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Service Manual Ultra & UHR Ultra - Snap

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1. 24 Theory of Operation RELATIVE CAMERA POSITIONING RCP It would be easy to say that we know the distance between the cameras because we designed and manufac ture the Camera Beam and cameras However the knowledge the aligner must have about the relationship of one camera to another is critical and must be known to high level of precision manufacturing tolerances in the beam and camera assemblies are too variable to be counted on When the aligner is installed the techni cian mounts the cameras onto the beam Later the technician performs a camera aim in which he she alters the position of the cameras Once all camera movements are completed it is time for us to help the program find out where the cameras are with respect to each other We must perform Relative Camera Positioning THE FIXTURE The fixture used to perform RCP is also used for camera aiming It consists essentially of a bar about 5 5 feet in length with a target attached on each end a front and rear Stands are used to place it on the alignment rack which should be at alignment height so the targets are visible to the cameras Due to manufacturing tolerances and transportation of the fixture we cannot be sure its dimensions are the same as the design We must measure it each time we perform RCP Of course we always have a highly accurate measurement tool at our disposal the 3D Aligner To measure the length of the fixture
2. 39 Calibration 11 Move the cal bar back on the rack approxi mately 2 feet on the rack Click on lt NEXT gt when done 12 Move the cal bar back again approximately 2 feet on the rack Click on lt NEXT gt when done 13 Move the cal bar back again to the front turntables Place the small target on the right rail and the large target on the left rail Center the feet front to rear Click on lt NEXT gt when done ege e Ea B 8 ef Se wei zeg Ee kopp re Fe 14 Place the cal bar on the left rail with the small target in the center of the front table and the large towards the rear outside of the rail Click on lt NEXT gt when done 40 Calibration 15 Extend the plunger under the rear foot Click TW on lt NEXT gt when done IRA Sab Congratulations You have successfully com pleted calibration ACTIVATE AND CALIBRATE THE RIDE HEIGHT MEASURING DEVICE From the Calibration Menu click on the System Configuration icon and click on Ride Height Target switch to activate the Ride Height Target feature CALIBRATE 1 From the Calibration Menu click on Ride Height Target Calibration icon to begin the calibration process 2 Locate the Ride Height Calibration fixture and place the fixture on one of the lift runways so the straight edge is toward the camera 3 Select the side of the rack you are to
3. EK 10 The program returns to the Target Selection screen to al low additional targets to be ID d Repeat this process for all targets A green check mark appears next to the targets that have been ID d CAMERA VIEW See the Diagnostic Chapter for details using Camera View 3 Calibration RCP Fixture Assembly Raise the lift to the alignment working height with no vehicle Set the lift down on the locks The RCP fixture must be assembled prior to use The components consist of e Aluminum bar e Large and Small Target Attach the small target to the single leg bracket Attach the large target to the double leg bracket Clean the targets using glass cleaner and a soft lint free towel DO NOT USE A SHOP TOWEL RELATIVE CAMERA POSITIONING RCP The purpose of the camera calibration procedure is to measure the cameras positions relative to each other This allows the aligner to make accurate measurements between the left and right sides of the vehicle For this reason the alignment program will not run until a valid RCP has been performed The unit is shipped from the factory with valid RCP factors and it is not necessary to perform RCP unless a Camera is exchanged Tools needed Fixed Length Steel Fixture with two targets 1 Raise the empty lift to working height no vehicle Close the garage door to block any stray daylight Prepare the Calibration Fixture Clean the two targets on the fixture according to t
4. Service Manual Ultra S UHR Ultra WHEEL ALIGNER September 2011 All information contained or disclosed in this document is considered confidential and proprietary by Snap on Tools Company All manufacturing use reproduc tion and sales rights are reserved by Snap on Tools Company and the information contained herein shall not be used in whole or in part without the express written consent of Snap on Tools Company Table of Contents CHAPTER 1 AC DC POWER DISTRIBUTION Se EE HR A E Me 3 FHANDEIN T STAHG SENSITIVE POB G carsronrau e ae E E E 3 lh Te GUIDELINE E 4 LOCKOUT AND OR TAGOUT SYSTEM PROCEDURE sese d AG THEORY OF OPERATION E 5 11 Oa Bot TER Le E 5 Re i 5 OF OFERATION eee ere ener cn ere tee er eee ee ee eee ee ere 5 POWER LN E 5 PUB BOARD ee 6 ULTRA CAMERA POD ASSEMBLY T 7 ULTRA UHR CAMERA STROBE ASSEMBLY 3D SYSTEM eres eer ee 8 CHAPTER 2 THEORY OF OPERATION IT EE 13 LET 13 NEE i hoes E eeeree eee ee er ee ee ee ee ee ce 15 TARGET RE 16 TARGET ACQUISTION WE 18 IDNR ION THE e re E ee eee eee ee ee ere eee 18 K E UE 18 FO ee all 20 TRE eT e D e a E E E E E E EE 21 eee MO IIe Re RT TTT 23 IDE ORs 8 a DETERMINA TON een eer nent ree here te ee eee er ee ee ee 24 RELATIVE CAMERA POSITIONING RG sse eee 25 TRE FATOR E 25 MODELING THE VEHICLE IN 3 DIMENSIONAL SPACE esse xx eee x eee ee eee 2 MEASURING STEERING ANGLE gene enon ee eerecrrr eet ect te ten tee te cee ee re er
5. Manual Local System Ci Workstation Creates an Started Automatic Network S CE WWAN AutoConfig This servic Manual Local Service 64 65 Diagnostics NOTES DD 309 Exchange Avenue Conway AR 72032 TEEWA5S46P4 Rev A 09 2011 2011 Printed in U S A
6. Strobe Gain Number of Planes Number of Images LE Good target measurement RAMS Target Blobs Blobs Distance Target Angle Strobe Gain Number of Planes Number of Images JS 26052 130 2 20 2 950 H 2605 2605 RE Good target measurement RMS Target Blobs Blobs Distance Target Angle 91 Strobe Gain Number of Planes Number of Images D 2643 195 4 21 2 1500 Q 2601 ZP Target Blobs Blobs Distance Target Angle Strobe Gain Number of Planes Number of Images RMS Target Blobs Blobs Distance Target Angle Strobe Gain Number of Planes Number of Images LR Good target measurement RMS 6 Target Blobs Blobs 26 52 Distance 1 125 2 Target Angle Co 24 1 Strobe 1000 Gain 0 Number of Planes 2654 Number of Images 2654 RR Good target measurement RMS 05 Target B obs Blobs 2541 Distance 199 Target Angle WA 26 1 Strobe 1800 Gain Lt Number of Flares 2650 Number of Images 2650 CES 1 Select the drive to use for file operations 54 Diagnostics COVERING THE BASICS These procedures must be followed before placing a call to tech support Failure to have these answers when asked result in longer customer down time and additional calls to TECHNICAL SUPPORT 1 Verify complaint Remember operator error requires proper training no service tools or service parts are needed 2 Note the conditions in great detail E
7. 1 1 devices USB 2 0 is much faster and is usually backward compatible with the older 1 1 but its possible that a USB 2 0 device could refuse to work on a USB 1 1 controller or external hub so check to see if there s a compatibility issue Assuming a firmware update is available you may need access to a USB 2 0 equipped computer to apply it Configurations for add on USB controllers Check the Windows Device Manager to see if the USB controller is recognized or is experiencing a conflict In Windows click Start Control Panel select the Systems applet click the Hardware tab and then click the Device Manager button The Device Manager will likely refer to the USB controller as a USB Root Hub USB Controller or USB Bridge The usual suspects of IRQ addresses and memory address conflicts are the first things to check PCI devices shouldn t have many problems being Plug and Play but EISA cards may require more adjustment If the hardware appears to work reinstall the drivers Integrated USB controller settings If you suspect the trouble is with your USB controller settings check the Device Manager for a conflict Depending upon how well integrated the controller is with Windows you may be able to adjust the IRQ or memory address settings from the Device Manager Try rebooting the PC and entering the BIOS configuration USB settings are usually listed in the Peripherals section You ll need to check for an entry marked USB Controller that
8. LED s and the 12 volts is used to run the strobe LED S The output connector on the power supply is labeled as V1 and V2 V1 is the 5 volt line and V2 is the 12 volt line Each output voltage has it s own separate ground When measuring the output voltage of the power supply the technician must attach the leads of the VOM to the ap propriate ground to receive back the correct voltage Failure to connect the VOM to the correct pins will result in a incorrect voltage reading and may cause the technician to prematurely replace a good power supply AC Input CN1 DC Output CN2 1 AC L White V1 5VDC Red 2 AC N Blu G1 5VGND BIK 3 GND BIK V2 12VDC White G2 12VGND Green To back of cabinet AC DC POWER DISTRIBUTION The DC output of the Camera Power supply feeds through a harness on the back of the cabinet Both the 5V and 12V power is fused at this location Should a camera stop working checks should be made to both fuses for proper continuity and both the 5V and 12V be checked for proper power using a VOM Inside Cabinet View U1 S From PC USB S Z g DO 3V GND From Power i Supply W HUB BOARD The HUB board is housed inside an aluminum extrusion behind the camera beam The HUB board s purpose is to pass information to and from each of th
9. OK when ready to proceed NOTE USE RIGID SUPPORTS JACKS ON LOCKS ANY DOWN MOVEMENT OF THE WHEELS CAN AND WILL CAUSE INCOR RECT MEASUREMENTS WHICH WILL IN TURN CAUSE INACCU RATE ALIGNMENT READINGS 35 Calibration 4 Once the system acquires the target an arrow indicates the direction to rotate the target wheel The initial rotation is 25 forward 5 Ifthe tire and wheel is rotated past the 25 point the meter will change to red letting the operator know to rotate back 6 Once the wheel has reached the desired location a stop sign will appear in the center of the wheel Hold the wheel steady as the aligner will take a reading 7 After the readings have been taken the screen instructs with arrows indicating to rotate the wheel and target back 90 This 90 degrees is from the first 25 forward rotate the tire back until a stop sign appears as in step 6 and hold the wheel steady as another reading will be taken 8 After the readings are taken the arrows indicate to rotate the tire and wheel assembly forward 90 Rotate the wheel until a stop sign appears and hold the wheel steady as a reading will be taken 36 Calibration 9 After the completion of a successful target ID the screen indi vat cates to lower the wheel This is not necessary if the opposite side target is needing to be ID click on the lt OK gt button and select the next target Lower the wheels after all four targets have been ID d HEE
10. Target Blobs Blobs 2652 Target Blobs Blobs 26052 Distance 130 2 Distance gt 175 2 Target Angle 7 20 2 Target Angle 24 1 Intensity 197 Intensity 190 Eror RTP Wector Flag S 20 9 Error RTP Vector Aag S209 Number of Planes 2714 Number of Planes 2769 Number of Images 2765 Number of Images 821 Di Good target measurement DI Good target Measurement RMS D RMS 05 Target Blobs Blobs 25643 Target Blobs Blobs 2641 Distance 195 4 Distance 7 199 Target Angle 91 21 2 Target Angle Co 76 1 Intensity 189 Intensity 713 Error RTP Vector Flag 9 D0 9 Error RTP Vector Flag OI 2019 Number of Planes 2704 Number of Planes 2762 Number of Images 2762 Number of Images 2818 50 Diagnostics The information in target RTP is the X Y We r ad om and Z coordinates of the targets relative to ZS e KL R lt the axix of rotation Spindle As described gt 3D Target RTP Calibration in the Theory of Operation chapter all the E Phi Alpha 09 967 targets are identical however each target is rotated differently to properly identify the location LF RF LR RR All relative data outlined in red should be consistent with Gil a ve each other based on the target location e ec Because each target is the same however W meng rotated generates either a positive or nega T ra tive number Ripa iby 0 COP 0 Hip 2 Ls Rip 7 LY The graphic below shows a LF target next Dear to a RR target If you were to look
