L.D.S. Laser Diffraction Sensor USER S PC SOFTWARE MANUAL V6.2 CERSA-MCI

L.D.S Laser Diffraction Sensor In-line Diameter measurement & control USER S PC SOFTWARE MANUAL V6.2 CERSA-MCI Conception Etude et Réalisation de Systèmes Automatisés Measure and Control Instruments Parc Expobat n 53 F13 825 CABRIES Cedex, France Tel: +33 4 4202 6044 Fax: +33 4 4202 7979 e-mail: sale@cersa-mci.com Web : www.cersa-mci.com

Contents INTRODUCTION...5 1. SOFTWARE INSTALLATION...5 2. MAIN SCREEN...6 3. CASE OF THE LDSN 2 AXIS...7 4. SESSION...8 4.1 SENSOR CONFIGURATION...8 4.2 SET SPOOL LENGTH...10 4.3 SAVE TO FILE...10 5. UTILITY...11 5.1 SCOPE...11 5.2 SOFTWARE CONFIGURATION...12 5.3 PASSWORD...12 6. UTILITY (PASSWORD SECTION)...13 6.1 LINEARIZATION...13 6.2 I/O AFFECTATION...16 6.3 SERIAL LINK SETTING...17 6.4 SENSOR ADDRESS...17 6.5 EXPOSURE TIME...17 6.6 LOAD FACTORY DATA...17 7. ACCESSORIES SELECTION...18 8. WSR ACCESSORY...19 8.1 WSR USE...19 8.2 WSR WINDOW...19 8.3 LABEL PRINTER WITH WSR...22 9. FOOT PEDAL ACCESSORY...23 9.1 SPECIFICATION OF THE APPLICATION...23 9.2 DIAMETERS TABLE :...23 9.3 GROUP TABLE :...24 9.4 STATISTICS RESULTS:...24 9.5 RECORD TO FILE USE...24 9.6 USE THE LABEL PRINTER WITH THE FOOT PEDAL:...25 10. PORTABLE...26 10.1 PORTABLE MENU ACTIVATION...26 10.2 SENSOR CONFIGURATION...26 10.3 DATA TRANSFER MENU...27 10.4 DATA RESET...29 11. LOADER...30 3

Software version Modifications User s PC software version October 10 2001 Last reference version 2.0 November 9, 2002 Update for the portable version and the oscillating support 2.1 November 9, 2002 LDSN150 replaced by LDSN200 2.2 December 23,2003 New Linearisation Menu 3.0 February 26,2004 WSR Menu 3.1 March 25,2004 Excel Portable Menu 3.2 May 03,2004 WSR Linearisation 3.3 V2.8 Changing the Loader uses. Removing the Noise recording function from the menu. V3.2 Equipments and LSONE software are now ready to display use both units system: micron and milli-inch (Mil). Update for the Software installation V3.3 New menu for Label setting 3.6 3.4 3.5 V3.8 Integration of the label setting to the WSR screen. Adding the serial link setting for the Label printer communication. 3.7 V4.0 Integration of the use of the Foot pedal V4.0 V6.0 Integration of the 2 axis version V6.0 V10.0 Modification of the WSR window V6.1 October 08, 2009 LDSN renames LDS V6.2 4

INTRODUCTION The LS software is globally written for LS (LDS or LPS) measurement instruments on production lines or laboratories. It gives the user the possibility to parameter its instrument for its application and to follow the production. In an extended version it is suited to manage the whole production from one single PC connected through a network to several instruments. This software gives the user access to the whole functions of the instruments. Each instrument measures the diameter, counts the length pulses and computes the wire speed. It gives the statistical parameters according to the production length, delivers information on the measurement situation (statuses). All those data can be transmitted to and recorded by the PC through the LSN software, but also by any user s PLC or computer through a proprietary communication software. 1. SOFTWARE INSTALLATION This section gives the LSONE software installation procedure. 1. Insert the CD software in the computer, after a few seconds automatically a windows environment will open. 2. Follow the instructions of the installation process. If this does not happen automatically, execute the SETUP.EXE in the Wire & Cable documentation and software\software for LDS and LPS directory by using the windows explorer and then, follow the instructions of the installation process. Installation Default Directory is C:\Program Files\Cersa\Lsone CD Rom contents: 5

