Manual. Line Sensor FZS 1024

Transcription

1 Manual Line Sensor FZS 1024

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3 Manual Line Sensor FZS 1024 SensoPart Industriesensorik GmbH, Am Wiedenbach 1, D Wieden, Telphone ( ) , Telefax ( ) E /00 Printed in Germany

4 Contents 1. Introduction Detection range Dynamic processes Lens assembly Equipment assembly For transmitted light mode For incident light mode Connection Putting into operation For transmitted light mode For incident ligth mode If something does not work Oscillograph intensity profile Protective tube Cleaning 9-1 Appendix A Intermediate ring dimension and working distance A-1 B Operating and adjustment modes B-1 C Exposure time measuring repetition rate C-1 D Function indicator and message output D-1 E Assembly aids E-1 F Technical data F-1 G Connector pin assignment IN/OUT G-1 H Connecting cable D7 H-1 I Ordering data I-1 J Lightings J-1

5 FZS Introduction Introduction The line sensor is used for the optical detection of edges for identification and process monitoring. The illuminated object level is projected onto a light-sensitive line (CCD line, Charge Coupled Device) with a camera lens. Detected edges are filtered by the selectable signal decoding. The position of the selected edge(s) is available as a current or voltage value at the analog output. The focal length of the lens and the distance between the device and the object plane determine the measuring accuracy. The f-stop setting can be used to adapt to lighting conditions. On our website you can download a program which helps you to select the right accessories. 1.1 Detection Range detection width b object plane working distance s a tan a/2 = b/2 s detection range image width image plane 14.3mm (1024 pixels x 14µm) Detection width: The range of the object plane projected onto the CCD line. The detection width b depends on the aperture a of the lens and the working distance s. Resolution: In the image plane, the smallest detectable measured value difference is one pixel (14µm). In the object plane the resolution a 1024th of the detection range. Objects are therefore resolved with 0.1% of the detection width.

6 Introduction FZS Dynamic Processes The resolution of objects moving in advance direction is determined by the exposure time of the line sensor. The exposure time is the time after which the readout procedure of the CCD line is repeated. Example: As shown in the diagram, a toothing is to be checked for completeness. At a transport speed of 140 m/min, the tooth and gap can only be detected reliably when the distance covered during a readout process of the CCD line is smaller than 20 mm. The exposure time must then be smaller than 8.6 ms. v : transport speed b : detection width bi : measured length 20mm 20mm v = 140m/min Idealized time behaviour of the measuring voltage Uout of the line sensor Uout b1 b2 b Umax U2 U1 t Line Sensor FZS 1024

7 FZS Lens Assembly Lens Assembly Line sensor, lens and any necessary intermediate rings are packed separately. Make sure first that you have all the components you require for your application. Assembly includes the following steps: 1. Pull out the sealing plug from the line sensor. 2. Check that the CCD line is clean and dust-free. To do this, wipe the glass of the line with a soft, dry cloth or a cotton wool bud. Make sure no grease film or lint or even scratches are left behind. 3. Remove the protective cap from the lens on the device side. Unscrew the intermediate rings with thread if available. Rings without thread are placed between the screwed rings. 4. Screw the lens onto the line sensor with intermediate rings. Z1 Z2 Z Z4 Z5 Intermediate ring dimension Z: = Z1 + Z2 + Z3 + Z4 + Z5

8 Equipment Assembly FZS Equipment Assembly The light-sensitive line is arranged in the direction in which the rear panel labelling can be read. The position of the equipment and the lighting must therefore be adapted to the task at hand. 3.1 For Transmitted Light Mode reading direction fluorescent tube working distance detection width detection range line sensor intensity intensity profile of the CCD line site 1. Select the working distance Maximum working distance: Given by the required resolution in the detection width Minimum working distance: Given by the minimum lens distance of the MOD lens (including intermediate rings) 2. Pre-assembly of the line sensor at the selected working distance.

9 FZS Equipment Assembly Pre-assembly of the lighting Maximum distance: Given by the angle of detection and the maximum useful length of the lighting. This corresponds to approx. 70% of the tube length for fluorescent tubes on account of the diminishing intensity towards the end of the tube. Minimum distance: Given by the working distance Please note:! - The lighting must be parallel to the line and ideally symmetrical in the detection range. - The tube manufacturer s labelling must be outside the detection range or set back. 3.2 For Incident Light Mode reading direction detection width working distance detection range fluorescent tube line sensor intensity site