11. an integrated replace ment or dividing the USB devices between different USB root hubs See below for more on bandwidth issues 60 Diagnostics Scenario Several devices never work but others are fine Possible causes Controller nhub compatibility configurations for USB controllers power management con troller drivers device drivers bandwidth Should you experience this issue move the working devices to another root hub to see if the problem is in a particular root hub or with the devices themselves If an Ultra camera is moved to a hub that has not loaded the device drivers the Operating system will prompt the user to load these drivers This procedure is auto matic Remove external hubs from the equation to see if they are the problem Try the problematic devices individually on the computer if they work it s either a device driver or power issue If they never work it s a controller compatibility issue a device driver problem or a lack of bandwidth Solving compatibility issues and driver errors requires updating drivers or obtaining appropriate patches Scenario Several devices occasionally stop working at the same time while others are fine Possible causes Power management device drivers bandwidth As you would with any other sporadic hardware conflict try to isolate the particular event that s common to all failures The system may be experiencing a sporadic controller failure if your devices are split across roo
12. at the ID dots you will see that they are in the same location on both the targets however since the entire RR target assembly has been rotated 180 the system assumes that the taget has been placed on the wheel upside down If TID had been done with the target upside down the numbers displayed on this screen above will be way different than the other targets This is useful to know so that when a user is performing a TID on a set of targets and there happens to be a 2nd alignment system next to the unit being calibrated it is possible that the RR target of a 2nd alignment system could be in the field of view of system 1 when calibrating the LF target The camera could possibly think the target is turned upside down thus generating erroneous values The same would happen if you were to rotate the LR target and place it next to the RF Wii il Left Front target Right Rear target upside down 51 Diagnostics ALIGNER DIAGNOSTIC The information from this screen is primare ly used for engineering CAMERA VIEW This screen shows the view as seen by the camera This is a good tool to use to verify live images The user can also use the lt CTRL ALT P gt function to capture im ages and live data for export purposes This screen displays a count of the re ceived images over each sides display If one camera is sending a lot less images than another 15 this may be an indica tion of a camera problem By clicking on the c
13. calibrate from 4 Place the tip of the target pointer into the hole in the base of the calibration fixture NOTE THE POINTER TIP MUST REMAIN IN THE HOLE DURING ALL STEPS OF CALIBRATION 5 Tilt the target to the first position The reflec tive surface of the target should be facing the camera The target should be steady during each step 41 Calibration 6 The lt NEXT gt button will illuminate once the target has been acquired Click on the lt NEXT gt button a check mark will appear prompting the user to proceed to step 2 7 Proceed with calibration until all three steps have been completed 8 Should calibration of the ride height target fail a warning dialogue box will pop up and the user must begin the process from the beginning After the process completes the 3rd step the software auto advance to the main menu 42 Calibration CALIBRATION BACKUP RESTORE Calibration and Preference backup offers the user or technician a way of backing up all customized options and alignment calibration to a flash drive Should an alignment machine require a hard drive replacement the user or technician can simply restore all data from a saved flash drive back on to the newly installed hard drive From the Calibration Menu click on the Backup icon Backup It is recommended after every calibra tion that the user backup the new data in case of a PC or Hard Drive failure This enables the user to quickly restor
14. dots and there is even one dot that is a donut It must be noted that these circles we see are geometrical ly the roundest circles we will ever encounter this is necessary for the interpre tation of angles as we will learn later Note also that the dots on the rear targets are larger than the front targets to allow vision at a further distance kal Kl S a Since the engineers designed the target dot pattern with great precision they know the exact dimensions of each dot and the distance from any one dot to another It is possible then to create a computer model of this pattern that the 3D Aligner software could use as it looked at camera images This would be usable in the program only if we were certain that the target attached to the vehicle matched the computer model Since it is impractical to have an engineer hand make each target to the required precision a detailed manufacturing process was created to make sure each target was an exact duplicate of the original design 15 Theory of Operation TARGETS 3D The new 3D targets are unique for each wheel The rotation of the sub targets defines the wheel position A quick glance at the targets the operator may think that both left targets are identical and both right targets are identical However the illustration below displays the difference of each set of targets to each wheel Looking at the identification dot on each target you will notice that on each wheel
15. e Poe LATO H ZA Pr A Cie igw a it EE Zen PERE E T LELER J b EE E e rt C N L E e det Jee ars B I a 4 GG 10 11 IMPORTANT SAFETY INSTRUCTIONS When using this equipment basic safety precautions should always be followed including the following Read all instructions Do not operate equipment with a damaged power cord or if the equipment has been dam aged until it has been examined by a qualified authorized service technician If an extension cord is used a cord with a current rating equal to or more than that of the machine should be used Cords rated for less current than the equipment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled Always unplug equipment from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline Keep hair loose fitting clothing fingers and all parts of the body away from moving parts Adequate ventilation should be provided when working on operating internal combustion engines To reduce the risk of electric shock do not use on wet surfaces or expose to rain Do not allow unauthorized personnel to operate the equipment Use only as described in this manual Use only manufacturer s recommended attach ments ALWAYS WEAR
16. e Weather e Temperature e Time of day e Sun position e Heater locations e CRT under the camera e CPU speed and type e Motherboard type e Installed memory e Printer type e Software revision e Machine serial e Modification Status e Hardware configuration e Is the machine using the latest files E software version level e Additional software that has been added e Additional Hardware that may have been added Is the condition repeatable If yes wnat sequence makes the condition occur Where is the machine located in the shop Distance from cameras to Turn plate centerline and distance between the camera pods ls the unit within the proscribed installation parameter What type of equipment is used near it Possible interference 7 Check camera view e Ensure Cal Target is visible and un obscured e Clean the targets e Clean the camera lens To clean camera use canned air don t touch lens with fingers 8 Verify TID and RCP File dates are valid VCD PLD The RCP and TID dates should be no older then the installation date of the unit NOTE RCCPPLD AND RCTPPLD TYPICALLY WILL HAVE DATES OLDER THAN THE INSTALL DATE THIS IS NORMAL 9 Verify Power and ground to unit is acceptable 115 volts 10 e Is this a dedicated circuit e Verify polarity correct orientation of hot neutral and ground e Verify ground Aligner must be properly grounded Resistance from Aligner to earth ground should be le
17. is off or inactive If this entry is already active check the IRQ and memory addresses Use the Device Manager to ensure that no other device is us ing those settings You may need to reboot a few times to find a valid IRQ memory address combination that won t conflict with other devices If the hardware settings are fine reinstall the drivers 59 Diagnostics USB Keyboards When editing the BIOS enable DOS USB Keyboard Support Enabling this option will allow you to use a USB keyboard when booting a system with a boot disk Controller drivers Many motherboard suppliers release driver combinations that include a number of hardware drivers Confirm that you have the latest driver installed Some operating systems also provide drivers so make sure you have the latest available software patch as well Scenario No device ever works Possible causes Operating system compatibility controller nub compatibility configurations for USB control lers controller drivers If a system is experiencing constant controller failure make sure the OS in use supports USB verify that the devices are supported by the controller and check the controller s settings and drivers The Ultra cameras use a generic controller Integrated controllers will likely require you to enter the BIOS to make changes while add on cards will require traditional troubleshooting according to the manufacturer s directions You can identify integrated USB controllers by th
18. the vision based 3D Aligner are the two cameras mounted on either end of a camera beam The cameras are high resolution CCD video type operating in gray scale similar to those used in security and surveillance applications The proprietary design lens is for this usage and is permanently mounted to the camera and triple sealed for protection The camera also has a band pass filter limiting the spectrum of light that can enter the lens With any camera there is an optical field of view that is a characteristic of the lens design Anyone who has used a camera knows that what you see is what you get no more no less The cameras on the 3D Aligner are no different The field of view Figure 1 2 is located along each side of the alignment rack and is a cone shaped tun nel that expands in size as it moves further away from the cameras The tunnel is approximately 21 2 feet in diameter near the front turntables The centerlines of the tunnels are close to vehicle spindle height and about 18 inches outside of the outer wheel surface of an average car In fact the cameras are initially aimed at the factory so that the targets when mounted onto an average vehicle would be located in the center of that tun nel This insures that any vehicle placed on the rack in front of the 3D Aligner from the widest to the narrow est will have the targets mounted within the cameras field of view The Strobe Board contains 80 infared LED s in an array
19. to provide a source of bright light to reflect off the targets when camera images are taken These LED S are rated for 100 000 hours continuous operation and up to 50 of the LED s can fail without affecting the cameras ability to see the targets These infared LED s are synchronized with the cameras so an image is captured every time the lights flash roughly 2 times per second 13 Theory of Operation Side Field of View PZ L Figure Top Field of View Figure 2 14 Theory of Operation TARGETS 2D The target s visual surface is a series of circles or dots made of a retroreflective material This material returns any light that hits its surface at a 180 degree angle directly back towards the source If we are look ing at the reflected light it is brightest at the center of the light source As we move away from the source the brightness of the light diminishes rapidly Street signs have retroreflection material on certain parts of their surface This material reflects light from a vehicle s headlights back to the motorist s eyes The portion of the sign that traffic control wants the driver to pay attention to is reflective while the rest of the sign fades into darkness Drivers in other cars cannot see the reflected light from the headlights of other cars because the angle of vie
20. upgrade a device s firmware which is basically a driver that runs on the periph eral The more advanced the device the more likely it is that the firmware can be upgraded Mice being simple devices don t require firmware upgrades Scanners hard disks printers optical disks and other sophisticated peripherals likely have upgradeable firmware Check the manufacturer s site to ensure you ve loaded the most recent update Bandwidth USB root hubs can each support up to 128 devices but they can run out of bandwidth depending on con sumption rates USB 1 1 is limited to 12 Mbps not counting the bus management overhead USB 2 0 has 480 Mbps with about 420 Mbps available so it can support more devices Combine an Ethernet adapter a printer and an external CD ROM or hard drive on a single USB controller though and the PC can quickly exhaust its capacity The only solution for bandwidth problems is to either stop using all the devices simultaneously or to distribute the load Make sure you put devices that will always see use like Ethernet adapters and USB speakers on different root hubs You may need to get additional USB controllers which are inexpensive 63 Diagnostics Disabling Windows Presentation Foundation Font Cache 3 0 0 0 Click Start Right Click Computer Left Click Manage Left Click Services and Applications Double Click Services Double Click Windows Presentation Foundation Font Cache 3 0 0 0 Chang