2. Main Screen LSONE ICON To open the LSONE program, connect the LDS with the serial link to the PC and click with on the LSONE ICON Instant diameter measurement LDS Status Diameter tolerances Diameter chart Speed chart Diameter statistics Speed tolerances Speed and length counting Internal temperature Amplitude of the fringes signal Scale of the X axis (Time) Red lines on graphic represent high and low margins of the diameter Grey lines on graphic represent high and low margins of speed The diameter and the speed charts are centered in the graphic window by using the nominal values. The left axis of the chart is the diameter axis. The right axis of the chart is the speed axis. 6

3. Case of the LDS 2 axis In case of the LDS 2 axis, the main screen will adapt automatically as following: Axis 1 and Axis 2 measurements Axis 1 and Axis 2 status Axis 1 diameter Axis 2 diameter Axis 1 and Axis 2 fringes amplitude 7

4. SESSION 4.1 SENSOR CONFIGURATION All of these data are saved in the sensor s memory. Please refer to the PASSWORD SECTION to modify the data. 8

Line settings - Number of pulses /m : Used by the LDS to compute the wire speed and length. Important : If you enter 0, the LDS will use the following parameters to compute the speed an length. o Capstan pulses: Number of pulses per turn of capstan o Capstan diameter: Dimension in mm of the capstan diameter. o Slip correction: This data is used to calculate the real length of the spool, the capstan wire shift being included. Default value : 1 - Length statistic: Wire length between 2 statistic calculations Important: If the length statistic is equal to zero, all the measures are included in the statistic calculations. Alarm settings - Production alarm Delay: Minimum alarm duration to activate the relay (When Speed alarm or diameter alarms are selected) - Production Alarm: Use this function to enable the production alarms (See alarm code in the User s Manual) Current output Option - Minimum analog output: Minimum diameter value for 4mA or 0mA - Maximum analog output: Maximum diameter value for 20mA - Range (0 20 ma) or Range (4 20 ma): Select the current output range - Analog Alarm : only use this function when the Range ( 4 20 ma) is selected. When this function is enabled the analog output gives an alarm information. 1 ma output No wire 2 ma output Low Signal 3 ma output Other Alarm 4/20mA output Measure Range CAUTION : The frequency of the LDS measure is between 30 Hz to 40 Hz, so the frequency of the ACQUISITION SYSTEM needs to be FASTER than 50 HZ, for short alarm detection. Voltage output option - Analog sensibility Output: The sensibility of the analog output when the Analog Regulation output is Validated: Output = ((measure nominal diameter) * sensibility) 9

Instrument Information - Sensor Model: Model of the Sensor (LDS200, LDS650, LDS2000 or LPS) - Version: Software Version in the Sensor - CCD Type: Type of CCD in the Sensor Instrument options - Wire Sample Rotation: Cross this box if you use the WSR Accessory. - Foot pedal: Cross this box if you use the Foot pedal Accessory. - Inches: Cross this box if you want to change the standard (µm) unit system to Mil. All measurement values and parameters in the software and on the local display will be converted in Mil (milli-inches). If your LDS is equipped with a unit-switch, the above function is not available. The mechanical switch is priority. Network option - Asking Address: Each sensor has its own communication address Comments: - All sensors respond universally to the Address 255, so be careful: don t use this address in a Network Configuration 4.2 Set Spool Length Length of the wire to spool before the internal relay switches off 4.3 Save to file This instruction starts or stops the recording of the measure on the PC, depending on the precedent state. Diameter and speed are saved in a data file (in ASCII standard Text format). The extension of this file is.xls. It is possible to read this file under Excel' (software) once recording is stopped. Time(s) Diam (µm) Speed (m/s) Temp ( ) Length (m) Alarm 1 99,03 0 30 0 0 2 99,03 0 30 0 0 3 99,03 0 30 0 0 4 99,03 0 30 0 0 10

