Single Point Sensor DynaVision¤ DLS2000 User Manual
Contents
1. BufferPtr 1 ELSE RevBuffer BufferPtr ByteIn IF BufferPtr 2 RevLength Byteln 3 BufferPtr BufferPtr 1 IF BufferPtr gt RevLength Got the Full Message StopTimeOutTimer Yes Stop the Timeout Timer MsgReceivedFlag TRUE ENDWHILE IF MsgReceivedFlag TRUE RevCRC 0 RevAddr RevBuffer 1 RevCmd RevBuffer 3 FOR loopctr 0 TO RevLength RcvCRC RevCRC RevBuffer loopctr IF RevCRC lt gt 0 CRCError TRUE ELSE IF RevCmd lt gt CmdByte CommandError TRUE ELSE SensorRange WORD RcvBuffer 4 ELSE TimeOutError TRUE TROUBLESHOOTING This section will help you with any difficulties you may have in operating the DLS2000 sensor Before following the suggestions be sure that you have a clean and regulated power source a calibrated voltage measurement device DVM Oscilloscope a computer optional Behavior Laser off When the laser is on a red light appears in the small circular window do not look at the laser What to do Check to see if the power is turned on Check cabling and ensure power is wired correctly Behavior No data comes from the sensor s serial port What to do 1 Check cabling and ensure that power and signals are wired correctly Make sure you have an RS 232 to RS 485 converter 2 Check to see that the laser is on The DLS2000 uses a visible red laser Do not look into the laser exit window 3 Check to see that the camera s field of2. IMI MEASUREMENT amp CONTROL ge 1139 single Point Sensor DynaVisiona DLS2000 User Manual Version 1 1 Laser Measurement International Inc Germany Finger GmbH amp Co KG 205 7088 Venture Street Sapelloh 84 Delta BC Canada V4G 1H5 31606 Warmsen Telephone 604 940 0141 Tel 49 0 5767 96 02 0 Fax 604 940 0793 Fax 49 0 5767 93004 Trademarks and Restrictions DynaVision is a registered trademark of Laser Measurement International Inc This product is designated for use solely as a component and as such it does not comply with the standards relating to laser products specified in U S FDA CFR Title 21 Part 1040 Windows 95 Windows 98 and Windows NT are registered trademarks of Microsofta Corporation No part of this publication may be copied photocopied reproduced transmitted transcribed or reduced to any electronic medium or machine readable form without prior written consent of Laser Measurement International Inc This product is covered under one or more of the following patents USA 5 096 922 4375 921 4 305 661 4 373 804 4 875 776 5 114 230 5 164 579 5 362 970 5 510 625 5 670 787 5 684 292 5 691 545 5 734 172 4 667 231 4 576 482 4 394 683 5 811 827 Australia 616 731 Canada 1 307 051 1 116 750 New Zealand 228 128 Germany 30 16 361 31 23 703 Finland 94551 Printed in Canada December 1999 Version 1 1 TABLE OF CONTENTS WELCOME TO THE DES200000icoconoionanaiia Ee dee cea Pa eat detta ten ais 5
3. UNPACKING ii nto Lii Ree d AR EUER TER tate on bo Ea a E E EE cot d Cei s 5 SAFETY 5e iini entend o aa ta oie ate etatis 5 Seri ii A A da 5 OEM Safety Responsibilities tti de n ein ee Pa E ede eei n RO OE CE Pee ETE EE Eee duae 6 Laser Warning Sien Foradada dt a edid feines t re i d ies AST Ae eH o saci 6 Laser Emission Warning Indicators essent nein tnt naar anno nete tnter enne 6 Beam Attenuators PM SRS EKn 6 USING THE DES2000 1 2 IER aed laica 7 PIU bep E AAA A AA A AA AA A A 7 Standoft Range A A a Rattan eens 7 A a 8 Standoff distance Range distance Object s Maximum Distance sess 8 Object Distance gt Standoff Range gt Out of Range nennen ntn 8 How do laser triangulation sensors work best ceceecseessessesseseeseeecececsecsecsecsecsecsecsecsecsecsecsecsecseesecseeaeeaeeaes 8 Do I need a computer to use the DLS2000 aera eur aeea aE nne nne nne nne niens entree tnnt 8 GETTING STARTED tte e bi e ren ec ERR E RH da 9 Necessary Equipment 3 ecrire Ee RR aaa Ey ee e ers e Pete NT ete eee 9 MECHANICAL MOUNTING eee tete lee e Pese e eae e p Fem tete ener 10 FIBI 3 eie te eem on aen C UN RR D ER dro dp eR eO e soe eet tare ee ut E et bees 10 Mechanical Specifications este det o re SEE ee edet P pen ana awn e eee ires 10 Electrical Specifications Jd tiet A da 10 Laser Specifications iom dq Ree stet esa teu a eee series inte iet eee 1
