NEW. Very high-speed profile measurement for industrial in line applications. 2D/3D profile sensor SENSORS & SYSTEMS

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1 SENSORS & SYSTEMS SENSORS & SYSTEMS By far the better solution PRINCIPLE NEW LLT28 Very high-speed profile measurement for industrial in line applications. High accuracy and very high frame frequency thanks to - innovative CMOS-technology - high-performance signal processing unit - flexible field of view 2D/3D profile sensor scancontrol 28

2 LLT 28 2D/3D Laser-Line Triangulation Measuring principle The laser-line profile sensor scancontrol 28 makes use of the triangulation principle for two-dimensional acquisition of profiles on the most varied target surfaces. In contrast to familiar point laser sensors, a line optical system projects a laser line onto the surface of the object to be measured. The back scattered light from the laser line is registered on a CMOS array by a high quality optical system. Along with distance information (z-axis), the controller also computes the true position along the laser line (x-axis) from the camera image and outputs both values in the sensor twodimensional coordinate system. A moving object or a scanning sensor will genera-te threedimensional representation of the object. Measuring principle x-axis z-axis CMOS array target System configuration scancontrol consists of a compact sensor and an intelligent controller connected together via cable of variable length. The controller outputs measurement raw data computed from both axes (standard) as well as related values of geometrical features (optional). Thanks to its exceptional speed of measuring and real time data output synchronisation scancontrol is not limited in its applications and is ideally suited for industrial in line inspection. The integrated FireWire interface enables scancontrol to be fully controlled from a PC, while insuring high data output rates and simultaneously preserving the bandwidth. Integrated via a PCI card in the bus system, FireWire also facilitates control of several scancon- TROL systems from one PC. light source receiver target Three ways of creating the application: PC solutions with the customer's own software (C++ library included in supplied items). PC solutions with the ICONNECT modular software with ready-made standard modules for control and evaluation. Integrated software packages (optional) in the digital signal processor (DSP) of the controller. Sensor LLT 28 Controller LLT 28 2

3 Special performance features scancontrol has been developed for industrial applications. In this respect, innovative technologies are employed through which the functionality of the system and adaptability to different applications are substantially increased. Synchronous measurement through synchronous illumination scancontrol uses an innovative CMOS array with a global, electronic shutter (high speed shutter) instead of a "rolling shutter" used in conventional scanners. Measurement therefore occurs synchronously along the laser line, thus eliminating any distortion of the measurement image due to scanning. The shutter can in addition be controlled in real time via an external trigger input (on the controller). The additional trigger input eases synchronizing several scancontrol systems together. The real time shutter renders the measurement system nearly independent of scanning or object displacement speed and acceleration. This is an important advantage in achieving short throughput times, particularly in automation where varying acceleration levels often occur in processes. Conventional line scanner with "rolling shutter" measurement process laser line target scancontrol with high speed shutter t output data distorted image Innovative high performance CMOS array A specially developed high performance CMOS array supports the illumination of the next image while the current image is still being read out. This means that for the same laser class higher measuring frequencies are achieved even with shiny or strongly absorbing surfaces. Conventional scanner Illumination Read Out Processing Illumination Read Out Processing Conventional scanners only execute one processing step per unit of time. With scancontrol the innovative CMOS array ensures, in conjunction with specially optimized hardware, time-synchronous processing of individual steps. This enables a substantially higher data acquisition and processing rate than with normal scanners. Flexible measuring field scancontrol Proc. Proc. Proc. Proc. Proc. Proc. Read Read Read Read Read Read Illu. Illu. Illu. Illu. Illu. Illu. t According to application, user may parameter the sensor privileging either data acquisition speed or width and/or depth of measuring field. The sole limit is acquisition of a max. of 256, points/sec eg.: user can elect to measure 256 points/profile: at profile frequency of 1 profiles/sec 512 points/profile: at profile frequency of 5 profiles/sec 124 points/profile: at profile frequency of 25 profiles/sec On top of speed and number of points selection, user can also decide width of profile line and depth of measuring field eg.: 512 points over a narrow profile thus increasing lateral resolution (for edge detection) or 256 points over a large profile to increase digitising speed (typical for large surface inspection) or any other combination among 96 possible. Flexible measuring field (examples) t measurement process output data target laser line t identical image The CMOS array active field (where measurement will be taken) can be programmed according to 96 predefined possibilities, eg. using only a portion of the array increases data aquisition speed, selecting the central area increases accuracy. 3