5. UTILITY 5.1 Scope This utility permits to display the CCD sensor signal on the PC screen. With the save menu, the screen can be saved in ASCCII values (.txt extension) or in binary values (.vid extension). Use this function to control the quality and the proper alignment of the instrument on the wire. It is also used to check the proper cleaning of the lenses. The amplitude and the number of the fringes depend on the wire. 11

5.2 Software Configuration - Language File : Use English for English language - Communication sensor Period: It is the period between two PC-sensor communications. - Hard disk data saving Period : It is the period between two data storages on the PC hard disk. - Change password: It is the password to access to the Linearisation and Calibration Menu (The password is global ) 5.3 Password The factory set password is global. By entering this password it is possible to modify the user s data in the Sensor configuration Menu and a new Utility menu will be activated (see preceding section). Of course a good comprehension of the sensor is necessary. 12

6. UTILITY (Password section) 6.1 Linearization 13

The user can build, save or load different linearisations corresponding to different types of wires by using this software. Calibration will use at maximum 20 points. The linearization table may contain a maximum of 20 references but a minimum of 2. Caution The linearisation table displayed in the windows is the permanent image of the table in the instrument. Each linearisation table is specific to each individual instrument. When the user loads a linearisation file in the LDS, the previous linearisation inside the LDS is replaced. Before any loading, the software will check the serial number of the linearisation table and the serial number of the LDSN, if they are not identical the file is not loaded inside the LDS. The display of the linearisation graph (top right) shows on the X axis the diffraction diameter and on the Y axis the difference diffraction diameter Reference diameter. The advantage of such a display is to enhance the random dispersion (due to uncertainties) of the reference wires compared to the diffraction effect. The diffraction effect is not linear but perfectly continuous over the whole diameter range. The PC software includes a regression curve and R² coefficient computation. This tool is interesting to reduce the uncertainties of the linearisations. The more reference wires (max 20) of random uncertainty, the better the accuracy of the linearisation. This permits to get a better accuracy than the accuracies of the reference wires. The software needs at minimum 4 points. When all linearisation points have a good continuity, the R² coefficient is near 1, in other cases this coefficient decreases. With the Erase and Point buttons it is possible to erase the bad points, and with Add and standards values, it is possible to add a new linearisation point. Regression Curve button: Add Button: Validate or not the choice Regression curve in the Utility/ Linearisation menu. Insert a reference wire. With the signal scope (bottom right) check the quality of the wire (the Amplitude of the fringes depend on the quality of the wire), check the Sensor status (Sensor Ok), validate the measure with the "Add" button: then, when the "Standard" panel is displayed, enter the diameter value of the wire in the "Standard" field, and validate the measure with the "Valid" button. Standard panel 14

WSR Acquisition Button: In case of WSR option, it is possible to execute a linearisation with the WSR. Insert a reference wire on WSR. With the signal scope (bottom right), check the quality of the wire (the amplitude of the fringes depending on the quality of the wire), check the Sensor status (Sensor Ok), validate the measure with the WSR Acquisition button. Then, when the Standard panel is displayed, enter the value of the wire in the Standard field, and validate the measure with the Valid button. After this, the WSR panel is displayed, and the user can execute the rotation with the wire, then validate the measure with the Add point button. If the user is not satisfied by the measure, he can proceed to a new complete turn after pressing the Restart WSR button. WSR panel Erase Button: At the left of the linearisation window, you find the list of the linearisation points. To select the point to erase, enter the number of the point in point field, and validate the action by click on Erase button. Be careful by using this action because all points erased are definitively lost. Load Calibration Button: Select in the directories the linearisation file to load and transfer to the instrument. Save Calibration Button: Save the current linearisation table corresponding to the different types of wires in the directory. 15

