LPS 's manual

17 17 Part V: Connexions and Interfaces 3.1 Digital Input/Output Outputs: Bidirectional floating static relay : 48V / 1A The logical state when the output is activated is configurable through the CIM software (Output active high or output active low) Output active high means that the internal static relay is open when the output is active. Output active low means that the internal static relay is closed when the output is active. The signal to be associated with the output pins is configurable through the CIM software Input states: Unidirectional opto-isolated input (reverse voltage protected). Minimum input voltage (IO+ to IO-) to ensure an active input : 5,6V Maximum input voltage (IO+ to IO-) to ensure an inactive input : 3V Sunk current : 5,6V, input impedance 2,2k_ohm IO in OUTPUT configuration : IO in INPUT configuration :

18 18 Part V: Connexions and Interfaces Remark: Lamp, Load and Relay are shown as application examples. Settings: Hold Time Event IO (ms): The time in milliseconds during which the output is maintained activated even if the configured event has disappeared. Can be useful for "slow" PLC, to be sure that the output activation will be taken into account properly. Signal : Events that can be attached to an IO are the following ones : Output signals Description when activated No signal Position Out High Diameter Low Diameter Lump & Neck Wrong Position Lump Neck High - low diameter Global Alarm L&N Length Input signals No signal LPS 's manual No signal is attached to the output ; the output is maintained inactive The object is out of the measurement area The object diameter is over the high tolerance of Diameter measure The object diameter is lower than the low tolerance of Diameter measure A lump or a neck has been detected accordingly to the parameters The object position is not correct A lump has been detected accordingly to the parameters (necks have no effect) A neck has been detected accordingly to the parameters (lumps have no effect) An out of tolerance on the diameter measure has been detected, either high or low. An error has been detected and the instrument is not available for measurements. That means that an error code is displayed on the local display. A Neck sequence has been detected (either a minor or a major defect) accordingly to the parameters. Description when activated No signal is attached to the input ; the input has no effect

19 19 Part V: Connexions and Interfaces Input signals Description when activated Spool Reset Reset the spool time and spool length computed by the instrument and displayed under CIM to localise the events. 4 Analog Output Floating analog output. Depending on the option chosen at the order, the output signal will be defined as a current loop or as a voltage. The associated measurement to this output is the diameter. Specifications for current loop option : Current range: Resolution: Accuracy: Max voltage: Min voltage: 0-20mA or 4-20mA (CIM software configurable) 10uA +/-100uA 20mA, overvoltage 48V 3V The current is sunk by the instrument. An external biasing is needed (the instrument interface is passive). 2 solutions can be used : Specifications for voltage output : Voltage range: +/-4V Output impedance: 100 to 200 ohm

20 20 Part V: Connexions and Interfaces Max output current: 10mA Resolution: 2mV Accuracy: ±50mV Remarks: Output scales are adjustable with the following parameters under CIM software (Parameters manager /Analog interface): Zero point: When the measured value reaches the zero point value, the corresponding analogical output is set to 0V. The unit of the zero point is the same as the corresponding measure. Scale: Is the number of volts per measure unit. For example for diameter in millimeters 2 [V/mm]: if the measure varies of 1mm the value of analog output varies of 2 Volt. Regulation: If this option is activated, then the zero point value is automatically forced to the nominal tolerance value of the corresponding measure. Otherwise the zero point can have any value. Average time: Is the average time used to compute the analog output signal. LPS 's manual

21 21 Part V: Connexions and Interfaces 5 Air supply A standard connector for 6mm PVC air pipe is included on the rear panel. The air exits inside the lens mechanical protection. A clean and dry air flow of 5 to 20 litres per minute is required to clean the optics and cool down the electronic. It has also the interest to avoid dust to deposit on the lenses. 6 LCD display and keyboard At start-up, after the led display self test, the led panel displays the serial number of the instrument. Then, the led panel displays the measured diameter in mm. The green "RUN" led is blinking, indicating that the instrument is measuring properly. In case of an instrument's error, the led panel will alternately display the last measured diameter and the error code "EXXX", with XXX the corresponding error code. The red "ALARM" led will then be lighted. The keyboard can be used to modify some instrument's parameters as described hereafter : Action Led panel Display Explanation Enter the settings menu Nominal Diameter in millimeters Use keys to modify the value H 1 second

