00 Manual Scansonic TH6D-User-Guide v1.7 En

TH6D Tracking Head 6 Dimensions

User's Manual Revision 1.7, 1. Date of issue: 31/05/2012

Translation of Original Operating and Installation Instructions

Legal details

Manufacturer

Scansonic MI GmbH Rudolf-Baschant-Straße 2 D-13086 Berlin, Germany

Important

Tel.:

+49 (0) 30 / 91 20 74 – 10

E-mail:

[email protected]

Fax:

+49 (0) 30 / 91 20 74 – 29

Internet: www.scansonic.de

Every person in charge of installing, operating or maintaining Scansonic processing heads must first read and understand the sections of the manual that are relevant to him or her. This User's Manual is a key part of the TH6D system and must be kept throughout the life span of the product. Any supplements issued later by Scansonic MI GmbH must be filed along with the User's Manual. The abbreviation UM will be used throughout to specify the User's Manual.

Note

Scansonic MI GmbH is not liable for the completeness or correctness of the information found in this manual. Due to continued development of the product, the contents of this manual are subject to change without prior notice at the discretion of Scansonic MI GmbH. Every attempt has been made to ensure that the information contained in this manual is complete and correct at the time it is printed.

Reproduction /

The contents of the User's Manual are the property of Scansonic MI GmbH.

Copyrights

No person or other business divisions or departments of other companies are permitted to reproduce, distribute or alter this manual in any way or by any means unless prior written authorization has been given by Scansonic MI GmbH. Furthermore, it is not permitted to use parts or the whole of this manual to manufacture or sell anything.

Customer

Sales and service partner

service

Scansonic IPT GmbH Rudolf-Baschant-Straße 2 D-13086 Berlin, Germany Tel.:

+49 (0) 30 / 91 20 74 – 10

Fax:

+49 (0) 30 / 91 20 74 – 29

E-mail:

[email protected]

Internet:

www.scansonic.de

Table of Contents 1.

Explanations for this Manual ........................................ 1-1

1.1

Purpose and related documents ................................................... 1-2

1.2

Using the User's Manual ............................................................. 1-2

1.3

Abbreviations and units .............................................................. 1-3

1.4

Symbols, warning levels and notice types ..................................... 1-5

2.

Safety........................................................................... 2-1

2.1

General safety instructions ......................................................... 2-2

2.2

Laser safety .............................................................................. 2-4

2.2.1

Dangers posed by class-3B lasers ................................................ 2-4

2.2.2

Retro-reflection ......................................................................... 2-5

2.2.3

Laser aperture on the TH6D sensor head ...................................... 2-5

2.2.4

Operating the laser safely ........................................................... 2-6

2.3

Particular dangers...................................................................... 2-8

2.3.1

Master machines ....................................................................... 2-8

2.3.2

Excessive pressure and emitted substances .................................. 2-8

2.4

Protective safety measures during normal operation ...................... 2-9

2.5

Proper and intended usage ......................................................... 2-9

2.6

Warrantee and liability ............................................................. 2-10

2.7

Information and warning signs on the TH6D sensor head.............. 2-11

2.8

Disposal ................................................................................. 2-12

3.

Product Information..................................................... 3-1

3.1

Overview .................................................................................. 3-2

3.1.1

Special characteristics ................................................................ 3-2

3.1.2

Possible applications .................................................................. 3-2

3.1.3

How it works ............................................................................. 3-3

3.1.4

Definition of the coordinate system .............................................. 3-4

3.2

Usage limitations ....................................................................... 3-5

3.2.1

The influence of work piece reflection ........................................... 3-5

3.2.2

Influences from the welding process ............................................ 3-6

3.2.3

The influence of accessibility ....................................................... 3-8

3.2.4

Influences of material thickness and step height ............................ 3-9

3.2.5

Limitations caused by the temperature range ................................ 3-9

3.2.6

Influence of the sensor's orientation in relation to the work piece surface .......................................................................... 3-10

3.2.7

Limitations caused by the gap dimensions .................................. 3-10

3.2.8

Limitations caused by the operating voltage ................................ 3-10

3.3

Descriptions of modules and components ................................... 3-11

3.3.1

TH6D sensor head ................................................................... 3-11

3.3.2

Safety glass unit...................................................................... 3-12

3.3.3

TH6D process computer ........................................................... 3-13

3.3.4

Mains power supply unit ........................................................... 3-14

3.3.5

Cable ..................................................................................... 3-14

3.3.6

Cooling module ....................................................................... 3-15

3.4

Additional machine-dependent modules...................................... 3-17

3.4.1

Analogue-digital interface (ADF) ................................................ 3-17

3.4.2

Calibration plate ...................................................................... 3-18

3.4.3

Network cable ......................................................................... 3-19

3.5

Status LED for the TH6D system................................................ 3-20

3.5.1

Status LED on the TH6D sensor head ......................................... 3-20

3.5.2

Status LED on the TH6D process computer ................................. 3-22

3.6

TH6D system interfaces............................................................ 3-24

3.6.1

Connections for the TH6D sensor head ....................................... 3-24

3.6.2

Connections for the TH6D process computer ............................... 3-26

3.6.3

Machine interfaces ................................................................... 3-27

3.7

Operating and configuration interface for THxDView..................... 3-28

4.

Set-up and Installation ................................................ 4-1

4.1

Included in the delivery .............................................................. 4-2

4.2

Returns .................................................................................... 4-3

4.3

Notes for set-up and installation .................................................. 4-3

4.3.1

Installation guidelines ................................................................ 4-4

4.3.2

Application environment ............................................................. 4-4

4.3.3

Cleanliness and cleaning ............................................................. 4-5

4.3.4

Check-list for set-up and installation ............................................ 4-5

4.4

Set-up and installation ............................................................... 4-6

4.4.1

Tool centre point (TCP) and sensor origin ..................................... 4-6

4.4.2

Tightening torque for screws ....................................................... 4-8

4.4.3

Earthing provisions .................................................................... 4-9

4.4.4

Installation and basic positioning of the TH6D sensor head ........... 4-12

4.4.5

Mounting the safety glass unit on the TH6D sensor head .............. 4-13

4.4.6

Mounting the cooling module on the TH6D sensor head ................ 4-15

4.4.7

Connecting the Ethernet cable to the TH6D sensor head and process computer.................................................................... 4-16

4.4.8

Connecting the power supply to the TH6D sensor head ................ 4-18

4.4.9

Connection for the cooling and purging air at the TH6D sensor head...................................................................................... 4-19

4.4.10

Connecting the liquid coolants to the cooling module ................... 4-21

4.4.11

Installing the TH6D process computer ........................................ 4-22

4.4.12

Connecting the power supply to the TH6D process computer......... 4-23

4.4.13

Connecting a user PC for the THxDView configuration software ..... 4-24

4.4.14

Overview of connections without the machine interfaces............... 4-25

4.5

Connecting the machine-dependent auxiliary modules.................. 4-26

4.5.1

Connecting the analogue-digital interface (ADF) .......................... 4-26

4.5.2

Connecting the power supply to the analogue-digital interface ...... 4-28

4.5.3

Connection overview with connected ADF ................................... 4-30

4.5.4

Connecting the Fanuc interface ................................................. 4-31

4.5.5

Connection overview with connected Fanuc interface ................... 4-32

5.

Initial Commissioning and Operation ........................... 5-1

5.1

Information about the initial commissioning and operation.............. 5-3

5.2

Switching the TH6D system on and off ......................................... 5-4

5.3

The graphical user interface: THxDView ...................................... 5-5

5.3.1

System requirements for THxDView ............................................. 5-5

5.3.2

Requirements for installing THxDView .......................................... 5-6

5.3.3

Installing THxDView ................................................................... 5-6

5.4

Using THxDView ...................................................................... 5-10

5.4.1

Starting up and exiting the THxDView software ........................... 5-10

5.4.2

Overview of the user interface................................................... 5-12

5.5

Menu bar ................................................................................ 5-14

5.6

Image area ............................................................................. 5-15

5.6.1

"Raw Data" main tab ................................................................ 5-15

5.6.2

"Evaluation" main tab .............................................................. 5-16

5.7

Reports area ........................................................................... 5-17

5.7.1

Errors and warnings ................................................................. 5-17

5.7.2

Events.................................................................................... 5-17

5.8

System Status area ................................................................. 5-18

5.8.1

Status of the network connection............................................... 5-18

5.8.2

Status and change of the operating mode ................................... 5-18

5.8.3

Status of the measurement process ........................................... 5-19

5.8.4

Status of the active job ............................................................ 5-21

5.9

Information area ..................................................................... 5-22

5.9.1

Information area – main tab Measurements ................................ 5-22

5.9.2

Information area – main tab sketch ........................................... 5-23

5.10

Parameter configuration area .................................................... 5-25

5.11

Parameter configuration area – "Profile" tab................................ 5-25

5.11.1

Seam Pattern tab .................................................................... 5-26

5.11.2

Seam Pattern tab – templates with seam pattern profiles ............. 5-27

5.11.3

Seam Pattern tab – parameter description .................................. 5-32

5.11.4

Camera tab ............................................................................. 5-42

5.11.5

Camera tab – parameter description .......................................... 5-42

5.11.6

Calibration tab ........................................................................ 5-43

5.11.7

Calibration tab – parameter description ...................................... 5-44

5.11.8

Process Control tab .................................................................. 5-45

5.12

Parameters area – main System tab .......................................... 5-46

5.12.1

Job List tab ............................................................................. 5-46

5.12.2

Machine Interface tab .............................................................. 5-48

5.12.3

Configuration tab ..................................................................... 5-49

5.13

Interfaces and associated parameters ........................................ 5-52

5.13.1

Machine interface – analogue-digital correction ........................... 5-52

5.13.2

Machine interface – Motoman reference path .............................. 5-54

5.13.3

Machine interface – Fanuc Ethernet ........................................... 5-60

5.13.5

Machine interface – IF UDP Data ............................................... 5-64

5.14

Set-up and configuration of the TH6D system ............................. 5-65

5.14.1

User login ............................................................................... 5-65

5.14.2

Establishing a network connection with a TH6D system ................ 5-67

5.14.3

Selecting the language ............................................................. 5-71

5.14.4

Selecting the set-up operating mode .......................................... 5-71

5.14.5

Positioning the TH6D sensor head .............................................. 5-72

5.14.6

Tool calibration........................................................................ 5-75

5.14.7

Measurement process optimization – changing camera settings ..... 5-79

5.14.8

Optimizing the measurement process – changing parameters ....... 5-80

5.14.9

Setting up profiles and creating jobs .......................................... 5-81

6.

Maintenance ................................................................. 6-1

6.1

Safety instructions ..................................................................... 6-2

6.2

Required maintenance................................................................ 6-3

6.2.1

Maintenance intervals ................................................................ 6-3

6.2.2

Diagnosis of the maintenance intervals......................................... 6-4

6.2.3

Overview of maintenance procedures ........................................... 6-5

6.3

Handling the components ........................................................... 6-5

6.3.1

Clean and change the safety glass ............................................... 6-5

6.3.2

Cleaning the TH6D sensor head ................................................... 6-8

6.3.3

Check the hose and cable connections.......................................... 6-9

7.

Troubleshooting ........................................................... 7-1

7.1

Notes ....................................................................................... 7-2

7.2

Information, warning and error code tables for THxDView............... 7-3

8.

Technical Data and Specifications ................................ 8-1

8.1

Technical data and specifications ................................................. 8-2

8.2

Electrical switching functions of the analogue-digital interface (ADF) ...... 8-7

8.3

Electrical switching functions of the Motoman interface .................. 8-8

8.4

Medium .................................................................................... 8-9

8.4.1

Compressed air specifications ..................................................... 8-9

8.4.2

Coolant specification .................................................................. 8-9

8.5

Ambient conditions .................................................................. 8-10

8.6

Accessories and spare parts ...................................................... 8-11

8.6.1

Base configuration for the TH6D system ..................................... 8-11

8.6.2

Optional components ............................................................... 8-12

8.6.3

Optional components for the ABB and KUKA robots...................... 8-13

8.6.4

Wearing parts – safety glasses .................................................. 8-14

9.

Appendix ...................................................................... 9-1

9.1

Annex ...................................................................................... 9-2

9.1.1

List of Figures ........................................................................... 9-2

9.1.2

List of Tables ............................................................................ 9-6

9.2

Check-list for set-up and installation ............................................ 9-7

9.3

Contamination Declaration .......................................................... 9-9

9.4

Condensation point table .......................................................... 9-10

1.

Explanations for this Manual This chapter contains helpful explanations for working with the User's Manual. 1.1

Purpose and related documents ...................................... 1-2

1.2

Using the User's Manual.................................................. 1-2

1.3

Abbreviations and units .................................................. 1-3

1.4

Symbols, warning levels and notice types ....................... 1-5

Scansonic_TH6D_AHB_v1.7_en.docx

Page | 1-1

Explanations for this Manual

1.1

Purpose and related documents CAUTION! You must read all relevant documentation and take additional training in order to work with the TH6D system!

The user's manual contains the necessary information describing the installation, operation, and maintenance for the following approved versions of the sensor system: Tracking Head 6 Dimensions:

•

TH6D-150-CFxx-yy

•

TH6D-150-KFxx-yy

The Tracking Head 6 Dimensions will be subsequently referred to as the TH6D in this document. Additional training is recommended due to the complexity of the device.

1.2

Using the User's Manual The complete document must be kept close to where the device is deployed and remain accessible to all personnel authorized to work with the device. This helps in avoiding errors when installing and operating the TH6D system, and ensures trouble-free operation.

The illustrations in this manual do not always include all details and do not always depict the latest components. They show only the most significant information for the reader. The User's Manual is divided up into chapters arranged according to technical and training topics.


Page | 1-2


1.3

Abbreviations and units Some of the German and English abbreviations used in this manual are explained below.

Abbreviations ADF

Analogue-digital interface

Base-T

Ethernet version

CCD

Charge-coupled device

C-MOS

Complementary metal oxide semiconductor

EMC

Electromagnetic compatibility

Ex.

Example

Fig.

Figure

IP

Internet protocol

L

Direction of beam

LED

Light emitting diode

LPC

Laser protection class

MD

Machinery directive

MPR

Maximum permitted radiation (according to 60825-1 (VDE 0837-1): 200805)

n

Normal

SP

Seam point

PTP

Peer to peer (networking connection)

PU

Polyurethane

r

Direction of reflection

S0

Sensor origin

t

Time

TCP

Tool centre point

TH6D

Tracking Head 6 Dimensions

UDP

User datagram protocol (network protocol)

UM

User's Manual

v

Viewing angle


Page | 1-3


θL

Incidence angle Theta L

θr

Angle of reflection

Units bar

Bar – measures pressure (1 bar = 105 Pa)

kW

Kilowatt

l/min

litre per minute

min

Minute

ms

Millisecond

m2

Square metre

nm

Nanometre

Pa

Pascal – measurement unit for pressure

s

Second

W

Watt

µm

Micrometre

µs

Microsecond

°C

Degrees Celsius

ØA

Outer diameter

ØI

Internal diameter


Page | 1-4


1.4

Symbols, warning levels and notice types The list below explains all symbols, warnings and notices used within this manual. They are used to increase the safety level, decrease the risk of danger and reduce injury and material damages.

Symbols The following symbols and icons are used to identify sources of danger. They are in compliance with the applicable standards at the time this manual was published and may occur at all warning levels.

Warning for a hazardous area (W000)

Warning for laser beams (W010)

Warning for materials that are dangerous to human health (W018)

Warning for hot surfaces (W026)

Warning for dangers in vicinity of the turning and reaching zone of the industrial robot (W079)

Warning for excess pressure (W080)

Warning for risk of hearing damage (W084)


Page | 1-5


General mandatory sign (M000)

Follow the instructions (M018)


Page | 1-6


Warning levels and notice types This manual uses the following warning levels. It is important to observe the accompanying instructions and comments. The warnings are listed in order of priority as indicated by their colour coding.

DANGER! This indicates particular dangers to life and limb. Failure to observe these notices will lead to death or serious injuries.

WARNING This indicates a situation that may be dangerous. Failure to observe these notices can lead to death or serious injuries.

CAUTION! This indicates a situation that may be dangerous. Failure to observe these notices can result in slight injuries. In addition, there is a risk of considerable damage to property.

The following notice types are used in this manual

NOTE! This is used for notices which, if not observed, can lead to a disruption in operating procedures.

TIP! This is used for notices which can lead to an improvement in operating procedures if observed.


Page | 1-7

2.

Safety This chapter describes how to handle the TH6D system safely and describes its correct and intended usage. 2.1

General safety instructions ............................................. 2-2

2.2

Laser safety .................................................................... 2-4

2.2.1

Dangers posed by class-3B lasers .................................... 2-4

2.2.2

Retro-reflection ............................................................. 2-5

2.2.3

Laser aperture on the TH6D sensor head .......................... 2-5

2.2.4

Operating the laser safely ............................................... 2-6

2.3

Particular dangers .......................................................... 2-8

2.3.1

Master machines............................................................ 2-8

2.3.2

Excessive pressure and emitted substances ...................... 2-8

2.4

Protective safety measures during normal operation....... 2-9

2.5

Proper and intended usage ............................................. 2-9

2.6

Warrantee and liability ................................................. 2-10

2.7

Information and warning signs on the TH6D sensor head ............................................................................. 2-11

2.8

Disposal........................................................................ 2-12


Page | 2-1

Safety

2.1

General safety instructions The following points contain general safety information that must be observed when operating the TH6D system. Obligations of

The TH6D system must only be mounted, operated and maintained by

the facility

trained personnel. These personnel must be able to recognize possible

manufacturer,

dangers or malfunctions based on pertinent experience gained from

operating

operating automated production facilities. They must also have knowledge

company and personnel

of all applicable standards and safety measures. It is the responsibility of the laser safety officer to ensure that personnel operating the laser system are sufficiently trained. Every person who installs, operates or services the TH6D system must understand and follow the contents of the manual. These regulations are also intended to prevent accidents and must be followed: • 2006/25/EC "minimum requirements to protect health and safety of workers from the risks arising from physical agents (artificial optical radiation)", • BGV B2 "laser radiation" (formerly VBG 93), • the standards DIN EN 60825-1 and DIN EN 60825-4 "Safety of laser equipment". Also observe the information found in Chapter 2.5, "Proper and intended usage".

Safety

The operator of the system is responsible for labelling the system properly.

equipment

The operator must also provide an adequate screening or perimeter to prevent access to the danger zone. The proper measures should be taken to ensure that no unauthorized personnel are allowed access to the danger zone. Please observe the information found in point 5.3 in DIN EN ISO 11553-1 "Carrying out corrective measures" which pertains to safety equipment. Ensure that automatic operation of the facility is impossible when safety equipment is open or disabled. The prescribed safety equipment required for operating this system must be available, installed and ready for use. Faults and malfunctions, in particular those that impair safety, must be rectified immediately. You must regularly check the effectiveness of the safety mechanisms!

Initial

The TH6D system should only be commissioned and used when it is in a

commissioning

technically flawless condition (refer to Chapter 5, "Initial Commissioning

and operation

and Operation"). Incorrect operation or misuse can result in danger to life and limb. The efficient functioning of the TH6D system can also be impaired. Damage to the TH6D system and to surrounding property is also possible. No personnel should be located in the danger zone of the facility during operations. Danger zones must be cordoned off and inaccessible.


Page | 2-2

Safety

Protective clothing

Always wear appropriate BGVB2-compliant (previously VBG 93) laser safety glasses when working in a designated laser radiation danger area. When replacing cables or the protective glass on the TH6D sensor head, allow the processing head to cool down after the work process or be sure to wear protective gloves.

Accident

The accident prevention regulation BGV B2 "Laser radiation" (previously

prevention

VBG 93) must be followed when operating the TH6D sensor system. The

according to the

employee liability insurance association and the relevant worker's safety

BGV B2

authorities should be notified before you start working with any class-3B

regulation

or class-4 laser equipment. You must mark and restrict the laser working ranges of any class-3B or class-4 laser equipment. The operator of the sensors must restrict access to the laser's working range.

Cleanliness

Contaminated optical elements (the protective glass and integrated protective glass in the reception and transmission modules) can impair the functionality of the TH6D sensor head! Therefore you should only work with clean equipment. Regular inspections and necessary cleaning should be carried out during servicing. A dirty protective glass should be cleaned or replaced. Contaminated integrated safety glasses must be replaced. The TH6D system should then be sent in for repair in such cases.

Maintenance

Always be sure that the power supply is disconnected before starting any

and repair

maintenance procedures. Also be sure that it cannot be accidentally switched on during maintenance. This will reduce the risk of dangers such as laser light, unanticipated robot movements or crushing hazards. Damaged components or safety glass may have sharp edges. Be very careful when replacing these parts. Use only genuine (original) spare parts and genuine expendable (wearing) parts. There is no guarantee that parts from third-party suppliers will meet construction specifications with regard to load capability or safety. When ordering parts, specify the exact name, the article number according to the spare parts list and the serial number of your device! Follow the information regarding maintenance and repair found in the DIN EN ISO 11553-1:2009-03 standard.


Page | 2-3

Safety

2.2

Laser safety Laser class

For the purposes of accident prevention regulations, a laser device's class indicates the radiation-related risk posed by the accessible laser beam. The following TH6D sensor types are classified as laser equipment in laser class 3B, according to DIN EN 60825-1 (VDE 0837-1): 2008-05. • TH6D-150-CFxx-yy • TH6D-150-KFxx-yy The TH6D sensor heads use laser diodes with a maximum power of 40 mW at a wavelength of 660 nm. For measuring purposes, they project three laser lines onto the work piece being processed. The actual output of the emitted radiation may be reduced depending on the beam shaping being used and the mode of operation.

Wave length

WARNING!

range and Laser radiation is dangerous to human health!

power

• Laser safety goggles should be worn when working with and on the TH6D system! The emitted laser radiation is hazardous to the eyes and can also harm the skin in certain cases. Please follow the related information found in the BGV B2 "Laser radiation" (previously VBG 93): § 2, section 3, number 4. Make sure that all persons in the vicinity of the running TH6D sensor system are wearing protective safety goggles which guard against laser radiation.

2.2.1 Dangers posed by class-3B lasers Overview

When operating the TH6D system, specific hazards may be present based on how the laser beam is used. Laser equipment can produce extremely intense, highly focused radiation in the visible, infra-red or ultraviolet spectrum. The laser radiation has photo-chemical, thermal and opto-mechanical influences which can be hazardous to your health.

CAUTION! Please refer to the instructions about accident prevention regulation found in BGV B2 "Laser safety" (section 2.1).


Page | 2-4

Safety

Dangers from

It is dangerous to look directly into the laser beam or into the beam's

laser radiation

reflection (see also section 2.2.2). ). Your eyes could be permanently damaged. It is essential that you wear safety goggles and maintain a safe distance from the maximum permissible radiation areas. In order to avoid accidents, work safety measures must be implemented and followed. The dangers posed by diffuse reflection from laser radiation are relatively low. However you should avoid exposure to longer periods of diffuse reflection (longer than 10 seconds). You should also avoid avoi observation distances under 13 cm. Work pieces, pieces, optical lenses or mirrors which lie in the beam's path can narrow the beam and actually increase the danger of directed or reflected laser beams. Make sure that such components do not lie in the beam's path! path

2.2.2 Retro-reflection General hazards

DANGER Danger from reflected laser beams! • Do not direct the laser beam towards reflective surfaces! Directional retro-reflections retro reflections can occur when working with reflective materials. Reflections of the laser beam off of the work material can damage your skin and eyes.

2.2.3 Laser aperture on the TH6D sensor head Position

The laser aperture is located at the bottom of the TH6D sensor head. (See Figure 1.) .) This location is marked with a warning label.

Aperture

Figure 1: TH6D sensor head – laser aperture


Page | 2-5

Safety

2.2.4 Operating the laser safely Overview

Laser devices which are supplied as components for a system are not subject to IEC 60825-1, 1, since the final product itself is subject to this standard. If the laser system can be removed and operated separately from a facility, then the requirements of IEC 60825-1 pertain to the stand-alone component. This also applies to TH6D-series laser equipment uipment that can be operated as stand-alone alone devices, especially for the sensor types listed in Chapter 1.1.

Sensor safety

According to DIN EN 60825-1 (VDE 0837-1): 1): 2008-05, 2008 every class-3B laser systems must have a key-operated operated main switch. The key for the switch must be removable. It must not be possible to switch swit on the laser beam when the key switch is deactivated. The TH6D sensor head has no dedicated key switch. The TH6D sensor head has a separate power supply for the diode laser so that the laser can operate safely. Thus the voltage for the laser diodes (24V_LSK) (24 is only applied when the laser safety circuit is closed, when the key is turned in the switch and when safe operations are ensured. The laser safety circuit has a safety lock function. No laser radiation is emitted when there is no laser power supply. Two redundant orange LEDs are used to signal when the laser power supply is applied to the TH6D sensor head. (Refer Refer to section 3.5.1.) This warning LED indicates s that laser radiation is being emitted or that the system is ready to emit laser radiation.

