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LaserProbe4500

CNC-STEP

"LaserProbe4500" 3D laser scanning system Instruction manual

LaserProbe4500 3D laser scanning system

Hylewicz CNC-Technik Siemensstrasse 13-15 D-47608 Geldern

Fon.: +49 (0) 2831 133236

E-Mail: [email protected]

Website: www.cnc-step.de

2

mailto:[email protected]

http://www.cnc-step.de/


Contents 1. Safety .......................................................................................................................................................4

1.1. Symbols used................................................................................................................................4

2. Purpose ...................................................................................................................................................4

3. Basic technical data and characteristics .................................................................................................4

3.1. Scanning parameters ...................................................................................................................4

3.2. Allowable synchronization methods .............................................................................................4

3.3. Series LA901 laser sensor ..........................................................................................................5

3.4. Synchronization unit.....................................................................................................................6

3.5. Optical isolation unit .....................................................................................................................7

4. Delivery set............................................................................................................................................7

5. Operation principle.................................................................................................................................8

6. Connection versions ..............................................................................................................................8

6.1. Connection to machines with direct stepper control .....................................................................8

6.2. Connection to Beaver 9A/12A/12AV/18A/24A/26A machines......................................................8

6.3. Connection to machines with encoder impulse signals ................................................................9

6.4. Connection to machines with command signal pulses or with differential output encoder

(for example, Beaver 26AVST with servo-controller) ...................................................................9

6.5. Connection to machines with sinusoidal encoder signals (3 wires)..............................................9

6.6. Connection to machines with sinusoidal and differential encoder signals (5 wires) ...................10

7. Connection of the optical isolation unit.................................................................................................10

7.1. Block diagram .............................................................................................................................10

7.2. Designation of contacts...............................................................................................................11

7.3. Connection to the synchronization unit .......................................................................................12

8. Selection of the synchronization option................................................................................................12

8.1. Connection to machine with direct stepper control .....................................................................12

8.2. Connection to machine with encoder impulse signals ................................................................13

8.3. Connection to machines with impulse differential encoder signals.............................................13

8.4. Connection to machines with analog encoder signals ................................................................14

8.5. Connection to machines with analog differential encoder signals ..............................................14

9. The «Dorgonia» software .....................................................................................................................15

9.1. Basic functions ............................................................................................................................15

9.2. Program start...............................................................................................................................15

9.3. Settings........................................................................................................................................16

9.3.1. Positioning of the sensor ....................................................................................................16

9.3.2. Setting-up of the laser sensor parameters .........................................................................16

9.3.3. Setting-up of program filters ...............................................................................................17

9.3.4. Setting-up of the scanning parameters ..............................................................................18

9.4. Generating scanning file for CNC ...............................................................................................18

9.5. Scanning of the item ...................................................................................................................18

9.6. Generate result file ......................................................................................................................18

10. Example of filter operation ...................................................................................................................19

11. System requirements ...........................................................................................................................21

12. Warranty ...............................................................................................................................................21

13. Example of the scanning result............................................................................................................21

14. Troubleshooting ...................................................................................................................................22

3


Name Value

Scanning grid for XY arbitrary

Scanning field for XY arbitrary

Scanning depth, mm 100 or customized*

Average scanning speed, points/s 4500

Source of synchronization signal Signal level value

Symbols used 1.1.

Table 2: Allowable synchronization methods

Safety Avoid metal chips getting into the optical isolation unit.

Check earth before connecting the system to a machine. Keep the 3D system in clean

condition. The handling of the system assumes knowledge of the instruction manual.

Basic technical data and characteristics 3.

1.

2. Purpose The “LaserProbe4500” system is intended for non-contact laser scanning of items for the purpose

of obtaining three-dimensional computer model and formation of model files suitable for subse-

quent use in CNC system. The system is designed for mounting onto working machines with

any type of control.

«Information» symbol: Information that can be useful.

1…30V

4

«Attention» symbol: Pay attention to the warning to avoid typical mistakes when

working with the 3D system.

1...30V Encoder on X-axis with impulsed output (differential or

non-differential)

CMOS/TTL Signals for direct stepper control along X-axis

Allowable synchronization methods 3.2.

Table 1: Scanning parameters

Any except transparent or reflecting materials

Materials to be scanned

Scanning parameters

Encoder on X-axis with sinusoidal output (differential or

non-differential)

3.1.


