ThermaViz The Innovative Two-Wavelength Imaging Pyrometer Operating Manual The integration of advanced optical diagnostics and intelligent materials processing for temperature measurement and process control. 1 P a g e
Table of Contents Contents Table of Contents... 2 Chapter 1 - Introduction... 3 Two-Wavelength Imaging Camera Features... 3 Image Processing Software Features... 3 Contacting Stratonics... 3 Chapter 2 Getting Started... 4 Chapter 3 ThermaViz Software Features... 5 Expanded view of Menu Bar pull-down options... 6 Expanded View of Data Window Tool Bar... 9 Image Display Tabs (left side of Sensor Image Display Area)... 9 Sensor Image Display Area, Color Scale, Range Adjustment Button... 10 Status Bar... 10 Chapter 4 Setting Alignment & Exposure... 10 Setting Alignment... 10 The system is aligned at Optomec prior to shipping using a calibrated source. The following steps can be followed to verify proper alignment.... 10 Setting Exposure... 12 Chapter 5 Recording, Saving & Analyzing Data... 13 Saving a sequence of frames (movie)... 13 Displaying a sequence of frames (movie)... 13 Analyzing data in a recorded frame or sequence of frames (movie).... 13 Appendix A Extended Range - Low Temperature Operation... 16 Appendix B Calibrations Separate Document Version Date Revision Description 1.0 1/2009 Original Manual 2.0 8/2012 Set-up procedures updated with figures and low temperature features included 2.1 03/26/15 Hardware & cable connections added 2.2 04/03/15 Camera specifications updated Information in this document is subject to change without notice. Companies, names, and data used in examples here are fictitious unless otherwise noted. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, without express written permission of Stratonics, Inc. 2011 Stratonics, Inc. All rights reserved. 2 P a g e
Chapter 1 - Introduction The ThermaViz System incorporates an innovative, two-wavelength imaging pyrometer with sophisticated image acquisition and analysis software. The pyrometer is packaged for harsh environments and the image processing computer is pre-installed with custom, Windows-based software featuring powerful operating modes. ThermaViz is a complete system that provides real-time, true temperature images and measurements. Two-Wavelength Imaging Camera Features Based on CMOS imaging technology Detector dimensions: 752 x 480 pixels, pixel spacing 6.45 microns Exposure: 0.1 130 milliseconds Frame rate: 25 frames/second @ 12 bit output Optical system Resolution range: 10 µm/pixel 1 mm/pixel Field of view range: 5 mm 500 mm Temperature Range: : 1000 to 2500 C Physical dimensions: 6.25" W, 6.5" L, 3.5 " H, weight 5 lbs Image Processing Software Features Computes temperature images Melt Pool: 2 wavelength calibration Global Heat Flow IR: 1 wavelength calibration Displays live, real-time temperature data Isolates regions of interest for detailed study, Test Set-up Automation Displays profiles, time histories, and histograms of thermal data Saves thermal image movies for analysis Exports data in a variety of standard formats, including.bmp,.emf,.avi, and.csv. Synchronizes with an external hardware signal to control data acquisition Parallel design takes advantage of multi-core CPUs Runs under Microsoft Windows XP, Windows Vista, and Windows 7 Contacting Stratonics Stratonics, Inc. 25002 Castlewood Street Lake Forest, CA 92630-3205 Phone: (949) 461-7060 Website: www.stratonics.com Email: info@stratonics.com 3 P a g e
Chapter 2 Getting Started ThermaViz System Hardware Connections 4 P a g e
Chapter 3 ThermaViz Software Launch the ThermaViz software, using the shortcut located on the desktop or from application in ThermaViz Folder. Position the ThermaViz Sensor to view heated object. The primary screen of the ThermaViz software has several regions: Menu Bar across top with 3 selections: File, Data, and Region Data Window Tool Bar Image Display Tabs on left: Temperature and Radiance Sensor Image Display Status Bar Color scale on vertical right side Temperature ( C), when Temperature Image Display Tab selected Intensity in counts, (12 bits is 4095 counts) when Radiance Image Display Tab selected Range Adjustment Button, located below color scale Main Software Window Menu Bar Data Window Tool Bar Image Display Tabs Sensor Image Display Status Bar Close Window Maximize Window Minimize Window Close Program Maximize Window Minimize Window Color Scale Range Adjustment Button ThermaViz Application 5 P a g e