4 LLT 28 Typical Applications Applications scancontrol 28 is designed for applications in industrial environments. High measuring rate and accuracy make the system ideally suited for applications requiring highest precision with short cycle times. scancontrol and ICONNECT The link between the FireWire high speed interface and the MICRO-EPSILON real-time software ICONNECT opens up an unlimited number of possible applications for scancontrol. Using the graphic user interface in ICONNECT, it is very easy for user to generate applications of their own. The modular programming principle allows complex links to be produced with just a mouse click. The real-time capability and high data throughput of ICONNECT supplement and support the high processing speed of scancontrol. Data are recorded, processed and visually displayed in real time, even at the highest scanning rate. ICONNECT can also be used as the real time control software and then acts as a line PLC. Tire profile Tire roundness Tire deformation Edge detection Positioning Height profile Sensor Controller Groove width and depth Robot guidance Coplanarity Deformation Lead position FireWire IEEE 1394 RS232 RS422 Sync-Out, Error, Control Video VSS Gap and flush Door edges Welding seam inspection Glue bead inspection Profile monitoring ICONNECT Visual programming of customerspecific software 4

5 Technical data Model Standard ranges, extended range in brackets (±5%) Measuring range z-axis 25 (55) mm.98" (2.17") 1 (245) mm 3.94" (9.65") Start of measuring range (SMR) 62.5 (5) mm 2.46" (1.96") 145 (115) mm 5.71" (4.53") Reference distance, midrange (MMR) 75 (82.5) mm 2.95" (3.25") 195 (235) mm 7.68" (9.25") End of measuring range (EMR) 87.5 (15) mm 3.44" (4.13") 245 (36) mm 9.65" (14.17") Resolution z-axis *.4% 1 µm 4 µm Linearity z-axis, ±3 * ±.2 % ±5µm ±2µm Measuring range x-axis SMR 13 (23) mm.51" (.91") 3 (5) mm 1.18" (1.97") EMR 18 (41) mm.7" (1.61") 5 (14) mm 1.97" (5.51") Laser aperture angle Resolution x-axis Linearity x-axis, ±3 * Profile frequency Measuring rate Light source Laser class Laser off Permissible ambient light (fluorescent light) Protection class Operating temperature Storage temperature Weight Sensor cable standard length Output analog preprogrammed x- and z-axis, alternative profile parameter ** Output/Input digital Synchron-connector, input *** Synchron-connector, output *** Video signal (test and set up mode) Supply sensor controller sensor controller Interface (measurement data and control commands) LLT / 512 points/profile (124 points/profile)**** ±.4 % SMR 6 µm / EMR 8 µm SMR 12 µm / EMR 2 µm to 1 profiles/s 256, points/s laser diode 655 nm, 15 mw class 2M remote - input and key switch 1, lx IP 64 IP C / F C / F 35 g 4 g 3.5 kg 2m ±1 V (16 bit, up to 15 khz) LLT28-1 3x IEEE 1394 ( FireWire ), 4 MBit/s (similar DCAM 1.3) 1x RS232 (1152 Baud) 1x RS422 (1152 Baud) sync-in, remote laser ON/OFF, mode sync-out, error, user mode (2x) 1V SS (BAS-signal, 8-bit-grey) 24 VDC (±15 %) /.5 A All specifications apply for a diffusely reflecting matt white ceramic target - marginal position tolerance of the measuring-field is possible (sensor depending) SMR = Start Measuring Range EMR = End of Measuring Range * for standard measuring ranges ( 512 points/profile preprogrammed) ** only for preprogrammed data, e.g. gap edge position, gap width, step heigth, angle *** preprogrammed, other function possible **** optional 124 points/profile only in extended range LASER RADIATION CLASS II LASER 2 P 15 mw; E 7 W/m ; =655 nm DO NOT STARE INTO BEAM The laser unit of scancontrol 28 uses a semiconductor laser with a wavelengh of 655 nm ( visible/red) and 15 mw optical output (class 2M). The sensor is classified as laser class 2M. A warning sign is attached to the sensor housing. 5

