Graphical Optic Measurment GOM

ATOS User Manual - Hardware

3 0 1 0 2 1 0 2 b v e r _ n e _ 0 5 7 v 0 0 8 0 0 4 o s _ 2 0 v e r _ 3 2 s o t a

ATOS II and III Triple Scan With 400 mm and 800 mm Camera Support

GOM mbH Mittelweg 7-8 D-38106 Braunschweig Germany Tel.: +49 (0) 531 390 29 0

E-Mail: [email protected] www.gom.com Fax: +49 (0) 531 390 29 15

Important Notes

Important Notes Symbols

•

In this user manual the following standard signal words may be used:

•

This label points to a situation that might be dangerous and could lead to serious bodily harm or to death.

AC power connection of of the unit must comply with the valid regulations of the respective countries. Replace fuses only with components having the same specifications.

This label points to a situation that might be dangerous and could lead to light bodily harm. This label points to a situation in which the product or an object in the vicinity of the product might be damaged. This label indicates important application notes and other useful information.

• •

•

•

Safety and Health Hazard Notes • • •

•

•

•

•

•

The used laser meets laser class laser class 1 according to DIN EN 60 825-1 (optical output power < 0.39 mW, wavelength 650 nm). Do not use equipment connected to AC power during heavy thunderstorms. Due to voltage variations and transient voltages in the low-voltage network, malfunctions and dangerous voltages between housing and other components may occur. In extreme positions, stands with horizontal extension arms may fall over. Avoid such positions. Use the product only on a safe and steady ground. When measuring large objects, make sure you comply with the respective valid accident prevention regulations.

Operate the equipment only with the operating voltages printed on the housing. Using an incorrect operating voltage may cause malfunctions or the risk of fire.

Legal Notes No part of this publication may be reproduced in any form or by any means or used to make any derivative work (such as translations, transformations or adaptations) without the prior written permission of GOM. GOM reserves the right to revise this publication and to make changes in content from time to time without obligation on the part of GOM to provide notification of such revision or change. GOM provides this manual without warranty of any kind, either implied or expressed, including, but not limited, t o the implied warranties of merchantability and fitness for a particular purpose. GOM may improve or change the manual and/or t he product(s) described herein at any time. Copyright © 2011

•

•

Never unplug or connect cables during operation! The devices must not come into contact with water. For cleaning, use a moist cloth but first disconnect the power plug. The ambient temperature must be between +5 and +40 °C. Make sure no rapid temperature variations occur that might cause condensation. The housing may only be opened when no voltage is applied. Do not stick any strange objects into the housing. Never cover the venting slots. Never operate the sensor without the corresponding air filter, see section 10.

Artificial optical radiation (projector light). When operating, operating, do not look into the light source for a longer time. Directly looking into the light source may be harmful for your eyes! (See also 2.1.1 Technical Data). Check cables and, if damaged, replace them by all means. Protect the cables from mechanical load (squeezing, tension, etc.). Damaged cables may cause short-circuits and the risk of fire.

Page 2 (44)

GOM mbH All rights reserved!


Important Notes

Important Notes Symbols

•

In this user manual the following standard signal words may be used:

•

This label points to a situation that might be dangerous and could lead to serious bodily harm or to death.

AC power connection of of the unit must comply with the valid regulations of the respective countries. Replace fuses only with components having the same specifications.

This label points to a situation that might be dangerous and could lead to light bodily harm. This label points to a situation in which the product or an object in the vicinity of the product might be damaged. This label indicates important application notes and other useful information.

• •

•

•

Safety and Health Hazard Notes • • •

•

•

•

•

•

The used laser meets laser class laser class 1 according to DIN EN 60 825-1 (optical output power < 0.39 mW, wavelength 650 nm). Do not use equipment connected to AC power during heavy thunderstorms. Due to voltage variations and transient voltages in the low-voltage network, malfunctions and dangerous voltages between housing and other components may occur. In extreme positions, stands with horizontal extension arms may fall over. Avoid such positions. Use the product only on a safe and steady ground. When measuring large objects, make sure you comply with the respective valid accident prevention regulations.

Operate the equipment only with the operating voltages printed on the housing. Using an incorrect operating voltage may cause malfunctions or the risk of fire.

Legal Notes No part of this publication may be reproduced in any form or by any means or used to make any derivative work (such as translations, transformations or adaptations) without the prior written permission of GOM. GOM reserves the right to revise this publication and to make changes in content from time to time without obligation on the part of GOM to provide notification of such revision or change. GOM provides this manual without warranty of any kind, either implied or expressed, including, but not limited, t o the implied warranties of merchantability and fitness for a particular purpose. GOM may improve or change the manual and/or t he product(s) described herein at any time. Copyright © 2011

•

•

Never unplug or connect cables during operation! The devices must not come into contact with water. For cleaning, use a moist cloth but first disconnect the power plug. The ambient temperature must be between +5 and +40 °C. Make sure no rapid temperature variations occur that might cause condensation. The housing may only be opened when no voltage is applied. Do not stick any strange objects into the housing. Never cover the venting slots. Never operate the sensor without the corresponding air filter, see section 10.

Artificial optical radiation (projector light). When operating, operating, do not look into the light source for a longer time. Directly looking into the light source may be harmful for your eyes! (See also 2.1.1 Technical Data). Check cables and, if damaged, replace them by all means. Protect the cables from mechanical load (squeezing, tension, etc.). Damaged cables may cause short-circuits and the risk of fire.

Page 2 (44)

GOM mbH All rights reserved!


Table of Contents

8. 8.1 8.2

Wireless Remote Control ____________________ ____________________ 28 Preparing the t he Remote Control__________________ __________________ 28 Explanation of the Function Keys _______________ _______________ 29

9. 9.1 9.2

Sensor Calibration _________________________ _________________________ 30 How to Handle Calibration Objects ______________ ______________ 30 Calibration Conditions ________________________ ________________________ 31

Table of Contents __________________________ _________________________________ _______ 3

9.2.1 9.2.2

When is Calibration Required? ______________________ 31 Prerequisites ____________________________________ 31

1.