1

Figure 2:: Location of the warning LED on the TH6D sensor head


Page | 2-6

Safety

The wavelength of the warning LED is 606 nm. When selecting safety goggles, ensure that you can still see the warning LED clearly with the goggles on. It the operating personnel cannot see the warning light visible from their secure positions, then additional acoustic or visual warning signals should be attached during the installation of the TH6D sensor system. When installing the sensor heads listed in section 1.1, make sure that the laser beam cannot inadvertently expose the skin or eyes over the allowable limits as specified in EN 60825-1 (VDE 0837-1): 2008-05. Safety measures

Possible safety precautions include setting up supervised access areas and implementing personal protective measures. Contacts made to the laser safety circuit (for monitoring the area in which hazardous laser radiation is present) must be fail-safe or redundant. The installer or commissioning engineer is responsible for ensuring safe operation for the TH6D system in compliance with DIN EN 60825-1 (VDE 0837-1): 2008-05. The safety clearance gap (with respect to the range of the unhindered laser beam) is 3 metres. A gap of 3 metres must also be maintained from reflected beams that could come from any other objects. Focusing optical elements may not intersect the beam path, since this would increase the minimum safety gap required. The currently valid MPE values (values of the maximum permissible exposure according to 60825-1 (VDE 0837-1): 2008-05) are as follows: • Irradiation of the cornea (exposure time 10 s to 3×104 s): 10 W/m2 • Irradiation of the skin (exposure time 10 s to 3×104 s): 2 kW/m2


Page | 2-7

Safety

2.3

Particular dangers The particular dangers that can occur while installing, mounting and operating the TH6D system within a production facility are described below. Design measures were carefully integrated into the construction of the TH6D system so that dangers posed by emitted substances ("media") and voltages would be minimized. Non-approved usage can cause damage to the modules or components. Your own health and the health of others should be your primary consideration. Ensure that all voltage sources have been switched off to the facility during set-up or maintenance procedures. The TH6D sensor system should be switched off and the pneumatic systems should be depressurized. Make sure that the facility cannot be turned on again unintentionally.

2.3.1 Master machines DANGER! There is a risk of injury from the master machines! • Do not stay in the swivel range of master machines when they are turned on! • Disconnect the power supply before working on any processing device! Depending on the particular application, the TH6D sensor head may be moved under the control of master machines. Serious injury or even death can result from being in the swivel range of a master machine. It is very dangerous and prohibited to work in the operating range of the master machine (e.g., when setting up the process). You should pay special attention to the instruction manuals of the other devices in use and their relation to the operation and safety of the master machines.

2.3.2 Excessive pressure and emitted substances WARNING Excessive pressure in the media lines can lead to eye and ear damage or other injuries! • Always wear the proper protective eye glasses, ear protection, and clothing when changing pressurized lines and hoses!!

Forbidden, excessive pressure leads to an increased risk of injury. Follow the pressure specifications given in the Technical Specifications section in Chapter 8. Extremely loud noises can occur when changing the pressurized media-supply hoses. Damage to hearing could result. Always wear proper ear protection while making the change. Pressurized lines can whip back and forth after they are disconnected. This can lead to eye or bodily injuries. Always wear proper eye protection and protective clothing while making the change.


Page | 2-8

Safety

2.4

Protective safety measures during normal operation Overview

The lifespan of the integrated laser diode may be shortened if you are operating with an enclosure temperature that exceeds the specified operating temperature. Make sure the temperature stays in the specified range. Operations outside of the specified temperatures will lead to a temperature-related decrease in the absolute measurement accuracy.

Protective

The following safeguards are available during normal operation:

measures • Glass panes with anti-reflective coating which have been built into the TH6D sensor head (refer to section 3.3.1) • An extra, standard safety glass unit with an additional plastic safety glass that has been integrated in front of the panes (refer to section 3.3.2) • Purging air is supplied to the TH6D sensor head in order to increase the durability of the plastic safety glasses • Built-in connections for air-cooling the TH6D sensor head

2.5

Proper and intended usage DANGER! Follow the proper and intended use guidelines! The TH6D system must not be used: • in facilities which have defective safety equipment. Follow the specification concerning the surrounding conditions and media as described in Chapter 8, "Technical Data and Specifications"!

Proper and

The TH6D system is used exclusively as a module that is installed as part

intended usage

of a production facility. The TH6D system is an optical measuring system that automatically detects the shape of work pieces. It represents stateof-the-art technology. The TH6D sensor head was designed to be mounted on a master machine (for example, a robot). It may also be used in facilities where the processing head is fixed in position and the work pieces move. The TH6D system was designed and manufactured in accordance with recognized technical safety regulations. The TH6D system should be used for its intended purpose only.


Page | 2-9

Safety

Proper and

Incorrect usage or incorrect operation can lead to danger of death or

intended usage

serious damage to health and property. Improper or incorrect usage

- continued

absolves the manufacturer from all liability! The TH6D system must only be operated when in perfect technical condition. During the initial commissioning,

all

necessary

safety

measures

must

be

taken

in

accordance with applicable regulations. You must observe the safety instructions and notices contained in this manual. The user must read and understand the manual before working with the TH6D system. We recommend that you take additional Scansonic training.

2.6

Warrantee and liability

CAUTION! Please observe the warrantee and liability claims description!

Warrantee and liability claims for personal injury and damage to property are not possible if they are attributable to one or more of the following causes:

•

Improper or incorrect usage of the TH6D system,

•

Incorrect installation, commissioning or operation of the TH6D system,

•

Operating the TH6D system when safety equipment is defective or not properly installed, or operating the module when safety and protective devices are not functioning,

•

Failure to observe the notices in the User's Manual regarding installation, commissioning and operating the TH6D system.

•

With all alterations of the TH6D system,

•

When operated outside of the specifications given in the configuration data sheets.


Page | 2-10

Safety

2.7

Information and warning signs on the TH6D sensor head The illustration below indicates the location of the notices and warning signs on the TH6D TH sensor head.

NOTE Always maintain the signs so that they are in a good, readable condition.

Table 1:: Position of notice and warning signs

Figure

Item 1

Description Serial number of the TH6D sensor head (example)

S/N: 14xxxxxx Manufacturing date 20xx/xx

1 2

Company logo with configuration number (example)

2

3 3

4

4

Labelled connections

5

Warning for laser beams (W010)

5 6

6


Page | 2-11

Safety

2.8

Disposal Note

The TH6D system can be returned free of charge to Scansonic IPT GmbH for disposal (excluding delivery charges). Otherwise, you should dispose of the TH6D system according to environmental regulations restricting the disposal of electrical waste.


Page | 2-12

3.

Product Information This chapter describes the properties and functions of the TH6D system. 3.1

Overview ........................................................................ 3-2

3.1.1

Special characteristics .................................................... 3-2

3.1.2

Possible applications ...................................................... 3-2

3.1.3

How it works ................................................................. 3-3

3.1.4

Definition of the coordinate system .................................. 3-4

3.2

Usage limitations ............................................................ 3-5

3.2.1

The influence of work piece reflection ............................... 3-5

3.2.2

Influences from the welding process ................................ 3-6

3.2.3

The influence of accessibility ........................................... 3-8

3.2.4

Influences of material thickness and step height ................ 3-9

3.2.5

Limitations caused by the temperature range .................... 3-9

3.2.6

Influence of the sensor's orientation in relation to the work piece surface ....................................................... 3-10

3.2.7

Limitations caused by the gap dimensions ...................... 3-10

3.2.8

Limitations caused by the operating voltage .................... 3-10

3.3

Descriptions of modules and components ..................... 3-11

3.3.1

TH6D sensor head ....................................................... 3-11

3.3.2

Safety glass unit .......................................................... 3-12

3.3.3

TH6D process computer................................................ 3-13

3.3.4

Mains power supply unit ............................................... 3-14

3.3.5

Cable ......................................................................... 3-14

3.3.6

Cooling module ........................................................... 3-15

3.4

Additional machine-dependent modules........................ 3-17

3.4.1

Analogue-digital interface (ADF) .................................... 3-17

3.4.2

Calibration plate .......................................................... 3-18

3.4.3

Network cable ............................................................. 3-19

3.5

Status LED for the TH6D system .................................... 3-20

3.5.1

Status LED on the TH6D sensor head ............................. 3-20

3.5.2

Status LED on the TH6D process computer ..................... 3-22

3.6

TH6D system interfaces ................................................ 3-24

3.6.1

Connections for the TH6D sensor head ........................... 3-24

3.6.2

Connections for the TH6D process computer ................... 3-26

3.6.3

Machine interfaces ....................................................... 3-27

3.7

Operating and configuration interface for THxDView ..... 3-28


Page | 3-1

Product Information

3.1

Overview The TH6D system is an optical measuring system that can detect and measure the shape of work pieces. It is designed for seam tracking during the joining process, but can be used for other measurement tasks. When integrated in a welding facility with other master machines and robots, this system can track the seam joint. The TH6D system can also measure the gap width, the edge offset and the distance of the joint line from the work pieces being welded or soldered. In addition, the TH6D system measures the orientation of the sensor head over the work piece surface (the push/drag angles, the lateral angle, the angle of rotation and the vertical axis). These measurements are used to automatically guide the production facility. The sensor system records any variations in the work pieces and positions. The weld seam can then be automatically corrected with high precision and reliability.

3.1.1 Special characteristics The TH6D system offers the following features and advantages:

•

Integrates the latest optical sensor technology

•

Three measuring lines are used to guarantee safe seam tracking

•

Also works with shiny surfaces such as aluminium or chrome-nickel steel

•

Can handle work piece surfaces that have high contrasts

•

Not sensitive to splashing or stray light

•

Minimal obstructive contour

•

Long operating clearance

•

Equipped with integrated cooling ducts for heat dissipation

•

Easy to operate with an intuitive user interface (GUI)

•

Minimizes the set up time required for individual production runs

•

Ensures a consistent quality in the process when producing large quantities

The TH6D system is being continuously improved upon and adapted to meet the needs of our customers. We are also constantly improving the interfaces to available machine controllers. The TH6D system has proven its usefulness with multiple robot variants in various industrial reference installations. In these facilities, the seam tracking system ensured that work piece/positional variances could not impair the welding process.

3.1.2 Possible applications The TH6D system can be used as a peripheral for automatic seam tracking in the following processes: laser welding, standard welding, joining processes, brushing and grinding. It can also be used in other applications requiring sensory guidance along a geometric structure, such as a robotic welding facility or a welding system that uses custom machines. The corresponding application interfaces for the TH6D system can be provided.


Page | 3-2

Product Information

3.1.3 How it works The measurement

The laser stripe sensors in the TH6D series provide no-contact detection

mechanism

and measurement of work pieces using the principle of laser triangulation. (As shown in Figure 3.) A light pattern consisting of three parallel laser lines is projected at an angle of 20 degrees onto the work piece surface and then scanned vertically with a digital camera. These light beams are influenced by the oblique projection at the joint; the beam interruption marks a seam point along the joint.

1 2 3 7

6

4

5 Figure 3: TH6D – The principle of laser triangulation

Description

Item

Description

1

Laser diode

2

Collimator optics

3

Projection optics

4

Measurement 1 and measurement 2

5

Measured object/work piece

6

Lens / receiver optics

7

Light detector


Page | 3-3

Product Information

3.1.4 Definition of the coordinate system The directions of movement for the TH6D sensor head are defined as follows:

S0:

+z

Direction

Sensor origin Direction of process feed

along the X

S0

axis:

+y

+x Direction

Lateral correction

along the Y axis Direction

Distance (gap) correction

along the Z axis:


Page | 3-4

Product Information

3.2

Usage limitations Overview

The possible usages for optical seam tracking systems are limited by the physical environmental conditions present during the welding process. The reflective properties of the work piece's surface are a major factor, since all measurements are deduced from the reflected beam pattern. Since the sensor head works in the immediate vicinity of the welding process, interference emitted by the process should not be able to impair the sensor functionality. Welding splatter, smoke, flickering light and EMC interference are all by-products of arc welding.

3.2.1 The influence of work piece reflection Overview

When using optical sensors for weld-seam tracking, a good understanding of surface reflectivity is required in order to optimally adjust the laser brightness and sensor orientation. When working with an ideal reflective surface (as shown in Figure 4 on left), the light source (a diode laser) is directed at the work piece surface at an angle of incidence θL so that the laser beam is completely reflected at the reflection angle θr. No light is emitted in the direction "n" towards the camera, so there are no laser lines visible in the camera image. However, for very smooth and shiny work piece surfaces, only a small fraction of the emitted light is diffusely reflected (as shown in Figure 4 on right), so that laser lines are faintly visible (when working with stainless steel and aluminium, for example).

Figure 4: Specular (left) and diffuse (right) reflection

Possible solutions

There are two possible ways to improve this situation. The laser output can be increased or the mounted position of the sensor head can be changed.

Increasing the laser output

More powerful laser output is not always available and results in unwanted stray light on the work piece and the surrounding clamping mechanisms.


Page | 3-5

Product Information

Changing the

If the sensor head is tilted slowly in the direction of travel, the angle θL is

mounting position

reduced and thus the maximum of the reflection lobe moves toward the camera window. The result is a pronounced change in brightness of the measured lines when the slope of the sensor changes. The surfaces of real work pieces, particularly for shipbuilding applications, can be very rough so that the laser beams are scattered diffusely. For such surfaces, hardly any brightness changes of the measurement lines should be expected. Incident beams

Reflected beams

Rough surface

Figure 5: Diffuse reflection on work piece with rough surface

3.2.2 Influences from the welding process Welding splatter,

Very strong interference can occur in the sensor camera's field of view

smoke

which can then harm the imaging. Welding splashes, smoke and intense brightness caused by the arc can interfere with the camera's image. The bright lines visible in Figure 6 represent splatter (molten welding metal) that extends radially in all directions from the welding process. Metal balls which have cooled are already present on the surface of the work piece.

Figure 6: Disturbances in the arc welding process


Page | 3-6

Product Information

Solution

In the TH6D system, the image is recorded using a camera with an

C-MOS camera

extremely broad range of light sensitivity. The brightest areas of the image can be portrayed equally well as the darkest areas. The master controller associated with the CCD camera is no longer needed with the TH6D system. Arc and laser welding tests carried out with the TH6D system clearly show that the C-MOS technology is superior for these applications.

Figure 7: MIG process – the inert gas nozzle is clearly visible on the right

Figure 8: Laser welding process – laser focus on right


Page | 3-7

Product Information

3.2.3 The influence of accessibility Accessibility

Another constraint on the use of the TH6D system is the unavoidable advance of the sensor origin in relation to the TCP. Especially during arc welding processes, this represents a significant constraint for the robot programming. Without the TH6D sensor head, the burner can be moved in any direction. With the TH6D sensor head, the welding tool is forced in a forward direction. Figure 9 illustrates this restriction using the example of a laser welding optics with the TH6D sensor head. Since there is a forward-leading sensor head, the weld seam cannot be processed all the way up to the vertical wall of the work piece. A closer approach to such a wall is only possible if the welding optics are put into an increasingly limited stabbing position.

Figure 9: Accessibility limitations at the end of the seam caused by the forward-leading sensor

Figure 10: Accessibility limitations in a seam curve caused by the forwardleading sensor


Page | 3-8

Product Information

3.2.4 Influences of material thickness and step height Overview

Problematic applications may limit the seam tracking system; such limits can be worked around by changing the position or alignment of the sensor.

Problem

Figure 11 illustrates a recorded measurement from the TH6D system. The measured area is divided visually into two sections (left and right); the three laser lines depict the step made by a lap joint. Visually, the number of laser lines changes from three to six. In this example of a border, the step height of the lap joint is so large that laser lines 2 and 3 (at left) coincide with laser lines 1 and 2 (at right).

left

right

1 2

1

3

2 3

Figure 11: Example of a border – the lap joint is too large

Solution

By changing the drag angle slightly by five degrees, this unfavourable situation can be resolved so that reliable detection is again possible. (As shown in Figure 12.)

left

right

1 2

1

3

2 3

Figure 12: Example of a border – the lap joint is too large – the solution

3.2.5 Limitations caused by the temperature range Overview

Usage of the TH6D system is limited by the permissible temperature ranges.

Information

Follow the specifications concerning the ambient conditions, as described in section 8.5!


Page | 3-9

Product Information

3.2.6 Influence of the sensor's orientation in relation to the work piece surface Overview

The mounted position of the TH6D sensor head on the tool must be flexible since the tool itself has precedence over priority positioning. Thus, the TH6D sensor head may need to be aligned at an angle lateral to the seam line or at a drag angle. For this lateral angle, limitations to the mounting positions are imposed by the diminishing reflection, particularly when working with smooth or specular surfaces. Field-tested lateral angles are in the range from 15 to 20 degrees. Other angles may be possible depending on the shape of the work piece (its T-joint). The TH6D sensor head is mounted in a lancing or drag angle of ± 40 degrees perpendicular to the work piece. The software will not function if the positioning angle is outside of this range.

3.2.7 Limitations caused by the gap dimensions Overview

For a butt joint, the lower limit of the gap is dependent on the quality of the surface, with the following dimensions: • TH6D-CFxx-yy at 0.2 mm and • TH6D-KFxx-yy at 1.0 mm. Preparing the seam can have a significant impact on the seam detection process. Even minimally rounded edges at the butt joint are very helpful and can stabilize the seam detection process. Since the TH6D system only evaluates the work-piece surface, the measured gap dimension is also strongly dependent on such rounding.

3.2.8 Limitations caused by the operating voltage Overview

Limitations imposed by the operating voltage are necessary for the proper functioning of the TH6D system.

NOTE! Make sure that you are using VDE-compliant and certified power supplies! Information

Please

note

the

voltage

specifications

as

listed

in

the

Technical

Specifications section found in section 8.1!


Page | 3-10

Product Information

3.3

Descriptions of modules and components

3.3.1 TH6D sensor head Overview

The TH6D sensor head consists of the following components:

1

9

2

8

3

7

3

6

5

4

Figure 13:: The TH6D sensor head

Components

Item

Description

1

Sensor enclosure

• Supports and protects the sensor components

2

Enclosure cover

• Protects the components

3

Notice and warning signs

• Informs and warns of dangers

4

Safety glass for laser diode

• Protects the diode

5

Rod for the safety glass unit

• For attaching glass unit

6

Protective

• Protects the camera

glass

Function

for

sensor

sensor

safety

camera 7

LED showing system status

• Displays status

8

LED showing power supply

• Displays status

9

Terminal area

• Power supply • Adjusting parameters • Cooling


Page | 3-11

Product Information

3.3.2 Safety glass unit Overview

The standard safety glass unit uses an extra plastic protective glass to cover the protective glasses that are built into the TH6D sensor head. This additional safety glass protects against long-term contamination from welding splatter and deposits. Thus it is difficult to clean and designed as a replaceable wearing part.

Increasing the

Splatter and deposits reduce the life of the plastic safety glass. This life

life span

span can be increased by using clean purge air. A hose for purge air can be connected to the X1 interface for this purpose (refer to section 4.4.9). The purge air should be turned on and off in a way that prevents excessive contamination. You may want to have lead time and follow time for the purge air. This can be useful when when you are using a long supply hose and because deposits and steam require some time to remove.

Construction

The safety glass unit consists of a protective plate and the receptacle which holds the safety glass. (Refer to Figure 14.) The protective plate shields the unit from radiation coming in from the sides.

1 5 2 3

4 Figure 14:: TH6D safety glass unit

Components

Item 1

Description Safety glass

Function • Holds the safety glass in place

clamps 2

Protective plate

• Protects against process influences

3

Protective plate

• Adjusts the opening of the safety glass unit to the particular process

tabs 4

Safety glass

• Protects the built-in built protective glasses on the TH6D sensor head

5

Receptacle

• Holds the safety glass and protective plate


the

Page | 3-12

Product Information

Adjusting the

CAUTION!

protective plate Do not bend the tabs on the protective plate into the measurement field. The safety glass unit can be adapted to various types of applications by gently bending the tabs on the protective plate. Do not bend the tabs into the sensor's measurement field. You can check that your positioning is correct by using the "raw data" image area in THxDView.

3.3.3 TH6D process computer Overview

The controller for the TH6D system runs on the TH6D process computer. • Controlling the sequence of the TH6D system

General tasks

• Controlling and monitoring of the TH6D sensor head • Processing and output of measurements from the TH6D sensor head • Interface for controlling the master machine/robot The TH6D process computer consists of the following components:

1

5 2

4

3 Figure 15: TH6D process computer

Components

Item

Description

Function

1

Housing

• Supports and protects the sensor components

2

Connection panel (front)

• Connection options • Status indication

3

Mounting rails

• Mounting the TH6D process computer

4

On/off switch

• On/off switch (standby)

5

Connection panel (back)

• Connection options

Mains power supply unit

• Power supply

-

(not pictured)


Page | 3-13

Product Information

3.3.4 Mains power supply unit Overview

The TH6D process computer and the TH6D sensor head require a separate power supply unit to supply power from the mains.

TH6D process computer

A power supply unit is included in the delivery and is used to supply power to the TH6D process computer. Section 4.4.12 describes the connections. Power can be supplied to the TH6D process computer using an industrial top-hat rail.

The TH6D sensor

A separate mains power supply (separated from the TH6D process

head

computer) should be used for the TH6D sensor head. A suitable mains power supply is available from Scansonic.

NOTE! For more information on power supplies, please contact Scansonic or your local service representative.

3.3.5 Cable Overview

The TH6D system comes with a set of cables. This set consists of one cable each for the: • Ethernet connection (see Figure 16) • Power supply (see Figure 17) The cable set can be configured to lengths of 10, 15 or 25 metres. The number of your cable configuration can be found in the list in section 8.3.

Cable for the Ethernet connection

An Ethernet connection is used as the data link from the TH6D sensor head to the TH6D process computer. • It supports 100BASE-T Ethernet (Fast Ethernet). • Section 4.4.7 describes this cable connection.

Figure 16: TH6D system – cable for Ethernet connection


Page | 3-14

Product Information

Power supply

A separate power supply unit is used to supply power to the TH6D sensor

cable

head. This power supply is built into the production facility. Section 4.4.8 describes this cable connection and pin assignments.

Figure 17: TH6D system – power supply cable

3.3.6 Cooling module Overview

The optional cooling module is made of chrome-nickel chrome steel. It consists of a heat shield and a cooling block. The cooling module is mounted to the housing of the TH6D sensor head. This additional cooling module is integrated into the facility's cooling circuit. It protects against permanent, excessive heat build-up build up during the production process.

Usage

The

cooling

module module

can be

used

under

the

following

application

conditions: • An ambient temperature above 45°C (seasonal / location) • When the workpieces are preheated before welding (must be verified) • Longer welding times and with multi-layer layer welding

ATTENTION! Refer to section 8.5 for more information on ambient conditions.


Page | 3-15

Product Information

Construction of

The cooling module consists of a heat shield and a cooling block used for

the cooling

connecting the cooling liquid. (Refer to Figure 18) 18 The heat shield is used

module

to shield against against lateral radiation and to dissipate the heat. The facility's cooling circuit is used as the heat exchange mechanism.

4

1

3 2

Figure 18: The TH6D sensor head's cooling module

Components

Item

Description

1

Cooling block

• Holds the safety glass and protective plate

2

Heat shield

• Protects against process influences

3

Screws

• Mounts to the TH6D sensor head

4

Coolant connections

• Connection for liquid coolant


Function the

Page | 3-16

Product Information

3.4

Additional machine-dependent machine modules Overview

The following auxiliary modules are available for the TH6D system: • Analogue-digital interface • Calibration plate • Network cable (patch cable for Ethernet)

3.4.1 Analogue-digital digital interface (ADF) Analogue-digital

The analogue-digital analogue digital interface (ADF) allows you to override and intercept

interface – ADF

signals going to or from the TH6D system. A WAGO bus terminal is used for the ADF. An Ethernet bus coupler is used to communicate with the TH6D system. The ADF is also used for the Motoman interface. Figure 19 shows the standardized construction of the analogue-digital analogue interface

(ADF).

The

interface

consists

of

a

bus

coupler,

digital

input/output terminals, analogue output terminals and one end terminal. ter

Figure 19: TH6D auxiliary module – analogue-digital analogue interface

Signal input

Process parameters are permanently assigned to the analogue outputs in

through the

the TH6D system. This means that a particular analogue output is always

facility controller

represented by the same process parameter. The user needs to integrate signals in the production facility's controller controller which are maintained there as process records.

Information

Section 4.5.1 includes a description of the types of bus terminals and the ADF connection. Section Sectio 8.2 contains more information about the input/output assignments.


Page | 3-17

Product Information

3.4.2 Calibration plate Calibration plate

The calibration plate helps you to calibrate the tool for various machine interfaces. The TH6D sensor head is aligned to the tool and the sensor coordinate system is aligned with the machine coordinate system.

1 2

Figure 20: TH6D auxiliary module – calibration plate

The following inserts must be ordered specifically: Item

Figure

Designation

1

Tip insert

• Recommended when using laser optics

2

Cross-hairs

• Recommended when using a welding torch

insert

Information

Description

Section 5.14 contains more information about setting up and calibrating the tool.


Page | 3-18

Product Information

3.4.3 Network cable Overview

Network cables (patch cables) are used by the following system components for Ethernet communications. • Analogue-digital interface (ADF) to TH6D process computer • Fanuc interface to TH6D process computer • THxDView (user PC) to TH6D process computer The ADF auxiliary module is delivered with a 0.5 metre cable. Network cables of varying lengths can be ordered from Scansonic for extensions or re-positioning.