4. indicating out of range Object Distance gt Standoff Range gt Out of Range How do laser triangulation sensors work best Laser triangulation sensors work best when the measurement surface is a diffuse reflector such as the surface of a piece of paper wood or non shiny metal and plastic The DLS2000 is a smart sensor incorporating an internal processor to handle calibration scaling and data conversion The DLS2000 provides analogue output 0 10 VDC current output 4 20mA and a digital serial output RS 485 57 6kBaud Do I need a computer to use the DLS2000 No the DLS2000 can be used without a computer control system using the voltage or current and or with a computer using RS 485 serial communication Without a computer The DLS2000 can be employed as an analogue sensor and does not require connection to an external computer Connect the cable to e a suitable power supply see Connections e a voltage measurement device or e a current measurement device With a computer The DLS2000 can be used in a computer based data acquisition or control system Commands requesting data are sent to the sensor and the sensor responds by providing range values Commands and data are exchanged with the DLS2000 using a simple serial protocol see Applications Programming To operate the sensor e Connect the cable see Multi Drop Configurations e Run the demonstration application DLS2000 EXE enclosed diskette This applic
5. the complete packet is not received in 500 ms The host application should abort the command and start looking for another STX character DynaVisiona APPLICATION PROGRAMMING INTERFACE Development of application programs for the DLS2000 is a simple task Requirements are e a suitable serial interface driver e a program that reads requests and receives character data byte stream using the Packet Format described in the previous paragraphs o By writing an application in the host computer you can e request data from the sensor e read and process data values returned from the sensor The Pseudo Code below describes a simple application program Pseudo Code MainLoop We ll talk to any attached sensor so we broadcast to sensor address 0 We want to read the sensor range which has a command value of 12 and length 1 WHILE NOT Finished SendSensorCmd 0 1 12 ReadSensorRange ENDWHILE 16 SendSensorCmd SensorAddress CmdLength CmdByte XmitBuffer 0 STX XmitBuffer 1 SensorAddress XmitBuffer 2 CmdLength XmitBuffer 3 CmdByte CRC STX SensorAddress CmdLength CmdByte 1 Write XmitBuffer COMPORT StartTimeOutTimer ReadSensorRange MsgReceivedFlag XmitBuffer 4 CRC FALSE WHILE NOT TimeOut AND MsgReceivedFlag lt gt TRUE IF ByteRcvd IF FirstByteFlag TRUE IF ByteIn STX FirtsByteFlag TRUE BufferPtr 0 FirstByteFlag FALSE RevBuffer BufferPtr ByteIn BufferPtr
6. view is not obstructed and that the window is clean 4 Connect an LED with a 3 3K ohm resistor in series across Pins 5 Out of Range and 12 5 Place a target within the sensor s range The LED should be lit 6 Block the path between the camera and the laser The LED should go out 7 Check the analogue output with a instrument capable of measuring DC voltage from 0 to 10 e g DVM VDC 8 Move the target back and forth Observe the analogue output It should change as the target is moved If the voltage changes it is likely that your serial port configuration and or cabling is incorrect If the voltage output does NOT change check your wiring again Behavior No data comes from sensor s analogue output What to do T t SON A Check cabling and ensure that power and signals are wired correctly Make sure you have an RS 232 to RS 485 converter Check to see that the laser is on The DLS2000 uses a visible red laser Do not look into the laser exit window Check to see that the camera s field of view is not obstructed and that the window is clean Connect an LED with a 3 3K ohm resistor in series across Pins 5 Out of Range and 12 Place a target within the sensor s range The LED should be lit Block the path between the camera and the laser The LED should go out Connect the serial port of the sensor to a host computer using an RS 232 to RS 485 converter 8 Move the target back and forth Observe the displaye
7. 0 Performance Specifications tio tede e oe ree P EP det oe EORR UTC eer RR Ee riae te een 11 Serial Communication Commands essent trennen e ettet trennen nennen 11 Environmental 5 1 eee eia duas im b b ete ERES 12 SENSOR ORIENTATION ia eds 12 APPLICATION PROGRAMMING 22 tritt tne tie etre er re o e tepore tener ined 13 General OVA 13 Communications Specificato S naenin ea E EERE EEE NE E AEA a Te 13 Interconnect Speciticati i c insnet eere iae E EE En eante aao ta RE e A EAE efe 13 M lti Drop Configurations Li go das hate hate 13 COMMUNICATIONS PROTOCOL iloa pe a a a e a A a a 13 General Packet Protocol E 14 NUMERIC FORMA TS perpe ee le ERU UU DEO 14 COMMUNICATIONS ERROR HANDLING eene ene nenntne tene tn ene tetnee tenete tene tne ne 15 What isa RI aet ipe ERDUC RI ERU EOBU PROBES 15 How do I process a received data packet oooooconicononicnonocconocnoncononcnncononnorco non non narco ron nnn nn ron rana rn nnne 15 What is the structure of a command packet 0 0 cc cecscsseseceecesceseeseeseeeceeceaeeseesecseseeceaecsecaececeeeeaeeaeaesaeeaeeaees 15 What if the sensor detects an error eeececescesseseeeceeseeseeseesecseceececeeceeseesecseceeceeceseesecseseeceaceseesenecsessesaesseeaeeaees 15 Re3Synchromzing Ai 15 Start of Transmission A eae e e Pe EH D ce Fee Lee E RR E dod 15 How do I make sure the host and sensor are synchronized seen 15 SeDSOE Scio nen yet e do