Introduction _______________________________ 5

9.3

Calibration Using Calibration Panel CP 40 ________ 32

2. 2.1

System Types _______________ ____________________________ _______________ __ 5 Overview of the ATOS Triple Triple Scan System Types __ 5

2.1.1

Technical Data ___________________________________ 6

2.2

Hardware and Software Components of Measuring System ________________ _____________________________ ____________________ _______ 6

9.3.1 9.3.2 9.3.3 9.3.4 9.3.5

Handling Instructions for Calibration Panel CP40 ________ 33 Loading the Calibration Data _______________________ 34 Preparing the Calibration Process ___________________ 34 Calibration Process Pr ocess _______________________________ _______________________________ 35 Calibration Result ________________________________ 36

9.4

Calibration Using Calibration Cross CC 30 ________ 37

9.4.1 9.4.2 9.4.3 9.4.4 9.4.5 9.4.6

Handling Instructions for Calibration Cross CC 30 _______ 37 Entering Calibration Data into ATOS _________________ 38 Preparing the Calibration Process ___________________ 38 Calibration Process Pr ocess _______________________________ _______________________________ 39 Calibration Result ________________________________ 39 Quick Calibration _________________________________ 40

10.

Checking and Cleaning the Air Filter __________ 41

11. 11.1 11.2

Cabling __________________________ ___________________________________ _________42 Cabling with 19" PC _________________________ _________________________ 42 Cabling with Laptop _______________ __________________________ ___________ 43

Table of Contents Important Notes _______________________________ __________________________________ ___ Symbols ______________________________ _________________________________________ ___________ Safety and Health Hazard Notes ______________________ ______________________ Legal Notes _________________________ ______________________________________ _____________

2 2 2 2

3. 3.1

Information About the Sensor ________________ 7 Sensor Configurations __________________ ________________________ ______ 8

3.1.1

Camera Positions and Camera Eccentric Stops _________ 9

3.2

Definition of Terms _________________________ ___________________________ 10

4. 4.1

Lenses_________________________ ___________________________________ __________ 11 Lens Types _______________________________ 11 Lenses for Camera Positions 400 and 800 ___________________11 Lenses for Camera Position SO ______________________ ___________________________ _____11


5. 5.1

Control Elements and LED Indicators _________ 12 Web Interface ________________________ ______________________________ ______ 13

6. 6.1 6.2

Operation of Pan and Tilt Head (Option) _______ 14 Positioning of Sensor ______________ ________________________ __________ 14 Locking Mechanism of Sensor Fixture ___________ 15

6.2.1

Mounting Direction of Sensor on Locking Mechanism ____ 15

7. 7.1 7.2 7.3

Sensor Setup _________________________ _____________________________ ____ 16 General __________________________________ 16 Measuring Volume _________________________ ___________________________ 16 Changing the Camera Camera Positions (Step (Step by Step) ___ 16

7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12 7.3.13 7.3.14 7.3.15 7.3.16 7.3.17 7.3.18 7.3.19 7.3.20 7.3.21 7.3.22

ATOS Triple Triple Scan Sensor Sensor With Cameras in Position 400 _ 17 Remove Camera Cover ___________________________ 17 Remove Air Filter ________________________________ 17 Remove Camera Lenses __________________________ 18 Mount Dust Covers Cover s _______________________________ 18 Loosen Projector Lens With Tool ____________________ 18 Unscrew Projector Lens Manually ___________________ 19 Remove Housing Screws __________________________ 19 Remove Upper Part of Housing _____________________ 19 Remove Cameras and Fixing Screws ________________ 20 Insert Cameras in Position SO ______________________ 20 Fix Cameras in Position SO ________________________ 20 Rotate Cameras Against Eccentric Stop and Fix Them ___ 21 Mount Upper Part of Housing _______________________ 21 Screw on the Upper Part of the Housing ______________ 22 Screw in Projector Lens Manually ___________________ 22 Hand-Tight Projector Lens with Tool _________________ 22 Remove Dust Covers _____________________________ 23 Screw in Lenses Hand-Tight _______________________ 23 Mount Camera Covers ____________________________ 23 Insert Air Filter __________________________________ 24 ATOS Triple Triple Scan Sensor Sensor With Cameras in Position SO _ 24

7.4

Set Up Sensor with ATOS V7 Software __________ 25

7.4.1 7.4.2

Camera Angle Angl e___________________________________ 26 Adjust the the Laser Pointers Pointers ___________ _________________ ___________ _________ ____ 27 Steps to adjust the laser pointers _____________________ __________________________ _____27

Page 3 (44)

Table of Contents


Page 4 (44)

Overview of the ATOS Triple Scan System Types

Introduction

1. Introduction This user information is intended for qualified personnel who is not or just a little familiar with the coordinate measurement technique but who has basic PC knowledge (windows-based programs and operating systems). This user information is configured to the transfer of knowledge of system installation, sensor settings, changing the camera support and other hardware relevant information. For being able to make optimum use of the system, we assume the ability to visualize in 3D and a color vision ability. This user information is divided into the following sections: •

The first page informs about important safety aspects.

•

Section 1 - Introduction

•

Section 2 describes the system variants.

•

Section 3 contains general information about the sensor.

•

Section 4 informs about how to handle the lenses.

•

•

Section 5 describes the control elements and LED indicators of the sensor. Section 6 describes the control elements of the optional 3D pan and tilt head.

•

Section 7 describes the setup of the sensor.

•

Section 8 explains the wireless remote control.

•

Section 9 describes the calibration of the sensor.

•

Section 10 informs about cleaning the air filter.

•

Section 11 contains the cabling of the system as laptop and 19" PC variants.