21. E ANALYSIS This allows the operator to examine a stored hmain diag file stored using Ctrl Alt P without having to search the hard drive This information can be used to troubleshoot a possible problem at a later time If a unitis Be experiencing problems the customer can simply press lt CNTRL ALT P gt The soft ware will record the information to the hard drive When arriving on site the technician can review the information using this func tion The diagnostic data being collected will abort when starting a new alignment Any data collected will over write previously collected data EXPORT DIAGOSTIC FILES The diagnostic file export icon allows the technician to easily export all potential diagnostic information to a jump drive The original location for this information is lo cated in the root directory of Thundercloud Insert the jump drive into an open USB port Click on the drive location and or folder that you would like to export the informa tion to and click on the export icon The information is written to the jump drive so that the technician can view it later or email the information for a more in dept anaylsis The files are e Wheel0 raw e Wheel3 raw e Wheel1 raw e Wheel2 raw e App hMain sav e App bam YT RMS Target Blobs Blobs Distance Target Angie Strobe Gain Number of Planes Number of Images RF RMS Target Blobs Blobs Distance Target Angle
22. R ICH10 Family USB Universal Host Controller 3434 Hewlett Packard Company support Intel R ICH10 Family USB Universal Host Controller 3A35 Action Center Website e Intel R ICH10 Family USB Universal Host Controller 3436 Windows Update l e Intel R ICH10 Family USB Universal Host Controller 3437 ee Computer name domain and workgi e Intel R ICH10 Family USB Universal Host Controller 3438 Tools ee i Intel R ICH10 Family USB Universal Host Controller 3439 5 USB Root Hub USB Root Hub USB Root Hub USB Root Hub USB Root Hub USB Root Hub USB Root Hub USB Root Hub See also 62 Diagnostics USB Device Drivers The ability to hot swap USB devices is a great feature but it relies on a Somewhat oversimplified set of general purpose drivers Some devices may appear to be general purpose devices when in fact they are not This means that you must install the drivers before you connect the device to the PC Sometimes you need to reboot to give the new drivers priority over the general purpose drivers This means that skipping the reboot will break the whole process If you think the new drivers aren t receiving priority completely uninstall the device in question You may have to leave the device connected to uninstall it properly At other times you may be able to remove a device s drivers using Control Panel s Add Remove Programs applet just as you would with other software Sometimes it s necessary to
23. Rotation Position should be performed any time a pod is changed or the towers are moved 4 Continue the process until all camera positons have been checked After the final rotation lever has been checked click on the lt Next gt button to exit NOTE I F A MISTAKE IS MADE DURING THE TEACHING PROCESS THE OPERATOR CAN SIMPLY CLICK ON THE RESET BUT TON TO CLEAR THE LEARNING PRO CESS AND START AT THE BEGINNING a tse Left Large Right Large Wgl p Note Pod Rotation Position should be performed any time a pod is changed or the towers are moved 34 Calibration Wheel Clamp Selection The customer has 4 different options of the types of wheel clamps being used De pending on which market the Aligner is sold in the most common clamp used will be the conventional and or single pole wheel clamp If additional wheel clamps are used the customer must enable them using the Wheel Clamp Types Any wheel clamps that are selected must be ID by the system Explained below before they are put into use TID The G4 system has 3 different types of wheel clamps available to the end user Each clamp has a specific use The Conventional Clamp comes standard with the aligner Each target clamp must be ID d before us ing them in the alignment process Once these targets have been 1D 0 the customer will then have to choose which clamp assembly he she will be using for each alignment The single pole wheel clamp is u
24. Safety Glasses Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses 10 AC DC POWER DISTRIBUTION All information contained or disclosed in this document is considered confidential and proprietary by Snap on Tools All manufacturing use reproduction and sales rights are reserved by Snap on Tools and the information contained herein shall not be used in whole or in part without the express written consent of Snap on Tools Connecto Camera P2 incoming P1 outgoing P3 incoming GR OO DU WN H hH H Cn UHE WIN HUNN P2 USB COMMUNICATION Mini Hub P1 incoming P4 outgoing P6 outgoing Motor Control J1 incoming RS imit Motor Alarm Bd 1 Hein GND 12 24 NC 12V GND Motor Enable are Bridge 2_HsOn SND 24 Lower Limit GND ON GAIN P2 USB COMMUNICATION P3 USB COMMUNICATION PB USB COMMUNICATION TARUN 20 CON OUIA UN eed od od od hh oo P7 appr Limit 10A SLO 250V Red Ei SN 10A SLO 250V EAWO235U458 9 R earn ee tied Pe Adjust SV out to Gerd GNDEARTH 11 MODEL REV DWG BY CHK BY MOD BY CHK BY TITLE DWG PAGE All information contained or disclosed in this document is considered confidential and proprietary by Snap on Tools All manufacturing use reproduction and sales rights are reserved by Snap on Tools and the information contained herein shall not be used in w
25. alled a fit algorithm how closely does that object match what it knows to be a target In this way objects that are not targets such as reflective lamps on the vehicle are ignored As each target is found and fitted or acquired it turns blue on the screen and appears attached to the wheel When a target is acquired the software hones in on that region of the camera view ignoring activity in the background This allows the system to be more responsive to changes in target position 3D VISION THEORY From the previous discussions of the components of the 3D Aligner we have a basic understanding of how the hardware system functions But how does the software take these camera images of target dots and inter pret them as wheel alignment angles PERSPECTIVE One of the things the 3D Aligner must determine is how far away each target is from the cameras at any given moment As everyone knows objects appear to get smaller as the move farther away even though their actual size remains the same If you look at a screwdriver 2 feet away from you it looks much larger than it does at 20 feet away This effect is called perspective Artists create the illusion of depth and distance in two dimensional drawings using this technique In the example above assume that the screwdriver is 6 inches long If you had a way to measure the exact size of the screwdriver your eye sees at some distance away through the application of high school l
26. amera diagnostic icon on the toolbar the user can manually con trol camera functions D Good target measurement 52 RMS Target Blobs Blobs Distance C Target Angle 91 Intensity Error RTP Vector Fag Number of Planes Number of Images DS 26052 EIS 20 2 197 9 20 9 2728 2779 Good target measurement RMS Target Blobs Blobs Distance Target Angle 91 Intensity Error RTP Wector Flag Number of Planes Number of Images 05 26 43 195 4 21 2 189 9 20 9 2717 rr RE Good target measurement RMS Target Blobs Bobs Distance Target Angle 51 Intensity Error ATP Vector Flag Number of Planes Number of Images D 26 52 125 2 24 1 190 CIE Y 2783 2835 Good tanget measurement RMS Target Blobs Bobs Distance C Target Angle o Intensity Error RTP Vector Flag Number of Planes Number of Images 05 26 41 199 26 1 213 a 20 9 2775 831 Diagnostics CAMERA TEST ms Ee ee E Test both the strobe and the gain of the camera and it s ability to recognize images with gain and strobe changes All adjust ment from this location are manual adjust lol bet Sour ments when exiting this test the camera Sc assembly will return to auto function Running the Strobe to full strength should over expose the targets in the field of view The user can easily switch from left to right s Left 5614 53 Diagnostics STORED DIAGNOSTIC FIL
27. and camera into the back of the console and check to see if the Device man ager recognizes an Ultra camera If so we can assume that the PC and USB root hub and Universal host controller and power supply are working correctly If the Ultra Camera does 5V GND not show up in the device manager remove the power connection and check for the proper voltage at the back of the console 45 A 12V Looking at the connector on the back of the cabinet check for both the 5V gi H E S and 12V remembering that each voltages utilizes separate ground see con a ES A nector pinout Should any of the two voltages be absent or not within range 2 TT replace the camera power supply and retest GND OTHER USB DEVICE TROUBLESHOOTING PROCEDURES Scenario One device occasionally stops working Possible causes Device drivers power management bandwidth It s important to isolate the particular event that s common to all failures Move the device to another root hub to see if the problem is in a particular root hub or in the device itself Remove external hubs from the equa tion to confirm they are not the problem Also try using the device when no other USB peripherals are con nected More than likely you have a driver problem but it could be a power or bandwidth issue Controller hub compatibility USB computers manufactured before 2002 are limited to USB
28. ation User mode Driver Framework Manages u Started Automatic Local System Gi Windows Error Reporting Service Allows erro Manual Local System S Windows Event Collector This servic Manual Network 5 Ci Windows Event Log This servic Started Automatic Local Service Ci Windows Firewall Windows Fi Started Automatic Local Service Ci Windows Font Cache Service Optimizes Started Automatic D Local Service CE Windows Image Acquisition WIA Provides im Manual Local Service Ci Windows Installer Adds modi Manual Local System Ck Windows Management Instrumentation Providesa Started Automatic Local System Ci Windows Media Center Receiver Service Windows M Manual Network S Windows Media Center Scheduler Service Starts and Manual Network S CE Windows Media Player Network Sharing Service Shares Win Manual Network S Windows Modules Installer Enables ins Manual Local System TTT Windows Presentation Foundation Font Cache 3 0 0 0 disabled CE Windows Remote Management DAS Management Windows R Manual Network S 4 Windows Search Providesc Started Automatic D Local System CE Windows Time Maintains d Manual Local Service G Windows Update Enables th Started Automatic D Local System CE WinHTTP Web Proxy Auto Discovery Service WinHTTP i Manual Local Service CE Wired AutoConfig The Wired Manual Local System CE WLAN AutoConfig The WLAN Manual Local System GA WMI Performance Adapter Provides p
29. cameras Most of this information is aA Distance 130 2 Distance 125 2 f e arge 7 20 Target Angle CO a4 used by engineering in development pam Gees 99 a G Eror RTP Wector Flag 9 2079 Error RTP Vector Aag a209 Number of Planes 2691 Number of Planes 2746 C AMERA DI AG N OSTI C Jo Number of Images 2742 Number of Images 2798 L KI A d Good larget measurement Good tanget measurement RMS 05 RMS 05 Target Blobs Blobs 26 43 Target Blobs Blobs 2641 Distance 195 4 Distance 196 9 Target Angle 91 21 2 Target Angle oi 26 1 Intensity 189 Intensity 713 Error RTP Vector Flag 9 20 93 Error RTP Vector Flag 9209 Number of Planes 2681 Humber of Planes 2738 Number of Images 2739 Number of Images 2204 Diagnostics By switching from Left to Right the techni cian can compare camera characteristics Both the Left and the Right camera should run parrallel information Camera SPI Errors S Temperature Camera I2C Errors Temperature V3 3 Status Strobe Vaa V3 3 Vdd ve Vdd Vio E ay Vio Software Version Camera Software Version Camera Software Version DSP e Software Version DSP Camera SPI Errors Camera I2C Errors Temperature Status Strobe V3 3 Vaa Vdd Vio Software Version Camera Software Version DSP Clicking the Back button will exit this test 3D Target Calibration TARGET RTP ed D Good target measurement RE Good target measurement RMS 06 RMS OS
