LaserProbe4500 CNC-STEP "LaserProbe4500" 3D laser scanning system Instruction manual
2 Hylewicz CNC-Technik Siemensstrasse 13-15 D-47608 Geldern Fon.: +49 (0) 2831 133236 E-Mail: info@cnc-step.com Website: www.cnc-step.de
3 Contents 1. Safety...4 1.1. Symbols used...4 2. Purpose...4 3. Basic technical data and characteristics...4 3.1. Scanning parameters...4 3.2. Allowable synchronization methods...4 3.3. Series LA901 laser sensor...5 3.4. Synchronization unit...6 3.5. Optical isolation unit...7 4. Delivery set...7 5. Operation principle...8 6. Connection versions...8 6.1. Connection to machines with direct stepper control...8 6.2. Connection to Beaver 9A/12A/12AV/18A/24A/26A machines...8 6.3. Connection to machines with encoder impulse signals...9 6.4. Connection to machines with command signal pulses or with differential output encoder (for example, Beaver 26AVST with servo-controller)...9 6.5. Connection to machines with sinusoidal encoder signals (3 wires)...9 6.6. Connection to machines with sinusoidal and differential encoder signals (5 wires)...10 7. Connection of the optical isolation unit...10 7.1. Block diagram...10 7.2. Designation of contacts...11 7.3. Connection to the synchronization unit...12 8. Selection of the synchronization option...12 8.1. Connection to machine with direct stepper control...12 8.2. Connection to machine with encoder impulse signals...13 8.3. Connection to machines with impulse differential encoder signals...13 8.4. Connection to machines with analog encoder signals...14 8.5. Connection to machines with analog differential encoder signals...14 9. The «Dorgonia» software...15 9.1. Basic functions...15 9.2. Program start...15 9.3. Settings...16 9.3.1. Positioning of the sensor...16 9.3.2. Setting-up of the laser sensor parameters...16 9.3.3. Setting-up of program filters...17 9.3.4. Setting-up of the scanning parameters...18 9.4. Generating scanning file for CNC...18 9.5. Scanning of the item...18 9.6. Generate result file...18 10. Example of filter operation...19 11. System requirements...21 12. Warranty...21 13. Example of the scanning result...21 14. Troubleshooting...22
4 1. 1.1. Safety Avoid metal chips getting into the optical isolation unit. Check earth before connecting the system to a machine. Keep the 3D system in clean condition. The handling of the system assumes knowledge of the instruction manual. Symbols used «Attention» symbol: Pay attention to the warning to avoid typical mistakes when working with the 3D system. «Information» symbol: Information that can be useful. 2. Purpose The LaserProbe4500 system is intended for non-contact laser scanning of items for the purpose of obtaining three-dimensional computer model and formation of model files suitable for subsequent use in CNC system. The system is designed for mounting onto working machines with any type of control. 3. Basic technical data and characteristics 3.1. Scanning parameters Name Value Materials to be scanned Any except transparent or reflecting materials Scanning grid for XY arbitrary Scanning field for XY arbitrary Scanning depth, mm 100 or customized* Average scanning speed, points/s 4500 Table 1: Scanning parameters 3.2. Allowable synchronization methods Source of synchronization signal Signals for direct stepper control along X-axis Encoder on X-axis with impulsed output (differential or non-differential) Encoder on X-axis with sinusoidal output (differential or non-differential) Table 2: Allowable synchronization methods Signal level value CMOS/TTL 1...30V 1 30V
5 3.3. Series LA901 laser sensor Name Value Base distance, mm 140 Range, mm 100 Total height from the machine table, mm 240 Error, mm ±0,1 Resolution, mm 0,03 Maximum operation speed, points/s 10000 Laser type 3 mw, wavelength 660 nm Class of protection IP67 Working temperature, С -10 +60 Time of continuous operation unlimited Overall and mounting dimensions, mm Fig.1 Weight, g 100 Table 3: Parameters of the Series LA901 laser sensor Note: * the system can be equipped with sensor offering different characteristics contact: info@cnc-step.com CABLE RIFTEK Input window Output window Base distance Working range Figure 1. Mounting and overall dimensions of Series LA901 laser sensor