2. System Types This user manual describes four types of the ATOS Triple Scan sensors. Mainly, the sensors are constructed similarly and differ in the cameras and in the length of the camera support. 3 0 1 0 2 1 0 2 b v e r _ n e _ 0 5 7 v 0 0 8 0 0 4 o s _ 2 0 v e r _ 3 2 s o t a

2.1 Type: Camera resolution: Length of the camera support:

Overview of the ATOS Triple Scan System Types

ATOS II Rev. 02

ATOS III Rev. 02

ATOS II Rev. 02 800

ATOS III Rev. 02 800

2448 x 2050 pixels

3296 x 2472 pixels

2448 x 2050 pixels

3296 x 2472 pixels

approx. 400 mm

approx. 800 mm

SO, 400

SO, 400, 800

ATOS Professional V7.2-0 and higher for Windows

ATOS Professional V7.2-5 and higher for Windows

Difference in size:

Possible camera positions: Application software:

Page 5 (44)

Hardware and Software Components of Measuring System

2.1.1

System Types

Technical Data

System

ATOS II Rev. 02 ATOS II Rev. 02 800

ATOS III Rev. 02 ATOS III Rev. 02 800

Measuring volumes for camera position 800

560 x 420 x 420 mm to 2000 x 1500 x 1500 mm (only for ATOS II Rev. 02 800 and ATOS III Rev. 02 800)

Measuring volumes for camera position 400

170 x 130 x 130 mm to 1400 x 1050 x 1050 mm

Measuring volumes for camera position SO

38 x 29 x 15 mm to 320 x 240 x 240 mm

Measuring points per individual scan or camera resolution Measuring point distance

approx. 5 000 000 (2448 x 2050 pixels)

approx. 8 100 000 (3296 x 2472 pixels)

800

0.23 to 0.79 mm

0.2 to 0.61 mm

400

0.07 to 0.62 mm

0.05 to 0.45 mm

SO

14.70 - 123.93 µm

11.58 - 95.46 µm

Transfer of image and control signals Projector light

via Gigabit data link with max. 2 Ethernet interfaces Artificial optical radiation blue, 400-500 nm (Medium risk according to DIN EN 62471, issue March 2009, when looking into the light source)

Ambient conditions

+5 °C to +40 °C (non-condensing)

Voltage range (typical)

90 - 240 V, 50 - 60 Hz

Power consumption

Typically 130 W max. 300 W

Power Factor Correction Max. cable length between sensor and PC, laptop

≥ 95%

30 m

For further information see http://www.gom.com

2.2 •

•

•

•

•

•

Page 6 (44)

Hardware and Software Components of Measuring System

ATOS sensor with stereo cameras, fringe projector, controller and power supply. Stand for secure and steady hold of the ATOS sensor. Please only use stands which are released by GOM for this sensor type. Otherwise the stand with the sensor may fall over! High-performance PC system with Microsoft Windows operating system and separate network interface card for the Gigabit data link. The factory settings of the separate network interface card (interfaces Cam L, Cam R) are optimized for the Gigabit data link and must not be changed! Never enable the firewall for this network interface card . ATOS application software (Windows) as of version V7 see 2.1 Overview of the ATOS Triple Scan System Types.


Information About the Sensor

3. Information About the Sensor Each configured ATOS sensor, in scan direction, has defined 3D areas within which a measuring object can be scanned. In the following, such a 3D area is called "measuring volume" (MV). The measuring volume determines the distance between sensor and measuring object and the set of lenses to be used.

In practice, depending on the measuring task, different measuring volumes might be required. Ideally, you have camera and projector lenses that are preadjusted to your measuring volume. In this case, you need to perform no or just very few steps for adjusting the sensor. A complete sensor setup is only required if the corresponding set of lenses has never been adjusted before or is decalibrated (wrong ad justments).

For a complete sensor adjustment, you need to adjust the angle relations of the cameras and set the focus and aperture of the lenses. Then, the complete system is calibrated by means of calibration panels or calibration crosses. If the measuring volume is adjusted successfully by calibration, you may start a measuring project.

The sensor adjustment is supported by the software. The software determines all necessary parameter settings. In order to achieve large, medium and small measuring volumes, the sensors support two or three different camera positions (Small Objects SO for small measuring volumes, 400 for medium measuring volumes, and 800 for large measuring volumes), see system types 2 and table 3.1. 3 0 1 0 2 1 0 2 b v e r _ n e _ 0 5 7 v 0 0 8 0 0 4 o s _ 2 0 v e r _ 3 2 s o t a

For camera position 400 or 800, you may install measuring volumes with two different camera angles. For example ATOS II/400/MV560 with 27° and ATOS II/400/MV 1000 with 15°. The eccentric stops ( , , , , ) are factory-preadjusted.

Never loosen these stops , , , specialist is allowed to adjust them.

or

, as only an authorized

Page 7 (44)

Sensor Configurations


3.1


Measuring areas

r o s n e S

n o i t i s o e p m a r a e N m a C [mm]

0 I 0 I I 8 S 2 0 0 0 O . 8 T v A e R

0 0 0 , 0 4 2 8 0 . 2 v 0 e . R v e I I I R I S I I O S T O A T A O S

0 0 I I 8 S 2 0 O 0 0 T . 8 A v e R

0 0 0 0 2 8 4 0 . 2 v 0 e . R v e I I R S I I O T S O A T A O S

) V M ( e m m m u l n o i v ) g H n x i r u s W a x e L M (

[mm]

e c n a t s i d t n i o p g n i r u s a e M

e c n e r e f e r d e d Ø n e m m m m s o t n c i e o R p

Camera cover e c n a t s i d g n i r u s a e M

e l g n a a r e m a C

[mm]

[mm]

[mm]

[°]