6 LLT 28 Sensor dimensions scancontrol Dimensions in mm (inch), not to scale (78 (3.7)) WS (2.52) 6.5 (2.38) 59.5 (2.34) 64 (2.52) 59.5 (2.34) mounting holes ø 4.5 mounting holes M4 depth max (.18) 4.5 (.18) 4 (.16) 22 (.87) 4 (1.57) 44 (1.73) 33 (1.3) 22 (.87) 11 (.43) 17.5 (.69) 46.7 (1.84) 72 (2.83) 5 (.2) 38 (1.5) 14 (4.9) 18.5 (4.27) LED laser window ø9 (.35) receiver window 21x18 (.83x.71) 18 (.71) 6 (.24) 3 55 (2.17) 5 (1.97) 62.5 (2.46) 25 (.98) (z-axis) 22 (.87) 3 laser linie 23 (.91) 13 (.51) laser line 5 (1.97) 62.5 (2.46) 55 (2.17) 25 (.98) (z-axis) 17.5 (.69) 48 (1.89) 69 (2.72) 18 (.71) 41 (1.62) standard measuring range extended measuring range Marginal position tolerance of the measuring-field is possible (sensor depending) 6

7 Sensor Dimensions scancontrol 28-1 Dimensions in mm (inch), not to scale ( 78 (3.7)) 64 (2.52) 6.5 (2.38) 59.5 (2.34) WS (2.52) 59.5 (2.34) mounting holes ø 4,5 mouting holes M4 depth max (.18) 4.5 (.18) 22 (.87) 18 (.71) 6 (.24) 115 (4.53) 145 (5.71) 3 laserline 5 (1.97) 3 (1.18) 245 (9.65) 1 (3.94) (z-axis) 245 (9.65) 1 (3.94) (z-axis) 5 (.2) 62 (2.44) 12.5 (4.74) 125 (4.92) 4 (.16) 22 (.87) 4 (1.57) 44 (1.73) 33 (1.3) 22 (.87) 11 (.43) LED laser window ø9 (.35) 17.5 (.69) 72.4 (2.85) laser line 115 (4.53) 145 (5.71) 97.7 (3.85) receiver window 21x18 (.83x.71) (.69) 74 (2.91) 95 (3.74) 5 (1.97) 14 (5.51) standard measuring range extended measuring range Marginal position tolerance of the measuring-field is possible (sensor depending) 7

8 laser off scancontrol 28 Controller Dimensions in mm (inch), not to scale reset 17 (4.21) 15.5 (4.15) on 24VDC mode power on laser on error control mode 1 3 mode 2 sensor RS 232 RS 422 analog video synchron (9.69) 146 (5.75) (7.35) 178 (7.1) 278 (1.94) Typical system includes (standard) - ICONNECT-demonstration software (FireWire interface) - Stand alone demo-software (standard FireWire or serial interface RS232) - C++ library for customer-specific application - IEEE 1394 cable - Calibration certificate Accessories (optional) - Sensor extension cable 3 m or 8 m - Cable analog output - Interface card IEEE ICONNECT modular software MICRO-EPSILON Koenigbacher Strasse Ortenburg / Germany Phone +49/8542/168- Fax +49/8542/168 9 info@micro-epsilon.com USA: 812 Brownleigh Dr. Raleigh, NC / USA Phone +1/919/ Fax +1/919/ me@micro-epsilon.com certified DIN EN ISO 91 :2 modifications reserved Y B215MLO