Maximum operation speed, points/s 10000

Laser type 3 mW, wavelength 660 nm

Class of protection IP67

Working temperature, °С -10…+60

Time of continuous operation unlimited

Overall and mounting dimensions, mm Fig.1

Weight, g 100

Figure 1. Mounting and overall dimensions of Series LA901 laser sensor

Working range

Table 3: Parameters of the Series LA901 laser sensor

window Output window Input Base distance

3.3. Series LA901 laser sensor

Name Value

Base distance, mm

Range, mm

Total height from the machine table, mm

Error, mm

Resolution, mm

140

100

240

±0,1

0,03

RIFTEK

CABLE

Note: * the system can be equipped with sensor offering different characteristics contact: [email protected]

5


PC communication interface USB 2.0


Dimensions, mm Fig.2

№ Designation

2 Connector for laser sensor;

3 Power connector +5V;

2 3

30,5

137 60,5

4 5

24,7 4

1

56,3

4 125

Table 5: Designation of connectors of the synchronization unit

USB-cable for connection of the system to PC. 5

4 Beaver

Table 4: Parameters of the synchronization unit

-10…+60 Working temperature, °С 6

Value Name

Synchronization unit 3.4.

24,7

Connector for machine, in case of mounting on Beaver 9A/12A/12AV/18A/24A/26A

machines, not used otherwise;

on Connector for optical isolation unit (for mounting

9A/12A/12AV/18A/24A/26A machines – 15-conductor cable to PC);

1

Figure 2. General view of the synchronization unit



Working temperature, °С -10…+60

Mounting on DIN-rail

- 1 piece

- 1 piece

- 1 piece

- 1 piece

- 1 piece

- 2 pieces

- 1 piece

- 1 piece

- 1 piece

- 1 piece

- 1 piece

- 1 piece

4.

36 45

LA901 laser sensor

Bracket for mounting sensor on machine

Synchronization unit with USB-cable for connection to PC

Cable for the synchronization unit

Power source Screw М3x18

Compact disc with drivers, software and operation manual

Optical isolation unit (optional)

Cable for the optical isolation unit (optional)

Cable for the synchronization unit «CABLE-001-15» (optional) Passport for the Series LA901 laser sensor Packing list

The delivery set includes:

Delivery set

Figure 3. General view of the optical isolation unit

3.5. Optical isolation unit

Name

16,6

7

87,4

158

Table 6: Parameters of the optical isolation unit

Fig. 3 Dimensions, mm 7

5

Value


Figure 5. Connection to Beaver machines through 15-conductor cable (in this case, optical isolation unit

is not required)

Sensor

Control

signals

Control

signals

CNC

machine

Synchronization

unit PC

USB () to PC

Power supply +5V

Connection to Beaver 9A/12A/12AV/18A/24A/26A machines 6.2.

Figure 4. Connection to machines with direct stepper control

Sensor

AGND

GND AGND GND

+5V +5V DIR Optical isolation

xDIR+ unit

CNC machine

DIR Synchronization

unit DIR

STEP xSTEP+ STEP STEP USB () to PC

Power supply

+5V

~110..220VAC

Connection to machines with direct stepper control 6.1.

Connection versions 6.

8

5. Operation principle The laser sensor is mounted onto the machine movement system. In the scanning mode,

the machine CNC system moves the sensor line-by-line over the item prototype. The sensor

measures the distance (Z coordinate) to the item surface. Data takeoff from the sensor is syn-

chronized with the sensor movement (XY coordinates), and the result is communicated to the

PC through the USB-port. Thus, XYZ coordinate array for the surface is formed, i.e. a digital pro-

totype model is created which is saved as a point cloud file as well as in a common STL format

suitable for subsequent use in CNC.


Figure 8. Connection to machines with sinusoidal encoder signals (3 wires)

Sensor

AGND GND AGND

GND +5V

xDIR+ +5V B CNC machine

DIR Synchronization

unit DIR Optical

isolation unit

STEP xSTEP+ STEP A USB () to PC

Power supply +5V

~110..220VAC

Connection to machines with sinusoidal encoder signals (3 wires) 6.5.