0.608

12

2330

18

1400 1400 x 1050 x 1050 0.397

8

1530

27

1000

1000 x 750 x 750

0.329

5

1530

27

560

560 x 420 x 420

0.199

3

1530

1400 1400 x 1050 x 1050

0.399

8

1000

1000 x 750 x 750

0.332

700

700 x 530 x 520

560

560 x 420 x 420

320

2000 2000 x 1500 x 1500

Calibration objects

p o t s c i r t n e c ) c e 1 . a . r 1 e 3 m e a e s C (

2 2 0 0 . . v v e e R R I I I I I I S S O T O T A A

0 0 0 0 8 8 2 2 0 0 . . v v e e R R I I I I I I S S O T O T A A

Name s s e h h n t s n t e g l g l e n n r o e e a l t l r l e l c a a j e c m c o o a o r F c F p

Standard calibration objects,

[mm] [mm]

Alternative calibration objects

( CC = cross, CP = panel)

---

G

20

20

CC30/MV2000x2000

---

G

20

20

CC40/MV1400

---

G

24

30

CP40/MV1000, CC30/MV1000x1000

27

---

G

40

50

CP40/MV560, CC30/MV500x500

1530

15

B

H

20

20

CC40/MV1400

5

1280

18

B

H

20

24

CP40/MV1000, CC30/MV1000x1000

0.213

3

830

27

B

H

20

24

CP40/MV700, CC30/MV700

0.176

3

830

27

B

H

24

30

CP40/MV560, CC30/MV500x500

320 x 240 x 240

0.104

1.5

830

27

B

H

40

50

CP40/MV320

170

170 x 130 x 130

0.053

0.8

830

27

D

H

75

90

CP40/MV170

320

320 x 240 x 240

0.095

1.5

490

28

C

H

24

30

CP40/MV320

170

170 x 130 x 130

0.055

0.8

490

28

C

H

40

60

CP40/MV170

100

100 x 75 x 70

0.031

0.4

490

28

C

H

60

90

CP40/MV100

60

60 x 45 x 35

0.017

0.4

490

28

C

H

90

120 CP40/MV60

38

38 x 29 x 15

0.012

0.4

490

28

C

H

105

150 CP40/MV38

0.789

12

1980

22

---

E

8

20

CC30/MV2000x2000

1400 1400 x 1050 x 1050 0.610

8

1530

27

---

E

8

20

CC40/MV1400

---

E

12

30

CP40/MV1000, CC30/MV1000x1000

2000 2000 x 1500 x 1500

1) or

2) or

1) or

1000

1000 x 750 x 750

0.413

5

1530

27

560

560 x 420 x 420

0.233

3

1530

27

---

E

23

50

CP40/MV560, CC30/MV500x500

1400 1400 x 1050 x 1050

0.617

8

1530

15

A

F

8

20

CC40/MV1400

1000

1000 x 750 x 750

0.411

5

1530

15

A

F

12

30

CP40/MV1000, CC30/MV1000x1000

700

700 x 530 x 520

0.335

5

830

27

A

F

8

20

CP40/MV700, CC30/MV700

560

560 x 420 x 420

0.226

3

830

27

A

F

12

30

CP40/MV560, CC30/MV500x500

320

320 x 240 x 240

0.126

1.5

830

27

A

F

23

50

CP40/MV320

170

170 x 130 x 130

0.070

0.8

830

27

A

F

40

90

CP40/MV170

320

320 x 240 x 240

0.124

1.5

490

28

C

F

12

30

CP40/MV320

170

170 x 130 x 130

0.071

0.8

490

28

C

F

23

60

CP40/MV170

100

100 x 75 x 70

0.045

0.8

490

28

C

F

35

80

CP40/MV100

60

60 x 45 x 35

0.023

0.4

490

28

C

F

60

120 CP40/MV60

38

38 x 29 x 15

0.015

0.4

490

28

C

F

80

150 CP40/MV38

2) or

Definitions: 1)

In case of one measuring volume or two measuring volumes with the same camera angle use eccentric stop

.

In case of two measuring volumes with different camera angles, adjust the smaller camera angle with eccentric stop gle with eccentric stop 2)

(see 3.1.1).

In case of one measuring volume or two measuring volumes with the same camera angle use eccentric stop

.

In case of two measuring volumes with different camera angles, adjust the smaller camera angle with eccentric stop gle with eccentric stop

Page 8 (44)

and the larger camera an-

(see 3.1.1).

and the larger camera an-




3.1.1

Camera Positions and Camera Eccentric Stops

Camera position 800 (approx. distance in mm)


Camera position SO

ATOS Triple Scan with camera positions SO, 400 and 800



Camera position SO

ATOS Triple Scan with camera positions SO, 400 Page 9 (44)

Definition of Terms


3.2

Definition of Terms

Camera position (approx. distance in mm)

ATOS sensor without cover of camera lenses

Camera lens right R Projector lens P Camera lens left L Measuring distance (from ATOS label to the center of the measuring volume) Camera angle

Width W (measuring volume)

Height H (measuring volume)

Center of the measuring volume

Length L (measuring volume)

Page 10 (44)


Lens Types

Lenses

4. Lenses The lenses shown in this example may, in some cases, differ from those delivered in practice. Therefore, the statements made here have to be used correspondingly. All lenses are marked with L (left) or R (right) or P (projector). Left and right are defined from the sensor view in normal operating position. Never switch on the sensor if the projector lens still is equipped with the lens cap! Due to the high light output, the lens cap and the pro jector lens may be damaged!

4.1 Camera lens left L

Lens Types

Lenses for Camera Positions 400 and 800

Projector lens P (fixed aperture) Camera lens right R Aperture setting ring with manual locking screw. Focus locking ring with hex socket head locking screw Screw thread; tighten carefully by hand in the housing! While doing so, lock focus locking ring! Lens name


Camera lens left L

Lenses for Camera Position SO

Projector lens P (fixed aperture) Camera lens right R

Aperture setting ring with manual locking screw. Lens name Focus locking ring with hex socket head locking screw Screw thread; tighten carefully by hand in the housing! While doing so, lock focus locking ring!