8. 16 What if transmission time exceeds 50 MS ceceeesseseeseseeseeseeeseeceseeseeeeseeseecesecseeeesecseeseeesaeeseesesecaeseereatets 16 NN 16 What if the complete packet is not received in 500 ms essent 16 DynaVisiona APPLICATION PROGRAMMING INTERFACE eere 16 Pseudo Code id 16 Main LOO ERE M 16 TROUBLESHOOTING itecto neret ec eic tenete tee ede e RR Un ee nie de a Hee gsi CH EE RE ce 18 GETFTING FURTHER HELP cuna 19 WELCOME TO THE DLS2000 The DLS2000 is a member of the DynaVisiona family of laser based ranging sensors These sensors employ a laser and the triangulation principle to make precise measurements of range as shown in Figure 1 UNPACKING Upon receipt unpack and visually inspect the sensor The sensor is a single metal enclosure with a connector on one side and with laser and sensor viewing windows on the opposite side Ensure there is no damage to the enclosure connector or view windows The enclosed diskette contains DLS2000 Demo Program DLS2000 EXE SAFETY Laser Safety DynaVisiona scanners employ one or more lasers that illuminate the measurement surface This requires that specific safety precautions be taken when servicing the optimizer system The DLS2000 is classed by the U S Food and Drug Administration FDA Code of Federal Regulations CFR 21 Part 1040 as Class Illa This classification is clearly marked on t
9. General Packet Protocol An asynchronous RS 485 serial communication link serves as the hardware interface between the host and the sensor s The software protocol describes the packet or group of information that is transmitted Generally this consists of e an address e acommand e optional data e aCRC Packet Description A packet consists of a string of bytes The same format is used to transmit from the host to the sensor and back What is a packet s maximum size The maximum size of any single packet is 259 bytes If the data block to be transmitted exceeds 259 bytes then the total data block must be transmitted with more than one packet For example if the total data consists of 700 bytes then this will take a total of 3 packets of data to be sent PACKET FORMAT STX Address CommandSize Command Data Data CRC STX 1 byte Start transmission character 02 hex Address 1 byte 0 broadcast to all sensors 1 255 addressing a specific sensor Note This byte identifies the sender when received by the host Command Size 1 byte Number of bytes from command to the last data byte Maximum 255 Command 1 byte 1 255 See command descriptions Data Data 1 byte Number of bytes is command dependent CRC 1 byte 2s Complement sum of all bytes inclusive of STX and last data byte PACKET EXAMPLE To request the current range value from the sensor the host computer program should send the following message pack
10. TATION Refer to the following diagram locating the light beam and viewing angles The light beam is projected perpendicular to the face of the sensor Incorrect Correct M F F Fe n DynaVision al cel i EMI 3E a ee e Ld Non reflective materials If the surface of the material being measured is non reflective e g wood non shiny metal the sensor should be mounted so the beam is projected perpendicular to the surface Semi reflective materials If the surface of the material being measured is semi reflective e g glossy painted surface the sensor should be rotated counter clockwise to reduce the direct reflection of the beam back to the sensor APPLICATION PROGRAMMING General Overview All communication between the host computer and the sensor is via an RS 485 serial interface All commands are initiated from the host computer to the sensor with the sensor responding to the commands Communications Specifications The DLS2000 is designed to use the RS 422 485 standard for its serial communication This is a differential driver receiver pair It is capable of transmitting up to 4000 feet The serial ports of most personal computers are based on the two wire RS 232 standard To use a personal computer as the host for a multi drop configuration you will need an RS 232 to RS 485 converter box The RS 485 option allows the sensor to be used in multi drop c