Characteristics

• Fully shielded CAT-6A patch cable • Shielded RJ45 connector • Oil-resistant • Suitable for 10GBit Ethernet

Figure 21: TH6D auxiliary module – network cable

Information

A listing of possible cable lengths is included in section 8.6.2.


Page | 3-19

Product Information

3.5

Status LED for the TH6D system

3.5.1 Status LED on the TH6D sensor head Overview

NOTE! The status LEDs on the TH6D sensor head display information about the state of the TH6D system. The LEDs on the TH6D sensor head display the status of the sensor and the Ethernet connection.

Functions

The P1 through P4 LEDs have following functions (refer to Figure 22): No.

Description P1

Laser supply voltage ON (redundant)

P2

Laser supply voltage ON (redundant)

P3

POWER indicator

P4

Ethernet link status indicator

P2 P1

P3 P4

Figure 22:: Status LEDs on the TH6D sensor head


Page | 3-20

Product Information

Status display

The P1 and P2 LEDs only show the status of the supply voltage. The P3 and P4 LEDs have the following additional functions: No.

Colour

P3

Off

Status • Supply voltage is OFF • or the power cable is not connected

Red

• Sensor start-up phase • or an internal error has occurred

Green flashing light Green

• The sensor is trying to establish an Ethernet connection • Ethernet link is established • The sensor is ready for operations

Off

P4

• No Ethernet connection • or cable is not connected

Red

Green flashing light Green rapidly flashing light


• Ethernet link is established but there has been no communication • Ethernet link is established • Communication is established • Laser is ON • The status is identical for automatic and set-up modes

both

the

Page | 3-21

Product Information

3.5.2 Status LED on the TH6D process computer Overview

NOTE! The status LEDs display information about the state of the TH6D process computer. The available LEDs display the following functions for the TH6D process computer.

Status LED

Designation

Description

PWR

Operating state of the TH6D process computer

HDD

Activity display for data storage

LNK1

Network connection for THxDView is connected

ACT1

Network

connection

for

THxDView:

data

being

transmitted LNK2

Network connection 2 is connected

ACT2

Network connection 2: data being transmitted On/off switch and supply voltage indicator

Figure 23: Status LEDs on the TH6D process computer


Page | 3-22

Product Information

Status indication

The LEDs on the TH6D process computer differ according to their status: No. PWR

HDD

LNK1

ACT1

Colour

Status

Green

• TH6D process computer is turned on

Off

• TH6D process computer is turned off

Flashing orange

• Data memory is active

Off

• Data memory is not active

Green

• A network cable is connected

Off

• No network cable is connected

Flashing orange

• Data is being transferred

Off

• No data is being transferred

LNK2

Refer to LNK1

ACT2

Refer to ACT1 Blue

• Supply voltage is present; TH6D process computer is turned on

Red

• Supply voltage is present; TH6D process computer is turned off

Off

• No supply voltage


Page | 3-23

Product Information

3.6

TH6D system interfaces

3.6.1 Connections for the TH6D sensor head Control

NOTE! The TH6D sensor head is designed so that it cannot be plugged in incorrectly. It is easy to connect with existing power supplies.

X3 X2 X1 X5 X4

Figure 24: Connections for the TH6D sensor head

No.

Description

X1

Purge air for the safety glass

X2

Cooling air input

X3

Cooling air output

X4

Power supply

X5

Ethernet (process computer)


Page | 3-24

Product Information

Purge for safety glass

• Connection as required for interface X1 • Hose diameter: 4 mm More information on connecting the purge air and the media can be found in sections 4.4.9 and 8.4.

Air cooling

CAUTION! The enclosure for the TH6D sensor head is made of aluminium. Never allow water to run through the cooling channels: this could lead to corrosion!

NOTE! When using air to cool the TH6D sensor head, you may use a branch line with reduced pressure as purge air for the safety glass (refer to the specifications in section 8.4). Cooling air input

• Connection to the interface X2 (cooling air input) • Hose diameter: 6 mm • Max. 6 bar • Max. amount of air is about 300 litres per minute.

Cooling air outlet

• Optional connection to the interface X3 (cooling air outlet) • Exhaust outlet for the used cooling air

Power supply

NOTE! The negative terminal for the system supply and laser supply voltage (0 V) is electrically isolated from the system ground. • Connection to interface X4

Plug X4 X4 Pin-out

M12-L, shielded, 4-pin, A-coded Signal

Designation

Pin

assignments 0V__Power

System supply voltage 0V

1

24V_Power

System supply voltage 12-36V

2

0V__LSK

Laser protective circuit 0V

4

24V_LSK

Laser protective circuit 12-36V

3


Page | 3-25

Product Information

Ethernet

• Connection to interface X5 T Ethernet (Fast Ethernet) is supported. • Only 100-BASE-T

Plug X5 X5 pin-out

M12 M12-L, shielded, 4-pin, D-coded Signal

Designation

Pin

assignments

Information

Tx+

Ethernet transmission line (+)

1

Tx-

Ethernet transmission line (-))

2

Rx+

Ethernet receive line (+)

3

Rx-

Ethernet receive line (-)

4

Section 4.4 describes the installation.

3.6.2 Connections for the TH6D process computer Connection

The following connections are available on the TH6D process computer.

overview

1 2

3

4

8

9

5

6

7

Rear side

10

11 12

13 14

Figure 25:: Connection overview for the TH6D process computer, rear side

Front side

15

Figure 26: Connection overview for the TH6D process computer, front side


Page | 3-26

Product Information

Connections for

Item

Description

Item

Description

the TH6D process computer

1

Not used

9

COM port (RS232)

2

Power supply

10

Ethernet (data output)

3

Not used

11

Ethernet (TH6D sensor head)

4

Not used

12

Not used

5

Ethernet (data output)

13

Not used

6

Ethernet (THxDView)

14

Not used

7

Not used

15

Not used

8

Not used

3.6.3 Machine interfaces Communication

The

following

interfaces are

available

for

communicating

with

the

production facility (especially for the robot and system controls): • Ethernet TCP/IP • Analogue/digital/voltage/current interface (ADF) Currently, communications can be established with the following master machines or robots: • Linear axes (via analogue/digital interface) • Motoman • Fanuc • REIS • ABB Information

More information about connecting and configuring the machine interfaces can be found in sections 4.5 and 5.9. The inputs and outputs of the analogue-digital interface and the Motoman interface are described in the interface assignment tables found in sections 8.2 and 8.3.


Page | 3-27

Product Information

3.7

Operating and configuration interface for THxDView Interface

The PC-based THxDView software can be used as an operating / configuration interface in order to manually configure the TH6D system. The software should be installed on a PC at the facility. The physical interface between the facility PC and the TH6D system uses an Ethernet connection.

Functions

THxDView has the following functionality: • Setting parameters • Monitoring processes

Communication

Installation

• Ethernet is used for the communication link between the TH6D system and THxDView. Section 5.3 describes the installation.


Page | 3-28

4.

Set-up and Installation This chapter describes the set-up and installation of the TH6D system. 4.1

Included in the delivery .................................................. 4-2

4.2

Returns........................................................................... 4-3

4.3

Notes for set-up and installation ..................................... 4-3

4.3.1

Installation guidelines .................................................... 4-4

4.3.2

Application environment ................................................. 4-4

4.3.3

Cleanliness and cleaning ................................................. 4-5

4.3.4

Check-list for set-up and installation ................................ 4-5

4.4

Set-up and installation .................................................... 4-6

4.4.1

Tool centre point (TCP) and sensor origin ......................... 4-6

4.4.2

Tightening torque for screws ........................................... 4-8

4.4.3

Earthing provisions ........................................................ 4-9

4.4.4

Installation and basic positioning of the TH6D sensor head .......................................................................... 4-12

4.4.5

Mounting the safety glass unit on the TH6D sensor head .. 4-13

4.4.6

Mounting the cooling module on the TH6D sensor head .... 4-15

4.4.7

Connecting the Ethernet cable to the TH6D sensor head and process computer .................................................. 4-16

4.4.8

Connecting the power supply to the TH6D sensor head..... 4-18

4.4.9

Connection for the cooling and purging air at the TH6D sensor head ................................................................ 4-19

4.4.10 Connecting the liquid coolants to the cooling module ........ 4-21 4.4.11 Installing the TH6D process computer ............................ 4-22 4.4.12 Connecting the power supply to the TH6D process computer .................................................................... 4-23 4.4.13 Connecting a user PC for the THxDView configuration software ..................................................................... 4-24 4.4.14 Overview of connections without the machine interfaces ... 4-25 4.5

Connecting the machine-dependent auxiliary modules .. 4-26

4.5.1

Connecting the analogue-digital interface (ADF) .............. 4-26

4.5.2

Connecting the power supply to the analogue-digital interface ..................................................................... 4-28

4.5.3

Connection overview with connected ADF ....................... 4-30

4.5.4

Connecting the Fanuc interface ...................................... 4-31


Page | 4-1

Set-up and Installation

4.1

Included in the delivery Information

NOTE! Depending on your particular configuration, your TH6D system may differ from the TH6D system described here. The ordering documentation sent to you contains a more detailed

overview

of

your

TH6D

sensor

system

configuration. Included in the

The following components are included in the delivery:

delivery Base

• The TH6D sensor head • Safety glass unit • TH6D process computer • Cable set (two each of: 10 / 15 / 25 m) • Power supply unit for the TH6D process computer • CD/DVD with software (THxDView) The following components are optionally included in the delivery:

Optional

• Calibration plate (if required for connecting to ABB or KUKA robots) • Power supply unit for the TH6D sensor recommends using a separate power supply)

head

(Scansonic

• Machine-based auxiliary components (interface hardware that is specific for your facility: ADF, converter, serial ports, repeaters, network cables, etc.) • Cooling module • Wearing parts (safety glases) Inspection

Check your delivery to confirm that it is undamaged and complete based on the delivery receipt.

Transportation damages, etc.

In the event that there is damage or any discrepancies, please first contact the shipper.

Storage or

Keep the original packaging for storage or for the event that you need to

disposal of

send the device back to Scansonic.

packaging

If you cannot keep the packaging, please dispose of it in accordance with the relevant national environmental regulations.


Page | 4-2


4.2

Returns Information

WARNING! Hazardous residues! • Clean the TH6D system before you send it back! • When shipping the TH6D system back, be sure that you first package it safely! • Fill out the Contamination Declaration form. Be sure to package the TH6D system safely when returning it for service or repair. Proper packaging will protect service and shipping personnel from any hazardous residual gases.

Cleaning

4.3

If the TH6D system is extremely dirty, clean it and all its cable thoroughly.

Notes for set-up and installation Overview

DANGER Danger to life and limb! The TH6D system should only be mounted and operated by trained personnel. Be sure to observe the following: • You configuration should be installed on the master machine only after all currents and pressures are switched off. • The facility operator should limit access to the working area (the danger zone). • Stop the automatic run mode by opening up the protective disconnect or interlock mechanisms. • The power supply for the processing devices should be routed through the facility's emergencystop control circuit. • The emergency-off mechanism and all other control equipment must fulfil the requirements stipulated in DIN IEC 60204-1 and DIN EN ISO 13849-1.


Page | 4-3


4.3.1 Installation guidelines Leave the TH6D

By maintaining your Scansonic product in its original condition, you help

system in its

us to replace or reproduce it more quickly. Operational malfunctions can

original

result when additional components are installed on the TH6D system

condition

which deviate from the approved configuration. We recommend avoiding such additions! Any structural changes made to the TH6D system will result in the termination of Scansonic's warranty and liability!

Routing the cables and

Make sure that you preserve the motion capabilities of the TH6D system and master machine when routing the connecting cables and media lines.

media lines

4.3.2 Application environment Overview

DANGER Danger from laser radiation! • Follow the specifications concerning the laser radiation, as described in section 2.2! • Always observe the proper safety procedures for working with lasers!

CAUTION! When operating in a humid environment, make sure that the built-in safety glasses do not fog up. The TH6D system is designed to be used in standard welding facilities or laser processing cells. Thus it can be considered as a part of a laser facility. Take all necessary protective measures in the danger zone. Access to designated laser radiation areas must be restricted properly. Observe the condensation and moisture specifications for the ambient temperature

and

coolant

water

temperature.

Sharp

temperature

fluctuations can lead to condensation which can cause damage to the device. Be sure to observe to information listed in the condensation table found in Chapter 8 "Technical Data and Specifications". The TH6D sensor head has a protection degree of IP64. Safety glass panes in the TH6D sensor head and the safety glass unit provide protection from dirt or splashed water during processing. Nevertheless, you should design you processes and work conditions so that contaminants and splashed water are minimized. Make sure that you use the protective packaging for the TH6D sensor system when it is not in use (e.g., during maintenance or storage).


Page | 4-4


4.3.3 Cleanliness and cleaning Overview

CAUTION! Before each use of the TH6D system, make sure that the safety glass unit is securely mounted to the TH6D sensor head and that it is fitted with a clean safety glass!

NOTE! As the quality of the seam detection decreases, the likelihood increases that the optical elements will get dirty. Dirty optical elements on the TH6D sensor head decrease the quality of the seam detection. Only use sensor systems with clean built-in safety glasses. Only use clean glass in the safety glass unit! Please refer to the instructions for cleaning and replacement in Chapter 6. Important

Contact customer service if the safety glasses built into the TH6D sensor head become dirty. Only Scansonic service technicians are authorized to clean and repair the internal sensor modules.

Information

The display showing the status of the measurement process (refer to section 5.8) also provides information about the contamination on the TH6D sensor head. A lower percentage indicates poorer quality seam detection and dirtier optical elements.

4.3.4 Check-list for set-up and installation Function

The set-up and installation check-list contains starting points for inspecting the TH6D system installation before initial use. We assume that you have followed all safety notices and instructions found in this manual, and that all training related to the installation was carried out. The check list covers usage with a robot or master machine.

Check list

• The check list is included in section 9.2.


Page | 4-5


4.4

Set-up and installation Overview

This chapter describes how to connect the TH6D system in a production facility and to a master machine.

Inspection

Scansonic strongly recommends conducting a thorough inspection after you have completely set-up and installed the TH6D system (i.e., before first use).

Function

• Inspecting the set-up and installation steps • Ensuring that the TH6D system operates smoothly • The check list for set-up and installation should be used as the basis of the inspection

NOTE! Follow the check lists for set-up and installation found in section 9.2.

4.4.1 Tool centre point (TCP) and sensor origin Overview

The TCP, sensor origin and advanced tracking are used to determine the tool position in relation to the TH6D sensor head.

TCP

The tool position is described by the "tool centre point (TCP)". This is a theoretical reference point defined at a suitable position on the tool in relation to the work piece.

Sensor origin

The "sensor origin" (S0) is used to specify the desired spatial position of the TH6D sensor head. The sensor origin describes the centre of the measuring range.

Advanced tracking

The distance from the TCP to the sensor origin is referred to as the "advanced tracking". This advanced tracking is necessary for determining the position of the TCP in relation to the sensor origin during measurement and processing.

Information

Section 5.14.6 contains more information about calibration.


Page | 4-6


Position of the sensor origin

The defined position of the sensor origin (S0) is 150 mm from the lower edge of the sensor head. (As shown in Figure 27.) Please refer to the dimensioning sheet for your TH6D system and the specifications found in 8.1 for more information.

Advanced tracking S0

S0

TCP

Figure 27: Sensor origin for the TH6D sensor head (CF variant)


Page | 4-7


4.4.2 Tightening torque for screws Overview

NOTE! The enclosure for the TH6D sensor head is made of aluminium. Be sure that you use the specified tightening torques! The following torque specifications and minimum screw-in depths pertain to the screws on the TH6D sensor head. Screw size

Note

Screw-in depth

Torque

M3

3.5 mm

0.56 Nm

M4

4.5 mm

1.30 Nm

Installation screws are not included in the delivery.


Page | 4-8


4.4.3 Earthing provisions Allgemein

ATTENTION! The TH6D sensor head must always be properly earthed (grounded)! There are two ways to earth the TH6D sensor head: • Via the robotics interface, • Or via the power supply. It is possible to earth the TH6D process computer. But it is not permitted to earth the TH6D sensor head via the TH6D process computer. The Ethernet connection does not constitute an electrical connection to the TH6D sensor head.

Earthing via the robotics interface

Note the following when earthing via the robotics interface: • Make sure that there is a metallic bond between the robot and the TH6D sensor head. Only then will the TH6D sensor head be connected to the robot's earth. • Do not connect the THxD power cable shield to the earth on the power supply (A) of the TH6D sensor head.

Variant 1

24V_Power 0V_Power 24V_LSK 0V_LSK

Shield

A

Figure 28: Earthing via the robotics interface, variant 1


Page | 4-9


Variant 2

The robot's earth can also be connected with a cable to the earthing screw (B) on the TH6D sensor head's housing (refer to Figure 29). • Connect the TH6D sensor head with the robot. • You can install an isolator (C) between the TH6D sensor head and the robot. • Connect the robot's earth with the earthing screw on the housing of the TH6D sensor head. • If this is the case, do not connect the THxD power cable shield to the earth on the power supply (A) of the TH6D sensor head.

C B


Shield

A

Figure 29: Earthing via the robotics interface, variant 2


Page | 4-10


Earthing via the

WARNING!

power supply Electric current can cause damage. • Connect the welding facility's earth.

power

source

with

the

Note the following when earthing via the power supply: • If an isolator (C) is installed between the TH6D sensor head and the robot, then the THxD Power cable shield must be connected with the earth on the TH6D sensor head's power supply (A).

C


Shield

A

Figure 30: Earthing via the power supply


Page | 4-11


4.4.4 Installation and basic positioning of the TH6D sensor head Positioning and installation

The installation of the TH6D sensor head in relation to the process should be positioned as follows: • In general: The TH6D sensor head should be attached in advance of the tool (as shown in Figure 31). • Distance to the surface of the work piece: 150 mm from the sensor's lower edge (without the safety glass unit! – as shown in Figure 27). • The system must be able to travel around interference contours presented by clamping jigs or other objects without touching them. • When required, the TH6D sensor head can be mounted to the master machine at an arbitrary angle to the surface of the work piece. • The angular position of the TH6D sensor head must allow sufficient reflections to be recorded in the sensor measurement field so that sufficient raw data is visible in THxDView.

Information

Section 3.2.1 contains more information about the influence of reflections on the work piece. Figure 31 below shows an example of a torch connection. Note the position of the TH6D sensor head.

7

8 6

1 5 2 3

4

S0 TCP

+y

+x

Figure 31:: Position of the TH6D sensor head (example)


Page | 4-12


Description of

Item

Description

Item

Description

components in Figure 31

1

TH6D sensor head

5

Tool (MIG/MAG torch)

2

Safety glass unit

6

Master machine/robot

3

Simulated laser beams

7

TH6D cable kit

4

Inert gas nozzle

8

Simulated mounting adapter for the TH6D sensor head

Orientation of the

The precise orientation of the TH6D sensor head to the process must be

TH6D sensor head

determined using the THxDView configuration software. Instructions for orientation can be found in section 5.14 " Set-up and configuration of the TH6D system", following the description of THxDView.

4.4.5 Mounting the safety glass unit on the TH6D sensor head Overview

NOTE! Measurements during the (joining) process should only be made when a safety glass unit with a clean safety glass has been attached to the TH6D sensor head! The safety glass unit (included in delivery) should be attached to the TH6D sensor head in order to protect the sensor head while it is processing the work piece. This protective glass unit includes a second protective glass, which is positioned in front of protective glass panes that are built into the sensor head.

Installing the safety glass unit

• Align the safety glass unit with the shape TH6D sensor head (as shown in Figure 32). • Put the safety glass unit on the TH6D sensor head by inserting the pins (1) into the corresponding holes. • Press the safety glass unit against the TH6D sensor head until the retaining springs click in with an audible click.

NOTE! The safety glass unit is properly seated when its edges are flush with the TH6D sensor head.


Page | 4-13


1

Figure 32: Installing the safety glass unit

Protective plate

A plate is mounted on the safety glass unit to protect against process splatter.

NOTE! You can adapt the plate to your particular application by manually bending the tabs along the unit's plate so that the protected area changes. Caution: Do not bend the plate into the sensor's measuring range! Check the positioning of the tabs in the "Raw data" imaging area within THxDView! Removing the safety glass unit

• Pull the safety glass unit out of the TH6D sensor head's enclosure. Remove in the opposite direction of installation.


Page | 4-14


4.4.6 Mounting the cooling module on the TH6D sensor head Overview

The cooling block and heat sink for the cooling module are delivered as individual parts. They must be mounted directly on TH6D sensor head.

Installing the

ATTENTION!

cooling module Be sure that you use properly sized screws!

• Align the heat sink (4), as shown in Figure 33 • Slide the heat sink on the TH6D sensor head. • Align the cooling block (3) with the holes in the heat sink. Attach to the TH6D sensor head using the supplied screws and antianti vibration washers (M3x18 (1) above and M3x12 (2) below) • Torque: 0.6 Nm

1

2

3

4

Figure 33: Mounting the cooling module


Page | 4-15


4.4.7 Connecting the Ethernet cable to the TH6D sensor head and process computer Overview

CAUTION! Danger of surge voltage! • Disconnect the power supply before connecting the cable to the components! In order to communicate, the TH6D sensor head must be connected with the process computer via an Ethernet cable. This connection is described below.

Connection details

4 • Type (TH6D sensor head) M12 device connector (male plug, 4pole, shielded, D-coded) • Type (TH6D process computer) RJ45 connector • Cable designation: Ethernet Mxxxxxx (the number of your cable configuration can be found in the list in section 8.3).

Figure 34: TH6D system – connecting the Ethernet cable

Connection

Connect the cables according to the following assignments (as shown in Figure 35):

Connection

TH6D sensor head


Description

assignments X5

to

11

Ethernet

X5 11

Figure 35:: Ethernet cable connection


Page | 4-16


Connecting To the TH6D sensor head To the TH6D process computer Disconnecting

The male and female plugs should be connected in the following way: • Align the female plug according to the coding and insert into the X5 plug. Tighten by turning the coupling nut clockwise. • Align the male plug according to the coding and insert into the socket (11) until you hear it click. The male and female plugs should be disconnected in the following manner:

From the TH6D sensor head From the TH6D process computer

• Turn the coupling nut counter-clockwise and pull the socket from the plug (X5). • Press the safety levers on the connector housing towards the plug. • Pull the plug out of the socket (11).


Page | 4-17


4.4.8 Connecting the power supply to the TH6D sensor head Overview

NOTE! The TH6D sensor head is designed so that it cannot be plugged in incorrectly. It is easy to connect with existing power supplies. A separate mains power supply should be used for the TH6D sensor head. A suitable mains power supply is available from Scansonic. The socket on the TH6D sensor head is located on the top of the sensor's enclosure.

Connection details

NOTE! The shield of the power cord should be connected to the protective earth (PE) terminal on the mains supply. • Type (TH6D sensor head): M12 device connector (male plug, M12L, 4-pole, shielded, A-coded) • Type (system controller): Open-ended cable for use with main power supply from Scansonic • Cable designation: Power Mxxxxxx (the number of your cable configuration can be found in the list in section 8.3).

NOTE! Power supply and laser protective circuit (0 V) are electrically isolated from the system ground.

Power cable pin-

Pin

out assignments

(M12)

Colour

Signal

1

Brown

0V_Power

• Power supply

2

White

24V_Power

• Power supply

3

Green

24V_LSK

• Laser protective circuit

4

Yellow

0V_LSK

• Laser protective circuit

Black

Shield

• Shield


Designation

Page | 4-18


Connection

Connect the cables according to the following assignments. (As shown in Figure 36.)

Connection

TH6D sensor head

Customer Customer-specific mains power

assignments

supply unit to

X4

Refer to pin-out pin

TH6D sensor head

X4 Mains power supply unit

Figure 36:: Power supply on the TH6D sensor head

Connect with the TH6D sensor head Disconnecting

• Align the female plug according to the coding and insert into the X4 plug. Tighten by turning the coupling nut clockwise. • Turn the coupling nut counter-clockwise clockwise and pull the socket from the plug (X4).

4.4.9 Connection for the cooling and purging air at the TH6D sensor head Overview

WARNING! Excessive pressure in the media lines can lead to eye and ear damage or other injuries! • Always wear the proper protective eye glasses, ear protection, and clothing when changing pressurized lines and hoses!!

CAUTION! Be careful to avoid damaging the equipment! • Follow the compressed air specifications for the TH6D sensor head as described in section 8.4.


Page | 4-19


NOTE! The enclosure for the TH6D sensor head is made of aluminium. Never allow water to run through the cooling channels: this could lead to corrosion! Connection

PU 6 and PU 4 hoses (with diameters of 6 and 4 mm) are used to connect the cooling and purge air to the TH6D sensor head. • Model type: Quick-lock coupling • The optimal quantity of purge air is based on the durability of the safety glass in the safety glass unit. (We recommend max. 1 litre per minute at max. 2 bar.)

Connection diagram

Connect the hoses in the following manner:

X3 X2 X1

Figure 37: Connecting the cooling and purging air to the TH6D sensor head

Connection

Description

Diameter

X1

Connection for safety glass purge air

4 mm

X2

Connection for cooling air for advanced

6 mm

tracking X3 Description of connections

Connection for return of cooling air

6 mm

• Insert the air supply line into the quick-lock coupling. • To disconnect, press the coupling's pressure ring gently towards the coupling and pull out the hose.