22 22 Part V: Connexions and Interfaces High Diameter tolerance in millimeters Use keys to modify the value L 1 second Low Diameter tolerance in millimeters Use keys to modify the value H 1 second Lump tolerance in millimeters Use keys to modify the value L 1 second Neck tolerance in millimeters Use keys to modify the value Position of the object seen by the instrument -1 2 P LPS 's manual Display nnnn in case of Position Out Exit the settings menu. All the parameters are written into the EEPROM s instrument

23 23 Part V: Connexions and Interfaces Notes: To change the values of tolerances with bigger increment keep hold buttons. The keyboard can be inhibited through the CIM software. In that case, the settings menu is then no more available through the keyboard. The led display can be inhibited through the CIM software. In that case, only the error codes are displayed in case of errors. The measured diameter won't be displayed.

24 24 Part VI: Instrument settings Part VI: Instrument settings A full set of parameters can be adjusted using CIM software. Remark: All parameters are stored and saved in an embedded EEPROM. 1 Tolerances The instrument monitors in real time if the measures are in or out of the product tolerances. In case of out of tolerance, the instrument will act as follow: Digital output state will change. Refer to the Digital I/O chapter. Data are transferred to CIM which will show events with full details about dating, positioning and extremum values. Here below is the logic used for tolerance control: Measure > Nominal tolerance + Warning high tolerance Measure < Nominal tolerance - Warning low tolerance Measure > Nominal tolerance + Out high tolerance Measure < Nominal tolerance - Out low tolerance EVENT WARNING HIGH (Not yet available) EVENT WARNING LOW (Not yet available) EVENT OUT HIGH EVENT OUT LOW Here below is the full list of tolerances parameters that can be adjusted with CIM software (Parameters manager /Tolerances): Parameter unit Description access level Avg. time diameter [ms] Avg. time lump neck RT. Avg. time lump neck rel. Hold time event diameter Hold time event lump neck Max. delta length lump neck [ms] [ms] [ms] [ms] Max. length lump neck Min. length lump neck Nominal diameter Out high diameter Out high lump neck Out low diameter Out low lump neck Rel.(ON) - Abs.(OFF) LPS 's manual Time during which the diameter will be averaged to compute out of tolerances. (enter zero to disable) Averaging time of the diameter for lump and neck detection. Averaging time to compute reference diameter for relative lump and neck detection. Represents the minimum time that diameter event is activated if detected. Represents the minimum time that lump and neck event is activated if detected. In the case of detection of small necks sequence. This parameter is the length for a sequence of small necks to be detected. As soon as the neck length is over the value of this parameter, the neck will be taken into account. In the case of detection of small necks sequence. This parameter is the minimum length for a small neck to be detected. Nominal diameter value. Maximum diameter tolerance. (enter zero to disable) Maximum diameter lump tolerance. (enter zero to disable) Minimum diameter tolerance. (enter zero to disable) Minimum diameter neck tolerance. (enter zero to disable) Logical mode used to detect lump and neck in relative supervisor supervisor supervisor supervisor supervisor supervisor supervisor supervisor supervisor

25 25 Part VI: Instrument settings mode or in absolute mode. The following graphs show the neck detection sequence and the use of the Max delta length lump neck, Max length lump neck, and Min length lump neck parameters : 2 Measure parameters Here below is the full list of measures parameters that can be adjusted with CIM software(parameters manager /Measures): Parameter unit Avg. time display NC. Avg. time display diam. Diam. offset A1 [ms] Diam. offset A2 Diam. offset A3 Pos. out tempo [s] [ms] Description access level Averaging time of the non-circularity measure shown on supervisor the local display and transferred to CIM. Averaging time of the diameter measure shown on the supervisor local display and transferred to CIM. This offset is applied on the diameter value of axis 1. It supervisor can be used to correct the calibration. This offset is applied on the diameter value of axis 2. It supervisor can be used to correct the calibration. This offset is applied on the diameter value of axis 3. It supervisor can be used to correct the calibration. If the object to measure leaves the measurement area supervisor during this time, it is considered as position out. All measures are forced to init value.

26 26 LPS 's manual Part VI: Instrument settings

27 27 Part VII: Installation on the line Part VII: Installation on the line 1 Mounting You do not need any fine adjustable support. A single horizontal metal plate, 3 mm thick, with 4x 4.20mm holes would be sufficient. You must reserve the possibility of a manual adjustment to adjust the position of the instrument on the cable axis. The cable should pass in the center of the instrument and should be perpendicular to the instrument casing. Remark: At very high production speed the cable itself becomes an important heating source. Air supply is necessary to maintain the internal temperature and ensure the behavior of electronic devices.