Figure 7. Connection to machines with command signal pulses or with differential output encoder

Sensor

GND AGND xDIR-

AGND

GND +5V

R- (B-) xDIR+ +5V CNC

machine R+ (B+)

xSTEP- Synchronization

unit

DIR Optical

isolation unit

F- (A-) STEP

DIR

xSTEP+ STEP F+ (A+) USB () to PC

Power supply +5V

~110..220VAC

Connection to machines with command signal pulses or with differential

output encoder (for example, Beaver 26AVST with servo-controller)

6.4.

Figure 6. Connection to machines with encoder impulse signals, including TTL

Sensor

AGND AGND

GND

+5V B+ CNC machine

Optical isolation unit xDIR+

Synchronization unit

DIR

xSTEP+ STEP A+ USB () to PC 9 Power supply

+5V

~110..220VAC

Connection to machines with encoder impulse signals 6.3.


A

To decode input signals and convert them to levels used for sensor, the unit contains

“Input decoders”. One of the operation modes of the “Input decoders” is chosen depending on

the position of the "Operation mode selector ".

The input decoder (CPLD) supports the following synchronization signals from different

Sources, such as:

• CMOS/TTL command signals for control of stepper along the X axis;

Figure 10: Block diagram of the optical isolation unit

Block diagram 7.1.

Connection of the optical isolation unit 7.

Figure 9. Connection to machines with sinusoidal and differential encoder signals

Sensor

AGND GND

B

AGND xDIR- GND

+5V xDIR+ +5V B CNC

machine

DIR xSTEP- Synchronization

unit

DIR Optical

isolation

unit

STEP xSTEP+ STEP A USB () to PC

10 Power supply

+5V

~110..220VAC

Connection to machines with sinusoidal and differential encoder

signals (5 wires)

6.6.


Contact name Group Designation

+5Vout Input Not used

xSTEP+ Input Adjusted positive input of steps, or A+ signal of encoder

xSTEP- Input Adjusted negative input of steps, or A- signal of encoder

xDIR+ Input Adjusted positive input of steps, or B+ signal of encoder

xDIR- Input Adjusted negative input of steps, or B- signal of encoder

AGND Input Earth relative to which xSTEP+/- xDIR+/- inputs work

+5V Output Power of the input part of the synchronization unit

STEP Output Step signal for the synchronization unit

GND Output Earth for the synchronization unit

• Encoder on the X axis with pulsed output;

• Encoder on the X axis with sinusoidal output;

• Encoder on the X axis with differential pulsed output;

• Encoder on the X axis with differential sinusoidal output.

The optical isolation unit forms STEP and DIR signals for the synchronization unit.

Table 7: Pin assignment of the optical isolation unit

Direction signal for the synchronization unit Output DIR

Figure 11. Arrangement of contacts of the optical isolation unit

Designation of contacts 7.2.

INFORMATION The use of CPLD (programmable logic microcircuit) makes it possible to decode practically

all input signals and form output synchronization signals for the laser sensor.

11


Red Power of the input part of the synchronization unit +5V

Blue Step signal for the synchronization unit STEP

White Direction signal for the synchronization unit DIR

Brown Earth for the synchronization unit GND

12 Wire color Designation Terminal on the optical isolation

unit

Table 8: Designation of wires of the synchronization unit “CABLE-001-15” cable

8. Selection of the synchronization option

Selection of the synchronization option is made by means of micro-switches on the optical isolation unit.

7.3. Connection to the synchronization unit

The optical isolation unit is supplied together with a cable whose 15-conductor connector on

the one end is connected to the synchronization unit while four wires on the other end are con-

nected to the optical isolation unit. Wire designations are shown in Table 8:

8.1. Connection to machine with direct stepper control

Diagram of control 5V

STEP+

signals:

0V

5V

DIR+

0V

3D item

Figure 12. Diagram for connection to machine with direct stepper control

To decode the above signals, the micro-switches of the optical isolation unit must be in the position shown in the following figure:

ON

SW2 SW1

Figure 13. Position of the micro-switches in the mode under consideration

ATTENTION! When the “LaserProbe4500” 3D scanning system is ordered for use on a specific machine, the optical isolation

Unit is supplied with pre-set micro-switches.


Figure 16. Diagram of signals for connection to machine with impulse differential encoder signals

3D item

B+

B-

A+ A-

Diagram of control signals:

Connection to machines with impulse differential encoder signals 8.3.