Page | 4-20


4.4.10

Connecting the liquid coolants to the cooling module Overview

WARNING! Be careful to avoid damaging the equipment! • Follow the liquid coolant specifications for the cooling module as described in section 8.4.

ATTENTION! The enclosure for the TH6D sensor head is made of aluminium. Never allow water to run through the cooling channels in the TH6D sensor head: this could lead to corrosion! Connection

PU 6 tubing (with 6 mm diameter) should be used to connect the liquid coolant to the cooling module. Section 8.4 contains more information informa on this subject.. subject.

Connection diagram

Connect the hoses in the following manner:

X6 X7

Figure 38: Connecting the liquid coolants to the cooling module

Connection

Description of connections

Description

Diameter

X6

Connection (intake) for liquid coolant

6 mm

X7

Connection (outlet) for liquid coolant

6 mm

• Insert the intake line into the quick-lock lock coupling. • To disconnect, press the coupling's pressure ring gently towards the coupling and pull out the hose.


Page | 4-21


4.4.11

Installing the TH6D process computer Overview

CAUTION! Pay

attention

to

your

cable

lengths

and

installation options! The TH6D process computer can be installed at various positions on mounting rails. (Additional mounting hardware is not included in the delivery.) Installation

NOTE! Do not mount the TH6D process computer on a robot axis; this could cause damages during operations. However, a static installation to a robot foot or on a transport trolley is possible. • Mounting rails (1) have been pre-assembled assembled to the bottom of the TH6D process computer. • The TH6D process computer should be installed in a clean environment (e.g. an electrical cabinet) that is protected from dust, dirt and water. • For optimal heat dissipation, the TH6D process proce computer should be mounted in a vertical position on the mounting rails (be sure to take the cable lengths into account). • Make sure that the operating temperatures are not exceeded (refer to section 8.5).

1

Figure 39:: Mounting rails for the TH6D process computer


Page | 4-22


4.4.12

Connecting the power supply to the TH6D process computer Overview

DANGER Electrical shock danger – risk of injury! • Disconnect the power supply for the production facility before working on the TH6D system! A power supply unit is included in the delivery and is used to supply power to the TH6D process computer. The connection is located at the rear of the TH6D process computer's case.

NOTE! Power can also be supplied to the TH6D process computer using an industrial top-hat rail. For more information on power

supplies,

please

contact

your

local

service

representative. Connection details Connection

• Type: DIN connector (female, 4-pin) Connect the cables according to the following assignment (as shown in Figure 40):

Connection

Mains power supply unit


assignments to

2


2

Figure 40: Power supply on the TH6D process computer

Connecting Disconnecting

• Align the plug according to its coding and insert in the socket (2). • Pull the plug out of the socket (2).


Page | 4-23


4.4.13

Connecting a user PC for the THxDView configuration software Overview

CAUTION! Danger of surge voltage! • Disconnect the power supply before connecting the cable to the components! The TH6D system is configured with the THxDView software, which must be installed on a user PC. An Ethernet cable connecting the TH6D process computer must be installed so that the TH6D system can communicate with the user PC. This connection is described below.

Information Connection details

Chapter 5 contains more information about THxDView. • Only 100-BASE-T T Ethernet (Fast Ethernet) is supported. • Model type: RJ45 connector • The number of your cable configuration can be found in the list in section 8.3.

Connection

Connect the cables according according to the following assignment (as shown in Figure 41):

Connection

User PC


assignments Ethernet jack

to

Ethernet jack

6

6

Figure 41: Connecting the user PC for THxDView

Connecting

• Align the male plug according to the coding and insert into the corresponding socket until you hear it click.

Disconnecting

• Press the safety levers on the connector housing towards the plug. Pull the plug out of the socket.


Page | 4-24


4.4.14

Overview of connections without the machine interfaces Overview

The base components should be connected according to Figure 42 and the

Section 4.4.8

Section 4.4.12

11 Section 4.4.13

2

Section 4.4.8

6

X4

X1

X5

X3 X2

Section 4.4.9

installation instructions provided in Chapter 4.

Figure 42: TH6D system – overview of connections without machine interfaces


Page | 4-25


4.5

Connecting the machine-dependent machine dependent auxiliary modules

4.5.1 Connecting the analogue-digital analogue interface (ADF) Overview

The communication links for the TH6D process computers and the customer's Fieldbus can use various implementations. The analogue-digital analogue digital interface is required when using analogue and digital interfaces to communicate with the TH6D process computer. A list of switchable system functions is included with the delivery of the product and also provided in section 8.2.

Analogue-digital

Figure 43 shows the standardized construction of the analogue-digital analogue

interface – ADF

interface (ADF). The interface consists of a bus coupler, digital and analogue input/output terminals and one end terminal.

BC

DI

DO AO ET

Figure 43: TH6D analogue-digital digital interface (standard)

Bus terminal types

The components and the bus terminals types are colour-coded. colour Designation

Component

Colour

Bus terminal

Inputs/

type

outputs

BC

Bus coupler

-

-

1

ET

End terminal

-

-

1

DI

Digital In

Digital input (DI)

16

DO

Digital Out

Red

Digital output (DO)

8

AO

Analogue

Blue

Analogue

4

Out


Yellow

output

(AO)

Page | 4-26


CAUTION! Danger of surge voltage! • Disconnect the power supply before connecting the cable to the components! Connection details

• Model type: RJ45 connector • Cable designation: Patch cable Mxxxxxx (the number for a replacement cable can be found in the list in section 8.3).

Connecting the ADF

Connect the ADF to the TH6D process computer using the supplied Ethernet cable according to the following assignment:

Connection

ADF


assignments Bus coupler (BC)

to

10


10

Figure 44: Connecting the ADF to the TH6D process computer

Connecting

Disconnecting

• Align the male plug according to the coding and insert into the socket until you hear it click. • Press the safety levers on the connector housing towards the plug. • Pull the plug out of the socket (10).


Page | 4-27


4.5.2 Connecting the power supply to the analogue-digital interface Overview

A connection to a bus coupler module is used to supply power to the analogue-digital interface. A power supply unit of at least 24-V is required.

Information Connection options

Appropriate power supplies can be purchased from Scansonic as needed. There are two connection methods: • The bus coupler and the bus terminals are supplied by connecting two external power sources. • The bus coupler and the bus terminals are supplied in parallel (pass through) with one external voltage source.

DANGER Electrical shock danger – risk of injury! • Disconnect the power supply before working on the analogue-digital interface! Connecting two

Connect the two power sources with cables as follows (as shown in Figure

external power

45):

sources

24 V Bus coupler

24 V Earthing Bus terminals

Figure 45: Power supply on the analogue-digital interface


Page | 4-28


Parallel connection

Connect one power source with cable as follows (as shown in Figure 46):

from an external voltage source

Pass-though connection of 24 V to bus coupler

24 V Bus terminals

Earthing

Figure 46: Parallel power supply connection to the analogue-digital interface

Connecting

Disconnecting

• Attach wire-end ferrules to the cable ends and insert into the corresponding socket. • Pull the cable end out of the socket.


Page | 4-29


4.5.3 Connection overview with connected ADF Overview


Section 4.4.8

Section 4.5.2 Section 4.4.12

10 Section 4.5.1

Section 4.4.13

2

11

Section 4.4.8

6

X1

X4

X5

X3 X2

Section 4.4.9

installation instructions provided in sections 4.4, 4.5.1 and 4.5.2.

Figure 47: TH6D system – overview of connections with ADF


Page | 4-30


4.5.4 Connecting the Fanuc interface Overview

CAUTION! Danger of surge voltage! • Disconnect the power supply before connecting the cable to the components! Make sure that each Fanuc robot being used has the proper hardware and software configuration for sensor management.

Connection details

• Ports (Fanuc controller, e.g. RJ-30iA): CD38A or CD38B • Model type: RJ45 connector • Cable specification: CAT 6 A • Cable designation: Patch cable Mxxxxxx (the number of your cable configuration can be found in the list in section 8.3).

NOTE! For more information, please contact your Fanuc service representative. Connection Connection

Connect the cables according to the following assignments. TH6D process computer

Fanuc controller

assignments to

5

CD38A or CD38B

5 5

Figure 48: Connecting the Fanuc interface

Connecting

Disconnecting

• Align the male plug according to the coding and insert into the socket until you hear it click. • Press the safety levers on the connector housing towards the plug. • Pull the plug out of the corresponding socket.


Page | 4-31


4.5.5 Connection overview with connected Fanuc interface Overview


CD38A / CD38B

Section 4.4.12

5 11 Section 4.4.13

2

Section 4.5.4

Section 4.4.8

6

X1

X4

Section 4.4.8

X5

X3 X2

Section 4.4.9

installation instructions provided in sections 4.4 and 4.5.4.

Figure 49: TH6D system – overview of connections with Fanuc interface


Page | 4-32

5.

Initial Commissioning and Operation This section describes the initial commissioning and operation of the TH6D system. 5.1

Information about the initial commissioning and operation ........................................................................ 5-3

5.2

Switching the TH6D system on and off ............................ 5-4

5.3

The graphical user interface: THxDView ......................... 5-5

5.3.1

System requirements for THxDView ................................. 5-5

5.3.2

Requirements for installing THxDView .............................. 5-6

5.3.3

Installing THxDView ....................................................... 5-6

5.4

Using THxDView ........................................................... 5-10

5.4.1

Starting up and exiting the THxDView software ............... 5-10

5.4.2

Overview of the user interface ....................................... 5-12

5.5

Menu bar ...................................................................... 5-14

5.6

Image area ................................................................... 5-15

5.6.1

"Raw Data" main tab .................................................... 5-15

5.6.2

"Evaluation" main tab ................................................... 5-16

5.7

Reports area ................................................................. 5-17

5.7.1

Errors and warnings ..................................................... 5-17

5.7.2

Events ........................................................................ 5-17

5.8

System Status area ....................................................... 5-18

5.8.1

Status of the network connection ................................... 5-18

5.8.2

Status and change of the operating mode ....................... 5-18

5.8.3

Status of the measurement process ............................... 5-19

5.8.4

Status of the active job ................................................ 5-21

5.9

Information area .......................................................... 5-22

5.9.1

Information area – main tab Measurements .................... 5-22

5.9.2

Information area – main tab sketch ............................... 5-23

5.10

Parameter configuration area ....................................... 5-25

5.11

Parameter configuration area – "Profile" tab ................ 5-25

5.11.1 Seam Pattern tab......................................................... 5-26 5.11.2 Seam Pattern tab – templates with seam pattern profiles . 5-27 5.11.3 Seam Pattern tab – parameter description ...................... 5-32 5.11.4 Camera tab ................................................................. 5-42 5.11.5 Camera tab – parameter description .............................. 5-42 5.11.6 Calibration tab............................................................. 5-43


Page | 5-1

5.11.7 Calibration tab – parameter description .......................... 5-44 5.11.8 Process Control tab ...................................................... 5-45 5.12

Parameters area – main System tab .............................. 5-46

5.12.1 Job List tab ................................................................. 5-46 5.12.2 Machine Interface tab ................................................... 5-48 5.12.3 Configuration tab ......................................................... 5-49 5.13

Interfaces and associated parameters .......................... 5-52

5.13.1 Machine interface – analogue-digital correction ............... 5-52 5.13.2 Machine interface – Motoman reference path .................. 5-54 5.13.3 Machine interface – Fanuc Ethernet ................................ 5-60 5.13.5 Machine interface – IF UDP Data .................................... 5-64 5.14

Set-up and configuration of the TH6D system ............... 5-65

5.14.1 User login ................................................................... 5-65 5.14.2 Establishing a network connection with a TH6D system .... 5-67 5.14.3 Selecting the language ................................................. 5-71 5.14.4 Selecting the set-up operating mode .............................. 5-71 5.14.5 Positioning the TH6D sensor head .................................. 5-72 5.14.6 Tool calibration ............................................................ 5-75 5.14.7 Measurement process optimization – changing camera settings ...................................................................... 5-79 5.14.8 Optimizing the measurement process – changing parameters ................................................................. 5-80 5.14.9 Setting up profiles and creating jobs .............................. 5-81


Page | 5-2

Initial Commissioning and Operation

5.1

Information about the initial commissioning and operation General

CAUTION!

information Follow all the information in Chapter 4 during the installation and assembly of the TH6D system! The commissioning and operation have been divided into hardware- and software-related procedures. Software

The THxDView software must be installed on a PC for the initial commissioning of the TH6D system. Section 5.3 describes the software.

Hardware

Section 5.14 describes the general operation of the TH6D system.

NOTE! Follow the check lists for set-up and installation found in section 9.2.


Page | 5-3


5.2

Switching the TH6D system on and off Overview

CAUTION! The THxDView configuration software must be installed on a separate PC. This user PC and THxDView are thus not affected when the TH6D system is switched on or off. The TH6D sensor head and the TH6D process computer can be switched on/off individually or as a complete TH6D system via the main switch. Since

the

interface

to

the

supply

voltage

can

have

separated

configurations, it may be possible to use more than one main switch. Turn on

NOTE! Three signal beeps can be heard as the TH6D process computer is booting up. A double beep can then be heard after the computer has booted up successfully. Any deviation from this beep tone sequence indicates an error.

Sequence for switching on Switch-on time

• In general: Switch on the TH6D sensor head and the TH6D process computer simultaneously. • TH6D system: approx. 1 minute

Information about

During the initial commissioning, the TH6D process computer may be in

switching on

standby mode after the power supply is switched on. Thus it may need to be switched on manually. If the status LED on the ON/OFF switch (7) of the TH6D process computer is red, press the switch briefly to start up. Section 3.5.2 contains more information on the status displays and position of the ON/OFF switches.

NOTE! If the power supply is interrupted to the TH6D process computer while it is switched on, then you should switch the TH6D sensor head and the TH6D process computer back on.


Page | 5-4


Information

The user PC running THxDView can be switched on and off separately

about

from the TH6D system. If the TH6D system is switched off before

disconnections

THxDView, then you will notice the disconnection in the THxDView software. The system status displays the message "No System". When switched back on, THxDView automatically connects to the previously connected TH6D system. This can be checked with the connection status in THxDView. (Refer to section 5.8.)

Switching off

• Follow the information and instructions about archiving data as described in section 5.14.9 before you switch off the TH6D system. • Then the TH6D system can be turned off using the main switch.

5.3

The graphical user interface: THxDView Overview

The THxDView GUI software is used to set and monitor parameters while working with the TH6D system.

NOTE! THxDView is licensed software!

Information

Section 5.14 contains set-up instructions.

5.3.1 System requirements for THxDView Program

PC hardware

THxDView, version 1.4.2

Standard PC/IPC hardware, Pentium 4 processor or faster, min. 2.0 GHz, min. 1 GB RAM, screen resolution of 1024 x 768

Operating

Windows XP, Vista, Windows 7

systems Memory

512 MB RAM (1024 MB RAM recommended) 10 MB hard disk space

NOTE! A local Java application is installed with the software. This Java application will also be removed if you uninstall THxDView.


Page | 5-5


5.3.2 Requirements for installing THxDView Prerequisites

CAUTION! Make sure that THxDView is not blocked by any security programs running on the user PC. The following are required in order to install and use the THxDView software: • Administrative access rights on the user PC • Compatibility with the firewall and anti-virus software installed on the user PC • Establishment of a peer-to-peer connection • Network connection settings made by the administrator account

5.3.3 Installing THxDView Overview

NOTE! The illustrations used here to show the software and installation may vary visually depending on your operating system. However the content and functionality will be similar.

Starting the installation

Insert the installation CD (included in the delivery) in your PC. The installation should start automatically. If automatic start is deactivated on the PC, you will need to follow the instructions below:

Otherwise

• Open up Windows Explorer or click on the My Computer icon. • Double click on the CD/DVD drive folder. • Search for the file with the following name: "THxDView_Setup_x.xx-xxxxxx.exe" • Double click on the file to start the installation.

Initialization

The installation begins with the window shown in Figure 50. • Choose the language of installation and click on the „OK“ button to continue

Figure 50: THxDView – initializing the installation


Page | 5-6


Installation

The following window details which software components will be installed.

information

(As shown in Figure 51.) • Click on the "Next" button to continue with the installation or • Click on "Cancel" to cancel the installation.

Figure 51: THxDView – installation information

License

The license agreement comes next. (As shown in Figure 52.)

agreement • Read the license agreement in its entirety. • Click on the "I Agree" button in order to accept the terms of the license agreement and start the installation, or • Click on "Cancel" if you do not accept the license terms. The installation will then be aborted.

Figure 52: THxDView – starting the installation


Page | 5-7


Changing the installation path

You can change the pre-set installation directory as follows: (As shown in Figure 53.) • Click on the "Browse" button (1).

1 2

Figure 53: THxDView – changing the installation directory

Selecting the installation directory

• Select a directory on your PC or network from the window (as shown in Figure 54) and then click on "OK". • Click on "Install" to continue with the installation (as shown by 2 in Figure 53).

Figure 54: THxDView – selecting the installation directory


Page | 5-8


Progress of

The required files are now copied to the hard drive. The status bar shows

installation

the progress. (As shown in Figure 55.)

Figure 55: THxDView – installation progress

Finishing the installation

The installation ends with the windows shown in the illustration. (As shown in Figure 56.) • Click on the "Finish" button.

Figure 56: THxDView – installation is finished


Page | 5-9


5.4

Using THxDView Overview

The THxDView configuration software is used to set and monitor parameters while working with the TH6D system.

NOTE! The user PC's subnet must be set to match the IP address of the TH6D process computer before any connection between the two computers can be established.

5.4.1 Starting up and exiting the THxDView software Starting THxDView

• Start THxDView using the shortcut created on the desktop (as shown in Figure 57).

Figure 57: THxDView – the desktop icon

Otherwise

• From the Windows Start menu, find THxDView under the following sub-menu: scansonic \ THxDView \ THxDView

Start-up window

THxDView starts with the following window. (As shown in Figure 58)

Figure 58: THxDView – the start-up window


Page | 5-10


User login

You must first login before you can work with THxDView or change settings.

Information

Section 5.14.1 contains more information about the user login.

Exiting

CAUTION!

THxDView Data loss is possible! • Make sure to save any changes you made to the parameters before you exit THxDView! • More information can be found in section 5.14.9. • Click on the "Exit" button (in upper right, as shown in Figure 59) in the opened window in order to exit.

Figure 59: Exiting THxDView


Page | 5-11


5.4.2 Overview of the user interface Overview Window areas

The user interface is divided into five different areas. No.

Designation

No.

Designation

1

Menu bar

4

System status area

2

Image area

5

Information area

3

Reports area

6

Parameter configuration area

6 1

2

5

3

4

Figure 60: THxDView – user interface

Brief summary

The following list gives a brief summary of the user interface areas in the THxDView software.

Menu bar

The menu bar (1) contains options for settings (refer to section 5.5): • Logging in • Extras

Image area

• Help • Selecting a system

The image area (2) allows you to choose between two different methods for representing the laser beams on the work piece: • Raw data (refer to section 5.6.1)


• Evaluation (refer to section 5.6.2)

Page | 5-12


Reports area

The report area (3) displays: • Errors and warnings (section 5.7.1)

System status area

The system status area (4) shows the status of the TH6D system. The following information is displayed: • Network connection between the TH6D process computer and the user PC (section 5.8.1) • Operating mode (section 5.8.2)

Information area

configuration

• Status of the active measurement (section 5.8.3) • Active job (section 5.8.4)

The information area (5) informs about system parameters and provides help for the configuration. The following information is displayed: • Measurements (section 5.9.1)

Parameter

• Events (section 5.7.2)

• Sketch (section 5.9.2)

Parameters can be set in the parameter configuration area (6). This area is divided into the main tabs:

area • Profiles (section 5.11)


• System (section 5.12)

Page | 5-13


5.5

Menu bar Menu bar

The following additional THxDView functions can be selected from the menu bar.

Figure 61: THxDView – menu bar

Login

The "Login" option allows you to select an access level for users of the TH6D system. More information can be found in section 5.14.1.

Extras Help

The "Extras" option allows you to change the language settings. The "Help" option allows you to view the system information. (As shown in Figure 62.)

Figure 62: THxDView – program information

Selecting a

The "Select System" option allows you to manage the sensor systems,

system

connect or disconnect to a TH6D system. If multiple TH6D systems are visible on the network, they will be displayed here. It is not possible to connect THxDView simultaneously with multiple TH6D systems. Section 5.14.2 contains more information about selecting the TH6D system.


Page | 5-14


5.6

Image area

5.6.1 "Raw Data" main tab "Raw Data" main tab

The "Raw Data" tab shows the laser lines resulting from the preliminary evaluation in the TH6D sensor head. (As shown in Figure 63.) The white lines indicate the edges of the work piece. The yellow dots indicate where a seam has been detected (seam points = SP). The laser lines are projected from the TH6D sensor head out towards the camera's field of view. Since the camera in the TH6D sensor head is protected against extraneous light by a narrow-band optical filter, only those areas of the work piece surface which are illuminated by the laser lines are visible. The coordinates for the "Raw Data" sensor image are defined as follows: • ∆X = gap between the laser lines • ∆Y = direction lateral to x • ∆Z = height

SP

+z

x

-z

+y

-y

Figure 63: Image area – raw data (example with V-seam)


Page | 5-15


5.6.2 "Evaluation" main tab "Evaluation"

The "Evaluation" tab shows the results of the analysed raw data. This

main tab

provides the user with information on the lateral and vertical positioning to the joint. (Refer to Figure 64 and Figure 65.) • Measuring inactive

Possible displays, with

• The red lines indicate the laser lines recorded by the camera.

example of Vseam

Figure 64: Image area – analysis, measuring inactive

• Measuring activated • The green lines indicate those sections of the laser lines recorded by the camera that can be analysed. • The measurement points on the detected seam are marked in yellow.

Figure 65: Image area – analysis, measuring activated

Note

NOTE! Flickering green lines and yellow dots indicate locations with insufficient seam detection. Fine tuning of the settings in THxDView can help fix this.


Page | 5-16


5.7

Reports area

5.7.1 Errors and warnings Overview

The "Errors and Warnings" section of the Reports area can be found in the lower left part of the THxDView window. This section displays errors, warnings and additional information. (As shown in Figure 66)

Figure 66: Reports area – Errors and Warnings (example)

Information

A list of possible information, warning and error messages is given in section 7.

5.7.2 Events Overview

Logged system events are displayed in the "Events" section of the Reports area. This section lists successful and unsuccessful save/delete actions, for example.

Figure 67: Reports area – Events (example)


Page | 5-17


5.8

System Status area Overview

The "System Status" area is located in the lower right of the TXxDView window. It displays the status of the TH6D system. This area displays the network connection between THxDView and the TH6D process computer, the

operating

mode,

the

active

measurement

process

and

the

composition of the active job.

Figure 68: THxDView – "System Status" area (example)

5.8.1 Status of the network connection Overview

The current status of the network connection between THxDView and the TH6D process computer is displayed in the left section of the "System Status" area. (Refer to the marked area in Figure 69.)

Figure 69: THxDView – "System Status", network connection (example)

• Displays the connected TH6D process computer

• Could not connect with the discovered TH6D process computer

• No TH6D process computer found

• Searching for a TH6D process computer

• No TH6D process computer is connected to the user PC

• Search is periodically

• Connection is successful

Possible status

repeated

• Network communication is blocked by THxDView

5.8.2 Status and change of the operating mode Overview

The current status of the operating mode is shown in the second (from left) section in the "System Status" area.


Page | 5-18


Figure 70: THxDView – system status, operating mode

• Automatic mode

Possible status

• Set-up mode

• No TH6D process computer found • No TH6D process computer is connected to the user PC • Network communication is blocked by THxDView Description of

Operating mode

Description

Automatic

• Operations are carried out automatically by the facility controller (robots).

operating modes

• System functions can be monitored. • Functions cannot be manually switched within THxDView. • System parameters cannot be changed. • By default, automatic mode is enabled when THxDView is started up. • A reduced number of measured values is transferred to THxDView. Set-up mode

• THxDView is used to configure the system. • System functions changed manually.

and

parameters

can

be

• Measurements are displayed within THxDView. Changing the

CAUTION!

operating mode It is not possible to change modes during active processing

in

automatic

mode!

Wait

until

the

program has finished. The status display is also a button that is used to switch the operating mode. • Click on the button to switch back and forth between automatic mode and set-up mode.

5.8.3 Status of the measurement process Overview

The current status of the measuring process is shown in the third (from left) section in the "System Status" area. (Refer to the marked area in


Page | 5-19


Figure 71.)

Figure 71: THxDView – system status, measuring • Measuring activated

Possible status

• Measurement was stopped • Displays the quality of the measuring process in percent (in this case 100%) • Displays the largest contiguous measurement error, counted in images (here 0)

• TH6D process computer was not found • TH6D process computer is not connected to the user PC • THxDView network communication is blocked Displays the

The

displays

for

the

quality

of the

measuring

process

and

the

quality of the

corresponding largest contiguous measurement error depend on the

measuring

particular application. Two important factors influencing this are the

process

shape of the work piece and the measurement path across the work piece. A definitive conclusion about measuring quality differences can only be made by comparing the measurements from identical test pieces and analysing the measurement data.

Measuring

It is only possible to manually activate/deactivate the measuring process

manually

while in set-up mode. The status display also serves as a button for this

activated / deactivated

function. • Click on the button to activate or deactivate a measurement process.