Expanded view of Menu Bar pull-down options File New Acquisition - Opens Data Window and acquires one frame. Load Data - Loads saved frame or sequence of frames (movie) Save Data Saves recorded frames Save Current Frame Saves the currently displayed frame to the hard drive. Export - Movie as AVI saves recorded or preloaded data as an AVI file Image as Bitmap saves a currently displayed single image as a bit map Exit Closes ThermaViz Software program Data Frame Rate Frame Rate Free Run - maximum allowable system rate Time Between Frames to adjust frequency Frame Averaging None (single frame) Average over # of frames Exposure Time Higher temperature scenes will require shorter exposures and lower temperatures will require longer exposures for optimum performance. Maximum intensities of 3000 to 3600 counts are desired in the Radiance Mode. The exposure time and the pixel clock frequency is set in this window. Observe the signal level in the brightest image. If it is saturated, then reduce the exposure time until the signal level comes into range, (3000-3600 counts). If the signal is to low, then increase exposure time until the signal level comes into range. External Gating Option is available when hardware is attached. The check-box at the top enables or disables the gating feature. The readout below shows the current state of the gate input. 6 P a g e
Region The Region Tool allows for the analysis of user defined regions of interest (ROI), either within a rectangle or along a line. An ROI Layout configuration is a set of user defined region of interests and user selected ROI Windows displaying analysis data. These user defined layouts can be saved and reloaded for future use. ROI Layout Load loads a previously saved ROI Layout Save saves ROI Layout currently displayed Define ROI Rectangle Click cursor within image display and drag to form rectangle. Rectangle Tool is also available on the Data Window Tool Bar. Line - Click cursor within image display and drag to draw line. Line Tool is also available on the Data Window Tool Bar. NOTE: When an ROI is drawn it displays as a dashed line and is sequentially labeled, Region #. This name can be changed using EDIT ROI. When an ROI is drawn in one image (either top or bottom), a reference ROI is noted in the other image in the same position and displayed as a dashed line. This reference ROI can be established using the Define ROI Tool to draw an actual ROI over the reference ROI. Hot spot tracking ROI An ROI is created that centers on peak temperature (not radiance intensity) and tracks the peak in each frame. The size of the hot spot ROI is defined by the user. Edit ROI Use cursor to select and highlight ROI and use Region Edit ROI ROI can be named and X-Y Coordinates changed, defining position and size. The ROI can also be repositioned using the cursor to select and move ROI. 7 P a g e
Delete ROI - Use curser to select ROI and delete Region Delete ROI Open New ROI Window An ROI Window can be displayed for any selected ROI Region Open New ROI Window The name of the selected ROI appears at the top of the ROI Window and displays Temperature if Temperature Mode was selected or Intensity if Radiance Mode was selected. The data within the ROI is sampled and this ROI Window displays image information. The ROI Data Tool Bar is found at the bottom of this window. Copy to Clipboard Chart Bitmap Chart Metafile Chart Source Data (text) Export Chart Bitmap (bmp) Chart Metafile (emf) Chart Source Data (csv) 1 2 3 4 5 6 7 8 ROI Window Data Tool Bar (descriptions from left to right) 1 View ROI Data o right click symbol: Copy to Clipboard or Export 2 Plot column sum profile o right click symbol: Copy to Clipboard or Export 3 Plot row sum profile o right click symbol: Copy to Clipboard or Export 4 View statistics as text o right click on symbol: Display Options o right click within window: Copy to Clipboard or Export 5 View ROI data as strip chart, plots data from sequence of previous frames o right click symbol: Trace Options o right click within window: Copy to Clipboard or Export 6 View ROI data as histogram o right click symbol: Histogram Setup o right click within window: Copy to Clipboard or Export Choose desired View and select Adjust plot axes to manually change chart or Quick-scale plot axes to automatically maximizes vertical axis. 7 Adjust plot axes 8 Quick scale plot axes scales axes to maximize fit current of data 8 P a g e