6 3.4. Synchronization unit Name Value PC communication interface USB 2.0 Class of protection IP67 Working temperature, С -10 +60 Dimensions, mm Fig.2 Table 4: Parameters of the synchronization unit 1 2 3 30,5 137 60,5 4 5 24,7 4 24,7 56,3 4 125 Figure 2. General view of the synchronization unit Designation 1 Connector for machine, in case of mounting on Beaver 9A/12A/12AV/18A/24A/26A machines, not used otherwise; 2 Connector for laser sensor; 3 Power connector ; 4 Connector for optical isolation unit (for mounting on 9A/12A/12AV/18A/24A/26A machines 15-conductor cable to PC); Beaver 5 USB-cable for connection of the system to PC. Table 5: Designation of connectors of the synchronization unit
7 3.5. Optical isolation unit Name Value Class of protection Working temperature, С Dimensions, mm Mounting Table 6: Parameters of the optical isolation unit IP64-10 +60 Fig. 3 on DIN-rail 158 87,4 7 16,6 45 36 5 Figure 3. General view of the optical isolation unit 4. Delivery set The delivery set includes: LA901 laser sensor Bracket for mounting sensor on machine Synchronization unit with USB-cable for connection to PC Cable for the synchronization unit Power source Screw М3x18 Compact disc with drivers, software and operation manual Optical isolation unit (optional) Cable for the optical isolation unit (optional) Cable for the synchronization unit «CABLE-001-15» (optional) Passport for the Series LA901 laser sensor Packing list - 1 piece - 1 piece - 1 piece - 1 piece - 1 piece - 2 pieces - 1 piece - 1 piece - 1 piece - 1 piece - 1 piece - 1 piece
8 5. Operation principle The laser sensor is mounted onto the machine movement system. In the scanning mode, the machine CNC system moves the sensor line-by-line over the item prototype. The sensor measures the distance (Z coordinate) to the item surface. Data takeoff from the sensor is synchronized with the sensor movement (XY coordinates), and the result is communicated to the PC through the USB-port. Thus, XYZ coordinate array for the surface is formed, i.e. a digital prototype model is created which is saved as a point cloud file as well as in a common STL format suitable for subsequent use in CNC. 6. Connection versions 6.1. Connection to machines with direct stepper control ~110..220VAC Power supply CNC machine STEP USB () to PC STEP DIR AGND xstep+ xdir+ AGND Optical isolation unit STEP DIR GND DIR GND Synchronization unit Sensor Figure 4. Connection to machines with direct stepper control 6.2. Connection to Beaver 9A/12A/12AV/18A/24A/26A machines Power supply USB () to PC CNC machine Control signals Synchronization unit Control signals PC Sensor Figure 5. Connection to Beaver machines through 15-conductor cable (in this case, optical isolation unit is not required)
6.3. Connection to machines with encoder impulse signals 9 CNC machine B+ AGND xstep+ xdir+ AGND ~110..220VAC Optical isolation unit DIR GND Power supply A+ USB () STEP to PC Synchronization unit Sensor Figure 6. Connection to machines with encoder impulse signals, including TTL 6.4. Connection to machines with command signal pulses or with differential output encoder (for example, Beaver 26AVST with servo-controller) ~110..220VAC Power supply CNC machine F+ (A+) USB () xstep+ STEP to PC STEP F- (A-) Optical xstep- DIR Synchronization R+ (B+) isolation DIR xdir+ unit unit R- (B-) xdir- GND AGND GND AGND Sensor Figure 7. Connection to machines with command signal pulses or with differential output encoder 6.5. Connection to machines with sinusoidal encoder signals (3 wires) ~110..220VAC Power supply CNC machine A B AGND xstep+ Optical isolation STEP DIR xdir+ unit GND AGND STEP DIR GND Synchronization unit USB () to PC Sensor Figure 8. Connection to machines with sinusoidal encoder signals (3 wires)