Page | 5-20


5.8.4 Status of the active job Overview

The status of the active job is shown in the fourth (from left) section in the "System Status" area. (As shown by the marked area in Figure 72.) This status is visible in automatic mode and set-up mode. In this example, the active job includes the seam pattern profile "a1_seam", the camera profile "a1_camera", the calibration profile "a1_calibration" and the process control profile "a1_process_control".

Figure 72: THxDView – system status, job

NOTE! The TH6D sensor head is not activated when the TH6D system is in automatic mode and receives no job number from the robot controller. Possible status

• Job is active • Displays the active job compilation • Manual mode (P)

• TH6D process computer is in automatic mode • No job is selected here – so the display is red and (0) • TH6D process computer is in automatic mode • Job is selected (here, job 2) • Displays the number")

active

job

compilation

("job

• TH6D process computer was not found • TH6D process computer is not connected to the user PC • THxDView network communication is blocked


Page | 5-21


5.9

Information area Overview

The information area contains the main tabs "Measurements" and "Sketch". These tabs inform about measured results and the system states of TH6D-sensor system and serve as a guide for setting parameters. Both tabs are explained in the following chapter.

5.9.1 Information area – main tab Measurements Overview

The main "Measurements" tab summarizes the values measured by the TH6D system. According to the geometry of the work pieces, the values change dynamically during the measurement. (As shown in Figure 73.)

NOTE! The measured values are only displayed while in set-up mode. No measurements are displayed while in automatic mode.

Figure 73: Parameters area – display of measurements (example)

Displayed measurements

The measured values displayed by the sensor system are related to the sensor

coordinate

system

which

influences

the

process

or

the

position/track corrections. • Process influences: gap width, step height (mismatch), surface • Position influences: ∆x, ∆y, ∆z,A, B, C (left / right) Information

CAUTION! Output data does not need to match the data sent to the robot! It is transformed based on the defined machine protocol.


Page | 5-22


5.9.2 Information area – main tab sketch The main

The "Sketch" tab in the information area provides graphic support to help

"Sketch" tab in

you with parameter changes in the "Parameter configuration area". The

the information area

graphical

display

can

be

used

as

a

guide

for

interpreting

the

corresponding parameter.

NOTE! Explanatory

diagrams

are

not

yet

available

for

all

parameters. The example in Figure 74 shows a diagram to explain the angle parameter setting (on the left).

Figure 74: Information area – diagram (example for adjusting the angle)

Structure

The main sketch tab is divided into two sections. In the upper section examples of the currently selected seam pattern profile are shown. At the bottom of the section the selected parameter is explained graphically.


Page | 5-23


By double clicking on the profile or parameter name, a separate window with an enlarged detail illustration opens.

Figure 75:: Information area - Detailed view of parameters

About the

NOTE!

parameter values The default values and allowed value ranges are shown when a parameter is selected. When selecting or modifying parameters, the default values and the allowable value range is shown above the tab label as a guide. (Refer to the example in Figure 76)

Figure 76: THxDView – Information about parameters

Information

Sections 5.11 and 5.12 describe the parameters and their functions.


Page | 5-24


5.10 Parameter configuration area Overview

The "Parameter configuration area" (as shown in Figure 77) consists of three tabs: • System

• Profile

Figure 77: THxDView – parameter configuration area

These main tabs allow you to specify and change parameters in order to optimize the seam tracking. The functions of each main tab and their associated sub-tabs are described below.

5.11 Parameter configuration area – "Profile" tab "Profile" tab

The seam detection is configured in THxDView using four profiles. They can be selected using the "Profile" tab within the parameter configuration area. Specific parameters can be activated, deactivated, or assigned values for each of these profiles. (As shown in Figure 78)

Profiles

No.

Designation

Description

1

Seam pattern

Setting the seam parameters

2

Camera

Setting the camera parameters

3

Calibration

Setting the calibration data

4

Sequence

Setting the machine data

controller

1

2

3

4

Figure 78: THxDView – parameter configuration area – profiles


Page | 5-25


5.11.1

Seam Pattern tab Overview

The "Seam Pattern" tab allows you to select pre-defined seam pattern profiles (templates). These templates contain specific parameters for recording the seam shape. By changing the parameters in the pre-designed templates, it is possible to create custom seam pattern profiles.

Figure 79: THxDView – Seam Pattern tab

Information

Section 5.11.3 describes the parameters contained in the seam pattern profiles. More information about creating and saving custom stitch patterns can be found in section 5.14.9.


Page | 5-26


5.11.2

Seam Pattern tab – templates with seam pattern profiles Overview

NOTE! Pre-defined seam pattern profiles are marked with the word

"(template)"

in

their

profile

names.

Saved

customized profiles contain the name of the template on which they were based. THxDView has various templates for different seam patterns. The user can select a template that matches his particular application. The parameter settings for the selected template can then be used to create the customer-specific seam pattern profile. This profile must be saved under a unique suitable name.

NOTE! Changed seam pattern templates must be saved under a different name! When restarting the TH6D system, the default

values

are

re-loaded

into

the

pre-defined

templates. Templates for the seam pattern

A drop-down list in the "Seam Pattern" tab allows you to select from the following templates for seam pattern profiles. (As shown in Figure 80)

profiles • Open edge

• V-Area

• TB-Area

• Overlap seam

• HY-seam

• M-Depth

• Tailored blank

• U-Seam

• V-seam

• HU-seam

Figure 80: THxDView – selecting the seam pattern profile

Information

NOTE! The "Sketch" information area contains helpful information describing the parameters.


Page | 5-27


Open edge

The "open edge"" seam pattern profile specifies a special form which can be used for all processes that run parallel to a work piece edge.

Example application

After cutting glass, the edge can be ground or an adhesive can be applied to the work piece edge in parallel.

Figure 81: THxDView – seam pattern template for an open edge

Overlap seam

The "overlap seam"" seam pattern profile can be used in a process where the work piece edges overlap. Figure 82 shows an example of the overlap joint.

Figure 82: THxDView – seam pattern template for an overlap seam


Page | 5-28


Tailored blank

The "tailored blank" seam profile is an all-purpose template for other seams that are not defined here. All parameters in this seam pattern profile can be changed. d

a

Gap a

Offset d

Example with gap a

Figure 83: THxDView – seam pattern template for a tailored blank

TB-Area

The seam sample profile "TB-Area" is suitable for geometries which are not defined as a standard seam pattern.

Figure 84: THxDView – seam pattern template for a TB-Area


Page | 5-29


V-seam

The seam sample profile "V-seam" can be used in applications where the seam has been prepared or where V-shaped shaped work pieces are positioned next to each other.

Figure 85: THxDView – seam pattern template for a V-seam V

Information

Shiny surfaces reflect in multiples directions so that there is some ambiguity when the images are evaluated. Section 3.2.1 contains more information about avoiding g such multiple reflections.

V-Area

The seam pattern template "V area" is suitable for applications of thick sheet metal, and for the multi-pass pass welding where the seam area is needed to calculate the number of layers.

Figure 86: THxDView – seam pattern template for a HV-seam HV


Page | 5-30


HY-seam

Pending

Figure 87: THxDView – seam pattern template for a HY-seam

U-seam

Pending

Figure 88: THxDView – seam pattern template for a U-seam

HU-seam

Pending

Figure 89: THxDView – seam pattern template for a HU-seam

M-Depth

The seam pattern template "M-depth" is suitable for applications where only the distance measurement is needed to create an even surface. This stitch pattern template is not part of the standard software.

Parameter

NOTE! The "Sketch" area contains helpful information describing the parameters for the seam pattern profiles.


Page | 5-31


5.11.3

Seam Pattern tab – parameter description Parameter

NOTE! The particular parameters contained within a seam pattern profile vary according to each profile. The parameters described below can be used and changed in order to optimize a seam pattern profile. Not all parameters are included in each seam pattern profile.

Line quality

Depending on the roughness of the work piece surface, there may be interruptions in the laser lines shown under the "Raw Data" tab. The "line quality" parameter is adapted to the surface roughness and influences the analysis and representation of the reflected laser lines. You can use the illustration in the "Evaluation" area to evaluate the importance of changing this parameter. The parameters are selected using a drop-down list. The following values can be selected: • Standard (baseline value): The "standard" baseline value is somewhere between fine and medium; it is a good compromise for many typical applications. • Fine: Can be set when the work piece has a very smooth surface and the laser lines (based on the surface reflection and the TH6D sensor head) have few or no interruptions. • Medium, coarse or very coarse: Can be set when working with less smooth surfaces, when interruptions in the laser line are being created by a rough surface so that non-aligned segments are being shown in THxDView. The example (refer to Figure 90: A, B and C) illustrates the line quality function.


Page | 5-32


Example of the line

In Figure 90, the "Evaluation" image area shows (A) the raw image of a

quality of a overlap

rough surface of the work piece. No changes to the parameters are made

seam

here. In Figure 90, a line quality of "fine" has been selected (B) for this work piece surface. There are many scattered line elements visible here. This makes the seam detection more difficult. In Figure 90, a line quality of "very coarse" has been selected (C) for this work piece surface. Multiple line elements have been merged together so the seam detection is functioning well.

A Raw data

B

C

Evaluation – "Fine" line quality

Evaluation – "Coarse" line quality

Figure 90: THxDView – line quality parameters (examples)

Used for seam pattern profiles

• Open edge

• V-seam

• U-Seam

• Overlap seam

• V-Area

• HU-seam

• Tailored blank

• HY-seam

• TB-Area


Page | 5-33


Pattern location

"Pattern location" describes the arrangement of work pieces (sheets) at the joint. It determines which side the upper sheet is on. The value "any" is suitable for a first test run. It should, however, be limited by the specification "upper sheet is right" or "upper sheet is left".


Reference area

• Open edge

• HY-seam

• Overlap seam

• U-Seam

• Tailored blank

• HU-seam

• TB-Area

A "reference area" is specified to determine an area to the left and right of the joint line where the measured values can be calculated. The reference area is also required for measuring the angle information. By default, the "sensor" setting does not have a reference area specified. The measured mismatch and gap width values are evaluated in the sensor coordinate system. So when the TH6D sensor head is aligned diagonally to the work piece surface, these measurements do not match up with reality.

Information on the overlap seam

For the "overlap seam" pattern, if the TH6D sensor head is aligned diagonally to the joint (as shown in Figure 91 A and B), then the measured mismatch is specified as the gap. If this gap is greater than 0.5 mm, then a reference area must be selected. Otherwise there will be no seam detection.

B

A

Gap

+z +y

+z +x

+y

+x

Figure 91: THxDView – reference area parameter at the overlap seam

Used for seam

• Overlap seam

• V-Area

• HU-seam

pattern profiles

• Tailored blank

• HY-seam

• TB-Area

• V-seam

• U-Seam


Page | 5-34


TCP alignment

"TCP alignment" is used to specify the precise position of the seam point. The point may lie on the left or right end, or between the end points and the laser lines. left

middle

right

Figure 92: THxDView – TCP alignment parameters


Depth

• Open edge

• V-seam

• U-Seam

• Overlap seam

• V-Area

• HU-seam

• Tailored blank

• HY-seam

• TB-Area

"Depth" is used to specify the distance from the top edge to the bottom edge of the work piece. The depth parameter must be specified so that the TH6D system can properly calculate the area.

Information on the

When using the "HV-seam" pattern and when the TH6D sensor head is

HV-seam

aligned diagonally to the joint, the seam is not detected over the entire depth of the work piece joint. Instead, the detection is carried out until the start of mutually parallel work piece edges of the joint.

+z +y

+x

Figure 93: THxDView – depth parameter, with the example of an HVseam

Used for seam

• HY-seam

pattern profiles

• U-Seam

• TB-Area

• HU-seam


Page | 5-35


Angle

The "angle" setting (left/right) is used to help avoid detecting false joints

left/right

on the work piece. You can eliminate multiple reflections in the evaluation by specifying the correct inclinations of the laser lines. This results in a more stable seam detection process. It must be possible to distinguish between the left and right angle since the angle is being measured from the joint line to the adjacent level. In the lines "angle left/right", the left value represents the smallest border while the right value e represents the largest border of the angular range.

Note

The

"angle

left/right"

parameters

refer

to

the

two two-dimensional

representation of the seam profile in the "Evaluation Evaluation" image area. The "Measurements" parameter range does not display the measured lateral angle C (left and right) for the seam profile.

Figure 94: THxDView – angle left/right parameters


Opening angle

• Open edge

• V-seam

• U-Seam

• Overlap seam

• V-Area

• HU-seam

• Tailored blank

• HY-seam

• TB-Area

In addition to the "angle left/right" parameters, parameters the "opening angle" between the edges of the seam can be specified. This is useful when you cannot define a boundary with "angle left/right" because the orientation of the sensor to the work piece has changed. If the TH6D sensor head is pivoted laterally from the joint line, this changes the inclination of the laser lines in the camera image. The angle constraint then becomes a hindrance. The opening angle, however, remains unchanged.

Used for seam

• V-seam

pattern profiles

• V-area


Page | 5-36

Initial al Commissioning and Operation

Interference at

When working with reflective surfaces (aluminium or CrNi steel), the joint

the seam

line is brightened by multiple reflections of the laser beams. This interferes with the measurement and evaluation for the seam tracking. The "interference at seam" (left/right) parameter ameter indicates an area of the seam that cannot be evaluated.

Used for seam

• V-seam

pattern profiles

• V-area

Mismatch

"Mismatch" is determined by the thickness of the work piece and any possible air gap. The "Mismatch" is the vertical distance from the reference area to the nearest edge of the second work piece. You can limit this value when you know the thickness of your work pieces in order to avoid faulty detection (refer to Figure 95). ). A large air gap between the overlapping work pieces can also be detected.

Note

It is very important is to limit the "Mismatch" whenever ambiguities arise in the camera image (i.e. if two similar seam shapes are visible). This could occur, for example, when there is a clamp positioned next to an actual seam.

Figure 95: THxDView – Mismatch parameter at the overlap seam

Used for seam

• Overlap seam

• U-Seam

pattern profiles

• Tailored blank

• HU-seam

• HY-seam

• TB-Area

Gap

"Gap" defines a gap at the joint between the work pieces. When using the seam shape "tailored blank",, it is possible (and sometimes desired) that there will be a gap at the joint line. (As shown in Figure 96.)

Note

The parameters "Mismatch" and "gap" are very helpful for eliminating visual ambiguities in the camera image.


Page | 5-37


Figure 96: THxDView – "gap" parameters (example of tailored blank)


• Tailored blank

• HU-seam

• HY-seam

• TB-Area

• U-Seam Interpolation

An isolated seam point is designated as the base point. The "Interpolation

point tolerance

point tolerance" parameter is used to expand the tolerance range of the

(l,v)

seam point in the side (S) and height (H) directions. It is used to calculate and evaluate the seam tracking. This is useful when there is minor damage to work piece edges which could cause an excessive excessi gap at the joint line (for example, on an overlap seam).

Example

In the example shown in Figure 97,, the end point of the left middle line of the joint line (vertical with red dashes) is too far away which corresponds to a gap.

Figure 97: THxDView – "Interpolation point tolerance" tolera parameter - 1


Page | 5-38


Example –

For example, by specifying a value of 1 for the "side" parameter (S), the

continued

algorithm accepts this deviation and recognizes the overlap seam flawlessly. Figure 98

Interpolation point tolerance" tolerance parameter - 2 Figure 98: THxDView – "Interpolation

Used for seam

• Overlap seam

• U-Seam

pattern profiles

• Tailored blank

• HU-seam

• HY-seam

• TB-Area

Search area

The parameter "search area" is used if there is major interference (i.e.

left/right

caused by reflections) in the proximity of the selected joint line. Such interference occurs less often in the edge region of the V-seam. V Therefore, it is often useful to define a search area for these points. The search area for the "overlap seam" shape is defined by starting at the joint on the left and right. For "tailored blank" and "v-seam",, you can define minimum and maximum limits for the search area independently of the joint. The search area to the right ght and left of the seam position can be defined by entering the minimum and maximum limits. For the seam pattern "open edge",, the position of the search area can only be defined to one selected edge. (The search area can be defined as an area or only as a line for all seam shapes.) It must be possible to reliably detect all three laser lines in this case.


• Open edge

• V-seam

• U-Seam

• Overlap seam

• V-Area

• HU-seam

• Tailored blank

• HY-seam

• TB-Area


Page | 5-39


Line length

By specifying the length of line,, only line elements for the joint detection

(left/right)

are selected which are contained in the specified range.


• Open edge

• V-seam

• U-Seam

• Overlap seam

• V-Area

• HU-seam

• Tailored blank

• HY-seam

• TB-Area

Line diff.

The "Line diff. (A, L)" parameter is used for smoothing those line eleele

(A, L)

ments that do not lie precisely on the theoretical line direction (angle = A). ). It is also used to merge small gaps (gap = L).

L

W

Figure 99: THxDView – " Line diff. (A, L)" L) parameter


• Tailored blank

• HY-seam

• V-seam

• U-Seam

• V-Area

• HU-seam

• TB-Area

Preferred joint

The "preferred joint position" parameter allows you to manually define

position

the seam position so you can eliminate ambiguities during the seam detection. This eliminates the risk of faulty detection. It can be used, for example, when an additional edge is located under the selected work piece ce edge or when a clamp causes two steps of equal height to be visible.


Page | 5-40


Examples of

Figure 100 shows two overlapping overlap seams; the position of the

preferred joint

upper sheet is not clear in such a case. Unambiguous detection is only

position

possible after the "preferred seam position" parameter has been specified.

Figure 100: THxDView – "preferred seam position" parameter (example)

Left/Right

By choosing the parameter "joint is on the left" or " joint is on the right", the detection of the seam position occurs in the middle position between the two higher or two lower lying surfaces. (As shown in Figure 101) Position of the seam – on the left

Position of the seam – on the right

Figure 101: THxDView – "preferred joint position" parameter (example)


Information

• Open edge

• HY-seam

• Overlap seam

• U-Seam

• Tailored blank

• HU-seam

• TB-Area

Sections 5.11 and 5.14.9 contain more information on the various templates for the seam pattern profiles and on creating additional profiles.


Page | 5-41


5.11.4

Camera tab Overview

The "Camera" tab allows you to select a pre-defined profile (template) which contains specific parameters for configuring the camera imaging in the TH6D sensor head. It is also possible to create custom profiles by changing the parameters in the existing templates.

Figure 102: THxDView – Camera tab

Camera profiles

Templates and custom camera profiles can be selected from the dropdown list.

5.11.5

Camera tab – parameter description Parameter

The following adjustable parameters influence the camera imaging:

Dynamic range

The "dynamic range extension" parameter can be used with extreme

extension

brightness to reduce the over-exposure of the camera. The "slight" setting is the default.

Exposure time

NOTE! Usually a short exposure time is recommended.

The "exposure time" controls the function of the shutter in a camera. Shorter intervals (smaller parameter values) mean that less light is registered by the photographic layer in the camera chip. This parameter can help you when movements of the camera are causing the image to blur. A shorter exposure time also helps to filter out traces of welding splatter, which show up on the image as points of light.


Page | 5-42


Laser power

The "Laser power" parameter affects the power of the laser diode. At higher power, the intensity of the laser light is increased. The actual setting of this value must be tested on the work piece. There is no recommended value for this parameter, since there are many variable factors for each situation (the sensor orientation, shape of the work piece surface, reflective properties or the surface, etc.). The brightness should only be set as bright as required. Unnecessary brightness would shorten the lifespan of the laser diode.

5.11.6

Calibration tab Overview

CAUTION! The calibration depends on the machine in use. It is only required when the TH6D system is used with linear axes and Kuka robots. Calibration data must be specified in order to define the advanced tracking compensation between the sensor origin and TCP. This is accomplished by assigning the measured data in the sensor coordinate system to the tool. The

"Calibration"

tab

allows

you

to

select

a

pre-defined

profile

(templates) which contains specific parameters for calibrating the TH6D sensor head. By changing the parameters in the pre-designed templates, it is possible to create custom calibration profiles. (Refer to Figure 103).

Figure 103: THxDView – Calibration tab

Note

Section 5.14.6 contains more information about carrying out the calibration.


Page | 5-43


5.11.7

Calibration tab – parameter description Parameter

The following parameters influence the calibration:

+z A

+x

+y B

C

TCP S0

∆xs Figure 104: THxDView – parameters for calibration S/N sensor

Serial number of the TH6D sensor head (automatic entry)

Orientation

Orientation of the calibration plate in the robot/machine coordinate system (manual entry)

Offset ∆xs

Gap between TCP and the centre of the "tip" or "cross-hairs" insert of the calibration plate (manual entry)

Tool ABC S0 position S0 orientation Advanced

Tool orientation in the robot coordinate system (manual entry) Sensor origin S0 in the robot coordinate system (calculated) Sensor orientation in the robot coordinate system (calculated) Gap between the sensor origin and the TCP (calculated)

tracking


Page | 5-44


5.11.8

Process Control tab Overview

CAUTION! The parameters and parameter functions in the "Process Control" tab depend on the selected machine interface. The "Process Control" tab allows you to select pre-defined profiles (templates) which contain specific parameters for the machine-dependent process control of the TH6D sensor head. By changing the parameters in the pre-designed templates, it is also possible to create custom profiles.

Example

Figure 105 shows an example of the process control of the overall A/D corrective interface. The analogue voltages can be scaled here and also assigned an offset. The user can check off which parameter should be sent as a voltage value to the controller.

Figure 105: THxDView – Process Control tab A/D-IF

Information

The interface can be chosen from the main "System" tab and then the sub-tab "Machine Interface" (section 5.12.2). Section 5.9 describes the interface-specific parameters.


Page | 5-45


5.12 Parameters area – main System tab Main tab

The "System" tab allows you to configure a job list and select the

"System"

machine interface. This is also where the operating range of the analysis software can be configured.

Tab

No.

Name

Description

1

Job list

Manage and create jobs

2

Machine Interface

Select the interface

3

Configuration

Sets the operating range for the analysis software

1

2

3

Figure 106: THxDView – parameters area – system

5.12.1

Job List tab Overview

The "Job List" tab can be used to create jobs from the parameter profiles that have already been defined in the "Profile" main tab. The user can create jobs for specific applications. These are then saved on the TH6D process computer. For the actual processing, the facility controller invokes the job needed for that particular application. This is achieved using the job number assigned by the sequence program.


Page | 5-46


Jobs

NOTE! For more information on setting up profiles and creating jobs, refer to section 5.14.9. A job consists of four customer-specific profiles: "seam pattern", "camera", "calibration" and "process control". (Refer to 1 in Figure 107.) More information about configuring the custom profiles can be found in section 5.11.

1

Figure 107: THxDView – job list

Information

The System Status area shows the job compilation that is currently being used. (Refer to 2 in Figure 108.) Sections 5.8.4 and 5.14.9 contains more information about Jobs, their status and creation.

2

Figure 108: THxDView – job compilation in the System Status area


Page | 5-47


5.12.2

Machine Interface tab Overview

The "Machine Interface" tab is used to select which machine interface is connected to the TH6D system. This selection must be specified because each interface provides different machine-dependent parameters for configuring the user interface.

Interfaces

Interface

Description

A/D correction

General interface for control of two auxiliary axes via the control voltage

Motoman

Interface to the Motoman robot controller, whereby the

reference path

track-specific correction takes place in the lateral (Y) and height (Z) directions. This is derived by comparing the current measurement with the stored reference value at one measurement point on the reference path.

Fanuc Ethernet

Interface to Fanuc controller: transmits the measured values

in

the

sensor

coordinate

system

without

advanced tracking compensation. This requires that the tool is calibrated using the 10-point method, as described in the Fanuc manual. IF UDP data

General interface for transmitting the measurements to an external receiver; interface for use with nonstandard protocols.

Changing the

NOTE!

interface The system is rebooted after the machine interface is changed. • Select the interface to use from the drop-down list (as shown by 1 in Figure 109). • Click on "Save" (2). • After changing the machine interface, the system automatically restarts. • The system then starts with the newly selected configuration.


Page | 5-48


2 1

Figure 109: THxDView – selecting the interface

NOTE! When an interface is changed, the assigned process control is loaded which provides the relevant parameters.

Information

For more information about the available interfaces and their parameters, refer to section 5.9.

5.12.3

Configuration tab Overview

The "Configuration" tab allows you to configure the settings for playing back the recorded image from the camera in the TH6D sensor head. (As shown in Figure 110.)

Parameter

Parameter

Description

Search window X

Rows of the exposure field in the X direction

Search window Y

Rows of the exposure field in the Y direction

In the "Evaluation" area, you can restrict the camera image to width X and height Y so that areas of interference can be ignored. If a welding process has a strong influence on the optical characteristics and image analysis, then you remove the problematic image area by defining a number of image rows (e.g. 0, 200). Rows outside of this specified range are ignored by the evaluation algorithm and no longer shown in the "Evaluation" image are.


Page | 5-49


Configuration

CAUTION! This configuration does not change the size of the TH6D sensor head's measuring field. Adjustments only affect the "Evaluation" image area. The only visual change in the "Evaluation" image is that the laser lines are shorter. The size of the visual frame remains unchanged. (As shown in Figure 110.)

x

y Figure 110: THxDView – configuring the "Evaluation" image area

Example

The change to the parameter "search window x and y" (as shown in Figure 111) has the following influence on the "Evaluation" image area:

751

20

x

100 400

y Figure 111: THxDView – configuring the "Evaluation" image area (example)


Page | 5-50


Example –

The changes have no effect on the sensor's field of measurement, as can

continued

be seen in the "Raw data" image area. (As shown in Figure 112)

x

y

Figure 112: THxDView – configuring the "Raw data" image area (example)


Page | 5-51


5.13 Interfaces and associated parameters 5.13.1

Machine interface – analogue-digital correction A/D correction

This general "analogue-digital (A / D) correction interface" provides digital status signals and is controlled via digital input signals. The correction values for lateral and vertical deviation, Mismatch and gap width are output as analogue voltages (e.g. for controlling auxiliary axes).