Expanded View of Data Window Tool Bar Acquire Single Image Stop Rewind to First Frame Picture Zoom Rectangle ROI Tool Live Preview Record Play recorded images Fast Forward to Last Frame Frame Counter Line ROI Tool These tools are accessible when Data Window is selected with cursor. Live Preview Displays the current live images of both cameras, inside the Sensor Image Display Area. Acquire Single Image Temporarily stores the image shown in the picture scene. This single image can be permanently saved using the File Save Current Frame option. Record Temporarily stores a sequence of images, movie, until the Stop button is selected. Frame Counter indicates number of frames recorded. This record can be permanently saved using the File Save Data option. Selecting the Record button again will overwrite previously recorded movie. Stop Stops the recording of multiple images. Play recorded images Replays the last recorded images that reside in temporary memory. If previously saved movies are loaded using File Load Data, this button will replay that sequence of saved images. Rewind Rewinds to the first frame of sequence. Fast Forward Fast forwards to last frame of sequence. Frame Counter Indicates the current frame number displayed in the Picture Scene, as well as the total number of frames in the movie. Picture Zoom Changes the magnification within the image display. Line ROI Tool With the selection of this button, a line Region-of-Interest (ROI) can be drawn within the Picture Scene for additional analysis. Using the cursor, draw the desired line. Data along this line can be further analyzed using Region Open New ROI Window Rectangular ROI Tool - With the selection of this button, a rectangular Region-of-Interest (ROI) can be drawn within the Picture Scene and data within this region can be further analyzed using Region Open New ROI Window Image Display Tabs (left side of Sensor Image Display Area) Temperature - This mode displays the image as a calculated temperature map. Temperatures are calculated using pre-defined calibration settings and displays a single image representing the ratio of both wavelengths. Radiance This mode displays both the short and long wavelength images, on the top and bottom, respectively, within the sensor image display area. 9 P a g e
Sensor Image Display Area, Color Scale, Range Adjustment Button Right-click within Sensor Image Display Area to access: Adjust Color Scale Autoscale Color Scale Status Bar Range Adjustment Button and the Autoscale feature adjust the maximum in the color scale to the brightest pixel in the entire FOV. Indicates x & y position of the cursor inside the picture scene and displays temperature ( C) at that point when the Temperature Tab is selected or intensity value when the Radiance Tab is selected. If the camera sensor is saturated, the word "SATURATED" will be displayed to the right of the cursor readout. If the levels get too high, the intensity saturates and the signals are not reliable. Chapter 4 Setting Alignment & Exposure It is important to align the sensor such that the melt pool is centered on the detectors and the exposure is set to operate at optimum signal levels. With the Radiance Tab selected (left side of Data Window), maximum signal levels between 3000 and 3600 are an appropriate range. If the intensity saturates, the signals are meaningless and must be adjusted into the appropriate range. Setting Alignment The system is aligned at Optomec prior to shipping using a calibrated source. The following steps can be followed to verify proper alignment. 1. Use the LENS System to create a burn mark in the position where the melt pool will be located during deposition processing. 2. Turn the lights on inside the processing chamber and direct them at the burn mark. 3. Remove the front filter cell from the sensor. It is the outermost cell. Hold focusing adjustment cell in place, while unscrewing filter cell Warning! Replace front filter cell, before running laser. Laser operation will damage sensor with filter removed.) 10 P a g e
4. Initiate the ThermaViz Software as directed in Chapter 2 Getting Started. A Data Window will automatically open upon initiating the software or one can be opened using File - New Acquisition. 5. Set the exposure time using Data Exposure Time Enter 132 ms as the exposure time and 5 MHz for pixel clock. 6. Set frame rate using Data Frame Rate Set Frame Rate to Free Run and Frame Averaging to None (single frame). 7. Select the Radiance Image Display Tab. Set Zoom so that top Radiance image fills the display, giving a good view of the alignment. 8. Load the SetUp.ROI file. Region ROI Layout Load (file located in ThermaViz Folder) The SetUp.ROI is a predefined layout that consists of a square region of interest (ROI) with cross hairs (two line ROI s) in both the top and bottom image which are centered on the detectors. In the SetUp.ROI Layout, the left side of the computer screen displays the Data Window containing the short and long wavelength images and the right side displays the intensity windows displaying the average intensities within the square ROI s. NOTE: Each system is pre-loaded with X and Y offsets that align each pixel of one camera to another. The Center Lines in the Setup ROI, although centered on the detector, will appear shifted in the Data Window. 9. Select Live Preview from the Data Window Tool Bar. Adjust Zoom to properly view and confirm melt pool location (i.e. burn mark images) are within the defined square ROI, approximately centered on the cross hairs of the SetUp.ROI. Adjust sensor position if necessary to center melt pool within 10-20 pixels of center. 10. IMPORTANT! - Replace front filter cell, before running laser or laser operation will damage sensor. 11 P a g e