11. ation will display the range readings from the DLS2000 in real time see Getting Started GETTING STARTED Necessary Equipment You will need a DC power supply 15VDC 30VDC 250mA an instrument capable of measuring zero 0 10 volts DC and or 4 20mA a flat surface Windows 3 1 Windows 95 or Windows NT if you are using the sensor with a computer an RS 232 to RS 485 converter Caution Always have the DC power supply turned OFF when connecting or disconnecting the cable to the DLS2000 Operating your DLS2000 sensor is quite simple You can use it either as a stand alone device or interfaced to a personal computer through the serial communication port 1 Place the sensor onto a table or flat surface Be sure that the pathway between target and the laser window round hole and the camera elongated window is not obstructed 2 Connect the DLS2000 in one of the following ways a Stand alone device connect the enclosed cable to e a suitable power supply a voltage or current measurement device e g a DVM With the power supply OFF connect the cable to the DLS2000 If you are using the analogue output only turn on your voltage measurement device Go to step 3 OR b Interfaced to a computer connect the enclosed cable to e a suitable power supply a voltage or current measurement device e g a DVM optional the serial port of a computer With the power supply OFF connect the cable to the DLS2000 Start the DLS2000 EXE a
12. d range value on your computer It should change as the target is moved If the values change and there is still no analogue output the analogue signals are probably incorrectly wired Behaviour In a multi drop configuration one or more sensors do not respond and do not provide data to the serial interface What to do 1 Connect the offending sensor by itself see previous to see if it operates correctly in a non multi drop environment 2 Ifthe sensor behaves correctly in 1 the problem may be that the sensor is incorrectly addressed when used in the multi drop configuration a Be sure you are using an RS 232 to RS 485 converter b Check that the wiring of the multi drop configuration is correct See Multi Drop Configurations C Check that the sensor addresses you are sending are correct Use the program DLS2000 EXE to reset any invalid sensor addresses GETTING FURTHER HELP If you wish further help on the DLS2000 contact your distributor For more information on Safety and Laser classifications contact Center for Devices and Radiological Health FDA Office of Compliance HFZ 305 Attn Electronic Product Reports 2098 Gaither Road Rockville Maryland 20850 19
13. et 02 address 1 12 CRC STX Character Device Address Command Size Command read NUMERIC FORMATS The following describes the format of numbers contained within a packet Byte Always an unsigned 8 bit number 0 255 Words All words used in commands data streams are signed 16 bit numbers Two bytes sent with a range of 0 to 65535 the least significant byte is sent first Decimal points are assumed depending on data content Example If the data is 12345 would represent 1234 5 mm COMMUNICATIONS ERROR HANDLING This section describes the error handling of the serial communications The validity of the data in all packets transmitted to and from the sensor is checked using the last byte of the packet as a CRC What is a CRC The CRC is the 2 s complement of the sum of all bytes in the packet excluding the CRC byte itself Adding the sum of all the bytes to the CRC should result in a value of zero How do I process a received data packet When receiving a data packet from the sensor the host application should verify the validity of the CRC byte To do this add the sum of all bytes excluding the CRC to the CRC in the received message Additionally the application should ensure that the command value returned matches the one sent in the request packet sent to the sensor A non zero result indicates an error What is the structure of a command packet Each command packet has the same structure as a data packet see Packet Exa