Page 11 (44)

Lens Types

Control Elements and LED Indicators

For the projector lenses, the aperture value is fixed and cannot be changed. Select a set of lenses matching the required measuring volume and camera positions (e.g. SO, 400, 800), and screw it into the cameras and the projector. To avoid getting dirt into the cameras and the projector, always equip the devices with lenses or blind caps, even when they are switched off. When changing the lenses, fix the new lenses in place immediately. Screw in the lenses carefully by hand, lock the focus locking ring, if necessary, to ensure screwing in without any problems.

5. Control Elements and LED Indicators

Yellow LED, illuminates in case of active Gigabit transmission at interface CAM L. Green LED, illuminates in case of data transmission at interface CAM L. • • •

Shows green light if the sensor is ready for operation. Shows orange light while the operating system of the sensor starts. Shows red light in the moment of being switched on or in case of a failure. You will find additional status information on the Web interface of the sensor, see 5.1.

Yellow LED, illuminates in case of active Gigabit transmission at interface CAM R. Green LED, illuminates in case of data transmission at interface CAM R. Pushbutton to switch the sensor on and off.

Page 12 (44)


Control Elements and LED Indicators

5.1

Web Interface

Web Interface

You reach the Web interface in the ATOS software via Digitize ► Sensor ► Hardware ► Analyze System ► Sensor Status ► ... Prerequisite: The sensor must be switched on and connected to the computer. The ATOS software is running but the sensor is not initialized ( )!

Start screen of the Web interface


Page 13 (44)

Positioning of Sensor

Operation of Pan and Tilt Head (Option)

6. Operation of Pan and Tilt Head (Option) 6.1

Positioning of Sensor

Always position the sensor using both hands (see figure below), one hand at the sensor handle and the other hand at one of the three pan and tilt handles of the pan and tilt head. Only this way you can position the sensor safely.

Always use both hands to position the sensor!

Rotate sensor horizontally


Tilt sensor to left/right Page 14 (44)

Tilt sensor forward/backward

Operation of Pan and Tilt Head (Option)

6.2

Locking Mechanism of Sensor Fixture

Locking Mechanism of Sensor Fixture

The hexagon plate holds the sensor in the locking mechanism. Always make sure that the hexagon plate really holds the sensor in the locking mechanism!

Locking mechanism with hexagon plate without sensor

You open the lock by first release it with lever same time with lever .

6.2.1

and unlock it at the

Mounting Direction of Sensor on Locking Mechanism


Mounting direction of sensor

Page 15 (44)

General

Sensor Setup

7. Sensor Setup 7.1

General

In order to adjust the sensor, the complete system including the ATOS software needs to be installed and the sensor must be equipped with a set of lenses matching the measuring volume and the camera position. For each measuring volume (MV), the set of lenses are factorypreadjusted. If you have the respective set of lenses for each measuring volume, setting up the sensor is easy as you do not need to carry out all the steps referring to adjusting the focus and aperture! You always need to perform a complete sensor setup if, for example, the corresponding set of lenses has never been adjusted before or is decalibrated.

7.2

Measuring Volume

Use the table in section 3.1 to determine a measuring volume. You create larger measuring volumes with camera positions 400 and 800 and smaller measuring volumes with camera position SO (see table 3.2). Please check whether the cameras are in the correct position. How to change the camera positions is described in section 7.3.

7.3

Changing the Camera Positions (Step by Step)

In order to change the camera distances, you need to open the sensor housing. Therefore, disconnect all cables from the sensor. It is not possible to operate the sensor without the upper part of the housing! In the following, we describe how to change the camera distance from 400 to SO. When you are changing the distance from SO to 400 or when you are changing to camera position 800, please proceed correspondingly.

Page 16 (44)



Sensor Setup

7.3.1

ATOS Triple Scan Sensor With Cameras in Position 400

ATOS Triple Scan sensor without connection cable

7.3.2

Remove Camera Cover

7.3.3

Remove Air Filter


Page 17 (44)


Sensor Setup

7.3.4

Remove Camera Lenses

7.3.5

Mount Dust Covers

7.3.6

Loosen Projector Lens With Tool


Page 18 (44)


Sensor Setup


7.3.7

Unscrew Projector Lens Manually

7.3.8

Remove Housing Screws

7.3.9

Remove Upper Part of Housing

Page 19 (44)


Sensor Setup

7.3.10

Remove Cameras and Fixing Screws

7.3.11

Insert Cameras in Position SO

7.3.12

Fix Cameras in Position SO 3 0 1 0 2 1 0 2 b v e r _ n e _ 0 5 7 v 0 0 8 0 0 4 o s _ 2 0 v e r _ 3 2 s o t a

Do not totally tighten the camera fixing screws now!

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Sensor Setup

7.3.13

Rotate Cameras Against Eccentric Stop and Fix Them

The figures show the eccentric stop

in camera position 400 (see section 3).

Fix the camera screws with a torque of 5 Nm. If for one camera position two eccentric stops are available, please read in section 3.1 which stop you need to use.

7.3.14

Mount Upper Part of Housing

Ensure that the cables run optimally before mounting the upper part of the housing!


Please do not squeeze any cable when mounting the upper part of the housing!

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7.3.15

Sensor Setup

Screw on the Upper Part of the Housing

Max. torque 2 Nm

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7.3.16

Screw in Projector Lens Manually

7.3.17

Hand-Tight Projector Lens with Tool



Sensor Setup


7.3.18

Remove Dust Covers

7.3.19

Screw in Lenses Hand-Tight

7.3.20

Mount Camera Covers

Please read in section 3.1 which type of camera cover ( A ... H) you need to use. The identification letters can be found on the rear side of the camera covers.