Machine-

The machine interface "analogue-digital correction" only works with the

dependent

auxiliary module "analogue-digital interface (ADF)." More information and

auxiliary modules

the installation instructions can be found in sections 3.4.1 and 4.5.1.

NOTE! Voltages are only output during automatic mode.

Digital inputs/outputs

The status of digital inputs and outputs is shown by fields (1). (As shown in Figure 113.) • Check mark in box:

Digital I/O high

• No check mark:

Digital I/O low

Analogue

The "Analogue On/Off" field is divided into four analogue inputs (2) and 4

inputs/outputs

analogue outputs (3). In the "Analogue Out" field (3), four analogue outputs are displayed for each default voltage value. The four analogue inputs (2) are by default not operated.

1

2

3

Figure 113: THxDView – analogue-digital correction interface


Page | 5-52


Corresponding

After the analogue-digital interface is properly selected, the parameters

process control

shown in Figure 114 are available for the process control. The user can check off which parameter should be sent as a voltage value to the controller. It is also possible to scale the parameter values and set an offset.

Figure 114: A/D interface – process control

Parameter description

Parameter

Description

Filter width

Mean value of the measured data for the specified number of images

∆x (scale, offset)

Scaling factor for the output of the measured value on the gap between the laser lines; added to the measured value

∆y (scale, offset)

Scaling factor for the output of the measured value on the position in lateral direction; added to the measured value

∆z (scale, offset)

Scaling factor for the output of the measured value on the position in height; added to the measured value

A (scale, offset)

Not used in this machine interface

B (scale, offset)


C (scale, offset)


C (left) (scale, offset)


C (right) (scale, offset)


Gap (scale, offset)

Scaling factor for the output of the measured value on the gap width; added to the measured value

Mismatch (scale, offset)

Scaling factor for the output of the measured value on the step height; added to the measured value


Page | 5-53


5.13.2

Machine interface – Motoman reference path Motoman reference path

This section explains how to use the "Motoman reference path" machine interface.

Figure 115: THxDView – Motoman reference path interface

Machine-

The "Motoman reference path" machine interface only works with the

dependent

auxiliary module "analogue-digital interface (ADF)." More information and

auxiliary module Prerequisites

the installation instructions can be found in sections 3.4.1 and 4.5.1. There are prerequisite conditions from Yaskawa/Motoman for two versions of the robot controller:

DX100 controller

Requirements for adapting the TH6D system to a Motoman DX100 controller:

Hardware

• YCP02-E board with plug for CN120 (analogue sensor card, complete) • Possibly: adapter for high-speed inputs (DIN adapter and cables) when using the analogue search function • Four digital inputs and eight digital outputs to control the TH6D • An additional XIO02 card (I/O card) may be needed

Software

• DS1.42-32


Page | 5-54


X100 controller Sensor parameter

• Sensor parameters that deviate from the initialization values: S1E021 = 2

S1E070 = 1

S1E022 = 3

S1E072 = 30

S1E027 = 100

S1E073 = 60

S1E028 = 100 NX100 controller

Requirements for adapting the TH6D system to the Motoman NX100 controller:

Hardware

General sensor card for analogue inputs: • Sensor board: NCP 02

• Connector: (3M-10136)

• Analogue board: NSL02-2

• Cover: (3M-10336)

Operating modes

The "Reference Path" field in the "Machine Interface" tab (as shown in

– basic settings

Figure 116) shows the currently selected operating mode (1) and the current controller mode (2). The display field (2) is also a control field in set-up mode used to specify whether the robot controller ("via robot" mode) or the operator (manual mode) control the operating modes of the TH6D system. In the "with robot" mode, the robot controller automatically switches between the "record", "ref. mode" and "correction" operating modes. When in manual mode, the toggle field (2) can be pressed repeatedly to switch modes. The default is the control mode "via robot" using the auto-switched operating modes shown below.

1

2

Figure 116: Motoman reference path – operating modes


Page | 5-55


The robot selects the operating

If the control mode "via robot" is activated, the field "operating mode" (1) is assigned to the field "selection" (2) in THxDView as follows:

mode Operating

Selection

Description

mode • Records the seam points in the sensor coordinate system with imaging frequency (IN 3 = 0, IN 4 = 0) • Transmits the difference between the current measured value and the measured value of the reference path (IN 3 = 1, IN 4 = 0) • Not used

Changing the

CAUTION!

control mode and The operating mode can only be changed manually while

manually

in set-up mode.

changing the operating mode

• While the control mode "via robot" is activated, click once on the "choice" button (2) to switch to manual mode (as shown in Figure 117). • By switching to manual mode, the "record" (1) mode is simultaneously activated, which is also displayed in the control field (2) (as shown in Figure 118).

1

2

3

4

Figure 117: Manually switching the control mode

Figure 118: Control mode "manual" – operating mode "record"

• Click once more on the "choice" field (2) to switch to the next operating mode. • The operation mode that has been selected is displayed in the field (1) after the switch. • After switching through the three manually selectable operating modes, the system will return to the "via robot" control mode.


Page | 5-56


• Click on the button "Save" (3) to change the default boot configuration permanently. The new configuration will then be loaded at the next system boot. Click on the button "clear" (4) to reset to factory default settings. Manually selecting

If the control mode "manual" is activated, the field "operating mode" (1)

the operating

is assigned to the field "selection" (2) in THxDView as follows. The

mode

assignments are listed in the order they are activated and displayed when manually changed: Operating

Selection

Description

mode • Records the seam points in the sensor coordinate system in imaging frequency • Transmits the difference between the current measured value and the measured value of the reference path • Not used

Set up with the

CAUTION!

robot Automatic mode and the "via robot" selection mode must both be activated in order to set up the robot.

NOTE! During the reference movement, the seam points are saved in the TH6D process computer and assigned to the active job. Each processed section of a work piece has its own job number and thus its own reference data.


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Set up with the

Function

Display

Bit

Field (1) shows:

IN3=0

robot – continued

The robot's path is initially programmed on a sample work piece (the teach-in).

IN4=0

Then the reference path is recorded as soon as the robot sets off (controlled by the program) on the

Field (2) shows:

learned path at its processing speed. It is important that the activation and deactivation of the TH6D sensor head occurs automatically in the programming. During the recording of the reference path, no corrective values are transmitted to the robot. When the work pieces are processed, the TH6D

Field (1) shows:

sensor head provides analogue corrective path-based

IN3=1 IN4=0

signals for lateral and height directions as differential values for the reference path. This requires that the

Field (2) shows:

robot switch to the "ref. mode".

Information field

NOTE! The speed needed for calculating the path length must be specified in the "Process Control" tab. The "Info" shows a brief summary analysis of the recorded reference path.

Example

In the example (in German language, as shown in Figure 119), a path of 100.6 mm was recorded. In this case there was an interruption in the seam detection of 0.3 mm at the seam position 47.9 mm.

Figure 119: THxDView – Motoman reference path – information field

Analogue and

NOTE!

digital In the operating mode "record", no corrective values are

inputs and

output to the analogue outputs.

outputs

The functions of the "Analogue On/Off" and "Digital I/Os" areas are the same as those of the analogue-digital interface (refer to section 5.13.1). The corresponding interface assignment table can be found in section 8.3.


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Corresponding

After the Motoman interface has been selected in the "Machine Interface"

process control

tab, the parameters shown in Figure 120 are available for the process control.

Figure 120: Motoman interface – process control

Parameter

The following parameters are used to optimize the measurement process.

description Parameter

Description

Speed

Speed value of the robot movement during the

(Rec, Track)

recording (Rec.) of the reference path Speed value of the robot movement during the seam tracking (Track)

Speed (Scale, Offset) Filter length

Not used Selectable range for smoothing the measured values (moving average) Caution: Only use filter width OR filter length!

Measurement data without

Not used

advanced tracking Filter width

Mean value of the measured data for the specified number of images Caution: Only use filter width OR filter length!

∆x (scale, offset)


Scaling factor for the output of the measured value on the gap between the laser lines; added to the measured value

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Parameter description – continued

5.13.3

Parameter

Description

∆y (scale, offset)

Scaling factor for the output of the measured value on the position in lateral direction; added to the measured value

∆z (scale, offset)

Scaling factor for the output of the measured value on the position in height; added to the measured value

A (scale, offset)


B (scale, offset)


C (scale, offset)


C (left) (scale, offset)


C (right) (scale, offset)


Gap width (scale, offset)

Scaling factor for the output of the measured value on the gap width; added to the measured value

Mismatch (scale, offset)

Scaling factor for the output of the measured value on the step height; added to the measured value

Machine interface – Fanuc Ethernet Overview

NOTE! Consult Fanuc's documentation when carrying out the machine-side integration. Caution: Scansonic MI GmbH is not responsible for the

content

and

maintenance

of

third-party

documentation! Prerequisites

The following prerequisites are needed for the Fanuc system configuration [source Fanuc]:

Hardware

• Controller (hardware): RJ30iA robot controller with RJ45 network input, numbered as CD38A

Software

• The proper Fanuc system software for communicating with the TH6D sensor head • Software packages for sensor communication and seam tracking: R691 universal sensor interface R648 user socket messaging


Page | 5-60


Fanuc Ethernet

The TH6D process computer communicates with the Fanuc robot controller using a separate PTP connection with a fixed IP address. • Refer to instructions for setting up the Ethernet link found in the Fanuc documentation.

Changing the IP

NOTE!

address of the The robot and the TH6D system must be in the same IP

TH6D systems

address range. After selecting the Fanuc interface, you must enter another IP address. The following steps should be taken to change the IP address using THxDView: • The "Eth1" option (1 in Figure 121) must be selected: it corresponds to the TH6D communication port used with the Fanuc controller. • Enter the desired IP address in the box (2). • The subnet mask (3) must always be 255.255.255.0. • Click on the "Save" button (4) to apply the change. • Restart the TH6D process computer by clicking the “Yes” button in the confirmation dialog box • OR select "Restart" from the menu bar, under "Extras"

2

3

4

1 Figure 121: Fanuc Ethernet interface – changing the IP address


Page | 5-61


Calibration

A job must be specified in order to calibrate with the Fanuc robotics controller. This job must be designated as job number 1, since the Fanuc controller automatically invokes this number for the calibration.

Our recommendation Creating the calibration job Creating and saving a profile

This job should consist of configurations (profiles) specifically set up and designated for the calibration. Create the profile and the first job according to the example below and the information found in section 5.14.9. Select the "Lap joint" template for the seam pattern. • Specify the "TCP position" parameter so that the TCP is positioned either to the left of right of the upper workpiece edge (upper plate) (refer to Figure 122 and section 5.11.2) Adjust additional parameters if necessary. Save the profile under a specific name (for example, "fanuc_calibration").

Figure 122: Fanuc Ethernet interface – creating a calibration profile

• Select the existing template for the camera profile. Change the parameters if necessary and save the profile under a specific name (as described in section 5.14.7) The profiles for "Calibration" and "Process Control" (refer to sections 5.11.6 and 5.11.8) should not be set. When compiling the job, you can use the system files or the place holders syscalib.xml (calibration) and syspctrl.xml (process control). Creating a

ATTENTION!

calibration job Do not delete the calibration job after the calibration has been carried out! Addition information about this calibration can be found in the documentation from Fanuc.


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Make sure that the calibration job is assigned job number 1 (Job 1)! • Set up Job 1 as a calibration job, using the previously created profiles (refer to the example in Figure 123) • OR: you can delete an existing Job 1 and create a new one based on the previously created profiles. • OR: you can change the number of an existing Job 1. Then create a new job as the calibration job with the previously created profiles. This job will automatically be assigned job number 1 and will be switched to the top position on the job list. • Additional information about creating jobs can be found in sections 5.12.1 and 5.14.9

Figure 123: Fanuc Ethernet Interface – creating a calibration job (example)

Corresponding

The protocol for the Fanuc Ethernet interface to the TH6D system has

process control

been specified. Thus, after restarting the TH6D system, the output of measurements can be either enabled or disabled in the process control. This is done by setting or removing the check mark (as shown in Figure 124).

Figure 124: Fanuc Ethernet interface – process control


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5.13.5

Machine interface – IF UDP Data IF UDP data

NOTE! The UDP-machine interface is used for non-standard applications. The following customer-specific adaptations can be made when using the UDP Data machine interface. • IP address: • Dead time

Figure 125: THxDView – UDP Data interface

Delay

Delay is the system delay time or response time required by the TH6D system when it outputs a data record. This value is automatically sent to the robot controller when the communication link is established.

ATTENTION! You should only change this delay value when the communication link between the TH6D system and robot controller times out! The value can then be adjusted accordingly but may not be less than 17 milliseconds! (Input value of 17000).


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5.14 Set-up and configuration of the TH6D system Prerequisite

The TH6D system must be installed as described in Chapter 4. THxDView must be installed on the user PC. The network link to the TH6D process computer must be established and operational.

Initial

During the initial commissioning the TH6D process computer may still be

commissioning

in standby mode. It must then be manually switched on using the ON/OFF

information

switch on the TH6D process computer. Refer to the information about the status display and the position of this switch as described in section 3.5.2. After it is booted up, the TH6D system is in automatic mode. Set-up mode must be activated in order to change parameters.

NOTE! Parameter changes and other adjustments can only be carried out while in the set-up mode. In this operating mode, the laser lines are switched on, unless this is prevented by the applicable laser safety regulations.

5.14.1

User login Overview

After the THxDView software is successfully installed and started up, the user must log on to the TH6D system. THxDView provides different levels of access, each of which is secured by a password. The default access level is "Parameterization" General access Serves the general overview function. Here, no adjustments can be made. • Access level:

Expanded view

• Password:

level1

Parameterization access Here the parameterization of TH6D system can be made. • Access level:

Adjusting parameters

• Password:

level2


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User login

• Click on the "Login" button (as shown Figure 126). • Select the desired access level. • Enter the password in the window that appears and then click "Login" (as shown in Figure 127). • The "Login" menu option then changes to show the current access level.

Figure 126: THxDView – user login

Figure 127: User login – password entry

Login failure

• An error message will be displayed if you enter a wrong password (as shown in Figure 128). • The password can be re-entered.

Figure 128: Login failure

Changing the

NOTE!

access level It is possible to switch to a lower access level without reentering a password.


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After logging in, you can click on the menu bar to change access levels. You will have to enter a new password if you are switching to a higher access level. • Click again on the "Login" option with the name of the current access level (as shown in Figure 129). • Select a different access level. • Enter the password if necessary.

Figure 129: Changing the access level after the login

5.14.2

Establishing a network connection with a TH6D system Overview

NOTE! The TH6D system is delivered with the factory default IP address and port permissions. Only Scansonic service personnel can change these settings. The TH6D process computer comes standard with the following default connection settings for the user PC with THxDView: • IP address:

192.168.0.201

• Subnet mask:

255.255.255.0

The user PC and the TH6D process computer must be in the same address range. The fourth number block in the IP address range may not be 201. The address for the subnet mask must stay as shown above. Examples of valid

• 192.168.0.214

IP addresses

• 192.168.0.105

Prerequisite

The user PC must be connected to socket 6 of the TH6D process computer, as described in section 4.4.13. THxDView must be installed on the user PC, as described in section 5.3.3.


Page | 5-67


Notes

NOTE! THxDView must not be blocked by any firewall or antivirus programs.

Checking the IP

NOTE!

addresses All connected TH6D systems will be shown in THxDView, even if they are in another address range. You can select the menu option "Select System" in order to display the TH6D systems connected to the user PC along with their IP addresses. You can select a system here. A sensor system management option is available for checking IP addresses and to operate a TH6D system with a specific serial number. Open the sensor system management

• Click on the "Select System" button in the menu bar (as shown in Figure 130). • Select the "Manage Sensor Systems" option.

Figure 130: THxDView – selecting a sensor system (example)

• Refresh the list by clicking on the "Refresh" button (as shown by 1 in Figure 131). • Check and compare the displayed TH6D systems and their specific IP addresses with the network settings of the user PC. • Make any necessary changes on the user PC (as network administrator). • Click on the "OK" button (2) to close the "Manage sensor systems" window.

1 2 Figure 131: THxDView – Manage sensor systems (example)


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Establishing a connection

After the network connections have been configured on the user PC, a link can be established to the TH6D system. • Click on the "Select System" button in the menu bar. • Click on the TH6D system that you plan to use. • The connection will then be automatically created.

Figure 132: Establishing the connection to the TH6D system (example)

Status display

A successful connection is indicated with green in the "system status"

for the

area and the name of the connected TH6D system. (Refer to the marked

connection Information

area in Figure 133.) Section 5.8 contains more information about the status display in the "system status" area.

Figure 133: THxDView – connected network status (example)

Information

The user PC running THxDView can be switched on and off separately

about

from the TH6D system. If the TH6D system is switched off before

disconnections

THxDView, then you will notice the disconnection in the THxDView software. The system status displays the message "No System". When switched back on, THxDView automatically connects to the previously connected TH6D system. This can be checked with the connection status in THxDView. (Refer to section 5.8.)


Page | 5-69


Setting the

NOTE!

automatic You can configure the settings so that a connection is

connection

automatically established between THxDView and the TH6D system when the software starts up. The next time you start THxDView, the program automatically tries to connect to the previously connected TH6D system. This process can be interrupted within four seconds. This automatic connection can be configured in the settings: • Click on the menu option "Extras". • Select the "Preferences" option (as shown in Figure 134).

Figure 134: THxDView – configuring the automatic connection

• Choose a value from the drop-down list for the automatic connection setting.

Figure 135: THxDView – choosing a value for the automatic connection


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5.14.3

Selecting the language Overview

NOTE! Additional languages are being prepared. Please contact your local sales and service partner. The standard version of the THxDView is available in German and English.

Changing the language

• Click on the "Extras" button (as shown in Figure 136). • Select the language in "Language" option. • A reboot is not required when changing the language.

Figure 136: THxDView – changing the system language

5.14.4

Selecting the set-up operating mode

Operating modes

NOTE! When selecting the operating mode, there must be an existing connection to a TH6D system and you must be logged in at the "Parameterization" access level. In order to set up the TH6D system using THxDView, you must be connected and logged in to a TH6D system and the "Setup" operating mode must be activated.


Page | 5-71


Selecting the

CAUTION!

set-up operating It is not possible to change modes during active

mode

processing

in

automatic

mode!

Wait

until

the

program has finished. The default operating mode when starting the TH6D system is the automatic mode. • Click in the "system status" area on the "Operation" button in order to switch to set-up mode. • This button is coloured red while in set-up mode (as shown in Figure 137). "Setup Mode" is activated

Figure 137: THxDView – the set-up operating mode

NOTE! When "Setup Mode" is activated, the laser lines are switched on, unless this is prevented by the applicable laser safety regulations.

5.14.5

Positioning the TH6D sensor head Prerequisites

First, the installation and connection of the TH6D sensor head, TH6D process computer, facility controller, user PC and THxDView must be carried out (as described in Chapter 4). The TH6D sensor head can then be positioned

NOTE! The emitted laser lines are much longer than the measuring field of the TH6D sensor head. Thus the sensor head must be carefully positioned over the joint.


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Positioning the TH6D sensor head

Move the tool (e.g. torch) to the desired working position. Align the sensor head TH6D sensor head as described below: • The TH6D sensor head should be positioned at a gap of 150 mm above the butt edge of the work piece.

The optimal

NOTE!

setting Set-up up mode must be activated in order to carry out configurations manually. To optimally adjust the lateral and vertical position of the TH6D sensor head above the butt edge of the work piece: • Verify that the position of the sensor is correct by observing the orientation movements in THxDView. • Position the butt of the work piece in the centre of the "raw " data" image area, as shown in Figure 138. • The middle line of the three laser lines should be aligned near the horizontal white line of the "raw data"" image area. area

Figure 138: Positioning the TH6D sensor or head – V-seam example

The example illustrations below show different gaps that the TH6D sensor head can have to the seam area, using an example of a V-seam: V • Too far away from the work piece surface. • The third laser line is almost gone from the camera's viewing range.


Page | 5-73


The optimal

• Too close to the work piece surface.

setting –

• The first laser line juts out from the camera's viewing range.

continued

• Moved too far laterally to the left. • The laser lines jut out of the sensor area.

• The optimal gap to the surface of the work piece. • The solid white line shown in the image area should be used as a reference. • The laser line in the middle is positioned on the reference line.

Active measurement

• Optimal positioning for the TH6D sensor head. head • Measuring is activated. • Yellow dots mark the detected seam for the active measurement.


Page | 5-74


5.14.6

Tool calibration Overview

CAUTION! The tool must be re-calibrated each time after the TH6D sensor head is replaced or installed. You must re-calibrate the tool each time after the tool (e.g. torch) or TH6D sensor head is installed on a master machine or robot. This tool calibration is required so that the sensor coordinate system and the master machine's coordinate system are synchronized to work with each other. Thus the position and orientation of the TH6D sensor head is determined in relation to the tool (the tool centre point).

Interface

The calibration steps and required accessories depend on the particular

specifications

type of interface being used. The calibration of the tool should be carried

and accessories

out either on the master machine/robot or on the sensor side, as shown in the following table: Interface Linear

TH6D system

Master machines

Accessories

x

-

Calibration

axes

(ADF)

plate

Motoman

No calibration – reference path principle

Fanuc

-

KUKA

x

x

Calibration plate

NOTE! Contact your system partner for assistance in performing a robot-side calibration. Tool calibration for linear axes

This section only describes the sensor-side tool calibration for the linear axes (refer to the table above).

(ADF) Required accessories: • Calibration plate • "Tip" or "cross-hairs" insert (depending on the tool)


Page | 5-75


Prerequisites

The following conditions must be fulfilled in order to calibrate the tool. • The calibration plate must be precisely aligned in relation to the world coordinate system (the robot's "base coordinate system") and mounted (preferably in direction +x). • The TH6D sensor head must be optimally mounted in relation to the tool and work piece (seam detection must be ensured across the entire path). • The TH6D sensor head and the tool must be aligned in the +x direction in relation to the calibration plate (as shown in Figure 139). • All cables connecting the TH6D sensor head, process computer, optional machine interface and the facility controller must be plugged in securely. • THxDView must be installed on a user PC which must be connected to the TH6D process computer. • A template or existing profile with parameters specifications must have been selected from the "Calibration" sub-tab of the main "Profile" tab.

+z A

+x

+y B

C

TCP S0

∆xs

Figure 139: Orientation of the TH6D sensor head in relation to the calibration plate


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Determining the

CAUTION!

calibration data Before calibrating the tools, it is imperative that the seam shape "Overlap Seam" is activated from the "Seam Pattern" tab! Drive the TCP

In the "Calibration" tab, parameters must be specified as the basis of the tool calibration. (Refer to Figure 140 and Figure 141) • Move the tool's TCP (1) in direction +x to the centre of the insert being used ("tip" or "cross-hairs”) (2) for the calibration plate.

2

1

+y +x

Figure 140: THxDView – specifying the parameters for calibrating - 1

Determine the data

• Move the tool from the centre in direction -x until the laser lines (3) are optimally aligned with the "V" (4) of the calibration plate. • All three laser lines must jut out over the edges of the "V" (4). You can check this setting in the "raw data" image area within THxDView (refer to Figure 142). • Read out the traversed path ∆xs and the tool angles A, B, C from the robot controller.

1

3

+y

4

∆xs +x

Figure 141: THxDView – specifying the parameters for calibrating - 2 Entering the

NOTE!

calibration data in The

THxDView

serial

number

(parameter

S/N

sensor)

will

be

automatically imported into THxDView. In the "Calibration" tab, parameters must be specified as the basis of the tool calibration. (As shown in Figure 142.)


Page | 5-77


• Use the drop-down down list to select the orientation (1) of the calibration plate in relation to the tool coordinate system (currently only +x available).

Entering the calibration data in THxDView –

• Enter the calculated values in the boxes (2) and (3) (see the example in Figure 142).

continued

• Click on the "Calibrate" button (5) in order to start the calculation for the sensor origin coordinates. • Do not press any other button during the calibration process! • A successful calibration will be shown in the reports area. • The calculated parameters "S0 Position", "S0 Orientation" "Advanced Tracking" and "Basic Sensor" are shown in the area (4). • Click on the "Save As" button (7) to save the entries and calculations in a newly named ed calibration profile.

V 8 1 2 3 4

5

6

7

Figure 142: THxDView – specifying the parameters for calibrating the tool

NOTE! Make sure you select the proper profile when compiling the jobs! Changing an existing calibration profile

Customer-specific specific calibration profiles can be changed after their creation. • Select a profile from the drop-down list (8)). • Make the changes as previously described. • Click on the "Save" button (6) to save your changes in the existing profile.


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5.14.7

Measurement process optimization – changing camera settings Overview

NOTE! Set-up mode must be activated in order to change parameters. Parameters values must be saved in the profile in order to save the values permanently. (Refer to section 5.14.9.) The first step in optimizing the measurement processes is adjusting the brightness of the laser lines and the exposure time of the camera to fit your particular application. The default values are 70 (laser) and 5 (shutter).