14. he DLS2000 Caution Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure WARNING The DLS2000 is a Class IIIa type laser device Regardless of the power rating or whether or not the laser is visible the laser should not be viewed directly or through a mirror as it may result in severe damage to the eyes Laser Sensor D Laser WARNING DO NOT look directly into the laser beam OEM Safety Responsibilities Laser Measurement International has filed a report with the US Food and Drug Administration FDA to assist OEM s in achieving certification of their own applications by referencing the report accession number The following paragraphs outline areas that are not covered by Laser Measurement International submission and need to be specifically addressed by the OEM Laser Warning Sign Format Laser warning signs must be located in the vicinity of the sensors such that they will be readily observed Refer to the following diagram for an example of the laser warning sign Different warning signs are required for different laser classifications These are specified in the CFR Title 21 Section 1040 An example is shown below for a Class IIIa sensor VISIBLE LASER RADIATION AVOID DIRECT EXPOSURE TO BEAM PEAK POWER lt 5 mW WAVELENGTH 600 710 nM CLASS llla LASER PRODUCT Laser Emission Warning Indicator
15. ject A Detected her Object B Detected here A ION DLS2000 CCD Array LASER C bu Lens Laser Beam As the distance from the sensor to the object changes the light from the object is Object at Position A detected at a different pixel on the CCD array il Object at Position B Figure 1 Standoff Range The distance from the reference face of the sensor to the sensor s first measurement is the Standoff The sensor cannot make any measurements before the Standoff If a target is placed within this area the analog output would read zero voltage output 4mA current output and the digital output will return a 32768 indicates out of range The distance from the sensor s standoff to the sensor s maximum measurement point for which it has been calibrated is the Range In between these two points the sensor will return a valid reading indicating how far the measurement surface is away from the standoff What is the maximum distance an object can be placed from the sensor s reference point The Standoff distance plus the Range distance is the maximum distance an object can be placed away from the face of the sensor Standoff 00mm l Range 300mm Figure 2 Standoff distance Range distance Object s Maximum Distance If the object distance from the face of the sensor is greater than the Object s Maximum Distance the sensors analog output will read zero volts and the digital output will return a 32768
16. l Specifications Dimensions 184 4mm x 98 6mm x 38 4mm Electrical Specifications Power Supply Voltage 15 VDC 30 VDC 250mA Analog Output 0 VDC 10 VDC 4mA 20mA Maximum Analog Output Load 550 V using current output 2000V using voltage output Laser Specifications Visible Laser RED Wave Length 670 nm Laser Power lt 5 mw Performance Specifications Standoff 100mm Range 300mm Accuracy Resolution Digital 0 025mm 0 001 Resolution Analog 0 075mm 0 003 Scan Rate 1800Hz Serial Communication Commands For complete packet protocol see Applications Programming section Read Current Position Purpose Returns the current reading in millimeters Command Format command Read command 12 single byte binary Response Format response position response 1 byte 12 position 1 word lt sensor range gt Example Send 12 Response 12 Data Value Pin out for the DLS2000 Pin Signal 1 Rx 2 Rx Xi mx 4 TX 5 Out RNG 6 10VDC 7 Common X 8 Common 9 4 20 10 Sync Front View of connector 11 GND 12 Power X Indicates a twisted pair Optional Supplied Cable Pin Out Environmental See pin out wire color supplied with the cable Environmental Ambient Temperature Operating MIN 08C 328 F MAX 508C 122 8 F Storage MIN 308 C 22 8 F MAX 708C 158 8 F Relative Humidity 95 Maximum Non Condensing at 40 8 C 104 8 F Housing Gasket aluminum enclosure SENSOR ORIEN
17. mple This means you must terminate each command packet with a CRC What if the sensor detects an error If the sensor detects an error in the transmission it will ignore the command and not respond If there is no response from the sensor within 20 ms then the host application should assume an error occurred and retransmit the original command Re Synchronizing Timing This section describes the method of synchronizing the serial transmission between the host and the sensor Start of Transmission STX Transmission of packets is initiated by the STX Start of Transmission character How do I make sure the host and sensor are synchronized Allow a period of 20 ms to pass without a response from the sensor BEFORE initiating a retransmission of the request to ensure synchronization 15 Sensor Upon receipt of an STX character the sensor will allow a maximum of 50 ms for the complete command packet to be transmitted by the host What if transmission time exceeds 50 ms The sensor will abort receiving the packet and start looking for another STX character To guarantee resynchronization of all sensors on a serial line the host application should stop all transmission for 200ms After this time all sensors on the serial line will be waiting to receive an STX character Host Upon receipt of an STX character the host should allow a maximum of 500 ms for the complete response packet to be transmitted from the sensor What if