30. ch of these components need to be working to acquire images for the PC processor to display the images on the screen for the operator Should any of these components fail the result could be no images or errattic images NOTE WHEN USING A TEST CAMERA AS A TROUBLE SHOOTING TOOL ALWAYS UNPLUG BOTH CAMER AS THIS WILL ENABLE YOU TO TEST THE SYSTEM WITHOUT HAVING TO TRANSFER SECURITY CODES TO THE NEW CAMERA USB devices normally requires an array of hardware settings that can create conflicts Debugging becomes a differ ent process since USB takes Plug and Play to a new level by allowing multiple devices to share a single path into the PC such as pointing devices printers remote readers and now Ultra Cameras Troubleshooting USB requires a bit more effort than other connection methods because the entire bus could be malfunctioning Examine the trouble shooting scenarios below until you find one that applies to your situation These scenarios provide general descrip tions of possible errors along with steps you can use to resolve the problem You ll also find tips for troubleshooting common causes of USB failures Become familiar with using the Device Manager as a troubleshooting tool Use the following sequence to open the Device Manager Hold down both the Windows Key and the Pause Break Key on the keyboard The user can also click on the lt START gt button and right click on lt My Computer gt and select lt Properties gt After open
31. d In that case electrical neutral connects to the hot side of the line The aligner operates normally but the PC board floats 110 VAC above safety ground Assume that points inside the aligner console are at 110VAC observe all safety precautions If you make measurements with grounded test equipment use an isolation transformer An oscilloscope is an example of such test equipment The aligner is susceptible to power line spikes and noise You must connect the equipment to safety ground Does your machine do strange things or exhibit intermittent problems Check for a proper ground at the machine and the power outlet If you re using an extension cord check that too It must be constructed of at least 16 gauge wire and under 50 feet long Schematic voltages refer to the return side of the line not safety ground When measuring AC voltages use the white wire on the line power terminal block as ground Don t use the third center safety ground terminal Another place to access ground is at the shield The black wire in the shielded transducer cables also connects to the ground return HANDLING STATIC SENSITIVE PCB S Electrostatic discharge can destroy high impedance ICs if uncontrolled Use the fol lowing techniques to avoid damaging ICs Leave new circuit boards in their antistatic bags until ready for use When replacing boards proms etc be sure to turn off power to the machine first Use an anti static wrist stra
32. e Startup Type to Disabled Click Apply Click Ok 0 Exit Services and reboot system a ee eS T A Computer Management File Action View Help e nel alb Hm 8 H IR Z Computer Management Local E System Tools Task Scheduler Windows Presentation Foundation _MName lt j Status S T On As Event Viewer Font Cache 3 0 0 0 TE Volume Shadow Copy Manages a Manual Local System S Shared Folders Ok WebClient Enables Wi Manual Local Service e Performance Se Windows Activation Technologies Service Performs Manual Local System a g Device Manager Optimizes performance of Windows eo S E ER Storage Presentation Foundation WPF Ea geen l Manages a Started Local Service ad Disk t applications by caching commonly used _ Gei Windows Audio Endpoint Builder Manages a Started Automatic Local System JE a D ra mg font data WPF applications will start this Windows Backup Provides W Started Manual Local System ie Services and Applica service if itis not already running It can lt l l Services x though doing so will degrade S Windows Biometric Service The Windo Manual Local System ES WMI Control the performance of WPF applications i Windows CardSpace Securely e Manual Local System GA Windows Color System The WesPl Manual Local Service CE Windows Connect Now Config Registrar WCNCSVC Manual Local Service Ci Windows Defender Protection Manual Local System GA Windows Driver Found
33. e 28 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE TROUBLESHOOTING THE SYSTEM EE 29 RE ae HERR RI 30 op go da Pe SC TI R ee terre ee et R eee ee ee er re 31 TARGE TIDO PROE T 35 EE VES VV E AEE E E E IE E E E E E AE E T 37 ROP FIXTURE ASSEMBLE EE 38 RELATIVE CAMERA POSIHONING ROP E 38 ACTIVATE AND CALIBRATE THE RIDE HEIGHT MEASURING OEVICGE sese xx e ee ee ee 41 CALIBRATION BACKUP ER EE 43 CHAPTER A DIAGNOSTICS STORE ENEE E EE 46 PAOK el 47 DATA EXAMINATION eege 48 CAMERA DIAGNOS RE 49 TARGETA TE e E 50 ALIGNER DIAGNOSTIG errar E E E eeunetentsnexeanonacss 52 OAMER AVIE eegene 52 GAMERA a RE 53 STORED DIAGNOS TIC FILE ANALYSIS EE 54 EXPOR Eege 54 CHAPTER 1 AC DC POWER DISTRIBUTION ELECTRICAL SAFETY PRECAUTIONS Make sure the aligner is unplugged before disconnecting any wires in preparation for replacing any boards cables or other items within the unit Use the Lockout and or Tagout procedure When working on this aligner keep three points in mind A CAUTION THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FOR THE UNIT TO OPERATE CORRECTLY REFER TO THE UNIT ID PLATE LOCATED ON THE BACK OF THE UNIT EXTENSION CORDS ARE NOT RECOMMENDED BUT IF AN EXTENSION CORD MUST BE USED USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG OR ABOVE 50 FEET AND LESS THAN 100 WITHA 14 AWG Aligner voltages refer to the return white side of the AC line Yet sometimes outlet wiring is reverse
34. e camera s directly to one of the USB Ports on the back of the PC The HUB board has 4 USB connectors for either a two camera system or a three camera system The Db9 connector at the bottom of the HUB Board is a direct link to the PC the other 3 connections are equiva lent for the camera s any camera will plug into any of the three camera connections There is also a Db15 connector on the HUB Board for future motor control Camera USB Camera USB Camera Pwr Camera Pwr To PC USB Camera USB Incoming Camera Pwr Camera Pwr z E S opis d PCH ASM EAPaZ38 508 REV B GL GI CR B In PCB EAPOQSBISIE REV A SCH EAP 238 338 REV E ka Motor Control AC DC POWER DISTRIBUTION ULTRA CAMERA POD ASSEMBLY When ordered the camera pod comes as an assembly however should a strobe board fail it can be ordered and replaced separately The camera pod is supplied with both 5VDC to power the Acquired target indica tors and directional LED s and 12VDC to power the strobe Camera Board Camera USB Strobe Board Camera Power The strobe is held on the camera pod assembly with 4 screws and lockwashers By viewing the LED s on the strobe board the technician should be able to quickly identify if both the 5VDC and 12VDC are present There are no test points available In the figure below all Target Indicators and Directional Indicators are lit up Each of these LED s require 5VDC to light these LED s with the exception of t
35. e failures and inaccuracies on conventional products There is not much about this aligner that is conventional Shop owners and alignment technicians easily recognize the many strengths of this system compared to conventional measuring head systems As the 3D Aligner was prepared for introduction into other Internation al markets such as Asia and Latin America it became evident that the tasks of developing language transla tions and market specific vehicle specification databases was overwhelming The decision was made in 1998 to develop a Windows based user interface for the 3D aligner in parallel with efforts to do the same for the company s conventional wheel alignment system In the fall of 1998 the Windows environment was intro duced The Windows compliant Pro32 software had a robust set of features added the familiarity and power of Windows and had 27 different languages and 13 different specification databases In addition Windows offered powerful networking capabilities that gained an importance as the automotive service industry discov ers the benefits of information sharing between the front point of sale counter and the back shop In the fall of 2010 Pro42 was introduced Pro42 added the versatility of added features plus it also opened up the area of using a higher resolution camera system Ultra High Resolution UHR The UHR system also incorporates a true 3D target This target is much smaller and lighter CAMERAS The eyes of
36. e location of the ports if they are adjacent to the PS 2 ports the USB service is likely provided by an integrated controller If the USB ports are located anywhere else on the back of the computer you re probably dealing with a USB add on card Front mounted USB ports can be either type You may have to open the PC case and visually inspect the USB ports to see whether they con nect directly to the motherboard or to an add on card Scenario All devices occasionally stop working at the same time Possible causes Power management configurations for USB controllers controller drivers bandwidth If the system experiences sporadic controller failure the primary suspect on the PC OS side is power manage ment although it could be either an intermittent conflict or a problem with the USB controller Try to isolate a particular event common to all the failures just as you would with any other sporadic hardware conflict This could lead you back to a power issue if you have bus powered scanners or hard drives that might be drawing more power than the PC can provide If the system requires more power try replacing the PC s power supply with one that provides more watts Bandwidth can also be an issue if several active devices are transferring large amounts of data Potential peripheral bandwidth hogs include printers scanners hard drives and CD DVD or CDR W drives Eliminating bandwidth problems might mean replacing a demanding USB device with
37. e the alignment system s calibration after the operating system has been restored It is recommended that each time the system is backed up the user date the flash drive This ensures that the most current data backup be restored Insert the flash drive into one of the open USB ports on the PC Click on the lt FIND gt button to point to the flash drive and click on lt OK gt After the selection is made click on the backup button The user is prompted to confirm the location alls ite FE wien ff Restore Should a hard drive failure occur simply install the last known alignment cali bration and preference data disk and restore the aligner back to the user s preferred prefer ence NOTE IF THE OPERATOR IS NOT SURE IF THE SAVED DATA ON THE FLASH DRIVE IS NOT CUR RENT IT IS RECOMMENDED THAT A CALIBRATION BE PERFORMED FAILURE TO HAVE ACCURATE CALIBRATION DATA CAN AND WILL CAUSE EXCESSIVE TIRE WEAR 43 NOTES 44 CHAPTER 4 DIAGNOSTICS The Diagnostics menu offers the technicians tools to troubleshoot and diagnose problems with the aligner only These diagnostic routines will not diagnose all problems that could arise The technician should also become familiar with the proper hookup and voltage that is Supplied to this unit Before troubleshooting the V3D Pro42 UHR system it is very important that
38. easured blobs e Translates error codes into text expla m nations that may aid in diagnostics The data examination mode displays a myriad of information The information is updated on going and can be used by the operator if a failure in the alignment mode occurs This test has two pages of infor mation By clicking on the small respec tive target identification in the upper left hand corner the operator receives the second page of information This is only available when you access this screen form the Menu mode and not from the camera view toolbar button Error RTP Vector Flag 9 7 1 9 Number of Planes Nu RMS Background noise should be 06 or less 15 is maximum Target Blobs Blobs Number of Blobs dots identified The number in parenthesis is the number of po tential dots Distance Distance from the camera to the respective target in inches Target Angle Angle of target Intensity The amount of light sent back from the target Minimum 100 Goal 160 Maximum 220 Error RTP Vector Flag Status of the V3D target and wheel clamp Vector reflects type of clamp being used s Error RTP 9 Good RIP 0 No RTP Left 4350 RTP is bad e Vector This data is use for the wheel diameter indicators on the single pole wheel clamp This data is VERY useful when acquiring targets and wheel clamps during rollback 0 Good 20 Can t find indicators or distorted indicators 65480 Upper G
39. edures 56 Diagnostics TID PARAMETERS These values are used when performing a Target ID TID These preferences are found in the CSR Prefer ences by clicking on the TID Preferences tab Measurement Angle Default 90 Total rota Reetz tion of the target from the forward position back ZT Forward Bias Angle Default 25 Maximum T amount of forward rotation for TID Wobble tolerance Default 10 The maxi mum amount of wobble during TID Maximum Claw Change Default 2 0 Maximum amount of claw change before software flags errors during TID TID Stability Count Default 5 Minimum amount of consecutive snapshots of the target before the unit identifies it as a valid target Reset Tolerances Resets the unit back to manufacture defaults COMMAND PARAMETERS Click on the Parameters Preferences tab to access and view Command Preferences The CSR Edited radio button must be selected to view and edit these parameters Click on lt OK gt to save changes and exit Positioning Stability Count Default 5 How many planes the unit must acquire in sequence before measurements are displayed e Caster Stability Count Default 5 How many planes the unit must acquire in se measurement Note The more it is the more repeatable the measurements Linear Stability Tolerance Default 10 Distance Measurement Measures the height of the target and must be constant to acquire a target Angular Stabilit