SW1 SW2

ON


Figure 14. Diagram of signals for connection to machine with encoder impulse signals

3D item

0V

B+ 5V

0V

A+ 5V

13 Diagram of control signals:

Connection to machine with encoder impulse signals 8.2.


Figure 20. Diagram of signals for connection to machine with analog differential encoder signals

3D item

B-

B+

A-

A+

8.5. Connection to machines with analog differential encoder signals



SW1 SW2

ON

To decode the above signals, the micro-switches of the optical isolation unit must be in

the position shown in the following figure:

Figure 18. Diagram of signals for connection to machine with analog encoder signals

3D item

B+

A+

8.4. Connection to machines with analog encoder signals



SW1 SW2 14 ON

To decode the above signals, the micro-switches of the optical isolation unit must be in the

position shown in the following figure:

A

A

B

C

D

E


Figure 22. Main window of the "Dorgonia" program

9.2. Program start

After starting, the program checks for availability of the USB cable for connection to the synchronization unit. If the device is found, availability of the license and its validity are checked,

and the laser sensor is switched on. The emergence of the working window (Fig. 22) shows that

the system is normal operation mode.

9.1. Basic functions

The software is intended for:

• Creation of the line-by-line scanning file for CNC system (G-codes), including the de- fining of the scanning region, discretization interval along the X and Y coordinates

and scanning speed;

• Parametrization of the laser sensor, including adjustment of smoothing filter and filter-

ing of measurement errors; • Data takeoff from the laser sensor;

• Visualization of data;

• Filtering and smoothing of results;

• Formation of standard format files .stl, .dxf, .txt.

The «Dorgonia» software 9.


SW1 SW2 15 ON


The window consists of several sections:

• "А" – section for setting of scanning parameters; • "В" – section for formation of files; • "С" – section for control and settings; • "D" – status section; • "E" – section for imaging of the scanned item.

Example:

CV = 80mm

Scan object = 40mm

Min Z: 100 – 80 = 20 – 1 = 19mm

Max Z: 20 + 40 = 60 + 1 = 61mm

Base Distance 140mm

Range 100mm Table

Scan object


9.3.2. Setting-up of the laser sensor parameters

To change laser sensor settings, call the setting window by pressing the "Settings" button (Section "С"). The view of the window is shown in Fig. 24. The “Laser settings”

window displays:

1) Unchangeable service information about the sensor: internal divider installed;

type of the device; serial number, working range and base distance; type of

synchronization.

2) Two fields for setting filters implemented directly in the laser sensor. The first filter deals with the moving average. Maximum allowable value of the filter width is

128. The second filter deals with the result delay time at an interval of 5 ms (see

Description of the Series LA901 laser sensor at www.cnc-step.de

After changing the settings, press “OK” button to save them.

Figure 23. Positioning of the laser sensor

9.3.1. Positioning of the sensor

Settings. 9.3.

16

Sensor edge

The base distance from the Scanner to the object is 140mm and the scanning depth is 100mm (Picture XY). The Scanner should be positioned so that the bottom is a minimum distance of 140mm and maximum 240mm from the object to be scanned. To determine the correct position you must select „Test-scanner“ (in section C of the software window) and the „actual value“ (CV) (in section D of the software window) should show a

value between 0 and 100 To determine the values for „Minimum Z“ and „Maximum Z“ (in section A) you should perform the following calculation: Min Z = Scan area (100) - CV / Max Z = Min Z + height of the scan object To ensure that the total object will be scanned, you must subtract +/-1mm from the Min Z value and add +/- 1mm to the Max Z value. This will increase the scanning area in both directions.

Tip: When scanning objects with large height variations, the scanner should be far away as possible from the object!

http://www.cnc-step.de/


Figure 25. Settings of the program filters

9.3.3. Setting-up of program filters

To change settings of the program filters, call the settings window by pressing the

"Settings" button, go to the «Program settings» tab, set the required width of the

median filter and smoothing filter (Gaussian core), and enable or disable display of the

model. To save the settings, press "ОК".

The "Display model" switch is intended for enabling/disabling of the model display function. This function is used when RAM is not sufficient.

Figure 24. Laser settings

17


9.6. Generate result file

The result of scanning is displayed in the section "Е". Control of the item image in this section is possible with the help of the mouse pointer:

- dragging of the mouse with the left key pressed – rotation of the item;

- dragging of the mouse with the right key pressed – movement of the item;

- scrolling with the mouse – zoom-in and zoom-out of the item (scaling). To obtain the result file, it is sufficient to press the “Generate result file” button, select the

file type (STL/DXF/TXT) in the emerging window (Fig. 26), enter the file name, select file folder

for saving and press the “Save” button.