LDS 2 axes case: In this case, each axis is independent, and then, you have to proceed to both axis linearization. At the beginning of the linearization procedure, the software will ask you which axis you want to make the linearization: After finishing the first axis, you have to proceed to the linearization of the second axis. 6.2 I/O Affectation This menu is used to affect the different types of alarms to the internal relays of the LDS. Global Alarm Output: All the Alarms activate the relay. No Wire Alarm Output: Without wire in the field of the sensor the relay is activated. Spool Full Alarm Output: When the length of the spool is equal to the Set spool length (see section set spool length ) the relay is activated. RS232 Controlled Output: The relay is activated by the PC through the serial link. Diameter Alarm Output: When the diameter is out of the diameter limits, the relay is activated. Speed Alarm Output: When the speed exceeds the speed limits, the relay is activated. 16

6.3 Serial link Setting Here are the default values for Serial Link communication 6.4 Sensor Address Change the communication Sensor Address, this address is loaded inside the Sensor. 6.5 Exposure time This function adjusts the laser intensity. Be careful with this function, in case of wrong value, the LDS may not work correctly. 6.6 Load Factory data Load the initial data factory in the LDS Memory. The previous values are lost. 17

7. Accessories selection Go to Session/Sensor configuration to choose your accessory. (Foot pedal or WSR) Choose the accessory you want to use 18

8. WSR accessory 8.1 WSR use First Consideration : To measure the ovality of a wire, it is necessary to do a half turn. To start the measure the user needs to do a quarter turn (for synchronization) and during the next half turn the LDSN measures the diameters at maximum frequency. The half turn is divided into 16 equal angle sections (180 /16 = 11.25 ) by a coder in order to track the angular position of the measures and to restitute the exact shape and average diameter independently of the rotation speed. Nevertheless this manual rotation should be as regular as possible. Within one angular division the maximum number of measures is 15. For every division, the software computes the average measure. After the half turn the average diameter of the wires is computed with the 16 division averaged measures. The Maximum number of measures in a half turn is 240 (16 angles x 15 measures). It is currently between 60 and 100. 60 measures give already a perfect resolution of the wire shape. 8.2 WSR window 19

Measurement chart: This chart displays the diameter vs the rotation angle. The 16 sectors are displayed by vertical black lines. The horizontal green line represents the diameter average. Red square dots: they show the rejected measures because of wrong signal (bad surface, dirty wire, wrong tension or alignment). These dots appear at the bottom of the graph. This shows where wrong measures are located due to defective surface quality. Measurement results: - Average, Max, Min, Ovality, Roundsness Total Points : This data results from the computing of the measures Measurements table: All measurement results can be continuously saved inside a file. The file is.wss extension type. You can easily import these file by using Excel Software. Recording status : On the right side of the Continue File button is displayed the recording status, it can be Recording or Not recording If status is Recording, then is displayed the full path of the.wss file. Important: If the status is recording, it means that the opened file is always updated. For example, if you erase the last group, it will be deleted on the screen and also in the file. The screen and the file contain always the same information. New File: By pushing on this button, you will create a new.wss empty file. The Recording status becomes Recording. From this time, all data will be store in this new file. Continue File: By pushing on this button, you will select an existing.wss file. You will be able to store new data at the queue of the existing data in the file. The Recording status becomes Recording. From this time, all data will be store in this existing file. Close File : By pushing on this button, you will close the opened file. The recording status becomes Not recording Measurement reports: - Title, Memo : Those fields are used for adding comments on the measures. They are part of the record. - Load, Save : All the data resulting from the measures on a wire can be saved on the hard disk of the PC with the Save File command. It is possible to load and display the contents of a file from the hard disk with the Load File command. 20

- Print: This command sends the report to the default printer. (See below) - Clear Memo: This command is used to clear the memo and title field. When saving a file a second time, with memo changed, you have to change the file name. You cannot replace one file already recorded. 21

8.3 Label Printer with WSR For label sizes and format, please refer to the LDS user s manual Some labels can contain a serial number composed by a string (serial number prefix) of 3 characters maximum and an incremental number (maximum 99999). Example : Serial number When you push on Valid button, these 2 data referring to the serial number are stored into the LDS memory. There is 2 ways to use the Label printer with WSR: (refer to the User s manual for the electric connection) The label printer and the LDS with WSR are both connected to the computer: In this case the WSR is plugged on the LDS. The LDS and the Label printer are both connected to the PC to 2 different communications ports. Before to use the printer, you have to configure the communication port of the LP in the serial link setting menu. To print the label, you have to use the Print on LP button on the WSR screen of LSONE. The counter will be incremented each time you finish a turn and you launch the label printing (2 conditions required).. The current serial number is permanently stored in the LDS memory even if the LDS power supply is turn off. The label printer is directly connected to the LDS with WSR : In this case the WSR is plugged on the LDS and the Label printer is directly connected to the LDS communication port, and then the PC is not used. You use this PC menu only to set the serial number. When this operation is done, you have to follow these instructions : 22