18. onfigurations This means that up to 32 units can be connected to the same serial line Each device must have a different address so that you are able to distinguish which unit you are talking to A standard utility is supplied to allow you to set the address of each DLS2000 unit Interconnect Specification Transmit and Receive lines are connected to the serial I O port of a host computer This serial I O port must be configured as follows Asynchronous 57600 baud 8 Data Bits One Stop Bit No Parity Multi Drop Configurations DLS2000 sensors can be wired in a multi drop configuration The serial communication must be wired as full duplex meaning four wires are required to complete the hardware connection as follows INSERT DIAGRAM MULTI DOC Tx of all the DLS2000 sensors are connected to the Rx Tx of all the DLS2000 sensors are connected to the Rx Rx of all the DLS2000 sensors are connected to the Tx Rx of all the DLS2000 sensors are connected to the Tx A 120V termination resistor must be connected across the Tx and Tx and the Rx and Rx at the end farthest away from the host computer A utility is supplied DLS2000 EXE from which you can set the address of each DLS2000 Remember that this program only works in Microsoft Windows environments COMMUNICATIONS PROTOCOL 13 This section describes the contents of the packet used to transmit commands and data between a host computer and a DLS2000 sensor
19. pplication on the computer Set the software to use the correct serial port settings This is located under the connections tab Go to step 3 The DLS2000 can be connected to both a computer and a voltage current measuring device at the same time NOTE Do not look directly into the laser output window nor point it in the direction of another person see Safety 3 Position a suitable target e g a cardboard box or wood block within the measurement Range of the DLS2000 see Figure 2 4 Turn on the power supply to the DLS2000 The DLS2000 does not have a power switch so turning on The power supply will activate the DLS2000 You should now see a red laser spot on the target and a display of the range readings on the computer screen and or a voltage current reading on the voltage current measurement device MECHANICAL MOUNTING The sensor enclosure contains a mounting plate with three pre drilled mounting holes see Figure 3 The accuracy of the sensor is dependent on a secure mechanical mounting Figure 3 Calibration of the DLS2000 is relative to the reference face of the sensor The minimum distance the target can be from the reference face of the sensor is the standoff distance see Figure 2 Any movement or vibration of the sensor relative to the object being measured will result in measurement errors The surface the sensor is mounted to must be flat within 0 030 0 76mm between the three mounting points Mechanica
20. s As specified by the US Food and Drug Administration Department of Health and Human Services Code of Federal Regulations 21 Section 1040 CFR 21 1040 the controls which operate the single point sensors must incorporate a visible or audible signal when the lasers of the sensors are active Typically this consists of a warning lamp which is illuminated when power is supplied to the sensor Additionally CFR 21 1040 standards require that the indicator be clearly visible through protective eyewear designed specifically for the wavelengths of the emitted laser radiation Beam Attenuators CFR 21 1040 standards also specify that a permanently attached method of preventing human access to the laser radiation other than switches power connectors or key control must be employed None of the items mentioned above are supplied with the DLS2000 and are the responsibility of the OEM to supply when incorporating the DLS2000 into their system or product USING THE DLS2000 The DLS2000 can be used in a wide variety of measurement applications including Object profiling Thickness measurement Parts inspection Object alignment Range measurement On line quality control The DLS2000 is a smart sensor incorporating an internal processor to handle calibration scaling and data conversion The DLS2000 provides analogue output 0 10 VDC current output 4 20mA and a digital serial output RS 485 57 6kBaud Triangulation Principle Ob
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