40. een selected the user is prompted to restart the alignment software NOTE IF THE INCORRECT CAMERA INDENTIFICATION IS SELECTED THE CAMERA IMAGES WILL BE SWAPPED FROM LEFT TO RIGHT AND ALL IMAGES WILL APPEAR IN THE CAMERA VIEW AS UPSIDE DOWN 32 Calibration There is also three additional selection buttons available once the Imaging system has been determined maging System Type 1 Less than 2 3 Meters 90 Inches e This button should be set to the ON up position if the cameras are lessed than 90 inch es from the turnplates Changes the acceptable range and tolerance of camera based on the the installation baseline 2 Ride height target in use calibration explained later e Ifa ride height target is available this must be turned on the utilize the ride height target capabilities 3 Front clamps uses 20 degree offset e If 20 degree offsets are used on the front clamps this selection must be turned on Motorized Pods If a 3 camera system is selected the user is given additional selection buttons Each of these buttons should be turned on the utilize the pod motors on the Arago system If the auto search mode is not working the user should check to ensure of these are on Motorized Pod P i s Pod Motors Available d E N Enable Motor Target Search Distance between limit switches inches 1 T 2 in s 2in s 7 Dorii 2 2 in s 2 3 in s After enabling the pod motors the
41. ese LED s require 5VDC to light these LED s with the exception of the Strobe LED s they require the use of the 12VDC The strobe LED s are infared and appear to be off during the alignment process however this Strobe ON LED indicator was added to the strobe board to alert the technician or alignment technician that the strobe LED S are firing This LED is located behind the intuitive cover and is not visible to the operator however it can be seen by looking closely The assembly is equipped with it s own power supply and DSP processing All of the image processing is done on the camera directly and sent to the PC as processed information unlike the legacy V3D which used the pc to process all of the images This new process has improved the speed and accuracy of the system The new UHR system is equipped with a 5 mega pixel camera compared to a 1 3 mega pixel of the legacy camera The higher resolution allows us to use a smaller target compared to the past The LED S used on the UHR camera system are much brighter also than those used in the past The new system uses the same USB and power cables eliminating the need to have multiple harnesses for troubleshooting The camera strobe pcb also uses an improved firmware security system This new security eliminates possible pirating of the firmware Relative Target Position RTP Security and lens correction is stored on the camera gii HILE 7 PIA pia Seco ob or WW Pirate Lia ager Lares b ae
42. evel mathematics you can determine how far the screwdriver is from your eye On the following page there is a more detailed explanation of the mathematical principles Crew ed ei ize Distance fom Eye cr In this example the camera is at a fixed point in space All fixed camera lenses have a fixed focal point The distance from the camera to the focal point is a known value F created by the designers of the lens The size of the pen is a known value P created by the designers of the pen The perceived size of the pen is measured by our software at the focal point and becomes a known value A The goal of this exercise is to determine the distance D from the camera to the pen 18 Theory of Operation Pen known length fixed Focal Length fixed by lens First we must find the angle r by applying formulas from basic trigonometry tanr A 2 and Z P 2 D F Since we know A F P and Z can be calculated and the angle can be found using trigonometric tables Once the angle is known we can use it in another trigonometry formula to find D D P 2 tan r Since we know P and r we can calculate D we now know the distance the pen is from the camera Applying this to the 3D Aligner the image analysis software takes each image and precisely measures the size of each dot on the photograph this is the perceived size A We already discussed the known values of focal length F and size of the dots P Thu
43. f the wheel is called the spindle The 3D Aligner locates the vehicle spindles directly using a procedure called positioning In positioning we rotate the wheel tire target by pushing the vehicle back As the vehicle moves the cameras track the loca tion and orientation of the target dots If the wheel went through a complete 360 degree rotation each dot would scribe a circle as illustrated in the picture below If we took our scribed circle and determined where the center of that circle was located we would find the spindle The dot moves back as well as rotating about the axis this allows the software to locate the spindle position in 3 dimensions with respect to the camera Of course there is more than one point on our targets that the cameras can track there are 33 reflective dots As we move the car back each dot Is tracked for distance and orientation with the software using this data to create 33 circles of different sizes Each circle is then analyzed for the center point with the results averaged to determine the vehicle s spindle Since there is a target on each wheel the software finds each of the 4 spindles simultaneously PE Movement of a Point During Positioning In the last paragraphs the positioning sequence described the targets dots scribing a circle through a 360 de gree rotation of the wheel In reality this is not practical a full wheel rotation would require a roll back of 5 to 7 feet depending on the circumference
44. fixture on the left runway so that both targets are in the visual field of the left cam era If we measure with one camera then measure with a different camera and get the same values we can be sure the fixture has remained stable and our RCP is valid If the final check reveals the fixture has changed dimensions during the process we are given notice and must repeat the RCP procedure from the beginning Because the Camera Beam is rigid the cameras are hard mounted to the beam And the structure is away from the action the system does not require periodic maintenance calibration The only way the accuracy of the RCP can be affected is if one camera moves with respect to the other not likely to happen in every day usage RCPY MODELING THE VEHICLE IN 3 DIMENSIONAL SPACE After Positioning is completed and the program is able to relate one side of the vehicle to the other the soft ware knows 4 distinct points that create a plane in space that are part of the vehicle It takes these points and creates a 3 dimensional model of the vehicle plane From this model all alignment angles caster SAI cam ber and toe are referenced to the vehicle plane This is in contrast to conventional measuring head aligners that use gravity or the rack surface as a reference For this reason the 3D Aligner does not rely on a level lift In reality the aligner does not require gravity to measure but our vehicle s physical state will change radical
45. for incred ible accuracy and resolution We have now seen how the aligner uses the camera images to determine the targets location and orientation in 3 dimensional space It now has the capability to measure but how does it use these principles to measure wheel alignment angles 22 Theory of Operation POSITIONING SEQUENCE The 3D Aligner knows where the targets are but it does not yet know where the vehicle is Of course the targets are attached to the vehicle s wheels and this provides the link to the vehicle s alignment angles The term wheel alignment is a bit misleading We don t adjust the wheels we adjust the suspension and steer ing components resulting in changes at the wheel It is the vehicle spindle that receives the alignment and the wheels are just along for the ride All wheel alignment equipment uses the spindle as a starting point usually by either placing the measuring device directly opposite the spindle or by performing a runout com pensation referencing gravity or the rack The 3D Aligner finds the spindles in a unique way that improves accuracy and speed Axis of Rotation A single point on the wheel tire is represented by the star If we rotate the wheel tire and track the position of the star at various points we would find the star movement forms a circle If we determine the center of the circle we have defined the axis of rotation of the wheel tire In automotive terms the axis of rotation o
46. he Strobe ON indicator it uses 12VDC The strobe LED S are infared and appear to be off during the alignment process however this Strobe ON LED indicator was added to the strobe board to alert the technician or alignment technician that the strobe LED S are firing This LED is located behind the intuitive cover and is not visible to the operator however it can be seen by looking closely Roll Directional Strobe ON Indicators Indicator Target Not Acquired Indicators P DZ e OOOO S FAK KI RR Saa Cn Ge 896 7 jz vz e Og Directional e 0 Indicators E a E OKLO lege WA k Gre Ze XY E s A Target Not Acquired Indicators AC DC POWER DISTRIBUTION When the targets have been mounted to the wheel and tire of the vehicle the Target Indicator LED S will illumi nate green once the targets have been acquired Target Acquired Indicators Target Acquired Indicators ULTRA UHR CAMERA STROBE ASSEMBLY 3D SYSTEM The UHR Camera Strobe PCB is all integrated onto one PCB The camera pod is supplied with both 5VDC to power the Acquired target indicators and directional LED s and 12VDC to power the strobe Camera Camera USB AC DC POWER DISTRIBUTION By viewing the LED s on the strobe board the technician should be able to quickly identify if both the 5VDC and 12VDC are present There are no test points available In the figure below all Target Indicators and Directional Indicators are lit up Each of th
47. he user manual Use a glass cleaning fluid and a soft cloth Make sure that the glass is free from grease and dirt Power on the Alignment System From the calibration menu click on the RCP icon to begin the process Slide the turntables to the outboard position Place the calibration bar on the right rack rail with the small target on the outside of the front turntable and the large target towards the rear center of the rail Click on lt NEXT gt when done 38 Calibration 7 Two images should appear in the upper left hand portion of the screen The aligner will sample the images and will automati cally prompt the technician for advance ment Click on the lt NEXT gt button when prompted Ee Pe piisi oi fe Bord bee od Ee ein le n Lear Fa res vee Ee ei 8 The aligner will sample and process the im ages Notice the progress bar in the lower right hand corner 9 After a period of time a message is dis played to raise the plunger on the double leg bracket This will cause the images to rotate on the screen Click on lt NEXT gt when prompted e 10 Retract the 1 5 plunger Place the cal bar with the small target on the right rail the large target on the left rail with the feet cen tered front to rear on the turntables Slide the turntables inboard if necessary Click on lt NEXT gt when done al or Pa ar RTRC oc bray E Ka PARE Fr n Fa
48. hese guidelines will result in longer repair times and repeated callbacks In using this guide always start with ba sics regardless of the complaint Some of the screen captures in this Chapter were taken using a two camera system Servicing an Ultra Arago will only add an additional camera view The troubleshooting is handled the same GUIDELINES e Before beginning any diagnosis verify the customer s complaint and aligner s condition in great detail In many cases the problem is not the equipment it s an operator error e Never make more than one change at a time on a defective machine This could result in extended repair times and unnecessary parts replacements e If the replacement part did not fix a problem reinstall the original component Before trying something else e If the replacement part appears to fix the machine take a few minutes to reinstall the defective part and verify the repair and diagnosis Verification always ensures that the problem has been resolved and usually prevents a return service call e When sending a defective part back for repair a detailed description of the failure should be included with it Failure to follow this procedure may result in a failed part getting returned to the field un fixed e Every Technician should keep a notebook with descriptions of errors and fixes he has encountered on the aligner It s easier to repair future problems based on known good experiences instead of guessing wha