10 Equipment Assembly FZS Select the working distance Maximum working distance: Given by the required resolution in the detection width Minimum working distance: Given by the minimum lens distance of the MOD lens (including intermediate rings) and the necessary arrangement with lighting. 2. Pre-assembly of the line sensor and the lighting For incident light mode, the operational reliability of the setup depends on the position of the lighting and line sensor in relation to the object level. working distance diffuse reflection targeted reflection The light-sensitive line must always be parallel to the object plane. If you are using a fluorescent tube for lighting you will get a targeted reflection. The proportion of the targeted reflection depends on the surface nature of the object. It is greater, the stronger the object reflects (e.g. painted surfaces, foils). Avoid evaluating targeted reflections! Select a setup in which largely diffuse reflection reaches the line sensor. Although this requires a smaller f-stop number and a longer exposure time under some circumstances, the setup is less sensitive.

11 FZS Connection Connection Please note:! - The line lengths between the tubes and the ballast may not be longer than 1 m if the ballast is mounted separately from the fluorescent tube for a tube lighting. - The connecting cable of the line sensor must be laid separately from the lines to the fluorescent tubes.

12 Putting Into Operation FZS Putting Into Operation If you use a fluorescent tube for lighting, this must have been in operation for at least three minutes before the line sensor is put into operation. The fluorescent tube reaches its stable operating state in this time. SENSOPART FZS 1024 display, 40 LEDs function indicator modes, exposure time Function Mode ExposureTime switch cover connection, 7-pole IN/OUT RS For Transmitted Light Mode 1. Remove the protective cap from the lens. 2. Remove the switch cover on the back of the unit. 3. Set the minimum exposure time by turning the Exposure Time switch to the 0 position (cf. appendix C). 4. Mode 7, Setting : Set mode 7 by turning the mode switch to position 7 or by applying High signal to the digital input (plug pin 5). 5. Set f-stop 4 on the lens.

13 FZS Putting Into Operation Aligning the arrangement The lighting and line sensor are positioned correctly when the free part of the lighting is shown and indicated on the display. If this is not the case, the lighting and the light sensitive line are not parallel. The arrangement must be adjusted. The position of the detection width and the subsequent correction to the lighting or line sensor can be determined by a test object (any non-transparent object). Display in mode 7: The left third of the CCD line is not lit Position of the CCD line If there is no display, you have to increase the exposure time at the smallest f-number until the function indicator lights up in orange. The maximum possible exposure time for the application is given by the necessary minimum measuring repetition rate (cf. Appendix C). 7. Correction of the f-stop until the function indictor changes from orange to green. 8. Check the position of the detection range and mount the arrangement permanently. 9. Position the object at the working distance if you have not already done so. 10. Mode 6, set Focussing - The digital input (plug pin 5) must be switched to High level here. - The function indicator must light green. If it is red, no adequate contrast is available for the focussing mode, the f-stop must be adjusted in mode 7. - The first body edge detected by the line sensor is checked for focus. The narrower the display the sharper the edge is projected.

14 Putting Into Operation FZS Checking the choice of intermediate rings Intermediate rings are required at a working distance below the minimum object distance (MOD) specified by the lens. The necessary intermediate ring dimension and the recommended intermediate rings can be taken from the tables in appendix A. Check the intermediate ring dimension given by the available intermediate rings, if applicable, by turning the focussing ring of the lens from infinite to MOD. Watch the display: a) The display lights up along the full length -> The working distance is not in the focussable working range. The intermediate ring dimension must be adapted to the working distance (cf. appendix A). b) The bar only gets smaller -> The intermediate ring dimension must be increased c) The bar only gets bigger -> The intermediate ring dimension must be reduced d) The display runs through a minimum -> The choice of intermediate rings is correct 12. Focus by turning the lens focussing ring to minimum display 13. Check the f-stop setting In lenses with a long focal length in particular, the aperture ratios of the lens are influenced by the lens position and the position of the focussing ring. The f-stop setting therefore needs to be checked after focussing. Switch to mode 7 (on mode switch or High to input) and check the f-stop setting. The setting is correct when the function indicator lights green. 14. Set the operating mode (cf. appendix B) 15. Screw on the switch cover