Camera settings

In the "Camera" option of the main "Profiles" tab, the value for the laser brightness (2) should be specified in the input box so that the laser lines in the "raw data" image area are still faintly visible. This value is very dependent on the roughness of the work piece surface and its colouration. For reflective surfaces (such as stainless steel and aluminium), a value of at least 200 must be specified here.

1 2 0 0 Figure 143: THxDView – changing the camera settings

Subsequently, the exposure time (1) must be reduced to the smallest possible value at which the laser lines in the "raw data" image area are still visible.


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5.14.8

Optimizing the measurement process – changing parameters Overview

NOTE! Set-up mode must be activated in order to change parameters. Parameters values must be saved in the profile in order to save the values permanently. (Refer to section 5.14.9.) Parameters can be changed in THxDView in order to optimize the measuring processes for the TH6D system. Parameters should be optimized in individual steps in order to isolate fault detection. New values can be specified directly in the corresponding fields located within the associated tabs. In order to change the parameters, you must have a connection established to the TH6D system. You must also be logged in at the "Parameterization" access level and the corresponding parameter must be activated.

Changing the parameters Entering parameters

At the "Parameterization" access level, you can change the corresponding parameters within their specified value ranges. • Select a parameter. If necessary, activate it by clicking on the check box. • Click in any field in the parameter line and enter a new value. • Set them according to the range of values which is specified in the help bar above the tab (as shown by 1 in Figure 144). • Parameter values that are changed are then highlighted in green (as shown by 2 in Figure 144). • All values entered must be confirmed with the "Enter" key before they are transmitted to the TH6D process computer. • The parameter values are shown in black after they have been successfully transmitted.

1

2

Figure 144: THxDView – changing parameters (example)


Page | 5-80


Input incorrect

• If an invalid value is entered, the initial value is displayed in red (as shown by 4 in Figure 145). • The help bar will show the wrong entry by marking it with a red circle and white X (as shown by 3 in Figure 145).

3

4

Figure 145: THxDView – incorrect parameter entry (example)

5.14.9

Setting up profiles and creating jobs Overview

NOTE! Jobs cannot be created using profile templates. They can only be created from customer-specific profiles. A job is composed of four profiles. Existing profile templates cannot be used to create jobs. Thus before a job is defined, you must first create, set-up and save a specific profile for it.

Creating a custom (customerspecific) profile

Setting up a new profile

• From the main "System" tab, select one of the tabs "Seam Pattern", "Camera", "Calibration " or "Process control " (as shown by 1 in the example in Figure 146). • Choose a template that is suited to your processing task, or choose an existing profile from the drop-down list (2) of the selected tab. • Change the parameters necessary for your optimizations (3). • Save the newly created profile using the following specifications. • If needed, repeat these steps for the other tabs (1).


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Setting up a new profile – continued

1 2

3

4

5

Figure 146: THxDView – setting up a profile

Saving a new

NOTE!

profile Tabs containing changed but unsaved parameters are marked with an "*" before the tab name. (Refer to 1 in Figure 146.) • Click on the "Save As" button (5 in Figure 146) after you have finished optimizing the parameters. You can then save your customization to a new profile. • Give the profile a clear name and click on "Save" (6 and 7 in Figure 147).

6 7 Figure 147: THxDView – saving a profile


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Changing an existing profile

Customer-specific profiles can be changed after they are created. • Select a profile from the drop-down list (2 in Figure 146). • Make the changes as previously described. • Click on the "Save" button (4) to save your changes in the existing profile.

Information about saving

• The "Reports” area shows when the profile has been saved successfully. • The profile that you created is now in the drop-down list (as shown by 8 in Figure 148) and can be selected when compiling a job.

8

Figure 148: THxDView – selecting the profile from the drop-down list

Creating a job

The profile can be compiled into application-specific jobs after the set-up is complete. These are created in the "Job List" tab under the main "System" tab. (As shown in Figure 149.)

Figure 149: THxDView – job list


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Creating jobs –

Jobs can be assigned a unique job name. Each job is assigned a unique

continued

number by which it is saved in the TH6D process computer. For the automated processing, the machine controller invokes the desired job using the job number. This job is uploaded to the TH6D process computer and executed. The machine controller cannot change this job during an active measurement.

Creating a new job

• Click on the "Create Job" button (9) in the "Job List" tab. • A new row (10) will appear in the job list with fields that you need to fill in.

10 00

9 0 Figure 150: THxDView – creating a new job

Assign a job name and profiles

• Click in the column (11) and enter a unique job name (as shown in Figure 151).

11

Figure 151: THxDView – entering a job name


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• Then assign the desired profile to each profile type from the dropdown lists (as shown by 12 in Figure 152). • All four profile types must be assigned profiles in order to save the job. • Templates cannot be selected.

12

Figure 152: THxDView – assigning a profile

Saving the created

CAUTION!

job

Data loss is possible! Don't forget to save the new jobs! Unsaved data will be lost if the voltage drops or the TH6D system restarts. The reference text "new" will appear under the assigned job number after you have named it and assigned a profile. (Refer to Figure 153.) This indicates that the job has been created but not yet saved. • Create as many jobs as you need based on these specifications. • Click on the "Save" button (13) to save the new jobs. • A message about the save status will appear in the reports area.

13 00

Figure 153: THxDView – saving a new job


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Changing of deleting a job

The composition and name of created jobs can be changed after the jobs have been created. The assigned job number remains the same. • Click on the row of the job you wish to change – the job entries can now be edited. • Change the job name or assign different profiles to the profile types. • The reference text "changed" will be displayed under the job number. • Click on the "Save"" button to apply the changes.

Figure 154: THxDView – changing the content of jobs

Information

The name of the template is based on the corresponding profile and shown in parentheses after the profile name. (Refer to 14 in Figure 155.)

14

15

Figure 155: THxDView – notes on the job list

The current job and its contents can be seen in the "System State" (15) area.


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6.

Maintenance This section describes the process of servicing the TH6D system. 6.1

Safety instructions .......................................................... 6-2

6.2

Required maintenance .................................................... 6-3

6.2.1

Maintenance intervals..................................................... 6-3

6.2.2

Diagnosis of the maintenance intervals ............................. 6-4

6.2.3

Overview of maintenance procedures ............................... 6-5

6.3

Handling the components ............................................... 6-5

6.3.1

Clean and change the safety glass ................................... 6-5

6.3.2

Cleaning the TH6D sensor head ....................................... 6-8

6.3.3

Check the hose and cable connections .............................. 6-9


Page | 6-1

Maintenance

6.1

Safety instructions You must observe and obey the following safety instructions during maintenance and servicing to the TH6D system. These relate to the use of the TH6D system in a production facility.

DANGER! There is a risk of injury from the master machines! • Do not stay in the swivel range of master machines when they are turned on! • Disconnect the power from the master machines before starting to work on the TH6D system!

WARNING Danger of getting stuck! • When the power supply is turned on, keep hands, hair, pieces of clothing and tools away from the moving parts of the processing equipment. • Disconnect the power supply before beginning work on the TH6D system.

WARNING Danger to health through harmful gases and fumes! • Never inhale the gases resulting from the work process! • Always be sure that there is sufficient ventilation and extraction for gases! • After a process has completed, wait for the gases to be sucked away before entering the work/laser cell.

WARNING Loud noises can be dangerous! The loud noises caused by emitted media can damage your hearing. • Always wear protective gear for your ears when changing pressurized hoses!! • Or make sure that you de-pressurize all facility components!


Page | 6-2

Maintenance

WARNING Danger from excessive pressure! There is a risk of head, eye or hearing injury. • Always wear protective gear for your eyes and ears when changing pressurized hoses! • Or make sure that you de-pressurize all facility components!

WARNING! Risk of injury from hot components! There is a risk of burn injury from hot components when carrying out maintenance work immediately following the work process. • Allow the work pieces to cool down or wear suitable protective gloves!

6.2

Required maintenance Some components or work pieces in the TH6D system must be regularly maintained. Maintenance may only be carried out by trained personnel in observance of the safety information stated in this document.

6.2.1 Maintenance intervals The frequency of the maintenance depends on the work load of the TH6D system and will vary according to the facility. Normally, a maintenance interval after every eight hours of processing time is adequate. Scansonic recommends a diagnosis of the maintenance intervals in order to determine more precise intervals.


Page | 6-3

Maintenance

6.2.2 Diagnosis of the maintenance intervals Overview

Depending on the application (e.g. for large-batch large productions), the durability of the safety glasses should be determined empirically in cycles. This provides a more precise estimation of when the safety glass should be replaced.

NOTE! If the quality of the seam detection deteriorates (as indicated by the value in THxDView), this indicates that you need to replace or clean the safety glass. (As shown in Figure 156.) A reference point here is the seam detection value provided in the "System Status" section THxDView. If the percentage value specified for the seam detection continually decreases while measuring the same sample work piece, this may indicate significant contamination co or deposits. (Refer to the marked area in Figure 156.) In this case, the safety glass should be checked and replaced if necessary.

Figure 156:: Preventive maintenance and diagnosis

After the safety glass is changed, the percentage value for the seam detection should return to the proper range. (As shown in Figure 157.)

Figure 157: Changing the safety glass – improved seam detection (example)


Page | 6-4

Maintenance

6.2.3 Overview of maintenance procedures CAUTION! The maintenance information in the table below is a recommendation but does not guarantee error-free functionality.

Table 2: Maintenance procedures

Component /

Maintenance procedure

Section

Page

8

6.3.1

6-5

• Cleaning the TH6D sensor head

When

6.3.2

6-8

• Check that the input and output sides are connected firmly and that there are no leaks or damage.

When

6.3.3

6-9

• Check that the input and output sides are connected firmly and that there is no damage.

When

6.3.3

6-9

module Safety glass

Hours of operation

• Cleaning • Glass may need changing

TH6D sensor head Hose connections

Cable connections

6.3

necessary

necessary

necessary

Handling the components This section describes how to handle the individual components and modules during the maintenance procedures.

6.3.1 Clean and change the safety glass Overview

NOTE! The TH6D system may only be used for welding processes together with a TH6D sensor head and an attached safety glass unit with a clean safety glass! The safety glass unit with the built-in safety glass protects the optical elements in the TH6D system from mechanical contamination, process splatter and deposits.


• Check regularly that the safety glass is clean (check for deposits or splatter) and undamaged. • Clean the safety glass. • Replace the safety glass if it is scratched.


Page | 6-5

Maintenance

Removing the

NOTE!

safety glass unit The TH6D sensor head and the safety glass unit may be heated up during the thermal processing. Allow the modules to cool down before removal, or wear suitable protective gloves! • Pull the safety glass unit out in the opposite direction of installation. Pull down and out of the enclosure for the TH6D sensor head. • Section 4.4.5 contains more information about the disassembly process. • In order to replace the safety glass, take hold of it with your thumb and forefinger at the red marks (as shown in Figure 158). Gently lift the safety glass up and pull out diagonally.

Remove the protective glass

Figure 158: Replacing the safety glass – removing the safety glass

Cleaning the safety glass

Any contamination of the safety glass from the process should be cleaned as follows: • Use only clean, lint-free cloths for cleaning. • Clean with ethanol (do not use water or chemically aggressive cleaning agents)! • Wear gloves or finger coverlets in order to avoid leaving finger prints.

Replacing parts

Within this module, the following components can or must be replaced:

Item

Designation

Article no. :

Can / must

1

Safety glass unit

M001592

Can

2

Safety glass

(Refer to

Can

section 8.3.)


Page | 6-6

Maintenance

To insert new

CAUTION!

safety glass

Do not touch the unprotected surfaces of the safety glasses!

NOTE! Safety glasses are coated on both sides with a protective foil. These foils must be removed during the insertion, according to the instructions below. • Take hold of the sides of the new safety glass using your thumb and middle finger (hold the marked points shown in Figure 159). • Carefully remove the protective foil on the bottom side (towards the safety glass unit). • Use your forefinger to push down on the safety glass so that it is positioned between the spring strips. • After it snaps into place, peel off the foil from the top side of the safety glass.

Figure 159: Replacing the safety glass – inserting the new safety glass

Installing the safety glass unit

• Install the safety glass unit (with the new safety glass) so that it is aligned flush with the TH6D sensor head and until you hear a clicking sound. • Section 4.4.5 contains more information about the installation.

Functional testing

Check

that

everything

has

been

installed

properly

before

re-

commissioning. Use a functional test with sample measurements. • Move the TH6D sensor head manually over the work piece. • Open up the THxDView program and switch the TH6D system into set-up mode. • Activate the measurement function in THxDView. Stop it after about ten seconds.


Page | 6-7

Maintenance

Function test – continued

• You can check the image by clicking on the "Raw Data" tab and then on "Evaluation" in the image area (refer to section 5.6). • When compared to measurements taken before the safety glass was replaced, the new test measurements should exhibit less or no errors and the percentage values for the seam detection should be improved. (Refer to the example in Figure 160.) • If the seam detection is functioning smoothly, you can switch the TH6D system to automatic mode and log out of THxDView. • If the seam detection is still problematic, check that the safety glass and the safety glass unit properly seated and consider changing the parameter settings (refer to section 5.14.8).

Figure 160: Maintenance – replacing the safety glass – function test

6.3.2 Cleaning the TH6D sensor head Overview

CAUTION! A re-calibration is required after the position of the TH6D sensor head is changed in relation to the tool or when it is dismantled. Also check the calibration after cleaning! The TH6D sensor head may get dirty depending on the nature of your process. Any such contamination should be removed regularly.


• Cleaning the TH6D sensor head • Cleaning the safety glass unit and the safety glass (and replacing when necessary, refer to section 6.3.1) • Cleaning plugs and media connectors

Cleaning

CAUTION! Disconnect the power supply before cleaning! Use

non-abrasive

cleansers

when

cleaning

the

safety glasses on the TH6D sensor head! • Use only clean, lint-free cloths for cleaning the safety glasses on the TH6D sensor head. • You may use a gentle, non-abrasive detergent (never use water or aggressive chemical agents!). • You may also use ethanol for cleaning.


Page | 6-8

Maintenance

6.3.3 Check the hose and cable connections Overview

The connections for the media-supply hoses and cables on the input side of the TH6D sensor head are under heavy stress due to the motions of the master machine/robot. These connections need to be inspected regularly.


Check that the hose and cable connections: • Are attached firmly • Do not leak • Are not damaged Replace any damaged hoses or cable.

Checking the hose

WARNING!

connections Your eyes and ears can be damaged by emitted media! • Always wear proper protective gear for your eyes and ears while carrying out maintenance work on pressurized lines! • Pressurize the supply circuit. • Check the hose connections to the TH6D sensor head to make sure there are no leaks (check for noise and feel for leaks) • Be sure to de-pressurize (switch off) defective supply circuits! • Replace the plugs, couplings or hoses. Checking the cable connections

• Switch off the electricity to the cable connections. • Visually inspect all related cable connections to the TH6D sensor head and TH6D process computer for possible damages. • Replace any defective cables.


Page | 6-9

7.

Troubleshooting The chapter describes errors that may occur, along with their causes and the appropriate measures that can be taken. 7.1

Notes .............................................................................. 7-2

7.2

Information, warning and error code tables for THxDView ....................................................................... 7-3


Page | 7-1

Troubleshooting

7.1

Notes

We learn from your feedback. It is not possible to totally exclude the possibility of malfunctions even after proper inspections have taken place. We do not yet have a comprehensive list of faults and solutions. Thus we recommend that you contact customer service if you are experiencing malfunctions or difficulties.

Scansonic

Scansonic IPT GmbH Rudolf-Baschant-Straße 2 D-13086 Berlin, Germany Tel.:

+49 (0) 30 / 91 20 74 – 10

Fax:::

+49 (0) 30 / 91 20 74 – 29

E-mail:

[email protected]

Internet:

www.scansonic.de

Sales and service partner


Page | 7-2

Troubleshooting

7.2

Information, warning and error code tables for THxDView These information, warning and error code tables can be used for finding sources of errors in the TH6D system.

Information No.

Code

1.

I750

Description

Information

Automatic tracking is

The TH6D system works in automatic mode.

activated

Warnings No.

Code

1.

W180

Description

Source of error / possible solution

Excessive

There is a problem with the TH6D sensor head's cooling

temperature at

(air or water).

sensor

• Check the coolant connections and coolant lines. • Check the temperature of the coolant (refer to the information in section 8.4 Medium)

2.

W400

Laser off

Status alert indicating that the laser is switched off (system standby). Automatic mode: The master machine has tried to turn on the TH6D system but an error has occurred. Manual mode: No connection from the TH6D process computer to the TH6D sensor head; error E100 appears at the same time. • Activate the TH6D system using the controller on the master machine or robot. • Check the connection between the TH6D process computer and the TH6D sensor head. • Check the power supply to the TH6D sensor head.

3.

W401

Laser

safety

off

circuit

The laser safety circuit (LSC) is open. • Check that the LSC is closed. • Check the LSC switch to make sure it is functioning properly. • Check the LSC cable. Replace it if it is defective.


Page | 7-3

Troubleshooting

No.

Code

Description


4.

W710

Manual mode

The TH6D system is in set-up mode. • Log in to THxDView (using the parameterization access level). Switch the TH6D system to automatic mode (refer to Sections 5.14.1 and 5.8.2)

5.

W720

Sensor change

The calibration profile for the actual job is no longer

without tool

valid because a sensor has been changed.

calibration

• Add the current calibration profile for the actual job. Attention: This warning message can occur after E720 has been fixed when an internal tool calibration has been carried out but not specified in the job.

Errors No.

Code

1.

E100

Description


No communication

Communication with the TH6D sensor head is not

with sensor

possible. • Check that the Ethernet and power cables and plugs are undamaged and properly attached. • Use the status LED on the TH6D system to check for proper function (refer to section 3.5) The TH6D sensor head may be defective if you have ruled out cable connectivity problems. • Contact your customer support representative and send in your TH6D sensor head for repair.

2.

3.

E105

E110

Sensor

The firmware is not properly configured.

is not configured

• Contact your customer support representative and send in your TH6D sensor head for repair.

There is an error with

The calibration version of the TH6D sensor head does

the sensor

not match with the software in the TH6D process

calibration.

computer. • Record the serial numbers of the TH6D sensor head and process computer. Contact your customer support representative.


Page | 7-4

Troubleshooting

No.

Code

Description


4.

E120

No reception of the

The

measurement data.

measurements for one of the following reasons:

TH6D

process

computer

is

not

receiving

Disruption of network communication between the TH6D sensor head and the TH6D process computer. • Check that the Ethernet and power cables and plugs are undamaged and properly attached. • Use the status LED on the TH6D system to check for proper function (refer to section 3.5) The TH6D sensor head is defective. • Contact your customer support representative and send in your TH6D sensor head for repair. The power supply to the TH6D sensor head is too low. • Check the output of the power supply and ensure that it is sufficient (refer to section 8.1 Technical Specifications) 5.

E150

Internal sensor error

Electronic defect in the TH6D sensor head. • Record the serial numbers of the TH6D sensor head and process computer. Contact your customer support representative.

6.

E300

Process

interface

is

not ready

The process interface to the master machine (section 5.9) is not able to communicate because of an initialization error. • Record the serial numbers of the TH6D sensor head and process computer. Contact your customer support representative.

7.

E310

No communication on

The connection between the master machine / robot

the process interface

and the TH6D process computer is malfunctioning. • Check that the cables and plugs are undamaged and properly attached. • Check the software on the master machine / robot. • Check the communication between the master machine / robot and the TH6D sensor system.


Page | 7-5

Troubleshooting

No.

Code

Description


8.

E600

Job is not selected

The job was not selected by the master machine / robot or no job number was sent by the master machine / robot to the TH6D system. • Check the programming on the master machine / robot to ensure that the jobs numbers are assigned properly.

9.

E605

Job number not

An improper job number has been selected or sent. The

allowed

job number is not assigned in the TH6D process computer. • Check the programming on the master machine / robot to ensure that the jobs numbers are assigned properly.

10.

E610

Error in job profile

The TH6D system has a software error. • First delete the job and then the corresponding profiles. Then create both again (refer to section 5.14.9)

11.

E620

Job profile is missing

The TH6D system has a software error. • First delete the job and then the corresponding profiles. Then create both again (refer to section 5.14.9)

12.

E650

Job internal error

The TH6D system has a software error. • Delete the corresponding job and create a new one.

13.

E720

Sensor change has

Code indicates that a TH6D sensor head was changed.

been detected

When a TH6D sensor head is changed, the TH6D system automatically switches to manual mode. When using an internal tool calibration: • Carry out a new internal tool calibration (refer to section 5.14.6) • Integrate the newly created calibration profile into your created job (refer to section 5.14.9) When using an external tool calibration: • Acknowledge this error by switching to automatic mode (refer to section 5.8.2) • Run the external tool calibration again. • Check the tool machine via the machine or robot.


Page | 7-6

8.

Technical Data and Specifications This section lists the technical specifications for the TH6D system. 8.1

Technical data and specifications .................................... 8-2

8.2

Electrical switching functions of the analogue-digital interface (ADF) ................................................................ 8-7

8.3

Electrical switching functions of the Motoman interface ......................................................................... 8-8

8.4

Medium........................................................................... 8-9

8.4.1

Compressed air specifications .......................................... 8-9

8.4.2

Coolant specification ...................................................... 8-9

8.5

Ambient conditions ....................................................... 8-10

8.6

Accessories and spare parts .......................................... 8-11

8.6.1

Base configuration for the TH6D system ......................... 8-11

8.6.2

Optional components ................................................... 8-12

8.6.3

Optional components for the ABB and KUKA robots .......... 8-13

8.6.4

Wearing parts – safety glasses ...................................... 8-14


Page | 8-1

Technical Data and Specifications

8.1

Technical data and specifications TH6D sensor head,

Characteristics

in general Configurations

• TH6D-150-CFAA-AB • TH6D-150-KFAA-AB

Power supply

• 12 – 36 V DC (125 mA max. at nominal 24 V) • Protected against false insertion

Weight

• TH6D sensor head 0.53 kg • TH6D sensor head including safety glass unit: 0.65 kg

Limiting acceleration (mechanical)

• 3 g (with or without functional operations)

Laser protection class

• 3B

Protection class

• IP64 (with plugged-in connectors)

Operating wavelength

• 660 nm

Max. laser output

• 50 mW

Dimensions

• 70 x 121 x 40 mm (L x H x W)

Figure 161: TH6D sensor head – dimensions


Page | 8-2


TH6D safety glass unit

Characteristics

Dimensions

Figure 162: TH6D safety glass unit – dimensions


Page | 8-3


Sensor head TH6D-150-CFAA-AB Field of measurement

• Width: ± 8 mm

(width / height)

• Height: ± 12 mm

Optical resolution in the TCP

• 0.07 mm/pixel along X axis • 0.03 mm/pixel along Y axis

Nominal working gap

• 150 mm from bottom edge of sensor

(z = 0 mm) Nominal working gap

• 10 mm from rear edge of sensor

(x = 0 mm) Operating range

S0

S0

Figure 163: Operating range TH6D-150-CFAA-AB


Page | 8-4


Sensor head TH6D-150-KFAA-AB Field of measurement

• Width: ± 22 mm

(width / height)

• Height: ± 40 mm

Optical resolution in the TCP

• 0.1 mm/pixel along X axis • 0.3 mm/pixel along Y axis

Nominal working gap

• 150 mm from bottom edge of sensor

(z = 0 mm) Nominal working gap

• 10 mm from rear edge of sensor

(x = 0 mm) Operating range

S0

S0

Figure 164: Operating range TH6D-150-KFAA-AB


Page | 8-5



Characteristics

Dimensions

• 270 x 200 x 105 mm (L x W x H) • 270 x 220 x 105 mm (L x W x H) with mounting attachment

Power supply

• 12 – 36 V DC (500 mA max. at 24 V), protected against false insertion

Weight

• Approx. 3.0 kg

Facility and plant integration

• Ethernet • Serial port

Figure 165: TH6D process computer – dimensions


Page | 8-6


8.2

Electrical switching functions of the analogue-digital interface (ADF) Note that the signals of one type are numbered consecutively. The inputs of the second digital input module, for example, represent the ADF inputs 5 through 8. This principle applies to all signal types. The assignments listed here are set as the default. It is possible to change these assignments.

NOTE! Seam search and measurement will only function when the currently selected job has been created and activated.

Signal type

Digital input

Digital output

Analogue input

Analogue output

Sequential no.

Designation

1 2 5 6 7 8 9 10 11 12 13 14 15 16

Laser On/Off Seam search Start/Stop

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Automatic mode System is ready Tracking is activated Seam is found

Job Job Job Job

No. No. No. No.

(bit (bit (bit (bit

The laser is switched on or off The measurement is started or stopped

0) 1) 2) 3)

Automatic mode is activated Seam tracking system is ready Tracking has been started The seam position is currently detected

1 2 3 4 1 2 3 4

Seam position Y Seam position Z Height difference Gap width


Page | 8-7


8.3

Electrical switching functions of the Motoman interface The electrical switching functions of the Motoman Interface are identical with the ADF, except for the differences which have been marked.

NOTE! Seam search and measurement will only function when the currently selected job has been created and activated.