49. hole or in part without the express written consent of Snap on Tools CRT POINTING DEVICE KEYBOARD PRINTER AC DC POWER DISTRIBUTION pes HUB PCB Motor Ctrl Connection Camera Connections Rocker Switch MN 5 AMP FUSE Soa l a Gaass IT Ss S O 12 Camera Camera Connections Connections Camera Connections LIS J7P9 MOTOR CNTRL CONNECTIONS CONNECTION 1 5V Redd 1 12V 2 5V Return Black 2 12V Ret 3 12V White Shield 4 Shield Lower Limit 3 NC BRIDGE 1_HsOn SDA 6 12V Return Green 12V Cisolated 12V Ret 9 Shield 3 4 5 6 Spare 1 7 8 10 Upper Limit 11 BRIDGE2_HsOn SCL 12 Spare 2 NM Cable End Console PCB End DWG BY CHK BY MOD BY CHK BY TITLE mn B CHAPTER 2 THEORY OF OPERATION GENERAL The 3D Image Aligner is a revolutionary concept in performing wheel alignments The system uses a camera based machine vision technology that provides many benefits to the shop owner and alignment technicians It is the fastest most accurate and easiest to use aligner ever made One of the benefits to new technolo gies is the use of state of the art components and computer programming that makes the task of servicing this product easier than previous generations of alignment equipment One of the most obvious differences is the lack of an electronic measuring head the source of many of th
50. ick PROPERTIES Click POWER MANAGEMENT 0 De select the ALLOW THE COMPUTER TO TURN OFF THIS DEVICE TO SAVE POWER check box Repeat Steps 5 8 for each USB ROOT HUB 11 Click OK 12 Close DEVICE MANAGER nN a OOND 2 System Ei Control Panel System and Security System File Edit View Tools Help Control Panel Home View basic information about your computer Se Device Manager n Windows edition Remote settings Windows 7 Home Premium e Copyright 2009 Microsoft Con Device Manager Service Pack 1 Get more features with a new ec System protection Se Advanced system settings e9 MOHU PRB RS Display adapters 0 22 DVD CD ROM drives Ma Human Interface Devices 4g IDE ATA ATAPI controllers H 2 Keyboards USB Root Hub Properties j x R Mice and other pointing devices System Manufacturer D E Monitors General Power Advanced Driver Details Power Management Model EF Network adapters Rating Ji Ports COM amp LPT USB Root Hub P EI Processors Pod Processor aQ Sound video and game controllers ged BR System devices mene T Allow the computer to tum off this device to save power Installed memory R l k ER 9 Universal Serial Bus controllers F Allow this device to wake the computer System type Intel R ICH10 Family USB Enhanced Host Controller 343A Pen and Touch N 8 Intel R ICH10 Family USB Enhanced Host Controller 3A3C l Intel
51. ing the System Properties click on the lt Hardware gt tab to open the hardware menu After opening the Hardware Menu click on the Device Manager button to open the device manager Locate the Univeral Serial Bus Controller at the bottom and click on the to view all of the active devices USB BASICS USB controllers are known as root hubs They re integrated on the motherboard in most computers Current moth erboards typically have between two and six root hubs each with at least two headers for connecting ports Older computers may only have one hub on the motherboard or a PC may have an add on PCI or EISA controller card that provides USB service The Ultra Aligner has a Hub PCB that relays information to and from the cameras to the PC and passes power from the power supply to the cameras The aligner loads a Generic USB HUB at startup and must be present in order to operate the cameras and pass information The Ultra Arago uses 3 Generic Hubs and each must be present Also the camera device drivers must be loaded and will also show up in the device manager The conventional will show 2 cameras and the Arago will show either 3 or 4 depending on whether the unit is equipped with aremote camera The Ultra Cameras will not show up in the device manager if the Generic USB Hub is not present The Ultra Arago will also show 2 USB motors used to drive the camera pods up and down the towers Check the Obvious Before you start
52. interlacing An interlacing error will be i Left cick the mouse on the evident by blobs that are non contiguous over each rene ino Ces line An interlacing error will indicate a faulty cam i image to zoom out era this has nothing to do with CRT interlacing Moving the cursor over the image display the pixel value intensity of the cursor location is displayed in red The brighter the cursor location the higher the intensity value Left clicking on the image using the mouse zooms in on that location The user must remember to view the cor rect intensity of a particular target he she must select it The two images shows a different intensity of the same Intensity 215 target location just by which target was selected x Laro the dake cn this image to zoom in Right click the mouse on the Click on OK or Cancel to exit this test Fe l image to zoom out 46 Diagnostics RACK CHECK This test checks how coplanar parallel the rack is Even though we are very resistant to rack problems non copla nar racks can introduce some error to our system The image aligner is designed to perform a perfect alignment every time The levelness of the rack side to side or front to rear is irrelevant to performing this perfect alignment however a rack that is non coplanar parallel will induce erroneous read ings because the suspension of the vehicle is under stress A Non Coplanar rack is evident
53. it is in a different location as it is also in a different location one each set of targets This location tells the camera which of the targets from the set is a back and which is a front target From the target assembly the back target on each wheel is the Master target Locate the dot on each master target and you will notice that the dot on the front target is turned either 90 CW or 90 CCW from the Master target Each target contains a total of 13 fids 5 large and 8 small this brings the target set to a total of 26 fids No more that 3 small fids can be blocked on any target before it is lost in the cameras field of view and none of the large fids can be blocked before it is lost in the cameras field of view Relative Target Position RTP is stored on the camera so each target is married to the camera that sees it The RTP is restored from backup information if used Configuration using conventional wheel clamp 16 Theory of Operation Configuration using single pole wheel clamp 17 Theory of Operation TARGET ACQUISTION When we begin a new alignment the program has no idea where the targets are located The software turns on the cameras and goes into a search mode looking throughout the cameras field of view for any targets We see this on the screen in the form of 4 red targets away from the wheels Since the software knows what a target looks like when it sees an object that may be a target it applies what is c
54. ixels received by the umber of Images Number of Images ge cameras have a brightness level of 0 to 255 Threshold tells the cameras to ignore gz any pixel with a brightness level below d a certain number Threshold levels are software controlled and are primarily for engineering use Good target measurement Acquire Count How many images it takes tee RMS s Target Blobs Blobs Number of Planes Number of target Ca AEN planes that the camera has acquired R m mx Ke iiaea Number of Images Number of raw im 3 ages that the camera has acquired at ee ay Acquire Count Number of Planes Number of Images The user can quickly jump to each targets information by clicking on the target identification icon This screen will display warning indications if any of the following criteria have been exceeded or if a target is not visible e Target angle greater than 48 degrees e Distance to front target greater than 160 inches 4 064 meters e Distance to rear target greater than 240 inches 6 096 meters e Target RMS greater than 0 10 e Number of target blobs less than 29 e Number of images is 0 for a particular camera e Number of planes is O for a particular wheel NOTE CLICK ON OK OR CANCEL TO un EXIT ALL TESTS 2a Z 8s amp The Data Examination Screen offers a few D Good target measurement RE Good target measurement E RMS 05 RMS 05 more diagnostic tools to troubleshoot the ear ae UHR
55. l be necessary to train the alignment system which side the new camera has been installed NOTE FAILURE TO FOLLOW THIS PROCEDURE AFTER A NEW CAMERA IN STALLATION WILL RESULT IN IN ACCURATE ALIGNMENT RESULTS 1 From the calibration menu click on the System Configuration icon 2 Select the proper Imaging System Type e Two Camera System e Three Camera System e Two Cameras with remote camera e Three Cameras with remote camera oe After selecting the correct camera configuration the each of the camera must be identified By clicking on Camera Identification icon a display with a camera beam will appear 31 Calibration After gaining access to the camera identification look closely at the illustration of the two camera beams The upper camera beam illustrates the left directional arrows illuminated and the lower camera beam illustrates the right directional arrows illuminated If a 3 Camera system was chosen in the previous screen the user will also need to identify the calibration camera or if a remote camera is present it will also need to be identi fied Use the pointing device click on the illustrated camera beam that matches the camera beam that is being serviced After selecting the correct illustration the illuminated directional arrows should swap from one camera to the other Again using the pointing device click on the camera beam that matches the beam being worked on After all cameras have b
56. ly in a weightless environment L S CS V 2 Theory of Operation MEASURING STEERING ANGLES The steering angles caster and SAI are defined by physical components of the vehicle suspension those that define the steering axis such as upper and lower ball joints on a short arm long arm suspension Conven tional aligners measure these angles using gravity gauges and the toe system by monitoring the affect these angles have on those angles as the wheels turn Once again the 3D Aligner is unique and superior The 3D program locates the steering axis directly in 3 dimensional space in the same way it found the vehi cle s spindles We locate the axis by putting our targets in motion about the axis by turning the wheels First we turn one direction 10 to 13 degrees The software monitors the movement of the target dots which scribe an arc The program finds the center of each of the 33 arcs averages and knows where the steering axis is located As with the spindle determination we check our findings by turning the wheels the other direction lf the two steering axis calculations agree we pass this along to other parts of the software that convert axis locations to caster and SAI angles referenced to the vehicle plane 28 CHAPTER 2 CHECKOUT CALIBRATION AND MAINTENANCE TROUBLESHOOTING THE SYSTEM Before using this troubleshooting guide there are some steps that the user must follow Failure to follow t
57. nique If it is chosen there are no other options available Conventional Clamp Used to perform Target Identification on Conventional Wheel clamps These clamps and target come standard with the aligner Universal Clamp Used to perform TID using the universal clamp Procedure is the same as Conventional Clamps Hub Pin Clamp Used to perform TID using the Hub Pin Clamp Procedure is the same as Conventional Clamps Single Pole Clamp Used to perform TID using the Single Pole wheel clamp Procedure is the same as Conventional Clamps TARGET ID PROCESS NOTE BEFORE PERFORMING A TID THE OPERATOR MUST CLEAN THE TARGETS WITH GLASS CLEANER AND A LINT FREE CLOTH THIS IS A VERY CRUCIAL PRO CEDURE ONLY 1 TARGET MUST BE IN THE CAMERA FIELD OF VIEW DURING THIS PROCE DURE 1 Click on any of the target ID icons to begin the process Make sure that the process chosen is for the correct target and wheel clamps For illustration purposes the Conventional Clamps are used 2 Move the box around the screen using the arrow keys and click NEXT or you can double click on the desired wheel 3 Once the wheel is selected the screen will instruct the operator to place the target clamp assembly on the front wheel and lock the steering wheel using the clamp This step insures the wheels will not move laterally during the Target ID procedure The next step on this screen is to elevate the front wheels to allow them to rotate as needed Click