15 FZS Putting Into Operation For Incident Light Mode 1. Remove the lens cap 2. Remove the switch cover on the back of the unit 3. Set the max. exposure time by turning the Exposure Time switch to position 7 (cf. appendix C) 4. Mode 7, Setting : Set mode 7 by turning the mode switch to position 7 or applying High signal to the digital input (plug pin 5) 5. Set lens f-stop for green function indicator 6. Align the arrangement The position of the lighting and the line sensor determine the detectable and displayable edges. Optimize the arrangement set up in pre-assembly. 7. Secure the position of the line sensor 8. Set mode 6, Focussing - The digital input (plug pin 5) must be switched to Low level here. In mode 6 the function indicator must light up green. If it is red, the available contrast is inadequate for displaying the state of focus in the display. You can improve this by turning the focus ring. If you still do not get a green light we recommend that you use a test object for the subsequent steps which enables sufficient contrast thanks to its colour and the nature of its surface. - When the function indicator is green, the first body edge detected by the line sensor is examined for focus. The narrower the display, the sharper the edge is projected. 9. Checking the choice of intermediate rings Intermediate rings are required at a working distance below the minimum object distance (MOD) specified by the lens. The necessary intermediate ring dimension and the recommended intermediate rings can be taken from the tables in appendix A. Check the intermediate ring dimension given by the available intermediate rings, if applicable, by turning the focussing ring of the lens from infinite to MOD. Watch the display:

16 Putting Into Operation FZS 1024 a) The display lights up along the full length -> The working distance is not in the focussable working range. The intermediate ring dimension must be adapted to the working distance (cf. appendix A). b) The bar only gets smaller -> The intermediate ring dimension must be increased c) The bar only gets bigger -> The intermediate ring dimension must be reduced d) The display runs through a minimum -> The choice of intermediate rings is correct 12. Focus by turning the lens focussing ring to minimum display. 13. Set mode Set the maximum permissible exposure time. The exposure time to be set is given by the required minimum measuring repetition rate (cf. appendix C) 15. Correct the f-stop until the function indicator changes from orange to green. If the intensity is inadequate at the required exposure time (red function indicator) you will have to make corrections: - Optimize the arrangement - Increase the lighting efficiency - Use a stronger lens We recommend you to monitor appropriate measures by oscillographing the intensity profile. The signal of the CCD line is available at pin 2 of the unit plug for this purpose. 16. Secure the position of the lighting 17. Set the operating mode 18. Screw on the switch cover

17 FZS If Something Does Not Work If Something Does Not Work 1. The unit reacts to an edge although there is no object in the detection range: - dust on the line, clean the line - inhomogeneities in the lighting 2. Insufficient focus In transmitted light mode the edge of the body is projected out of focus due to allround radiation of the object. - increase the distance of the lighting from the object - rounded edges (pipes, wire) cannot be set sharper 3. For partially transparent objects (foil, glass) the contrast is inadequate in transmitted light mode - use lighting with a higher absorbent wavelength (UV or IR) 4. In mode 7 the function indicator reacts oversensitively to f-stop adjustment especially in transmitted light mode - place a diffusor in front of the lighting (e.g. Delrin, 2 mm thick) - use lens grey filter - use a weaker lens 5. Modes cannot be set - High level at the digital input switches the unit to mode 7 and locks the Mode switch. Low level releases the switch again.

18 Oscillographing the Intensity Profile FZS Oscillographing the Intensity Profile Monitoring of the intensity profile of the CCD line can be of great advantage particularly for critical tasks in incident light mode. The signal is available at pin 2 of the unit plug for oscillographing. Please note: - The CCD signal may not be carried with the synchronisation signal on one line - The CCD signal line should be as short as possible - The synchronisation signal can be used for triggering - The output is not designed for supplying loads!

19 FZS Protective Tube Protective Tube The protective tube protects the tube accoring to protection class IP65. In addition, it locks the setting on the lens. It is delivered complete with O-ring for sealing the line sensor housing. The protective glass is available as a spare part. Screw-on ring Glass Tube O-ring Flat seal FZS 1024 Protective tube 55: Tube length 55 mm, for lenses 1.8/12.5 and 1.8/25, incl. any necessary intermediate rings Protective tube 75: Tube length 75 mm, for lens 1.8/50, incl. any necessary intermediate rings

20 9-1 Cleaning FZS Cleaning Use a cloth soaked in white spirit to clean the housing and the lens. Clean the lens glass with a damp cotton wool bud only. Make sure you do not scratch the lens or leave a film of grease on it. Never clean the unit with organic solvents. A protective tube is recommended to protect the lens from getting dirty. The plain surface of the protective glass makes cleaning easier. We recommend that you blow the protective glass with compressed air in a humid environment or in the event of spray water.!

21 FZS 1024 A: Intermediate Ring Dimension and Working Distance A-1 1. Lens 1.8/12.5 (MOD=400mm) Intermediate ring dimension Working distance z / mm s* / mm recommended intermediate ring types , x0,5mm x1mm 1, x0,5mm; 1x1mm x1mm 2. Lens 1.8/25 (MOD=500mm) Intermediate ring dimension Working distance z / mm s* / mm recommended intermediate ring types x1mm x1mm x5mm 3. Lens 1.8/50 (MOD=1000mm) Intermediate ring dimension Working distance z / mm s* / mm recommended intermediate ring types x1mm x5mm x5mm; 2x1mm x5mm x5mm; 2x1mm x10mm; 1x5mm * The range focussable by the specified working distance s depends on the depth of focus and the f-stop setting.