Close the LSONE software. Disconnect the RS232 cable from the computer and connect it to the LP interface cable (refer to the LDS user s manual). To print the label, you have to push 3 seconds on the red button placed on the WSR.. The counter will be incremented each time you finish a turn and you launch the label printing (2 conditions required).. The current serial number is permanently stored in the LDS memory even if the LDS power supply is turn off. 9. Foot Pedal accessory 9.1 Specification of the application The foot pedal is used as an interface for the operator. One short push (<2 sec) on the foot pedal will store the current diameter in the LDS memory. You can store until 99 diameters. One long push (> 2 sec) will close the diameter group, and then the equipment will compute statistics on this group. 9.2 Diameters table : Each time the operator pushes a short time (<2 sec) on the foot pedal, a diameter is added to the Diameters table. This table shows always the diameters of the last group. When the operator wants to close the group, he pushes a long time on the pedal. One group can contain from 1 to 99 diameters. 23

9.3 Group table : When the group is closed, the statistics are computed and displayed, and then the operator can start to store a new group of diameters. Each line in the Group statistics contains the statistics data of one group. If you double click on a line, then, in the Diameter table are displayed all diameters of the selected group. You can click on Erase last group if you are not satisfied with the last group results. 9.4 Statistics results: Date and Time: It is the date and the time of the computer when the operator closes the group (long pulse on the pedal). Average: It is the average diameter of the whole group. Minimum and Maximum are the extremes diameters of the group. Difference is equal to Maximum - Minimum. Standard deviation. Here below is the formula used to compute the standard deviation of the group : ( Average φ i)² Std = Nb in the group. with φ : each diameter of the group and Nb : number of diameter Number: It is the total number of diameters in the group. 9.5 Record to file use All data can be continuously saved inside a file. The file is.fp extension type. You can easily import these file by using Excel Software. Recording status : On the right side of the Continue File button is displayed the recording status, it can be Recording or Not recording If status is Recording, then is displayed the full path of the.fp file. Important: If the status is recording, it means that the opened file is always updated. For example, if you erase the last group, it will be deleted on the screen and also in the file. The screen and the file contain always the same information. New File: By pushing on this button, you will create a new.fp empty file. The Recording status becomes Recording. From this time, all data will be store in this new file. 24

Continue File: By pushing on this button, you will select an existing.fp file. You will be able to store new data at the queue of the existing data in the file. The Recording status becomes Recording. From this time, all data will be store in this existing file. Close File: By pushing on this button, you will close the opened file. The recording status becomes Not recording 9.6 Use the Label Printer with the Foot pedal: If you want to use the Label Printer, in this case the LDS and the Label printer are both connected to the PC to 2 different communications ports. Please refer to the user s manual for the electronic connection. Before to use the printer, you have to configure the communication port of the LP in the serial link setting menu. If you cross Automatic print, each time a group is closed, a label with statistics results is printed. If you want to print it manually, you have to click on Print last group. 25

10. PORTABLE 10.1 Portable Menu Activation To use the specifically Portable Menu PC-Software, your equipment needs to have the Portable option. 10.2 Sensor Configuration - Recording Automatic Stop : When this function is enabled the sensor stops the recording of the measure in the sensor memory and also stops the statistic calculation when the number of the measures is equal to the programmed number of measures. - If you disable the Recording Automatic Stop, you decide by pressing the portable button (see user s manual) when you stop to record the measures and also to compute the statistics. You can compute the statistics the time you like, but the maximum number of measures stored in memory cannot exceed 200 per machine. - Number of Measures (1 to 200) : When the recording automatic function is enabled, enter the number of measures to be recorded in the sensor memory. - Inches : Cross this box if you want to change the standard (µm) unit system to Mil. All measurement values and parameters in the software and on the local display will be converted in Mil (milli-inches). If your LDS is equipped with a unit-switch, the above function is not available. The mechanical switch is priority. - Sensor Model: Model of the Sensor (LDS2000 or LDS650 or LPS) - Version: Software Version of the Sensor - CCd Type: Type of CCD in the Sensor 26