Signal

Sequential

type

number

Digital input

Digital output

Analogue input

Analogue output

Designation

1 2 3

Laser On/Off Seam search Start/Stop Reference movement

4 5 6 7 8 9 10 11 12 13 14 15 16

Corrective movement Job No. (bit 0) Job No. (bit 1) Job No. (bit 2) Job No. (bit 3)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Automatic mode System is ready Tracking is activated Seam is found

The laser is switched on or off The measurement is started or stopped 0 = reference recording track, 1 = reference movement 1 = active (then DI3 has no effect)

Automatic mode is activated Seam tracking system is ready Tracking has been started The seam position is currently detected

1 2 3 4 1 2 3 4

Seam position Y Seam position Z Height difference Gap width


Page | 8-8


8.4

Medium

8.4.1 Compressed air specifications Characteristics

Compressed air specifications Type of connections

Required air quality Recommended

flow

• Purge air: Quick-lock coupling for Ø

Outer

= 4 mm

• Cooling air: Quick-lock coupling for Ø

Outer

= 6 mm

• Oil and water free, filtered, dry rate

for

• 1 l/min

purging Allowable maximum pressure

• 6 bar

for cooling

8.4.2 Coolant specification ATTENTION! This information is relevant only when using the optional cooling module! • Do not allow any liquid coolants into the TH6D sensor head!

Coolant specifications

Characteristics

Type of connections

• Quick-lock coupling for ØOuter = 6 mm

Type of coolant

• Suitable for DI water (stainless steel version)

Flow quantity

• 2 l/min at 6 bar

Minimum coolant temperature

• > 15 °C

Maximum coolant temperature

• 25 °C

Maximum pressure

• 6 bar

Conductivity

• Conductivity to 2 µS/cm

pH value

• 5.5 – 8

Maximum particle size

• < 50 µm


Page | 8-9


8.5

Ambient conditions Please follow the information about the ambient, environmental conditions for the TH6D system given in the table below. Table 3: Ambient conditions

Storage temperature Operating temperature

-10 to +60 °C (observe dew point!) TH6D sensor head: +10 to +50 °C (min. 5 °C above the condensation point!) TH6D process computer: +5 to +50°C (min. 5°C above the condensation point!)

Enclosure temperatures

+25 to +45 °C

for achieving the specified measurement precision Permitted relative

< 95 % (non-condensing!)

humidity


Page | 8-10


8.6

Accessories and spare parts The following accessories and spare parts are available for the TH6D system.

NOTE Please specify the article number and name when ordering.

8.6.1 Base configuration for the TH6D system Item

Article No.

Designation

Description / function

1

M001806

TH6D TH6D-150-CFAA-AB

TH6D sensor head

Figure

For thin sheet metal applications

2

M001879

TH6D TH6D-150-KFAA-AB

TH6D sensor head For thick sheet metal applications

3

M001592

Safety glass unit

Protection against process splatter and deposits

4

5

M001797

M001585


System controller,

with software

measurement analysis

THxD cable set [10 m]

Consisting of M001704 and M001705

6

M001704

THxD power cable [10 m]

Cable for power supply to the TH6D sensor head

7

M001705

THxD Ethernet cable [10 m]

Ethernet cable for connecting the TH6D sensor head to the process computer


Page | 8-11


Item

Article No.

Designation


8

M001587

Power supply unit 24V-3, 24V

Power supply

2A

TH6D sensor head

9

M001713

THxDView ver. 1.0

Figure

CD with configuration software

License agreement

10

Comes with THxDView

(M001713)

8.6.2 Optional components Item

Article No.

Designation


1

M001589

Modbus TCP analogueanalogue

For the ADF and Motoman

digital interface

interfaces


Consisting of M001706

2

M001586

Figure

and M001707

3

M001706


Cable for power supply to the TH6D sensor head

4

M001707

THxD Ethernet cable

Ethernet cable for connecting

[15 m]

the TH6D sensor head to the process computer

5

M001618


Consisting of M001708 and M001709


Page | 8-12

Technical ical Data and Specifications

Item

Article No.

Designation


6

M001708


Cable for power supply to the

Figure

TH6D sensor head

7

M001709

THxD Ethernet cable

Ethernet cable for connecting

[25 m]

the TH6D sensor head to the process computer

8

M001852

Patch cable (1 m)


9

M001853

Patch cable (2 m)


10

M001854

Patch cable (5 m)


11

M001855

Patch cable (10 m)


8.6.3 Optional components for the ABB and KUKA robots Item

Article No.

Designation


1

M001799

Calibration plate THxD

Tool for calibrating the TH6D

Figure

sensor head

2

M001834

Cross Cross-hairs insert for the

Insert for calibration plate, to

calibration plate

help calibrate welding applications (arc welding)

3

M001835

Tip insert for the calibration

Insert for calibration plate, to

plate

help calibrate laser applications


Page | 8-13


8.6.4 Wearing parts – safety glasses Item

Article No.

Designation


1

M001652

Safety glass

Scaled 1–9

2

M001612

Safety glass

Scaled 10-24

3

M001610

Safety glass

Scaled 25-49

4

M001613

Safety glass

Scaled 50-99

5

M001614

Safety glass

Scaled 100-499

6

M001615

Safety glass

Scaled 500-999

7

M001609

Safety glass

Scaled 11000 +


Figure

Page | 8-14

9.

Appendix 9.1

Annex ............................................................................. 9-2

9.1.1

List of Figures ............................................................... 9-2

9.1.2

List of Tables................................................................. 9-6

9.2

Check-list for set-up and installation............................... 9-7

9.3

Contamination Declaration .............................................. 9-9

9.4

Condensation point table .............................................. 9-10


Page | 9-1

9.1

Annex

9.1.1 List of Figures Figure 1: TH6D sensor head – laser aperture .................................................................... 2-5 Figure 2: Location of the warning LED on the TH6D sensor head.......................................... 2-6 Figure 3: TH6D – The principle of laser triangulation .......................................................... 3-3 Figure 4: Specular (left) and diffuse (right) reflection ......................................................... 3-5 Figure 5: Diffuse reflection on work piece with rough surface .............................................. 3-6 Figure 6: Disturbances in the arc welding process .............................................................. 3-6 Figure 7: MIG process – the inert gas nozzle is clearly visible on the right ............................ 3-7 Figure 8: Laser welding process – laser focus on right ........................................................ 3-7 Figure 9: Accessibility limitations at the end of the seam caused by the forward-leading sensor .......................................................................................................................... 3-8 Figure 10: Accessibility limitations in a seam curve caused by the forward-leading sensor .......................................................................................................................... 3-8 Figure 11: Example of a border – the lap joint is too large .................................................. 3-9 Figure 12: Example of a border – the lap joint is too large – the solution .............................. 3-9 Figure 13: The TH6D sensor head .................................................................................. 3-11 Figure 14: TH6D safety glass unit .................................................................................. 3-12 Figure 15: TH6D process computer ................................................................................ 3-13 Figure 16: TH6D system – cable for Ethernet connection .................................................. 3-14 Figure 17: TH6D system – power supply cable ................................................................ 3-15 Figure 18: The TH6D sensor head's cooling module .......................................................... 3-16 Figure 19: TH6D auxiliary module – analogue-digital interface .......................................... 3-17 Figure 20: TH6D auxiliary module – calibration plate ........................................................ 3-18 Figure 21: TH6D auxiliary module – network cable........................................................... 3-19 Figure 22: Status LEDs on the TH6D sensor head ............................................................ 3-20 Figure 23: Status LEDs on the TH6D process computer .................................................... 3-22 Figure 24: Connections for the TH6D sensor head ............................................................ 3-24 Figure 25: Connection overview for the TH6D process computer, rear side......................... 3-26 Figure 26: Connection overview for the TH6D process computer, front side......................... 3-26 Figure 27: Sensor origin for the TH6D sensor head (CF variant) .......................................... 4-7 Figure 28: Earthing via the robotics interface, variant 1 ...................................................... 4-9 Figure 29: Earthing via the robotics interface, variant 2 .................................................... 4-10 Figure 30: Earthing via the power supply ........................................................................ 4-11 Figure 31: Position of the TH6D sensor head (example) .................................................... 4-12 Figure 32: Installing the safety glass unit ....................................................................... 4-14 Figure 33: Mounting the cooling module ......................................................................... 4-15 Figure 34: TH6D system – connecting the Ethernet cable.................................................. 4-16


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Figure 35: Ethernet cable connection ............................................................................. 4-16 Figure 36: Power supply on the TH6D sensor head ........................................................... 4-19 Figure 37: Connecting the cooling and purging air to the TH6D sensor head........................ 4-20 Figure 38: Connecting the liquid coolants to the cooling module ........................................ 4-21 Figure 39: Mounting rails for the TH6D process computer ................................................. 4-22 Figure 40: Power supply on the TH6D process computer ................................................... 4-23 Figure 41: Connecting the user PC for THxDView ............................................................. 4-24 Figure 42: TH6D system – overview of connections without machine interfaces ................... 4-25 Figure 43: TH6D analogue-digital interface (standard)...................................................... 4-26 Figure 44: Connecting the ADF to the TH6D process computer .......................................... 4-27 Figure 45: Power supply on the analogue-digital interface ................................................. 4-28 Figure 46: Parallel power supply connection to the analogue-digital interface ...................... 4-29 Figure 47: TH6D system – overview of connections with ADF ............................................ 4-30 Figure 48: Connecting the Fanuc interface ...................................................................... 4-31 Figure 49: TH6D system – overview of connections with Fanuc interface ............................ 4-32 Figure 50: THxDView – initializing the installation .............................................................. 5-6 Figure 51: THxDView – installation information.................................................................. 5-7 Figure 52: THxDView – starting the installation ................................................................. 5-7 Figure 53: THxDView – changing the installation directory .................................................. 5-8 Figure 54: THxDView – selecting the installation directory .................................................. 5-8 Figure 55: THxDView – installation progress ..................................................................... 5-9 Figure 56: THxDView – installation is finished.................................................................... 5-9 Figure 57: THxDView – the desktop icon......................................................................... 5-10 Figure 58: THxDView – the start-up window.................................................................... 5-10 Figure 59: Exiting THxDView ......................................................................................... 5-11 Figure 60: THxDView – user interface............................................................................. 5-12 Figure 61: THxDView – menu bar .................................................................................. 5-14 Figure 62: THxDView – program information ................................................................... 5-14 Figure 63: Image area – raw data (example with V-seam) ................................................ 5-15 Figure 64: Image area – analysis, measuring inactive ...................................................... 5-16 Figure 65: Image area – analysis, measuring activated .................................................... 5-16 Figure 66: Reports area – Errors and Warnings (example) ................................................ 5-17 Figure 67: Reports area – Events (example) ................................................................... 5-17 Figure 68: THxDView – "System Status" area (example) .................................................. 5-18 Figure 69: THxDView – "System Status", network connection (example) ............................ 5-18 Figure 70: THxDView – system status, operating mode .................................................... 5-19 Figure 71: THxDView – system status, measuring ............................................................ 5-20 Figure 72: THxDView – system status, job ...................................................................... 5-21 Figure 73: Parameters area – display of measurements (example) .................................... 5-22


Page | 9-3

Figure 74: Information area – diagram (example for adjusting the angle) ........................... 5-23 Figure 75:: Information area - Detailed view of parameters .............................................. 5-24 Figure 76: THxDView – Information about parameters ..................................................... 5-24 Figure 77: THxDView – parameter configuration area ....................................................... 5-25 Figure 78: THxDView – parameter configuration area – profiles ......................................... 5-25 Figure 79: THxDView – Seam Pattern tab ....................................................................... 5-26 Figure 80: THxDView – selecting the seam pattern profile................................................. 5-27 Figure 81: THxDView – seam pattern template for an open edge ....................................... 5-28 Figure 82: THxDView – seam pattern template for an overlap seam ................................... 5-28 Figure 83: THxDView – seam pattern template for a tailored blank .................................... 5-29 Figure 84: THxDView – seam pattern template for a TB-Area ............................................ 5-29 Figure 85: THxDView – seam pattern template for a V-seam ............................................. 5-30 Figure 86: THxDView – seam pattern template for a HV-seam........................................... 5-30 Figure 87: THxDView – seam pattern template for a HY-seam ........................................... 5-31 Figure 88: THxDView – seam pattern template for a U-seam............................................. 5-31 Figure 89: THxDView – seam pattern template for a HU-seam .......................................... 5-31 Figure 90: THxDView – line quality parameters (examples) ............................................... 5-33 Figure 91: THxDView – reference area parameter at the overlap seam ............................... 5-34 Figure 92: THxDView – TCP alignment parameters........................................................... 5-35 Figure 93: THxDView – depth parameter, with the example of an HV-seam ........................ 5-35 Figure 94: THxDView – angle left/right parameters .......................................................... 5-36 Figure 95: THxDView – Mismatch parameter at the overlap seam ...................................... 5-37 Figure 96: THxDView – "gap" parameters (example of tailored blank) ................................ 5-38 Figure 97: THxDView – "Interpolation point tolerance" parameter - 1 ................................. 5-38 Figure 98: THxDView – "Interpolation point tolerance" parameter - 2 ................................. 5-39 Figure 99: THxDView – " Line diff. (A, L)" parameter........................................................ 5-40 Figure 100: THxDView – "preferred seam position" parameter (example) ........................... 5-41 Figure 101: THxDView – "preferred joint position" parameter (example)............................. 5-41 Figure 102: THxDView – Camera tab .............................................................................. 5-42 Figure 103: THxDView – Calibration tab ......................................................................... 5-43 Figure 104: THxDView – parameters for calibration .......................................................... 5-44 Figure 105: THxDView – Process Control tab A/D-IF......................................................... 5-45 Figure 106: THxDView – parameters area – system ......................................................... 5-46 Figure 107: THxDView – job list..................................................................................... 5-47 Figure 108: THxDView – job compilation in the System Status area ................................... 5-47 Figure 109: THxDView – selecting the interface ............................................................... 5-49 Figure 110: THxDView – configuring the "Evaluation" image area ...................................... 5-50 Figure 111: THxDView – configuring the "Evaluation" image area (example) ....................... 5-50 Figure 112: THxDView – configuring the "Raw data" image area (example) ........................ 5-51


Page | 9-4

Figure 113: THxDView – analogue-digital correction interface ........................................... 5-52 Figure 114: A/D interface – process control .................................................................... 5-53 Figure 115: THxDView – Motoman reference path interface .............................................. 5-54 Figure 116: Motoman reference path – operating modes .................................................. 5-55 Figure 117: Manually switching the control mode ............................................................. 5-56 Figure 118: Control mode "manual" – operating mode "record" ......................................... 5-56 Figure 119: THxDView – Motoman reference path – information field ................................. 5-58 Figure 120: Motoman interface – process control ............................................................. 5-59 Figure 121: Fanuc Ethernet interface – changing the IP address ........................................ 5-61 Figure 122: Fanuc Ethernet interface – creating a calibration profile ................................... 5-62 Figure 123: Fanuc Ethernet Interface – creating a calibration job (example) ....................... 5-63 Figure 124: Fanuc Ethernet interface – process control ..................................................... 5-63 Figure 125: THxDView – UDP Data interface ................................................................... 5-64 Figure 126: THxDView – user login ................................................................................ 5-66 Figure 127: User login – password entry ......................................................................... 5-66 Figure 128: Login failure ............................................................................................... 5-66 Figure 129: Changing the access level after the login ....................................................... 5-67 Figure 130: THxDView – selecting a sensor system (example)........................................... 5-68 Figure 131: THxDView – Manage sensor systems (example) ............................................. 5-68 Figure 132: Establishing the connection to the TH6D system (example) ............................. 5-69 Figure 133: THxDView – connected network status (example) ........................................... 5-69 Figure 134: THxDView – configuring the automatic connection .......................................... 5-70 Figure 135: THxDView – choosing a value for the automatic connection ............................. 5-70 Figure 136: THxDView – changing the system language ................................................... 5-71 Figure 137: THxDView – the set-up operating mode......................................................... 5-72 Figure 138: Positioning the TH6D sensor head – V-seam example...................................... 5-73 Figure 139: Orientation of the TH6D sensor head in relation to the calibration plate ............. 5-76 Figure 140: THxDView – specifying the parameters for calibrating - 1 ................................ 5-77 Figure 141: THxDView – specifying the parameters for calibrating - 2 ................................ 5-77 Figure 142: THxDView – specifying the parameters for calibrating the tool.......................... 5-78 Figure 143: THxDView – changing the camera settings..................................................... 5-79 Figure 144: THxDView – changing parameters (example) ................................................. 5-80 Figure 145: THxDView – incorrect parameter entry (example) .......................................... 5-81 Figure 146: THxDView – setting up a profile.................................................................... 5-82 Figure 147: THxDView – saving a profile......................................................................... 5-82 Figure 148: THxDView – selecting the profile from the drop-down list ................................ 5-83 Figure 149: THxDView – job list..................................................................................... 5-83 Figure 150: THxDView – creating a new job .................................................................... 5-84 Figure 151: THxDView – entering a job name .................................................................. 5-84


Page | 9-5

Figure 152: THxDView – assigning a profile..................................................................... 5-85 Figure 153: THxDView – saving a new job ...................................................................... 5-85 Figure 154: THxDView – changing the content of jobs ...................................................... 5-86 Figure 155: THxDView – notes on the job list .................................................................. 5-86 Figure 156: Preventive maintenance and diagnosis ............................................................ 6-4 Figure 157: Changing the safety glass – improved seam detection (example) ....................... 6-4 Figure 158: Replacing the safety glass – removing the safety glass ...................................... 6-6 Figure 159: Replacing the safety glass – inserting the new safety glass ................................ 6-7 Figure 160: Maintenance – replacing the safety glass – function test .................................... 6-8 Figure 161: TH6D sensor head – dimensions ..................................................................... 8-2 Figure 162: TH6D safety glass unit – dimensions ............................................................... 8-3 Figure 163: Operating range TH6D-150-CFAA-AB .............................................................. 8-4 Figure 164: Operating range TH6D-150-KFAA-AB .............................................................. 8-5 Figure 165: TH6D process computer – dimensions ............................................................. 8-6

9.1.2 List of Tables Table 1: Position of notice and warning signs .................................................................. 2-11 Table 2: Maintenance procedures..................................................................................... 6-5 Table 3: Ambient conditions .......................................................................................... 8-10


Page | 9-6

9.2

Check-list for set-up and installation This check-list for set-up and installation references the information found in sections 4.3 and 4.4. Item

Procedural steps

1

Mechanical mounting

Completed

Overview: Please follow the instructions for installing the TH6D system in Chapter 4. Mounting: The TH6D sensor head should be mechanically connected to the master machine. (Refer to section 0.) Orientation: The TH6D sensor head should be aligned with the work piece surface so that the edges of the work piece can be detected in the sensor measuring range. (Raw data in THxDView) Screws should be tightened by hand. (Caution! Aluminium housing) Safety glass unit with safety glass should be mounted on the TH6D sensor head. (Refer to section 4.4.5.) The Ethernet cable should connect the TH6D sensor head (plug-in slot X5) to the TH6D process computer (plug-in slot 5). (Refer to section 0.) The power cable should connect the TH6D sensor head (plug-in slot X4) to the mains power supply unit. (Refer to section 4.4.8.) The power supply cable should be connected to the TH6D process computer (plug-in slot 2). (Refer to section 4.4.12.) The TH6D process computer should be mechanically connected to the master machine. Strain relief mechanisms should be in place for the individual cables and hoses. 2

Media supply The compressed air supply for the cooling air (for the optional cooling air) should be connected with the TH6D sensor head (plug-in slots X2, X3, X3). (Refer to section 4.4.9.)


Page | 9-7

Item

Procedural steps

Completed

There should be sufficient capacity in the hoses to supply the media (compressed air and purging air). The outer hose diameter should be 4/8 mm. The quality of the supplied media should be verified. Optional: For high power applications, an additional heat sink should be attached to the TH6D sensor head by the customer. 3

Installation and construction The compressed air supply (cooling and purging air) should be connected to the proper maintenance unit via a cut-off valve (with filter and dehumidifier). The pre-pressure of the cooling air should be ≤ 6 bar. The pre-pressure of the purging air should be ≤ 3 bar.

4

Software configuration / parameterization Overview: To ensure smooth operations, follow the instructions for installing and configuring THxDView as described in Chapter 5. THxDView should be installed on the user PC (refer to section 5.3). The user PC running THxDView should have an Ethernet connection to the TH6D process computer (at plug-in slot 6). The processing parameters should have been verified and specified when necessary using THxDView.


Page | 9-8

9.3

Contamination Declaration Notes

When returning the TH6D system, please fill out this declaration completely. With

this

declaration,

you

confirm

the

correctness

and

completeness of the following data. Adding a device Configuration number: Serial number: Reason for return:

Type of contamination: Type of medium used: The device was cleaned by the customer using: Other details:

Declaration (legally valid) Company Address

Telephone Contact person: Date:


Signature:

Page | 9-9

9.4

Condensation point table Condensation point temperatures (in °C) at a relative air humidity level of: Air temperature 2 °C

45 %

50 %

55 %

60 %

65 %

70 %

75 %

80 %

85 %

90 %

95 %

-7.8

-6.6

-5.4

-4.4

-3.2

-2.5

-1.8

-1.0

-0.3

0.5

1.2

4°C

-6.1

-4.9

-3.7

-2.6

-1.8

-0.9

-0.1

0.8

1.6

2.4

3.2

6°C

-4.5

-3.1

-2.1

-1.1

-0.1

0.9

1.9

2.7

3.6

4.5

5.4

8°C

-2.7

-1.6

-0.4

0.7

1.8

2.8

3.8

4.8

5.7

6.5

7.3

10°C

-1.3

0.0

1.3

2.5

3.7

4.8

5.8

6.8

7.7

8.5

9.3

12°C

0.4

1.8

3.2

4.5

5.6

6.7

7.8

8.7

9.6

10.5

11.3

14°C

2.2

3.8

5.1

6.4

7.6

8.7

9.7

10.7

11.6

12.6

13.4

15°C

3.1

4.7

6.1

7.4

8.5

9.6

10.7

11.7

12.6

13.5

14.4

16°C

4.1

5.6

7.0

8.3

9.5

10.6

11.7

12.7

13.6

14.6

15.5

17°C

5.0

6.5

7.9

9.2

10.4

11.5

12.5

13.6

14.5

15.4

16.2

18°C

5.9

7.4

8.8

10.1

11.3

12.4

13.5

14.6

15.4

16.3

17.3

19°C

6.8

8.3

9.8

11.1

12.3

13.4

14.5

15.5

16.4

17.4

18.2

20°C

7.7

9.3

10.7

12.0

13.2

14.4

15.5

16.5

17.4

18.4

19.2

21°C

8.6

10.2

11.6

12.9

14.2

15.4

16.4

17.4

18.4

19.3

20.2

22°C

9.5

11.2

12.5

13.9

15.2

16.3

17.4

18.4

19.4

20.3

21.2

23°C

10.4

12.0

13.5

14.9

16.0

17.3

18.4

19.4

20.4

21.3

22.2

24°C

11.3

12.9

14.4

15.7

17.1

18.2

19.2

20.3

21.4

22.3

23.2

25°C

12.2

13.8

15.4

16.7

18.0

19.1

20.2

21.4

22.3

23.3

24.2

26°C

13.2

14.8

16.3

17.7

18.9

20.1

21.3

22.3

23.3

24.3

25.2

27°C

14.1

15.7

17.2

18.6

19.8

21.1

22.2

23.3

24.3

25.2

26.1

28°C

15.0

16.6

18.1

19.4

20.9

22.1

23.2

24.3

25.3

26.2

27.2

29°C

15.9

17.6

19.0

20.5

21.8

23.0

24.2

25.2

26.2

27.3

28.2

30°C

16.8

18.4

20.0

21.4

23.7

23.9

25.1

26.1

27.2

28.2

29.1

32°C

18.6

20.3

21.9

23.3

24.7

25.8

27.1

28.2

29.2

30.2

31.2

34°C

20.4

22.2

23.8

25.2

26.5

27.9

28.9

30.1

31.2

32.1

33.1

36°C

22.2

24.1

25.5

27.0

28.4

29.7

30.9

32.0

33.1

34.2

35.1

38°C

24.0

25.7

27.4

28.9

30.3

31.6

32.8

34.0

35.0

36.1

37.0

40°C

25.8

27.7

29.2

30.8

32.2

33.5

34.7

35.9

37.0

38.1

39.1

45°C

30.3

32.2

33.9

35.4

36.9

38.2

39.5

40.7

41.9

43.0

44.0

50°C

34.8

36.6

38.5

40.1

41.6

43.0

44.3

45.6

46.8

47.9

49.0

(1) Values are rounded off. The condensation point tables indicates when condensation will occur at different surface temperatures, and depending on the air temperature and relative humidity. Example: At an air temperature of 20°C and a relative humidity of 70%, the condensation point will be reached when the object temperature is 14.40°C. Our recommendation: Make sure that you choose an operating temperature (cool water temperature) that is high enough so that there is no chance of condensation even when there are changes in the surrounding temperature or air humidity. You may need to temper the effect of the coolant water if you are in doubt. The information is provided here to the best of our knowledge but is not legally binding for any third parties. The purchase still has an obligation to check the information himself. The user is responsible whenever the equipment is used at temperatures above the condensation point.


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00 Manual Scansonic TH6D-User-Guide v1.7 En

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