Carlson FiX1 User manual

FiX1 manual - H-9944-8070-1-B March 2021
FiX1
automated stockpile monitoring system
installation manual

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Contents
1Customer information.............................................................................................................................................................................5
1.1 Dear customer .............................................................................................................................................................................5
2FiX1 system overview ............................................................................................................................................................................6
2.1 System introduction .....................................................................................................................................................................6
2.2 Operation .....................................................................................................................................................................................6
2.3 Single and multiple unit installations...........................................................................................................................................12
3FiX1 components .................................................................................................................................................................................14
3.1 FiX1 unit ....................................................................................................................................................................................14
3.2 Mounting plate ...........................................................................................................................................................................19
3.3 Ethernet cable............................................................................................................................................................................20
3.4 Power cable...............................................................................................................................................................................20
3.5 USB and serial cable .................................................................................................................................................................20
3.6 Wi-Fi and cell antennae .............................................................................................................................................................21
3.7 Transit case ...............................................................................................................................................................................22
4Hardware checks and preventative maintenance .................................................................................................................................23
4.1 In use.........................................................................................................................................................................................23
4.2 FiX1 unit ....................................................................................................................................................................................23
5Locating and installing the FiX1 unit.....................................................................................................................................................24
5.1 Safety ........................................................................................................................................................................................24
5.2 Determining the best location on-site .........................................................................................................................................24
5.3 Installing the mounting plate.......................................................................................................................................................28
5.4 Surveying in the mounting plate .................................................................................................................................................29
5.5 Attaching the FiX1 to the mounting plate....................................................................................................................................30
5.6 Mounting the cell phone and Wi-Fi antennae .............................................................................................................................31
5.7 Power connection ......................................................................................................................................................................32
6Networking the FiX1.............................................................................................................................................................................33
6.1 Data connections - introduction..................................................................................................................................................33
6.2 First connection to the FiX1........................................................................................................................................................34
6.3 Recovery mode..........................................................................................................................................................................34
6.4 Connection options ....................................................................................................................................................................36
6.5 Hub-and-spoke installations .......................................................................................................................................................45
6.6 Remote support .........................................................................................................................................................................46
7Volume computations ..........................................................................................................................................................................47

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7.1 Base surface..............................................................................................................................................................................47
7.2 Scan coverage...........................................................................................................................................................................47
7.3 Processing.................................................................................................................................................................................47
7.4 Areas of Measurement...............................................................................................................................................................48
7.5 Hub-and-spoke installations .......................................................................................................................................................48
7.6 Verification.................................................................................................................................................................................48
8FiX1 web application – introduction......................................................................................................................................................50
8.1 Remote updates and support .....................................................................................................................................................50
8.2 User access...............................................................................................................................................................................50
8.3 Web application UI.....................................................................................................................................................................51
9FiX1 Web application – Scans .............................................................................................................................................................53
9.1 Scanning....................................................................................................................................................................................53
9.2 Scan list.....................................................................................................................................................................................54
9.3 Scan graph ................................................................................................................................................................................57
10 FiX1 web application – Schedule .........................................................................................................................................................59
11 FiX1 web application – Settings ...........................................................................................................................................................61
11.1 Units ..........................................................................................................................................................................................61
11.2 Information.................................................................................................................................................................................62
11.3 Scanner .....................................................................................................................................................................................64
11.4 Reporting ...................................................................................................................................................................................67
11.5 Geo-referencing.........................................................................................................................................................................69
11.6 Surfacing ...................................................................................................................................................................................71
11.7 Network setup options................................................................................................................................................................74
11.8 Management system..................................................................................................................................................................79
11.9 Hub-spoke .................................................................................................................................................................................79
11.10 Calibration .................................................................................................................................................................................80
12 FiX1 web application – Language ........................................................................................................................................................82
13 Online 3D viewer .................................................................................................................................................................................83
14 System specifications ..........................................................................................................................................................................84
15 Product information..............................................................................................................................................................................86