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Sensor Setup

7.3.21

Insert Air Filter

7.3.22

ATOS Triple Scan Sensor With Cameras in Position SO


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Set Up Sensor with ATOS V7 Software

Sensor Setup

7.4


You adjust the sensor using the workspace Set Up.

The software automatically identifies the connected sensor type. Using the icon Set Up Sensor , you may register in the software the requested measuring volume and the camera distances used, see 3.2. All further adjustment parameters will automatically be determined by the software (measuring distance, filters, focuses, ...). A software dialog guides you through the required individual steps. If you use a set of lenses that has never been adjusted before or that is decalibrated, you also need to adjust the aperture and the focus. To adjust the aperture and the focus, you need to remove the camera covers (see 7.3.2) and the air filter (see7.3.3). The yellow arrows point to the clamping screws for adjusting the focus and the white arrows point to the clamping screws for adjusting the aperture.


You need to loosen the clamping screws before starting to adjust the focus and aperture. Start the adjustment from left to right by choosing the corresponding icons in the main toolbar.

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Sensor Setup

For the setup work, you need special setup sheets.

Setup-Sheet A is required for focus adjustments. Setup-Sheet B is required for aperture adjustments. •

Software dialogs help you to adjust the sensor.

•

Adjust focus of left camera

•

Adjust focus of right camera

•

Adjust projector focus

•

Not required for Triple Scan sensors (polarization filter)

•

Not required for Triple Scan sensors (polarization filter)

•

Adjust left camera aperture

•

Adjust right camera aperture

7.4.1

Camera Angle

The camera angles are already preadjusted by fixed eccentric stops (see 7.3.13) in order to ensure fast and easy change of the measuring volume.

Due to this fixed setting, slight divergencies might occur between the projected cross in the 2D camera images and the cross hairs displayed by the software. These divergencies do not affect the measuring accuracy!

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Sensor Setup

7.4.2

Adjust the Laser Pointers

In addition to the target, the ATOS Triple Scan sensors have two laser pointers (right and left) to determine the center of the measuring volume. When you changed the measuring volume and now use a different measuring distance ( see Sensor Configurations 3.1), you need to readjust the laser pointers. For each laser pointer, two adjusting screws (A and B) are available at the front side of the sensor.

The figure shows the adjustment possibilities for the laser pointers. The adjustment screws A and B move the laser beam with respect to each other.

Steps to adjust the laser pointers • •

Position the sensor at the measuring distance (see section 3.1 and 3.2) in front of a light surface.

•

Remove the camera covers.

•

Switch on the sensor (pushbutton on the rear side of the sensor).

• •


You already set up the sensor according to section 7.4.

Switch on the laser pointers via the ATOS software. Adjust the laser pointers to the center of the projected cross.

Adjust the laser pointers to the projected cross at measuring distance A

You cannot see the laser pointers in the 2D camera image if you use an ATOS Triple Scan sensor with blue light technology!

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Preparing the Remote Control

Wireless Remote Control

8. Wireless Remote Control Your ATOS system will be delivered with a wireless remote control. Remote Control with Accessories 1 x wireless remote control. The remote control allows for measurements without using the mouse or keyboard. 1 x receiver for the wireless remote control. The receiver is operated at a USB connection of the measuring computer. 1 x dry cell battery.

(R03, AAA, Micro: 1.5 V) 1 x bag for the wireless remote control.

8.1

Preparing the Remote Control

Equip the wireless remote control with the battery and insert the receiver into the USB connection of the measuring computer.


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Explanation of the Function Keys

Wireless Remote Control

8.2 Key, Key Press:

Explanation of the Function Keys

Function:

Remote control on/off

Snap images during calibration and start function Measure. Control the button functions in error dialogs according to the display.

Control the button functions in error dialogs according to the display.

Maximize or minimize the live view. You may use this function also during a measurement.

Abort a running measurement.


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How to Handle Calibration Objects

Sensor Calibration

9. Sensor Calibration Calibration is a measuring process during which the measuring system with the help of calibration objects is adjusted such that the dimensional consistency of the measuring system is ensured. During this process, the software determines geometrical parameters, for example position and orientation of each camera, based on the recorded camera images. In addition, the image characteristics of the camera lenses and the camera chips are determined. Based on these settings, the ATOS software calculates from the points of the calibration object in the 2D camera image their 3D coordinates. For the ATOS Triple Scan sensors, three different calibration objects are used (panel with magnetic support, panel in the case, and cross). Crosses are used for large measuring volumes and panels in the case are used for medium-size measuring volumes (MV 700 to 320 for camera position 400). Panels with a magnetic support are suitable for the smallest measuring volumes, e.g. MV 170 for camera position SO.

Calibration panel for MV 170

Calibration panel in the case for MV 320

Calibration cross for MV1500

Generally, each measuring volume (MV) has its own calibration object. The table in section 3.1 informs you about which calibration object is required for your measuring volume. Carry out the calibration only with the calibration object intended for your measuring volume.

9.1

How to Handle Calibration Objects

Always handle the calibration objects with utmost care and prevent them from getting dirty and being scratched. Make sure you do not touch the surface of the calibration object if possible. After each use, duly accommodate the calibration objects. Clean the surface of the calibration object using the enclosed microfiber cloth from the standard tool box. Wipe the surface gently only. Never exert any pressure.

Microfiber cloth for cleaning the calibration panels

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Calibration Conditions

Sensor Calibration

9.2 9.2.1 •

•

•

Calibration Conditions When is Calibration Required?

Before starting measurements for the first time, the respective ATOS measuring volume needs to be calibrated. Also, if the adjustment of the camera lenses or the position of the cameras with respect to each other is changed, the system requires calibration again. If the system indicates a possible decalibration, you should perform a new calibration.