6.6. Connection to machines with sinusoidal and differential encoder signals (5 wires) 10 CNC machine A A B B AGND xstep+ ~110..220VAC Optical STEP STEP DIR xstepisolation DIR xdir+ unit xdir- GND AGND GND Power supply Synchronization unit USB () to PC Sensor Figure 9. Connection to machines with sinusoidal and differential encoder signals 7. Connection of the optical isolation unit 7.1. Block diagram Figure 10: Block diagram of the optical isolation unit To decode input signals and convert them to levels used for sensor, the unit contains Input decoders. One of the operation modes of the Input decoders is chosen depending on the position of the "Operation mode selector ". The input decoder (CPLD) supports the following synchronization signals from different Sources, such as: CMOS/TTL command signals for control of stepper along the X axis;
11 Encoder on the X axis with pulsed output; Encoder on the X axis with sinusoidal output; Encoder on the X axis with differential pulsed output; Encoder on the X axis with differential sinusoidal output. The optical isolation unit forms STEP and DIR signals for the synchronization unit. INFORMATION The use of CPLD (programmable logic microcircuit) makes it possible to decode practically all input signals and form output synchronization signals for the laser sensor. 7.2. Designation of contacts Figure 11. Arrangement of contacts of the optical isolation unit Contact name Group Designation out Input Not used xstep+ Input Adjusted positive input of steps, or A+ signal of encoder xstep- Input Adjusted negative input of steps, or A- signal of encoder xdir+ Input Adjusted positive input of steps, or B+ signal of encoder xdir- Input Adjusted negative input of steps, or B- signal of encoder AGND Input Earth relative to which xstep+/- xdir+/- inputs work Output Power of the input part of the synchronization unit STEP Output Step signal for the synchronization unit DIR Output Direction signal for the synchronization unit GND Output Earth for the synchronization unit Table 7: Pin assignment of the optical isolation unit
7.3. Connection to the synchronization unit The optical isolation unit is supplied together with a cable whose 15-conductor connector on the one end is connected to the synchronization unit while four wires on the other end are connected to the optical isolation unit. Wire designations are shown in Table 8: 12 Wire color Designation Terminal on the optical isolation unit Red Power of the input part of the synchronization unit Blue Step signal for the synchronization unit STEP White Direction signal for the synchronization unit DIR Brown Earth for the synchronization unit GND Table 8: Designation of wires of the synchronization unit CABLE-001-15 cable 8. Selection of the synchronization option Selection of the synchronization option is made by means of micro-switches on the optical isolation unit. ATTENTION! When the LaserProbe4500 3D scanning system is ordered for use on a specific machine, the optical isolation Unit is supplied with pre-set micro-switches. 8.1. Connection to machine with direct stepper control Diagram of control 5V STEP+ signals: 0V DIR+ 5V 0V 3D item Figure 12. Diagram for connection to machine with direct stepper control To decode the above signals, the micro-switches of the optical isolation unit must be in the position shown in the following figure: ON SW1 Figure 13. Position of the micro-switches in the mode under consideration SW2
8.2. Connection to machine with encoder impulse signals 13 Diagram of control signals: A+ 5V 0V B+ 5V 0V ON 3D item Figure 14. Diagram of signals for connection to machine with encoder impulse signals To decode the above signals, the micro-switches of the optical isolation unit must be in the position shown in the following figure: SW1 SW2 Figure 15. Position of the micro-switches in the mode under consideration 8.3. Connection to machines with impulse differential encoder signals Diagram of control signals: A+ A- B+ B- 3D item Figure 16. Diagram of signals for connection to machine with impulse differential encoder signals