Setting Exposure 1. In Radiance Mode, select Live Preview from the Data Window Tool Bar. 2. Set exposure time to 1 ms and Pixel Clock to 5 MHz as a starting point Data Exposure Time. The 12 bit camera image has 4095 counts at saturation and recording at maximum intensities of 3000 to 3600 counts is optimum. 3. Right-click within Sensor Image Display Area and select Adjust Color Scale 4. Set Min = 1 and Max = 3500 Cursor can be placed in the hot spot and the value of this point can be read in the status bar. 4. Set the zoom to observe the brightest image (top or bottom) during LENS operation. Observe the signal levels in the image for saturated pixels, (any pixels above 3500 will be white). Set the exposure level such that little saturation occurs with the Max setting at 3500. If the signal level is too high, i.e., saturation is frequent, then reduce the exposure until the signal level is just below saturation. If the signal level is too low, (brightest pixels below 3000), then increase the exposure time until the signal level is in the optimum range. 5. IMPORTANT - Right-click within Sensor Image Display Area again and select Adjust Color Scale Set Max = 4095 12 P a g e
Chapter 5 Recording, Saving & Analyzing Data The ThermaViz software is a powerful and flexible program that provides multiple features to analyze a variety of data. This section illustrates the options of: Recording and replaying movies Placing ROI s on to images to sample data Plotting sample data Exporting data to external files NOTE: Data recorded is stored in temporary memory until saved or written over. If another sequence of data is attempted to be recorded, the software will prompt you to save the previous file if desired. This avoids losing data by over writing it. Saving a sequence of frames (movie) Set thermal scene as desired and select File New Acquisition. Set the alignment and exposure as directed in Chapter 4. Set the desired frame averaging Data Frame Rate. Select the Record button from the Data Window tool bar. The Frame counter increases with each frame. Press the Stop button when complete. To save acquired images Select File Save Data, create new folder, input file name and save. Files have the.raw.viz file format and contains the raw averaged data. Displaying a sequence of frames (movie) To replay a sequence of frames (movie), select File Load Data. Select desired folder and holding the Shift Key, highlight all frames within the movie and select Open. Press the Play button on the Data Window Tool Bar to replay the sequence of frames. Analyzing data in a recorded frame or sequence of frames (movie). Once an image or sequence of images is loaded, a particular frame can be displayed and analyzed either in Radiance or Temperature Mode. The Region of Interest (ROI) tool, (line or rectangle), can be drawn to extract data within the defined region. NOTE: When an ROI is drawn it displays as a dashed line and is sequentially labeled, Region #. This name can be changed using EDIT ROI. When an ROI is drawn in one image (either top or bottom), a reference ROI is noted in the other image in the same position and displayed as a dashed line. This reference ROI can be established using the Define ROI Tool to draw an actual ROI over the reference ROI. LINE ROI A line region of interest (ROI) can be drawn within the image displayed either using the Line Tool on the Data Window Tool Bar or Region Define ROI Line in the main menu. Line ROIs with Intensity Profiles 13 P a g e
Select the line tool, click within the image and drag the cursor to draw a line, release to end the line. (Holding the Shift Key will create a straight line). The line can be repositioned with the mouse by selecting it, dashed line will become solid, and drag to desired position. With the line selected, chose Region Edit ROI to change name or end points of the line. With the line selected, chose Region Open New ROI Window to display data along this line. A new window opens displaying a temperature or radiance profile. This window can be adjusted in size and positioned within the screen. With the line again selected, chose Region Open New ROI Window which opens another new window. Other data can be displayed using the tools from the ROI Window Data Tool