9.2.2

Prerequisites

We recommend letting the sensor warm up for approximately 15 to 20 minutes (camera and projector switched on), so that calibration can be carried out under operating conditions. A prerequisite for successful calibration is the correct setup of the sensor. The measuring object defines the measuring volume and thus the set of lenses to be used. Depending on the measuring volume, you either need to use a calibration panel or a calibration cross. The measuring distance to the calibration object has to be adjusted according to the sensor used, see the sensor configuration table in section 3.1. At the beginning of the calibration process, you need to enter the temperature into the software at which the calibration is carried out. Measure the temperature using the thermometer intended for this purpose. Make sure you measure the temperature on the rear side of the calibration object or at the edge of the case in order to prevent the sensitive point markers from being scratched!


Measuring the temperature of a calibration panel which always remains in its case at the edge of the case.

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Calibration Using Calibration Panel CP 40

Sensor Calibration

Measuring the temperature on the rear side of a calibration panel with magnetic support

9.3


This section describes the calibration using the calibration panel CP40 with an ATOS Triple Scan sensor on a stand. There are two types of this calibration panel: • •

For measuring volumes with camera position 400 and 800 only, With magnetic support for measuring volumes with camera position SO only.

Calibration using the panel "CP40 with magnetic support" is similar, but in that case you generally use the sensor together with an electrically adjustable lift.


Calibration object CP40 for measuring volumes with camera position 400 in the case (without case cover)

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Sensor Calibration

The CP40 calibration objects consist of black points on a white background. The larger points in the middle inform the ATOS software about the calibration panel type, e.g. calibration object CP40 for measuring volume MV320. Each point was measured photogrammetrically in the factory. Not only the black points are used for c alibration but the white spaces as well (calibration of individual cameras). Therefore, always ensure that the calibration panel is clean (see section 9.3.1). For each calibration panel there is a CD containing the calibration data (file extension .calobj) and the certificate. A unique serial number provides for correct matching of calibration ob ject, certificate and calibration data.

Calibration CD with serial no. File name calibration data

9.3.1

Serial no. of calibration panel

Certificate with serial no.

Handling Instructions for Calibration Panel CP40

The surface of the calibration panel is very sensitive. Therefore, never touch the surface directly with your hands.


Calibration panels for measuring volumes with camera position 400 and 800 remain in the case during the calibration process. Only the case cover is removed. Please remove the case cover carefully to prevent any damage to the surface of the panel. Clean the surface of the panel using the enclosed microfiber cloth from the standard tool box. Wipe the surface gently only. Never exert any pressure. Damaged points will not be used for calibration. Dirty white areas will be ignored during calibration and the process uses the clean neighboring areas. Soiling and damages in the area of the larger calibration points in the middle may cause that the ATOS software does not identify the panel! If you use multiple ATOS Triple Scan sensors, please check that the serial number of your calibration object matches the calibration data in the software. The software only checks the correct type of the panel but not the serial number. It is mandatory that the serial number of the calibration object is identical to the serial number of the calibration object in the ATOS software! Otherwise your measuring system may provide inaccurate measuring data! Page 33 (44)


9.3.2

Sensor Calibration

Loading the Calibration Data

When using a measuring volume for the first time, you need to load the corresponding calibration data into the ATOS software and calibrate the sensor. If you purchased the measuring volume together with the complete ATOS system, the calibration data is already loaded. Insert the CD belonging to the calibration object into the computer and start the ATOS software. Select workspace Set Up ► Calibrate Sensor .

►

Click with the right mouse button (RMB) into the dialog and choose Import Calibration Object. Choose the calibration file with the extension .calobj from the CD. Now, the calibration file is available in the ATOS software.

9.3.3

Preparing the Calibration Process

When you want to calibrate a measuring volume, the sensor is already set up (see section 7) and the ATOS software knows which measuring volume and which camera position you want to use. Based on this information, the software determines the required focal lengths of the lenses. Open the calibration dialog in workspace Set Up ► Calibrate Sensor .

►

Choose the required calibration object the mouse, and start the process with Next.

with

Maybe you are asked whether the settings are to be reset to the recommended calibration settings. This always happens when the calibration object has never been used before or it was used in connection with a different camera position (SO, 400, 800). Confirm the request with Yes. In the following windows, enter the current measurement temperature and accept the adjusted focal lengths (camera and projector lens). Place the calibration object in its case on the floor and use the stand to position the sensor at the measuring distance orthogonally over it. As the laser pointers are already adjusted to this distance (see section 7.4.2), you only need to move the sensor on the stand up or down until the two laser points become one.

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Sensor Calibration

Calibration object at measuring distance to sensor

9.3.4

Calibration Process

After that the software will guide you through the individual calibration steps. In the first step, you are asked to place the sensor and the calibration object in the center of the measuring volume. Enable

the Automatic exposure time.

In exceptional cases it might happen that the function Automatic exposure time cannot work correctly.


In this case, disable the function and use the exposure time wheel to adjust the optimum exposure time for the camera image.

Exposure time adjustment for calibration

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Sensor Calibration

An optimum exposure time is given when the red overexposed areas are just no longer visible. In the subsequent steps you are then asked to place the calibration object in 12 defined distances perpendicular to the sensor. The software (as of ATOS V7.5 and higher) leads you to the correct positions in the measuring volume.

The image shows the first positions of the calibration panel (1-12) in the measuring volume.

As of calibration step 13, the panel is tilted in the center of the measuring volume. Please follow the instructions of the software until the end of the calibration process.

9.3.5

Calibration Result

At the end of the calibration process, the calibration result is shown separately for camera and projector. The green icon indicates a good calibration result. The red icon indicates an insufficient calibration result. In case of an insufficient calibration result, repeat the calibration and check the sensor settings (see 7.4), the correct camera lenses and ensure that the cameras and lenses are mounted tight. If only the projector calibration is insufficient, check if the projector lens and the lens settings are correct and ensure that the lens is mounted tight. You reach the calibration results with Digitize ► Sensor ►Calibration ► Show Information. As of software version V7.5 and higher the calibration is saved in the Triple Scan sensor. Page 36 (44)


Calibration Using Calibration Cross CC 30

Sensor Calibration

9.4


This section describes the calibration process using a calibration cross. Due to the size of the cross you can only calibrate the sensor in a horizontal position. Therefore it is useful to mount the calibration cross on a stand.