To decode the above signals, the micro-switches of the optical isolation unit must be in the position shown in the following figure: ON 14 SW1 Figure 17. Position of the micro-switches in the mode under consideration SW2 8.4. Connection to machines with analog encoder signals Diagram of control signals: A+ B+ 3D item Figure 18. Diagram of signals for connection to machine with analog encoder signals To decode the above signals, the micro-switches of the optical isolation unit must be in the position shown in the following figure: ON SW1 SW2 8.5. Connection to machines with analog differential encoder signals Diagram of control signals: A+ A- B+ B- Figure 19. Position of the micro-switches in the mode under consideration 3D item Figure 20. Diagram of signals for connection to machine with analog differential encoder signals
To decode the above signals, the micro-switches of the optical isolation unit must be in the position shown in the following figure: ON 15 SW1 Figure 21. Position of the micro-switches in the mode under consideration SW2 9. The «Dorgonia» software 9.1. Basic functions The software is intended for: Creation of the line-by-line scanning file for CNC system (G-codes), including the defining of the scanning region, discretization interval along the X and Y coordinates and scanning speed; Parametrization of the laser sensor, including adjustment of smoothing filter and filtering of measurement errors; Data takeoff from the laser sensor; Visualization of data; Filtering and smoothing of results; Formation of standard format files.stl,.dxf,.txt. 9.2. Program start After starting, the program checks for availability of the USB cable for connection to the synchronization unit. If the device is found, availability of the license and its validity are checked, and the laser sensor is switched on. The emergence of the working window (Fig. 22) shows that the system is normal operation mode. E A A B C D Figure 22. Main window of the "Dorgonia" program The window consists of several sections: "А" section for setting of scanning parameters; "В" section for formation of files; "С" section for control and settings; "D" status section; "E" section for imaging of the scanned item.
9.3. Settings. 9.3.1. Positioning of the sensor 16 The base distance from the Scanner to the object is 140mm and the scanning depth is 100mm (Picture XY). The Scanner should be positioned so that the bottom is a minimum distance of 140mm and maximum 240mm from the object to be scanned. To determine the correct position you must select Test-scanner (in section C of the software window) and the actual value (CV) (in section D of the software window) should show a value between 0 and 100 To determine the values for Minimum Z and Maximum Z (in section A) you should perform the following calculation: Min Z = Scan area (100) - CV / Max Z = Min Z + height of the scan object To ensure that the total object will be scanned, you must subtract +/-1mm from the Min Z value and add +/- 1mm to the Max Z value. This will increase the scanning area in both directions. Tip: When scanning objects with large height variations, the scanner should be far away as possible from the object! Example: CV = 80mm Scan object = 40mm Sensor edge Min Z: Max Z: 100 80 = 20 1 = 19mm 20 + 40 = 60 + 1 = 61mm Base Distance 140mm Scan object Range 100mm Table Figure 23. Positioning of the laser sensor 9.3.2. Setting-up of the laser sensor parameters To change laser sensor settings, call the setting window by pressing the "Settings" button (Section "С"). The view of the window is shown in Fig. 24. The Laser settings window displays: 1) Unchangeable service information about the sensor: internal divider installed; type of the device; serial number, working range and base distance; type of synchronization. 2) Two fields for setting filters implemented directly in the laser sensor. The first filter deals with the moving average. Maximum allowable value of the filter width is 128. The second filter deals with the result delay time at an interval of 5 ms (see Description of the Series LA901 laser sensor at www.cnc-step.de After changing the settings, press OK button to save them.