10.3 Data Transfer Menu Into Excel File Caution : To use the Excel data transfer function, it is necessary to install the software Microsoft Excel on your computer. With the Portable option for each machine, in line, the following data s will be stored in the memory: the mean value of the diameter the max value of the diameter the min value of the diameter the standard deviation the number of measures during the recording The user can transfer the data from the sensor to the PC in the Excel file. Open Button: Open the Excel file in which the data will be saved. Caution : You have to use a model file to transfer the data s. You will find a file named Master LDS microns.xls in the data directory. Keep this file and never modify it. You have to Save as the file with a new name and use this new file to transfer the data s Save As Button: Save the Excel file with a new file name Save Button: Save the Excel file 27

Data Transfer Button: Transfer the data from the sensor to the PC (Before, it is necessary to open an Excel file) Close Button: Close the application During the data transfer, the PC software automatically creates new Excel sheets for the new machines. The recorded data are sorted by date in the Excel file. The diameter and standard deviation charts are updated at each transfer. Example of data transfer into Excel File with 5 machines (1 sheet per machine): 28

Into Txt File The interest to transfer the data s in a txt file is that all the measures will be transfer. It is not the case with the excel transfer where you find only the statistics and not all the measures. Save the Txt file into the new file name. The data has an ASCII format as following. N;yyyy;mm;dd;hh;mm;ss;Average;Min;Max;Std;Nb_measure;m1;...;mn <CR><LF> N Number of the line (Machine) yyyy;mm;dd;hh;mm;ss Average Average diameter during the acquisition (statistics) x 100 µm Min Min Diameter during the statistic acquisition x 100 µm Max Max Diameter during the statistic acquisition x 100 µm Date and time of the acquisition (year-month-day hour:min:sec) Std Standard deviation during the statistic acquisition x 100 µm Nb_measure Number of measure during the statistic acquisition m1;...;mn The measures (mn max = 200 ) <CR> The carriage return The line feed <LF> ; The data separation This text file can be imported with your Excel software, in this case choose the separator ; to import the data. 10.4 Data Reset Erase all the measure data in the sensor memory. Before this action, ensure that all your data has been transferred into the Excel file or into the Txt file. 29

11. LOADER This section gives you the instructions on how to upgrade the LDS embedded software. If CERSA has to send you a new version of the LDS embedded software, follow next instructions. 1. Copy the new file.out into the c:\program files\cersa\lsone\loader directory (default directory) or your specific directory if different. 2. Connect the LDS to the PC with the RS232 serial cable. Ensure that the power supply and the serial link cables are properly connected. Caution: DURING THE WHOLE LOADING TIME DO NOT DISCONNECT THE LDSN. AN INTERRUPTION OF THE LOADING PROCESS COULD LEAD TO MISWORK AND YOU WOULD HAVE TO SEND THE INSTRUMENT BACK TO CERSA-MCI, THIS WORK IS NOT INCLUDED IN THE WARRANTY. 3. Execute the loader command in the LSONE menu 4. Click on Open Configuration menu of the Flash Loader software. Select the loading configuration file.cfg in the LSONE/loader folder. Depending of your equipment (Standard LDS, Portable LDS or Oscillating LDS), please choose the adapted file. 30

5. Execute the Start Loading command «Start Loading» command 6. After a few seconds, when the loading is finished, you have this screen updated and ready for use. State counter of Loading «Abort Loading» command During all the time of the loading, the State counter is increasing. When the loading is finished, the value of this counter is equal to 100%. 7. Return to the LSONE main menu by selecting Abort Loading, and switch off and again on the LDS. 31