58. of the tire Most alignment racks cannot handle this The engineers were able to shorten the wheel rotation angle to 35 degrees 5 This works out to 6 to 10 inches of roll back which is easy to accomplish with most vehicles 23 Theory of Operation When the vehicle is rolled back the 3D software directly locates the spindles and now knows 4 distinct points in space with respect to the cameras that are part of the vehicle Since the vehicle is now back off the rack turntables it is necessary to roll it forward to perform any corrections The aligner uses the software when rolling the vehicle forward as a check of the results of the roll back As the operator moves the vehicle for ward we repeat the positioning sequence When the vehicle returns to the turntables we have a new mea surement of spindle locations The software then compares the results of the roll back with those of the roll forward if they agree the program is satisfied and moves on if they do not agree an error message appears called Wheel Wobble and we are forced to repeat positioning until they agree This is one of many exam ples of where the 3D Aligner performs quality checks to insure the highest degree of accuracy possible SIDE TO SIDE DETERMINATION The 3D Aligner gathers target images utilizing two cameras mounted on the ends of a beam This beam is positioned higher than the vehicle s wheels to allow the cameras to see the rear targets the front targets a
59. p Connect it to chassis ground on the equipment or to an available raw ground Touch the chassis of the equipment to put yourself at the same static potential as the equipment Grasp the PCB from opposite sides using your fingertips Do not grasp the components on the board A WARNING USE STANDARD ANT STATIC PROCEDURES WHILE PERFORMING THESE INSTRUCTIONS AC DC POWER DISTRIBUTION When inserting PCB s e Place boards on a grounded static mat after removal e Remove the new PCB from the original package onto a grounded static mat Save packaging to use when returning defective boards e Remove power from the machine un plug from wall before installing the PCB e Avoid handling components needlessly e Do not set PCBs on insulating surfaces such as paper glass rubber or plastic e Static is generated by friction The following actions promote static generation e Wearing silk or nylon clothing e Walking on carpets e Walking with rubber soled shoes Static generation is increased when certain environmental conditions exist Conditions of low humidity com bined with wearing silks or nylons walking on carpets or walking with rubber soled shoes may create large electrostatic charges on your person capable of blowing a hole in the substrate of an IC SERVICE GUIDELINES ON GH Gn BEFORE REPLACING circuit boards verify that the main power supply operates within specifications VERIFY that board connectors are f
60. rabber is mounted updside down on single pole 21 Not looking for marks The wheel diameter indicators are only used at the beginning of a rollback s Flag larget s information lt 9 Bad target 9 Good target 10 Front Sub target blocked 11 Back target blocked 12 Found a front target but has issues Camera sees front target on another wheel but cannot locate front target on respective wheel 13 Found a rear target but has issues Camera sees rear target on another wheel but cannot locate rear target on respective wheel 48 Diagnostics Retrieve additional data by clicking onthe W a em target identification icon The information displayed depends on the type of camera H cme D sateen being used Ultra or Ultra UHR RMS 06 RMS 06 N Target Blobs Blobs 26 52 Target Blobs Blobs 26 52 Distance 130 2 Distance 125 2 Target Angle 20 2 Target Angle 9 24 1 L F l 0 208 Intensity 197 Intensity 190 l Error RTP Vector Hlag 9 20 9 Error RTP Vector Flag 9 20 9 D Number of Planes 2686 Number of Planes 2740 Number of Images 2737 Number of Images 2792 DI Good target measurement DI Good target measurement RMS 05 RMS 04 Target Blobs Blobs 26 43 Target Blobs Blobs 26 41 Distance 195 4 Distance 199 Target Angle 21 2 Target Angle 26 1 Intensity 189 Intensity 212 Error RTP Vector Flag 9 20 9 Error RTP Vector Flag 9 20 9 x x Number of Planes 2675 Number of Planes 732 Threshold All p
61. re smaller allowing easier viewing of the rear Each camera can see a front and rear target on its side of the vehicle and thus determine their locations and orientations and find the two spindles on that side However each camera cannot see the targets on the other side of the vehicle When determining alignment angles such as thrust angle and setback it is necessary to connect the vehicle sides to know the relationship of the left side to the right side To do this the 3D Aligner must know the positions of each camera with respect to one another To get an idea of the type of analysis the 3D Aligner program must do In the picture there is a vehicle with all targets attached The program can determine the distance from each camera to the front and rear targets on its side of the vehicle as indicated by the check marks using perspective What it cannot do directly is deter mine the distance from the camera to the front and rear targets on the other side question marks The way to find the cross distance is to know the distance between the 2 cameras called RCP on the figure If RCP is known it is straightforward mathematics to determine the cross distance in question since two sides of a right triangle are known Pythagorean Theorum a b c But how does the program know the dimen sion RCP We must tell it RCP
62. s using the above math the 3D Aligner can measure the distance from the cameras to any dot on the targets and can do so with a high degree of accuracy it can measure a target 20 feet away to less than 1 mm accuracy Theory of Operation FORESHORTENING The discussion earlier about perspective and the screwdriver example assumed that the screwdriver or target was normal to your eye Normal means the object is being viewed straight on perpendicular or at 90 degrees so its full length is observed Look what happens to the observed size of the screwdriver when it is rotated away from 90 degrees to your eye it appears smaller The observed size of the screwdriver becomes shorter The more it is rotated the smaller it appears to be This effect is called foreshortening As before if you know the actual size of the screwdriver is 6 inches by measuring the observed size and applying mathematics it is possible to determine the screwdriver s angle of orientation with respect to the normal view 20 Theory of Operation Focal Length fixed by lens Pen known length fixed In this example the camera is at a fixed point in space All fixed camera lenses have a fixed focal point The distance from the camera to the focal point is a known value F created by the designers of the lens The size of the pen is a known value P created by the designers of the pen The observed size of the pen is measured by our software a
63. ss 0 5 Ohms 10 Check for mechanical issues Clamps cables damage to unit 55 Diagnostics CSR PREFERENCES There should be no reason for the preferences of the aligner to be changed Changes made in the preferences can ultimately af fect the aligners accuracy Listed are the preferences and a brief explanation of it s use This feature should be used with extreme caution STEPS FOR CHANGING PARAMETERS User Login Identification 1 From the Main Menu click on the Preference tab and then click on the Log In Out button CSR 2 Login as CSR using the 20 digit code given from technical Besteet support 3 Click on the CSR Preferences icon in the Preference menu 4 The Main Preference screen has 3 option tabs CSR Prefer ences TID Preferences and Parameters Radio buttons are provided for changing from factory defaults Parameter Group e Standard e OEM e Show e CSR Edited e Allow Positioning Wobble Default checked Allows the operator to by pass Wheel Wobble if box is unchecked the op erator must redo and pass wheel position ing on all 4 wheels e Allow Caster Roll Default checked Al lows the operator to by pass Wheel Roll during caster sweep If the box is unchecked the operator must redo and pass a successful caster sweep without wheel roll s Allow Individual Toe Editing Default unchecked This allows for individual toe specification edit during specification editing proc
64. t hubs Try moving the devices to another root hub to see if the problem is in a particular root hub or in the devices themselves Remove external hubs from the equation to see if they are the problem Try the prob lematic devices individually on the computer if they work it s a device driver power issue or bandwidth pinch Power management Most computers have some form of sleep mode connected with the screensaver A controller is not harmed when an energy setting kicks and eliminates its power However the OS may fail to power up the controller again You can eliminate this error by opening Power Options and disabling System Standby Excessive loads on the bus can also cause power problems The USB controller can power USB devices Small devices like mice and keyboards aren t a significant drain but larger devices such as scanners hard drives Web cams and speakers can draw considerable power You might be able to eliminate the problem by spreading the power hungry devices across multiple root hubs Otherwise acquire a good self powered external USB hub 61 Diagnostics Managing the USB Hubs Change USB Root Hub settings as follows Click START Right click on COMPUTER Click PROPERTIES Verify Windows Service Pack 1 Blue Arrow is installed If not this update can be found on Mi crosofts website Click DEVICE MANAGER Double click to expand the UNIVERSAL SERIAL BUS CONTROLLERS branch Right click USB ROOT HUB Cl
65. t the focal point and becomes a known value B The goal of this exercise is to determine the angle of orientation R away from the normal position THE CIRCLE Hopefully by now we have some understanding of how the 3D Aligner can determine how far away the targets are and their angle of orientation Of course when placed on a vehicle the dots are likely to be at varying dis tances from the cameras and at varying angles or orientation at any given moment An observer to the above may ask how can the aligner tell the difference between the effects of perspective and foreshortening All it Knows Is the targets images are smaller than their actual size What about orientation changes in 3 dimen sions The answer is a powerful geometric shape the circle As you will find out the circle was chosen as the geometric shape for the targets because of its mathematical relationships For this discussion assume the aligner targets consist of a single large dot Y Normal View of Circle Moving Away The circle has some unique characteristics that make it useful for the 3D Aligner When you look at a circle from the normal position straight on or a 90 degree angle the diameter across is equal no matter where it is measured As the circle moves away from you the diameters appear to get smaller due to the effects of perspective as discussed earlier 21 Theory of Operation Now look what happens as the circle is rotated about the X axis in t
66. t was done the last time this problem was seen e Always have current software on hand Current software revision levels can be found at http www equiserv com techsupport ServiceSoftware SoftwareMatrix AlignerMatrix htm 29 Calibration CALIBRATION UTILITIES The Calibration Utilities are special utilities designed to calibrate different parts of the alignment system It also includes a utility used to back up the calibration data and to aid a technician in the proper troubleshooting of the V3D system E ISO he Utility used for performing ISO calibration A special fixture is required to perform this proce Ure The procedures are included with the fixture This should only be done by a qualified nu 1 technician SYSTEM CONFIGURATION Utilities used to configure the systems camera configuration TID Utilities used for performing Target Identification for 3 different types of clamps available to the end user including Standard Clamps Universal Clamps and Hub Pin Clamps CAMERA VIEW Live camera view This utility is very useful for determining proper camera operation RELATIVE CAMERA POSITION RCP Process used to identify the camera s distance from one another RIDE HEIGHT TARGET CALIBRATION Utility used to calibrate the Ride Height Target if available CALIBRATION UTILITIES Utility used for backing up calibration data 30 Calibration SYSTEM CONFIGURATION After a camera has been installed it wil
67. troubleshooting a USB problem double check your fundamentals Check to make sure that the Generic USB hub is loaded check to ensure that the two Ultra Cameras are loaded check to ensure USB cables are physically connected Confirm that any USB hubs are properly connected and plugged in to powered electrical out lets Many failures can be traced to unplugged equipment or devices that are plugged into outlets that aren t receiv ing power The Ultra Aligner has a dedicated Power Supply for the cameras For troubleshooting you should have an extra Ultra Camera that has tested OK on another computer You can try using the device on the PC experiencing the problems to verify that the USB port not a faulty device or cord is caus ing the trouble This can be easily accomplished by plugging an extra Ultra Camera directly into the PC s USB port on the back of the PC 58 Diagnostics CAMERA TROUBLESHOOTING Scenario 1 One camera never works Check the device manager to make sure that it recognizes two cameras If it does you can assume that the PC Camera Power Supply Cable from the console to the Hub and of the Hub is good Unplug both cameras from the Hub and plug a spare camera into the Hub location of the camera that is not working If the spare camera is working the problem is either the camera or the cable If the spare camera does not come on the problem is in the hub Scenario 2 Both cameras stop working Plug a Spare power usb cable