17 Figure 24. Laser settings 9.3.3. Setting-up of program filters To change settings of the program filters, call the settings window by pressing the "Settings" button, go to the «Program settings» tab, set the required width of the median filter and smoothing filter (Gaussian core), and enable or disable display of the model. To save the settings, press "ОК". The "Display model" switch is intended for enabling/disabling of the model display function. This function is used when RAM is not sufficient. Figure 25. Settings of the program filters
18 9.3.4. Setting-up of the scanning parameters Before scanning is started, it is necessary to use section A to define the size of the scanning field (X - width, Y field length), discretization interval along the X and Y coordinates, range of heights of the item to be scanned (Z minimum and Z maximum) and select the type of machine whereto the scanner is connected. After the parameters are set, the program calculates the allowable scanning speed and displays it in the parameters windows. 9.4. Generating scanning file for CNC To form the scanning file for the machine CNC system, it is necessary to set scanning parameters according to par. 9.3.4, press the "Generate file for CNC» button in the section "В" of the program working window (Fig. 22), and define the place in the PC memory where the control file must be written. The output text file contains control G-codes for correct movements of the machine. ATTENTION! The allowable scanning speed is calculated automatically based on the sensor response speed and the scanning grid specified, its value being set in the formed scanning program. Forced changing of the scanning speed may cause distortion of the picture obtained. 9.5. Scanning of the item To perform scanning it is necessary to: use control program for CNC to open the file formed by the Dorgonia program according to par. 9.4; position the machine movement system to a point from which scanning must be started; press the "Start session" button in the section "С" of the program working window; start the machine to execute the program. The task execution time depends on the size of the scanning region, speed and step values with which the carriage moves along the X and Y axes After the machine has executed the program, it is necessary to switch the scanning mode off by releasing the "Start session" button. 9.6. Generate result file The result of scanning is displayed in the section "Е". Control of the item image in this section is possible with the help of the mouse pointer: - dragging of the mouse with the left key pressed rotation of the item; - dragging of the mouse with the right key pressed movement of the item; - scrolling with the mouse zoom-in and zoom-out of the item (scaling). To obtain the result file, it is sufficient to press the Generate result file button, select the file type (STL/DXF/TXT) in the emerging window (Fig. 26), enter the file name, select file folder for saving and press the Save button. To make changes in the region already scanned (discretization interval along the X or Y axis, length and width of the region), it is necessary to enter new values and press the Recalculate region button (section С in Fig. 22). To return to the initial view of the model (if filters were used and limits along Z were set), it is sufficient to switch off the filters and press the Recalculate region button.
19 Figure 26. The window of result saving 10. Example of filter operation Figure 27. Initial view of the item directly after scanning Fig. 27 shows the result of scanning obtained without programmed filtration used. The peaks in the picture are caused by the influence of vertical walls of the item. Fig. 28 shows the image of the item in the case where Median filter with a width of 9 was used (see par. 9.3.3.). As seen in the picture, the peaks disappeared.
20 Figure 28. The use of median filter with the width of 9. A substantial reduction of the image noise can be achieved by using programmed smoothing. Fig. 29 shows the result of programmed smoothing obtained by employing the filter with the width of 7. Figure 29. The use of programmed smoothing.
11. System requirements 21 Stable work of the «Dorgonia» software requires the following system: Processor: RAM: Disk space: Video card: Operating system: Other: not lower than Intel Pentium 4 2.0GHz. not less than 1024 MB (recommended 4096MB). not less than 20 GB, NFTS file system required. ATI/NVidia and not less than 256MB of video memory. Windows 2000/ Windows XP. USB 2.0 is required. 12. Warranty Warranty period of the LaserProbe4500 3D laser scanning system is 24 months from the date of putting in operation. Guaranteed storage time is 12 months. 13. Example of the scanning result
22 14. Troubleshooting The «Dorgonia» program gives an error message: «Error: no scanner found» The «Dorgonia» program gives an error message: «Error: scanner does not respond» The «Dorgonia» program gives an error message: «Error: data file is empty» Problem Cause Solution 1. USB drivers not installed. 2. USB cable not connected. The «Dorgonia» program gives an error message: «Erroneous data file» 1. Sensor is not connected to synchronization unit. 2. Power supply unit () not connected to the synchronization unit. 1. There are no signals of synchronization with the machine. 1. There is a problem with Synchronization signals (STEP/DIR) coming from machine (through the optical isolation unit, if available). 1. Reinstall drivers from original compact disc 2. Check USB cable connection. 1. Check connection of the sensor to the synchronization unit. 2. Check connection of power supply to the synchronization unit. 1. Using oscilloscope, check for availability of synchronization signals from the machine (if optical isolation unit is in place, this must be done through the optical isolation unit). It is possible that no power is supplied to the optical isolation unit (if available). 1. Using oscilloscope, check for availability of STEP/DIR signals