9 SENSORS & SYSTEMS High speed profile measurement SENSORS & SYSTEMS PRINCIPLE NEW scancontrol 281 The high speed profile sensor High speed measurement up to 4 khz Dynamic detection of the profile Easy setup software Highly flexible for a variety of measurement applications 2D/3D profile sensor scancontrol 281

10 scancontrol 281 Principle and system advantages Application The system scancontrol 281 detects beads (e.g. a seam) or grooves (e.g. a channel or gap) and computes their characteristic dimensions inside the controller. The system evaluates the measurements taken and provides control signals via analog and digital outputs. The system can be easily configured via the parameterization software included with the sensor package. Bead Groove The highest point of a bead has the smallest z-distance value due to scaling from the sensor's viewpoint. The z-distance value is maximum for a groove. Measuring principle High speed real time measurement Due to the high measuring rate of up to 256, measurement points/s, a significant increase in cycle time is achieved in real time quality inspection or online process guidance. Depending on the resolution and size of the measurement range, a profile frequency of up to 4, profiles/s can be attained. Synchronous measurement through synchronous shutter Instead of the conventional "rolling shutters" (reading out line by line), scancontrol has an innovative CMOS array with an instant high speed electronic shutter, which grabs the entire profile and reads out immediately. Flexible measuring field (examples) light source CMOS-array z-axis receiver The CMOS array active field (where measurements will be taken) can be programmed according to 96 predefined possibilities, eg. using only a portion of the array increases data aquisition speed, selecting the central area increases accuracy. target x-axis Measurement principle The laser line scanner scancontrol 281 makes use of the triangulation principle for the two-dimensional acquisition of a profile on various target surfaces. Unlike familiar point laser sensors, a static laser line is projected onto the surface of the measurement object. A high quality optical camera system focusses the diffuse reflected light from this laser line onto a CMOS array. The controller computes the profile data from the camera picture and outputs it as calibrated x/z measurement coordinates. In addition the dimensional properties of the adhesive bead or groove are computed by the controller and transferred to the output. Flexible measurement field Depending on the application, with scancontrol either the data processing rate or the pixel resolution (x or z axis) can be further increased through the variable measurement field. Each second a maximum of 256, points are processed: 64 points/profile: Profile frequency of 4, profiles/s 128 points/profile: Profile frequency of 2, profiles/s 256 points/profile: Profile frequency of 1, profiles/s 512 points/profile: Profile frequency of 5 profiles/s 1,24 points/profile: Profile frequency of 25 profiles/s Apart from the processing rate and the number of measurement points to be read out, the height and width of the measurement field can be adjusted: e.g. 512 points over a narrow measurement strip (e.g. edge detection) or 256 points over a wide strip for high speed applications (e.g. inspection of glue beading). 2

11 Applications scancontrol 281 was specially developed for measurements on beads (buldges, bumps) or grooves (indentations, gaps). It operates in a stationary mode - e.g. a fixed installed sensor unit looking at moving parts - and in the scanning mode - e.g. in conjunction with a motion control device or a robot. The application examples given here are just some of numerous possible applications. Typical applications Welding bead / welding seam Glue bead profile visualisation Gap / joining contact Welding seam inspection Glue bead inspection Profile monitoring Groove width / depth Robot guidance Positioning Door edges Gap and flush Edge detection Height profile Web width Groove width / groove depth Angle measurement Step & height measurement Surface control Planarity Lead-Position Welding bead control 3