28 28 Part VIII: Maintenance, security and troubleshooting Part VIII: Maintenance, security and troubleshooting 1 Optical system cleaning The lenses cleaning should be performed regularly depending on the environment. In most of the cases, a simple dry air blowing action each month into the lenses protection is sufficient. Remember that dusts on the lenses degrade the measurement s accuracy. To clean the lenses, please follow this procedure: 1. Unplug the power supply. 2. Remove the mechanical protection. 3. Use dry air to eliminate the biggest particles. 4. Use cotton or dry tissue with IPA (IsoPropylic Alcohol) and clean carefully each lens. 5. Check visually the surface of the lenses. 6. Replace the mechanical protection. Mechanical protection Optical system w ithout m echanical protection 2 Error codes In case of measurement problem or error, the instrument will show on the local display an error code "EXXX" only for the negative values of the event code following table. This code is also transferred to CIM which will display a short text. For further details about these codes, please refer to the following table: Event code Text displayed in CIM value 501 (none) 500 LPS 's manual (none) Description Lump and Neck detection sequence : Two consecutive minor defaults have been detected. An ACK order is needed to clear the alarm on the led display and the corresponding IO if configured. Lump and Neck detection sequence : A major default has been detected. An ACK order is needed to clear the alarm on the led display and the corresponding IO if configured.

29 Part VIII: Maintenance, security and troubleshooting Event code Text displayed in CIM value 11 WARNING HIGH 8 WARNING LOW 5 OUT HIGH 2 OUT LOW 0 OK -2 RESET SPOOL -4 EVENT MAX -16 RS232 ERR. -27 RECONF HIGH TEMP HW ERROR HW ERROR HW ERROR HW ERROR HW ERROR CAPT_T WATCHDOG POSITION OUT WRONG POSITION WIRE OUT OF RANGE -400 SIGNAL LOW SIGNAL DIRTY LENSES -599 SIGNAL 29 Description Tolerance current state warning high Tolerance current state warning low Tolerance current state out high Tolerance current state out low Status is OK Indicates a spool length reset event CERSA Internal event (Overflow of events) RS232 communication error The instrument is currently self-reconfiguring and is not ready for measurements. This normally occurs once during few seconds at power-on. Temperature is too high CERSA Internal event (CCD) CERSA Internal event (EEPROM) CERSA Internal event (ECAN) CERSA Internal event (Version) CERSA Internal event (Reconfiguration failed) Temperature sensor is out of order CERSA Internal event (Restart due to Watchdog) The object position is out of the measurement area The object position is not correct The object is either too small or too large for the instrument Signal is not correct for analyse. The lenses may need to be cleaned. CERSA Internal event.signal is not correct for analyse. Signal is not correct for analyse. The lenses may need to be cleaned. Signal is not correct for analyse. The shadow can't be analysed (too much wires seen by the instrument) Positive event code value are not displayed on the local display, excepted 500 and 501 codes "OK" event code is not displayed on the local display, and is replaced by the green led "RUN" blinking. Error codes "RESET SPOOL" and "EVENT MAX" are displayed only under CIM software. 3 Safety rules There is no particular protection constraint for s in the case of a normal operation of the devices. Nevertheless hazardous reflections can be emitted afforded by the aversion response for unaided viewing. Laser source information: Class 2M laser device according to the classifications given by the "American National Standards Institute", document ANSI Z , page 1.

30 30 Part IX: Embedded software versions Part IX: Embedded software versions The following history table highlights the technical changes made to the instrument embedded software. Embedded version Date Evolution /2015 New version for CIM compatibility Diameter and LN events at CCD line period added. Software version displayed under CIM. Events Holes added. Offset and gain auto-compensation added. Fifo'ed UART used to transfert large blocks of parameters Status LED is now "breathing" LPS 's manual CIM compatibilit y Yes Yes

31 31 Part X: User's manual versions Part X: User's manual versions The following history table highlights the technical changes made to the instrument 's manual. User's manual version Date Evolution 2013/02/ /01/05 LPS-H is now compatible with CIM Added events LN, Diameter and Holes Added description of signals available on IO Updated error codes Embedded software