Bar. This window can also be adjusted in size and positioned within the screen. This ROI layout can be saved for later use, Region ROI Layout Save. Once a layout is saved, it can be re-loaded Region ROI Layout Load and will install itself on the existing image or movie. This is a very convenient feature. RECTANGLE ROI A rectangular region of interest (ROI) can be drawn within the image displayed either using the Rectangular Tool on the Data Window Tool Bar or Region Define ROI Rectangle in the main menu. Select the rectangle tool, click within the image and drag the cursor to draw the rectangle. (Holding the Shift Key will create a square). The rectangle can be repositioned with the mouse by selecting it, rectangle changes from dashed line to solid, then drag to desired position. With the rectangle selected, Region Edit ROI to change name or corner points. With the rectangle selected, chose Region Open New ROI Window which opens a new window displaying the intensity or temperature data within the ROI. This window can be adjusted in size and positioned within the screen. With the rectangle again selected, chose Region Open New ROI Window which opens another new window. Other data can be displayed using the tools from the ROI Window Data Tool Bar. This window can also be adjusted in size and positioned within the screen. Once the additional data windows are displayed, the movie of frames loaded can be played, providing the system with data from each frame. This ROI layout can be saved for later use, Region ROI Layout Save. Once a layout is saved, it can be re-loaded Region ROI Layout Load and will install itself on the existing image or movie. This is a very convenient feature. 14 P a g e
A Rectangle ROI with Text data window indicating average and sigma and Strip Chart for the data presented in all movie frames loaded. Copying or exporting data The multi-frame signal in the Strip Chart may be saved in a CSV file. Right mouse click within the plot to open the Copy and Export options. Save the *.csv file in the user defined folder. Saving the plot data to CSV file. 15 P a g e
Appendix A OPTIONAL Extended Range - Low Temperature Operation This is an optional feature and not available on all systems. The extended range option has been provided to measure temperatures below those that can be measured in a normal, single exposure, where the peak signal is in range and not saturated. In this normal exposure mode with the ND filter in place, the peak signal is set near 3000 counts, a peak temperature of 2000 C is common and the minimum temperature measured is typically 1200 to 1400 C. The minimum temperatures correspond to the noise floor in the camera. However, if the camera exposure is increased, the peak signals will saturate and lower temperature regions of the scene will rise from the noise, into the measurable range of the camera. To use the extended range feature for the high temperature range, 1000 to 2000 C, position the ND filter into the optical path and to measure the lower temperature range, 600 1000 C, position the ND filter out of the optical path. The extended range feature directs the cameras to acquire a sequence of images at 3 different exposures, continuously in time. The first image is the normal in-range exposure, 1 ms. The second image uses an exposure of 10 ms, which brings lower temperature regions of the scene into the camera range of measurement. The third image uses an exposure of 132 ms (the longest possible) to measure even lower temperatures. These exposures will provide temperatures across the extended range by superimposing the in range regions of each exposure into a single image and an extended range temperature map is produced. In either case, set the 3 exposures to 1, 10 and 132 ms. These exposures will provide temperatures across the either extended range by superimposing the in range regions of each exposure into a single image and an extended range temperature map is produced. The superposition algorithm uses the background, low and high intensity thresholds, 0, 100 and 4095, respectively. Select extended range click setup under DATA menu: 1- Select Extended Range (ER) and click on setup. 2- Position ND filter in optical path for high temperature measure, or out of optical path for low temperature operation. Set ER, exposures to 1, 10 and 132 ms, 3- Set Background intensity, low and high intensity threshold to 0, 100 and 4095, respectively, 4- Click okay on ER screen, click okay on initial screen, 5- Open Temperature Calibration screen under Data pull down menu, 6- Note Intensity thresh-holding set upper limit to 500,000 and lower limit to 500, click okay 7- Now, proceed to live display, and record movie as desired. 16 P a g e