12 scancontrol 281 Sequence of profile computation In the following application example, the measurement on an adhesive bead and the possible calculated dimensions are shown. Automatic tracking by an anchor point In order to detect the area of interest within the changes of its position in the X and Z direction an anchor point is specified for the profile. This anchor point serves also as an absolute reference feature to provide the orientation on the target. Therefore the scanning line does not need to be accurately guided in order to follow the bead or groove. This feature allows an easy inspection especially for parts with various radii or very uneven base material. Reference lines for profile computation After defining the anchor point, one or two lines are now specified within the profile section which serve as a reference basis for the measurement. These sections can be dynamically defined on various levels. This offers advantages particularly when the quality of the surface on one or both sides of the adhesive bead changes along the adhesive beading. Possible types of reference lines - One line (left or right) possible anchor points reference area - Two lines The selection of the anchor point can therefore be adapted to the task in hand. With the scancontrol 281 the following points can be defined as anchor points: First/last point of the profile The first/last point can be the leading or trailing edge of the surface. This means, for example, that the relative distance of the adhesive bead to the edge of the disk is obtained as the measurement. Highest point This is recommended when the adhesive bead itself always represents the highest point. This is usually the case on flat areas. Lowest point When the glue bead is at the edge of a groove and/or its position is of interest. - Two lines at an angle to one another - Two lines of one step 4

13 Graphical user interface The parameterization software facilitates flexible adjustment to various test criteria and target conditions, which are then saved in the controller. These settings are made via the FireWire interface using a notebook or PC. The easy to use parameterization allows a quick adjustment of new test criteria. Evaluation and signal output Along with other information, the following measurement results can be output over the three digital and two analog outputs. z H A a c x W Height, width and area X and Z values of various prominent points or computed values Control signal for exceeding of high or low limits Possible configurations Parameterization via Notebook/PC Only for parameterization Analog 1: Width Analog 2: Height Switching output 1: Glue bead present machine control Parameterization and signal processing via PC Profile and glue bead information Visual display/storage parameterization Top-hat rail industrial PC with preinstalled software 5

14 scancontrol 281 Categories, scope of supply and accessories Overview of measurement categories Designation Description Remarks General Anchor Point X/Z [mm] Anchor point coordinates x, z separately Computation Time Computation time In µs Error Code Error code Reference Lines Number of Points Number of valid measurement points in the basic range Left/right separately Angle Angle of the reference lines Left/right, A:.1 Offset [mm] Offset of the reference lines Left/right separately Sigma [mm] Standard deviation of the measurement points for reference line Left/right separately Profile Number of Points No. of profile points on the bead / groove Height [mm] Height of the bead / groove Width [mm] Width of the bead / groove Area [mm²] Area of the bead / groove Left Point X/Z [mm] Left end of the bead / groove x, z separately Maximum Point X/Z [mm] Highest/lowest point of the bead / groove x, z separately Right Point X/Z [mm] Right end of the bead / groove x, z separately Items included: - Sensor, controller and sensor cable - C++ library for linking into user applications - Operating software under Windows 2 / Windows XP for the configuration and control of measurement tasks - Connecting cable for IEEE Sensor log Accessories: - Sensor extension cable 3mor8m - Connection cable for analog output - Top-hat rail industrial PC (see description on the right) Top-hat rail industrial PC for the parameterization, visualization and storage of measurement data: - Saving and loading parameter settings - Logging (selected) measurements and the status of the digital outputs - Control of the system via serial interface (RS232) or Ethernet (UDP, TCP/IP) including evaluation of the measurement process, logging of the evaluated measurement process - Starting and stopping a continuous measurement - Single measurement - Selection / switchover of parameter settings Options: - High speed version with 4 khz - 5 mw laser power - Various cable lengths and cable types - Trigger and synchronization options Top-hat rail industrial PC with preinstalled operating and display software 6