To make changes in the region already scanned (discretization interval along the X or Y

axis, length and width of the region), it is necessary to enter new values and press the “Recalcu-

late region” button (section “С” in Fig. 22). To return to the initial view of the model (if filters

were used and limits along Z were set), it is sufficient to switch off the filters and press the “Re-

calculate region” button.

9.5. Scanning of the item

• To perform scanning it is necessary to:

• use control program for CNC to open the file formed by the “Dorgonia” program according

to par. 9.4; • position the machine movement system to a point from which scanning must be

started;

• press the "Start session" button in the section "С" of the program working window;

• start the machine to execute the program. The task execution time depends on the size of the scanning region, speed and step

values with which the carriage moves along the X and Y axes

After the machine has executed the program, it is necessary to switch the scanning

mode off by releasing the "Start session" button.

ATTENTION! The allowable scanning speed is calculated automatically based on the sensor response speed and the scanning

grid specified, its value being set in the formed scanning program. Forced changing of the scanning speed may

cause distortion of the picture obtained.

9.4. Generating scanning file for CNC

To form the scanning file for the machine CNC system, it is necessary to set scanning parameters according to par. 9.3.4, press the "Generate file for CNC» button in the section "В" of

the program working window (Fig. 22), and define the place in the PC memory where the control file must be written. The output text file contains control G-codes for correct movements of the machine.

18

9.3.4. Setting-up of the scanning parameters

Before scanning is started, it is necessary to use section “A” to define the size of

the scanning field (X - width, Y – field length), discretization interval along the X and Y

coordinates, range of heights of the item to be scanned (Z minimum and Z maximum)

and select the type of machine whereto the scanner is connected. After the parameters

are set, the program calculates the allowable scanning speed and displays it in the pa-

rameters windows.


19

Fig. 27 shows the result of scanning obtained without programmed filtration used. The

peaks in the picture are caused by the influence of vertical walls of the item.

Fig. 28 shows the image of the item in the case where “Median filter” with a width of 9

was used (see par. 9.3.3.). As seen in the picture, the peaks disappeared.

Figure 27. Initial view of the item directly after scanning

Example of filter operation 10.

Figure 26. The window of result saving


Figure 29. The use of programmed smoothing.

A substantial reduction of the image noise can be achieved by using programmed

smoothing. Fig. 29 shows the result of programmed smoothing obtained by employing the filter

with the width of 7.

Figure 28. The use of median filter with the width of 9.

20


21

Example of the scanning result 13.

Warranty period of the LaserProbe4500 3D laser scanning system is 24 months from the date of putting in operation. Guaranteed storage time is 12 months.

Warranty

11. System requirements

Stable work of the «Dorgonia» software requires the following system:

Processor:

RAM: Disk space:

Video card:

Operating system: Other:

not lower than Intel Pentium 4 2.0GHz.

not less than 1024 MB (recommended 4096MB).

not less than 20 GB, NFTS file system required.

ATI/NVidia and not less than 256MB of video memory.

Windows 2000/ Windows XP.

USB 2.0 is required.

12.


Problem Cause Solution

The «Dorgonia» program gives an

error message: «Error: scanner

does not respond»

1. Using oscilloscope, check for availability of

STEP/DIR signals

1. There is a problem with Synchronization signals

(STEP/DIR) coming from

machine (through the optical

isolation unit, if available).


error message: «Erroneous data

file»

1. Check connection of the sensor to the synchronization unit.

2. Check connection of power supply to the

synchronization unit.

The «Dorgonia» program gives an error message: «Error: data file

is empty »

1. Using oscilloscope, check for availability of synchronization signals from the machine

(if optical isolation unit is in place, this must be

done through the optical isolation unit). It is

possible that no power is supplied to the

optical isolation unit (if available).

1. Sensor is not connected to


2. Power supply unit (+5V)

not connected to the


1. There are no signals of

synchronization with the

machine.

22 1. Reinstall drivers from original compact disc

2. Check USB cable connection.

1. USB drivers not installed.

2. USB cable not connected.


error message: «Error: no scanner

found»

Troubleshooting 14.

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