22 B-1 B: Operating and Adjustment Modes FZS 1024 Modes reading direction fluorescent tube left direction edge postion of the detection width right detection edge intensity profile of the CCD line site display dependent on set mode x w z y Mode Description Measured value 0 range between the first falling and the next rising edge length w 1 range between the first rising and the next falling edge length x 2 from the left detection edge to the first falling edge length y 3 from the left detection edge to the first rising edge length z falling edge: change from light to dark in reading direction rising edge: change from dark to light in reading direction reading direction: from left to right on the display

23 FZS 1024 B: Operating and Adjustment Modes B-2 Mode 4: Count parts, max. 100 edge pairs reading direction fluorescent tube left detection edge position of the detection width right detection edge intensity profile of the CCD line site display: edge pairs: Output signal in FZS 1024 U:Uout = 0.4 V for 4 edge pairs (corresponds to 10V for 100 edge pairs) The parts (objects or holes) to be counted must be fully in the detection range independently of the operating mode (incident or transmitted light mode).

24 B-3 B: Operating and Adjustment Modes FZS 1024 Mode 5: Position of the part centre nominal position of the part centre reading direction fluorescent tube left detection edge right detection edge detection width intensity profile of the CCD line site part centre: display:

25 FZS 1024 B: Operating and Adjustment Modes B-4 Mode 6: Focussing reading direction detection width object plane working distance image width focussing image plane first edge in reading direction intensity profile of the CCD line display in Mode 7: setting reading direction display in Mode 6: focussing first edge out of focus first edge in focus, ideally only two LEDs light up The lens is set in focus when the displayed bar has minimum width.

26 B-5 B: Operating and Adjustment Modes FZS 1024 Mode 7: Setting Mode 7 can be set both with the Mode switch and by High signal at the digital input (plug pin 5). The measuring output is then at 0% irrespective of what is happening in the detection range. The display and function indicator have the following tasks in this mode: Display: All the edges in the detection range are displayed. This simplifies alignment. Function indicator: The 3 colour LED indicates the lighting intensity of the CCD line. Function Description Message Remedy indicator output orange The lighting intensity is too high Low - Close aperture for at least one pixel. The line is - Reduce exposure time overmodulated. - Use lens grey filter green The lighting intensity is adequate High for at least one pixel. red None of the 1024 pixels is Low - Open aperture adequately lighted. - Optimise arrangement - Lengthen exposure time if possible - Use stronger lens - Increase the lighting efficiency

27 FZS 1024 C: Exposure Time and Measuring Repetition Rate C-1 Exposure time The intensity profile of the CCD line is read out cyclically. Whilst the readout time is fixed at 1 ms, the time of the subsequent readout procedures is selectable. Exposure time: The time after which the readout procedure is repeated. Measuring repetition rate: Reversal value of the exposure time or the number of measurements per second te1 tr tp1 te2 tr tp2 te: exposure time tr: readout time tr = 1 ms, constant tp: pause time The exposure time is set at the Exposure Time rotary switch. Exposure Time Exposure Time Measuring repetition rate switch position te / ms 1 / s

28 D-1 D: Function Indicator and Message Output FZS 1024 Function Indicator and Message Output Mode Meas. output Function indicator Message output Meaning % green High necessary edges 3 available 4 1% je Teil red Low at least one edge missing % 6 0% green High sufficient contrast available red Low contrast inadequate 7 0% orange Low CCD line overmodulated green High lighting intensity correct red Low lighting intensity inadequate

29 FZS 1024 E: Assembly Aids E-1 Angle Bracket 01 - For assembly in direction of the T-groove of the FZS With elongated holes for setting the unit position - M8 screw connection enables assembly with standard aluminium section systems material: die-cast aluminium

30 E-2 E: Assembly Aids FZS 1024 Angle bracket 02 - Assembly transversely to the T-groove of the FZS With elongated holes for setting the unit position - M8 screw connection enables assembly with standard aluminium section systems material: die-cast aluminium

31 FZS 1024 E: Assembly Aids E-3 Joint 01 - Can be assembled with rotary axis in direction of the groove or transversely to the groove - M8 screw connection enables assembly with standard aluminium section systems