68. ully seated NEVER remove boards or disconnect a connector with the power on MAKE SURE that you completely understand what the aligner does If it works you can t fix it Refer to the Aligner Operator s Manual application notes and flow diagrams BE CAREFUL when handling circuit boards Wear an anti static wrist strap WHEN TRANSPORTING circuit boards use anti static bags NOTE RELATIVE HUMIDITY HAS A DIRECT EFFECT ON STATIC CHARGE BUILDUP AS HUMIDITY DECREASES STATIC BUILDUP USUALLY INCREASES LOCKOUT AND OR TAGOUT SYSTEM PROCEDURE 1 Notify all affected employees that a lockout or tagout system is going to be utilized and the reason thereof The authorized employee shall know the type and magnitude of energy that the machine or equipment utilized and shall understand the hazards thereof If the machine or equipment is operating shut it down by the normal stopping procedure depress the stop button open toggle switch etc Operate the switch valve or other energy isolating device s so that the equipment is isolated from its energy source s Stored energy such as that in springs elevated machine members rotating flywheels hydraulic systems and air gas steam or water pressure etc must be dissipated or restrained by meth ods such as repositioning blocking bleeding down etc Lockout and or tagout the energy isolating devices with individual lock s or tag s After ensuring that no personnel are e
69. user must calibrate them Using a tape measure measure the distance from the bottom camera switch on the beam and the top camera switch on the beam Each side must be identical for proper operation Move the slider bar until the correct distance in displayed 72 9 used on our system Make sure the camera pods are free from all obstructions and click on the calibrate camera motor button The system will run the pods from top to botton or vice versa After the pods have automatically calibrated the system will auto input the inches per second that the pods are traveling Calibration In order to maximize the Arago 3 alignment system the cameras have been mounted on a swivel pod assembly This swivel pod allows the right and left cameras to rotate in order to see the targets in all field of views Narrow Normal and Wide The Arago does not require RCP because the third camera maintains constant calibration 1 From the calibration menu single click on the Pod Rotation icon 2 Adjust the camera lever s to the illustrated position shown on the screen and click on lt Next gt x 7 180 0 0 0 0 0 k i F Move the pod levers to the displayed position and press Next De Left Small Right Small 2 E 3 After clicking on Next as indicated in step 2 the camera rotation levers change positions Move er E S the camera levers to the position shown and click E gt on lt Next gt v i Note Pod
70. w is too large In the case of the 3D Aligner light is generated by the LED s hits the target and returns along the same path to the camera when placed in the center of the LED array we L 2 The retroreflection material is placed on an aluminum backing plate to insure the reflective pattern remains flat This assembly is then mounted into a hard ABS plastic housing for shock and damage protection Fi nally a special piece of tempered glass is placed on top of the retroreflection material for final protection from damage The top glass is special for two reasons First it is an optical grade glass that is free of imperfections and impurities This is necessary so the reflected image the cameras see is not altered by glass imperfections Second the backside of the glass contains a pattern of dots etched from a jet black emulsion material This dot pattern created by the glass allows the cameras to see a very unique item that the 3D Aligner recognizes The various dimensions of this pattern of dots is a known quantity that is stored within the program and is used as a constant forming the basis of our vision based measuring system There are 33 dots on each target laid out in a very distinct manner A great deal of time and effort was placed on designing this pattern of dots In some ways the dots appear to be randomly placed but in other ways appear to have some symmetry Some of the dots are larger than other
71. we place the assembly on the right runway of the rack in the view of the right camera RCP MI Z The right camera measures the distance to the front target and the rear target and subtracts the two with the difference being the fixture length This is stored in memory for usage later in the RCP procedure v 7 25 Theory of Operation To determine Relative Camera Position we need to take the fixture of a length we know and place it across the runways placing one target in the left camera s vision and one target in the right camera s vision RCPY The right camera measures the distance to the right target the left camera measures the distance to the left target and the memory has the fixture length We have 3 of the 4 sides of a trapezoid and through applica tion of mathematics we can determine the fourth RCP We also recheck our calculations several times by placing the fixture back on the runways at different points before proceeding The RCP procedure establishes the missing dimension that allows side to side determination each cam era s position with respect to each other The accuracy of this calculation is highly dependent on the fixture being dimensionally stable as we move it from point to point on the rack The final step is to recheck the fixture to make sure it is the same length We call this rechecking the fixture length 26 Theory of Operation We do this by placing the
72. when one runway is tipped down more than the opposite runway e This test checks how coplanar parallel the rack is Even though we are very resistant to rack prob lems non coplanar racks can introduce some error to our system e If the lag between rails is less then 0 02 inches 0 5 mm the rack is considered to be coplanar e Ifthe lag is greater then 0 02 inches and less then 0 3 inches we display the value but leave it up to the individual shop to decide what to do Although this will not cause a great deal of problems is will affect the alignment readings a small amount e If the lag is over 0 3 7 5mm inches we tell the user to adjust the rack to the manufacturers specifica tions as this will affect alignment accuracy This test requires the use of the RCP fixture The technician must have this fixture to check the rack rails for a coplanar parallel condition 5 Place the RCP fixture across the rack with the small target on the RF turntable and the large target on the LF turntable and press OK 6 Move the RCP fixture towards the rear of the rack just FORWARD of the rear slip plates 7 Read the results Click on OK or Cancel to exit this test 47 Diagnostics DATA EXAMINATION e This mode allows the operator to look at raw plane generation data as it arrives This information de pends on the camera being used Ultra or Ultra UHR e Displays the number of proto blobs potential target blobs as well as m
73. wo dimensions it appears to be an el liptical shape Y Y A Rotated A The more we rotate the circle about the x axis the smaller the y axis diameter appears In fact a mathemati cal relationship exists that says if you can measure the length of the y axis line and the length of the x axis the circle s true diameter you can determine the angle of rotation To put this all together no matter how you rotate the circle in any dimension X Y Z the true diameter axis is always visible This is called the ellipse s Jong axis The 3D Aligner measures every diameter on the target dot and uses the long axis it finds as the true diameter to determine how far away the target is through per spective Then it looks at the diameters in the other dimensions that are 90 degrees to the true diameter to find the short axis and determines the angle of orientation away from normal with foreshortening Using these methods it determines where the target dot is in three dimensional space with respect to the camera both distance and orientation It is the circle s unique characteristics that allow the aligner to distinguish between the effects of perspective and orientation Examine below to see and example of a target rotated in different directions For this discussion we assumed the target has only one dot In reality each target has 33 dots and there are 4 targets and the 3D Aligner s powerful computer system analyzes each circle simultaneously
74. xposed and as a check on having disconnected the energy sourc es operate the push button or other normal operating controls to make certain the equipment will not op erate CAUTION RETURN OPERATING CONTROL S TO NEUTRAL OR OFF POSITION AFTER THE TEST DE ENERGIZED STATE The equipment is now locked out or tagged out AC DC POWER DISTRIBUTION AC THEORY OF OPERATION Always use one hand rule when working with AC voltages by keeping one hand in your pocket or behind your back Before removing any wires on the equipment always verify that the equipment is turned OFF Turn off the Main Power switch in the back of the unit and unplug the AC power cord from the AC outlet A WARNING DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT AC DISTRIBUTION Alignment Console primary voltage is 110VAC 60Hz via the hot side black wire of the AC power cord On the Alignment console the power comes to a power strip then is distributed to the Monitor Printer and if so equipped the battery charger for voice control module For the camera power supply box the power comes via the hot side black wire of the AC power cord to an EMI filter to a on off switch then to the power supplies D C THEORY OF OPERATION POWER SUPPLY The power supply is a COSEL LEB100F 0512 The output voltage of the power supply is 5V 5A and 12V 5 Peak 10 A The power supply is used to supply the camera with 5 volts to run the wheel indicator
75. y Tolerance Default 05 Angle of the target Measures the width of the target and must be constant to acquire a target Positioning Angle Default 40 How many degrees the target must rollback before acquiring a reading Positioning Angle Tolerance Default 10 Minimum Maximum for Positioning Angle Centering Tolerance Default 25 The maximum a target can be turned before the unit will ask the operator to steer the wheels straight ahead Steering angle during centering Positioning Wobble Tolerance Default 10 Maximum angle that a target can move during positioning before wheel wobble occurs Caster Roll Tolerance Default 201 Maximum angle that a target can roll during caster sweep before wheel roll occurs Smoothing Factor Default 7 Smooths out display meters Note Keeps meters from jumping Dropout 10ms units Default 350 Amount of time it takes to drop a target when a target is blocked Front First Threshold Default 1 3 sets the value at which the Adjust Front First Indicator Icon ap pears on any of the rear reading screens See operator manual for details NOTE RUNNING IN THE EXTREME WEATHER MODE CHANGES DEFAULTS 57 Diagnostics TROUBLESHOOTING THE SYSTEM The Ultra Aligner can be easily broken down into these major components e PC usb amp drivers e Power Supply e Hub PCB 3 on Arago e Camera s 3 on Arago e Cables e USB Motors Moveable Beam amp Arago Ea
76. you check to make sure the cor rect wheel clamps are select in the Preference Menu It is possible that a user could inadvertanly change the wheel clamp type not knowing the consequences This could cause the service technician to improperly troubleshoot and diagnose a problem Having the incorrect wheel clamp may be the problem 1 From the Main Menu select the Preference Icon 2 Select the System Configuration Icon 3 Click on the Clamp Selection Icon 4 Ifthe single pole wheel clamp is selected no other wheel clamp is available There are 4 types of wheel clamps e Conventional Clamp e Universal Clamp e Quick Clamp e Single Pole Clamp 45 Diagnostics From the Main Menu select the Diagnostic Icon at the top Weem of Carousel STORED IMAGE ANALYSIS i wy Allows the user to view and zoom into stored images oe ae stored using Ctrl Alt P This feature is available any time that the system has target view on the screen The Boe system is set to acquire images for every Ee a an 2 seconds for a known time after whcih it will switch to 4 seconds and then 20 sec onds and then 1 minute The system will automatically stop the process when the user goes to the home screen to begin a new alignment This feature is helpful if a system is experiencing problems radomlly e Allows you to view individual pixel intensity levels e Display interlaced images to allow for verification Intensity 147 of correct

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