Calibration cross CC 30

During calibration, the sensor configuration is determined. This means that the camera positions and the orientation of the cameras to each other are defined, and the image characteristics of the cameras are determined. Based on these settings, the software calculates from the points of the calibration object in the 2D camera image their 3D coordinates. The calculated 3D coordinates are then calculated back again into the 2D camera images. For the position of the reference points, this results in the so-called reference point deviation (intersection error). The calibration cross also contains the information of two scale bars (one on each cross axis). The scale bar information is a s pecified distance between defined points.


For each calibration cross there is the calibration certificate with the calibration data. You can also see the calibration data on the rear side of the cross.

Calibration date example on the rear side of a CC 30 calibration cross

9.4.1

Handling Instructions for Calibration Cross CC 30

The point surface of the calibration cross is very sensitive. Therefore, never touch the surface directly with your hands. Clean the surface of the cross using the enclosed microfiber cloth from the standard tool box. Wipe the surface gently only. Never exert any pressure. The calibration cross must be totally unfolded.

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Sensor Calibration

If you use multiple ATOS Triple Scan sensors, please check that your calibration object matches the calibration data you entered in the software. Make sure that the calibration cross does not touch the floor during the calibration process as otherwise deformation effects may lead to wrong results during the calibration.

9.4.2

Entering Calibration Data into ATOS

When using a measuring volume for the first time, you need calibrate it and the corresponding calibration data need to be entered into the ATOS software. If you purchased the measuring volume together with the complete ATOS system, the calibration data is already entered. Select workspace Set Up ► Calibrate Sensor .

►

Click with the right mouse button (RMB) into the dialog and choose Add Cross (coded) ... . Enter all required parameters of the calibration object into the software dialog. Please make sure that all calibration data are entered correctly into the ATOS software! Otherwise your measuring system may probably provide inaccurate measuring data!

9.4.3

Preparing the Calibration Process

When you want to calibrate a measuring volume, the sensor is already set up (see section 7) and the ATOS software knows which measuring volume and which camera position you want to use. Based on this information, the software determines the required focal lengths of the lenses. Open the calibration dialog in workspace Set Up ► Calibrate Sensor .

►

Choose the required calibration object the mouse, and start the process with Next.

with

Maybe you are asked whether the settings are to be reset to the recommended calibration settings. This always happens when the calibration object has never been used before or it was used in connection with a different measuring volume. Confirm the request with Yes. In the following windows, enter the current measurement temperature and accept the adjusted camera focal lengths. Place the calibration object at the measuring distance in front of the sensor using a stand (option). As the laser pointers are already ad justed to this distance (see section 7.4.2), you only need to move the stand until the two laser points become one.

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Sensor Calibration

9.4.4

Calibration Process

After that the software will guide you through the individual calibration steps. In the first step, you are asked to place the sensor in the center of the measuring volume with respect to the calibration object. Enable

the Automatic exposure time.

In exceptional cases it might happen that the function Automatic exposure time cannot work correctly. In this case, disable the function and use the exposure time wheel to adjust the optimum exposure time for the camera image.

Exposure time adjustment for calibration

An optimum exposure time is given when the red overexposed areas are just no longer visible. In the subsequent steps you are then asked to place the calibration object at defined distances and angles to the sensor. If you have not chosen the automatic exposure time setting, you need to adjust the exposure time for each new image again. Please follow the instructions until the end of the calibration process.


In order to capture the entire measuring volume, you need to move the sensor during calibration. For this, the following general rule applies: You should move the sensor by 1/3 of the measuring volume height closer to the object and by 1/2 of the measuring volume height further away – in each case starting from the center of the measuring volume. After you recorded the last calibration image, finish the calibration with Compute.

9.4.5

Calibration Result

At the end of the calibration process, the calibration result and the scale bar deviation is shown with icons. The green icon indicates a good result. The red icon indicates an insufficient result. In case of an insufficient result, repeat the calibration and check the sensor settings (see 7.4), the correct lenses and ensure that the lenses are mounted tight. You reach the calibration results with Digitize ► Sensor ►Calibration ► Show Information. As of software version V7.5 and higher the calibration is saved in the Triple Scan sensor. Page 39 (44)


9.4.6

Sensor Calibration

Quick Calibration

If during a measurement it is indicated that the s ystem might be decalibrated (e.g. if you slightly knocked against the cameras), you may perform a quick calibration. You reach the software dialog with Digitize ► Sensor ►Calibration ► Quick Calibration. During this process, the calibration object needs to be placed into three positions - in the center of the measuring volume, further away from the sensor and closer to the sensor. These three new images are combined with the original calibration and thus a new calibration is calculated for the following measurements. This method is fast and can easily be used during recording a measuring project. However, the image characteristics of the cameras must not have changed! If, for example, you inserted new lenses, you need to perform a complete new calibration! The calibration cross must not have been taken apart during the last calibration and the quick calibration!


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Checking and Cleaning the Air Filter


10. Checking and Cleaning the Air Filter Check the air filter of the sensor in regular intervals. We recommend cleaning the filter every 3 months or more often. You thus avoid a shutdown of the sensor due to overtemperature during operation.

Removing filter


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Cabling with 19" PC

Cabling

11. Cabling 11.1 Cabling with 19" PC Please do not mix up the Gigabit data links CAM L and CAM R. Otherwise the sensor cannot be initialized.


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Cabling with Laptop

Cabling

11.2 Cabling with Laptop The data link to a laptop always is a Gigabit data link. Please use the CAM L connection. If you have a connection cable for two Gigabit data links (CAM L, CAM R), please do not connect the CAM R cable.


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Graphical Optic Measurment GOM

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