32 F-1 F: Technical Data FZS 1024 Technical Data Operating voltage UB: VDC Max. residual ripple: 10% Reverse polarity protection: yes Current consumption in no-load: 80 ma at UB = 24V Standby delay: < 1s Measuring repetition rate: max /s Casing: Casing material: Protection class: Weight: Fixing: Lens connection: Connection type: Ambient temperature range: Storage temperature range: Measuring output: Voltage output: Current output (optional): see drawing aluminium, black anodized IP65/IP50, with/without protective tube 500 g (without lens) 2 T-grooves C mount 7-pin round connector 0 C C -40 C C V; 9.76mV/pixel; max. 10A mA; mA/pixel: max. 500ohms Digital outputs: Switching output Short-circuit protection: Voltage drop at switching output: Pulldown resistor: Output 1: synchronisation pulse: Output 2: message output: PNP (SP) max. 100 ma yes <2.4 V at IL = 100 ma 22 kohm tp=1, 1ms, T= exposure time reports High for correct setting Input: Switching input: Low= -15 to +7V; High = +15 to +28V, max. 5A Input function: remote control of mode 7 CCD line: relative sensitivity: max. sensitivity: sensitive range: pixel size: Lenses: Format: Connection: Equipment: >50% between nm 600 nm 14.3 x mm 14 mm x 14 mm 1", max. diagonal 16 mm C mount fixed focal length, manual aperture

33 FZS 1024 F: Technical Data F-2 Dimensions

34 G-1 G: Connector Pin Assignment IN/OUT FZS 1024 Connector Pin Assignment IN/OUT Synchronous output 2 Intensity profile of the CCD line (only for service with oscilloscopes) 3 UB+ (24V) 4 UB- (0V) 5 Input (remote control of mode 7) 6 Message output for correct setting 7 Message output (0...10V or mA)

35 FZS 1024 H: Connecting Cable D7 H-1 Connecting cable D coupling socket, 7-pin Cable: LiYCY, screened Stranded wire structure: 7 x 0.25 mm 2 Protection class: IP65 Line length: 5 m Ambient temperature range: C Storage temperature range: C Connector pin assignment Pin Wire Function 1 grey synchronous output brown UB+ (24V) 4 blue UB- (0V) 5 yellow input (remote control of mode 7) 6 green message output for correct setting 7 pink message output 4 white 0V message output - screen PE Bestelldaten Name Technical data Order number Coupling socket, 7-pin IP Connecting cable D7 7-pin, PVC sheath, 5m (incl. coupling socket)

36 I-1 I: Ordering data FZS 1024 Line sensor FZS 1024 Meas. output Type Order number V FZS 1024 U mA FZS 1024 I CCTV- Lenses (C-mount) Focal length Light intensity Type Order number 12,5mm 1,8 Lens 1,8/12, mm 1,8 Lens 1,8/ mm 1,8 Lens 1,8/ Lenses with other focal length or light intensity on request Intermediate rings Length Version Type Order number 0,5mm without thread intermediate ring 0, mm without thread intermediate ring mm with thread intermediate ring mm with thread intermediate ring x0,5; 2x1; 1x5; 1x10mm intermediate ring set Protective tubes, for lens protection (IP65) Dimensions Assembly Type Order number Ø61 x 55 M56 x 1 Protective tube 55** Ø61 x 75 M56 x 1 Protective tube 75** Substitute glass panel diam. Ø54.5 x 2mm ** complete with glass panel and seals Assembly material Name Technical data Order number Angle bracket 01, 68 x 68 x 28mm, Al for longitudinal assembly Angle bracket 02, 68 x 68 x 68mm, Al for transverse assembly Joint x 40 x 40mm, Al Manual FZS Power supply units up to 2A on request

37 FZS 1024 I-2

38 J-1 J: Lightings FZS 1024 Lightings: Versions LZS HL LZS LZS LZS * LZS * LZS LZS *

39 Type Useful area Dimensions Operating Lighting Protection Order number mm mm voltage medium class LZS HL x x 40 x 22 24V DC LED-Zeile IP Kabel 2m rot, 660nm LZS Ø16 x 200 Ø60 x V AC TL 8W/33 IP LZS Ø16 x 360 Ø60 x V AC TL 13W/33 IP LZS * Ø26 x x 45 x V DC TL 18W/25 IP LZS * Ø26 x x 45 x V AC TL 18W/25 IP LZS Ø26 x 420 Ø70 x V AC TL 18W/25 IP LZS * Ø26 x x 45 x V DC TL 36W/25 IP Holding clip diam. Ø60: Holding clip diam. Ø70: * mounting rail included Lightings: Technical Data FZS 1024 J: Lightings J-2

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