15 Technical data Model Standard ranges, extended range data (±5%) in brackets Measuring range z-axis 25 (55) mm.98 (2.17) " 1 (245) mm 3.94 (9.65) " Resolution z-axis 1.4% 1 µm 4 µm Measuring range x-axis SMR 13 (23) mm.51 (.91) " 3 (5) mm 1.18 (1.97) " EMR 18 (41) mm.7 (1.61) " 5 (14) mm 1.97 (5.51) " Resolution x-axis Profile frequency Measuring rate Light source Laser class (EN ) Laser off Permissible ambient light (fluorescent light) 256 / 512 / 1,24 2, option: 64 / 128 points/profile up to 1, profiles/s (option: up to 4, profiles/s) up to 256, measurement points/s laserdiode655nm,15mw(option:5mw) class 2M (option: 3B) remoteinputandkeyswitch 1. lx Protection class sensor IP 64 controller IP 4 Operating temperature Storage temperature...5 C ( F) C ( F) Electromagnetic compatibility (EMC) Vibration (IEC ) Shock (IEC ) Weight (without cable) Sensor connecting cable Dimensions controller Output analog Profile parameter on page 6 3 Output/Input digital Interface (measurement data and control commands) Synchron-connector, input 4 sensor controller LxWxH Synchron-connector, output 4 Sync-Out, Error, User Mode (2x) Video signal (test and set up mode) 1V SS (BAS-signal, 8-bit-grey) Supply 24 VDC ±15 %;.5 A All specifications apply for a diffusely reflecting matt metallic target SMR = Start of measuring range EMR = End of measuring range Marginal position tolerance of the measuring-field is possible (sensor depending) 1 for standard measuring ranges points/profile only in extended range possible (up to 128, points/s, option up to 256, points/s) 3 only for preprogrammed data (e.g. width, heigth, area) 4 preprogrammed, other function possible scancontrol scancontrol EN (emitted interference) EN (immunity to interference) 2g/2...5Hz 15 g / 6 ms 35 g 3.5 kg standard 2 m 278 x 187 x 17 mm ±1V(16Bit,upto15kHz) 3x IEEE 1394 ( FireWire ), 4 MBit/s, DCAM 1.3 standard 1x RS232 (115,2 Baud) 1x RS422 (115,2 Baud) 4 g Sync-In, Remote Laser ON/OFF, Mode LASER RADIATION CLASS II LASER 2 P 15 mw; E 7 W/m ; =655 nm DO NOT STARE INTO BEAM The laser unit of scancontrol 281 uses a semiconductor laser with a wavelengh of 655 nm ( visible/red) and 15 mw optical output (class 2M). The sensor is classified as laser class 2M. A warning sign is attached to the sensor housing. 7

16 Dimensions in mm (rounded inch), not to scale scancontrol (1.73) 64 (2.52) 64 (2.52) 18 (.71) 6 (.24) 3 5 (1.97) 62.5 (2.46) 22 (.87) 3 Laser 23 (.91) 13 (.51) 5 (1.97) 62.5 (2.46) 17.5 (.69) 48 (1.89) scancontrol (1.73) WS (.71) 6 (.24) 115 (4.53) 5 (1.97) 3 (1.18) 245 (9.65) 69 (2.72) 145 (5.71) 3 Laser 1 (3.94) (z-axis) 18.5 (4.27) 55 (2.17) 25 (.98) (z-axsi) 18 (.71) 41 (1.62) 64 (2.52) 22 (.87) 3 (.12) 115 (4.53) 145 (5.71) 245 (9.65) 1 (3.94) (z-axis) standard range extended range 55 (2.17) 25 (.98) (z-axsi) 64 (2.52) 17.5 (.69) 74 (2.91) 95 (3.74) 125 (4.92) 5 (1.97) 14 (5.51) standard range extended range Marginal position tolerance of the measuring field is possible (sensor depending). Detailed sensor and controller dimensions you can find in the scancontrol 28 datasheet. MICRO-EPSILON Koenigbacher Strasse Ortenburg / Germany Phone +49/8542/168- Fax +49/8542/168 9 info@micro-epsilon.com USA: 812 Brownleigh Dr. Raleigh, NC / USA Phone +1/919/ Fax +1/919/ me@micro-epsilon.com certified DIN EN ISO 91 :2 modifications reserved Y A155MLO