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1 Customer information
1.1 Dear customer
The FiX1 laser scanning system is designed to offer end users ‘hands off’ operation and to deliver automated,
accurate volumetric results without any intervention required. The safe and reliable running of the FiX1, as well as
the quality of the results, are fully dependent on the correct installation and mobilization of the system on the
customer’s site.
This manual is for personnel involved in the installation, running and maintenance of a FiX1 system. It covers all
hardware components, installation, care, troubleshooting and day-to-day usage of a FiX1 system.
It is important that you read this manual carefully before beginning to work with a FiX1 system. Thereafter, always
keep the manual available for reference.
A separate FiX1 users’ manual is available for end users of the FiX1. The users’ manual is only concerned with
minor configuration of the system through its web-interface during normal day-to-day use.
This manual has been compiled with care. However, should you discover any errors, we would be grateful if you
could contact Carlson directly.
For any feedback or comments, or if there are questions about the FiX1 system which are beyond the scope of this
manual, contact Carlson.
Alternatively, for information on your local Carlson-approved service centre, visit our website: www.carlsonsw.com.
The information in this document is subject to change without notice.

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2 FiX1 system overview
2.1 System introduction
Computing stockpile volumes is an essential job within many industries such as quarrying, mining, agriculture, or
highway maintenance. Whether the aim of the exercise is related to optimising logistics, satisfying accounting
requirements or assisting operational planning, the required deliverables are the same: accurate, repeatable,
scheduled volumes of stockpiled material.
Commonly a team of surveyors may be employed to carry out a survey of stockpiles using GNSS systems or
traditional survey equipment. More recently drones are used to carry out surveys from the air. Sometimes rough
guesses are relied on, with volumes being arrived at via experience, visual inspections or with reference to indirect
data such as vehicle movements to and from the stockpile.
The FiX1 has been introduced to provide a fully automated stockpile measurement system which negates the need
to involve survey teams, estimates, drone operations or inaccurate, indirect calculations.
After trained staff have carried out the initial FiX1 system mobilisation, accurate volumes can be produced with no
intervention from any personnel.
The provision of accurate volumes via the FiX1’s automated scanning and processing routines helps to increase
on-site safety and operational efficiency. It ensures the absolute minimum involvement of on-site personnel. This is
invaluable in industries where sites can be dangerous or inaccessible, or where time-consuming permits and
authorisations are required for on-site access.
2.2 Operation
This section gives an initial overview of the setup and operation of the FiX1. Each stage is dealt with in greater
depth later in this manual.

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2.2.1 Installation
During the initial installation of the FiX1 by trained staff, the unit is secured in position above the stockpiles to be
scanned. The FiX1’s position should give the clearest possible view of the area of interest.
Once installed, the FiX1 is surveyed in place on the site’s local coordinate system. This ensures that all data
collected by the FiX1 is correctly georeferenced.
A base surface, geo-referenced on the same coordinate system as the FiX1 and representing the floor level beneath
the stockpile, is uploaded into the FiX1. This acts as a reference for all volumetric calculations.
Figure 1 Fix1 installation surveyed into the local coordinate system
Figure 2 The base surface file defines the floor level on the local coordinate system

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2.2.2 Data connections
You may setup a data connection to the FiX1 in a variety of ways. The recommended configuration is to connect
the unit to the local area network by Ethernet cable so the FiX1 can be accessed conveniently from any device on
the network.
The FiX1 can also be connected wirelessly to the local area network using the Wi-Fi client mode.
Local
area
network
Figure 3 Wired Ethernet connection
Local
area
network
Figure 4 Wi-Fi client mode

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The FiX1 can be set as a Wi-Fi access point, allowing direct connection from another Wi-Fi enabled device or
from another FiX1.
Alternatively, a SIM card in the FiX1 allows connection by mobile phone. This sets up a connection completely
independent of the site network.
Once there is a successful connection to the FiX1, you can access the web application which is run from the
processor onboard the FiX1. This is also where all computations are run, and all data is stored. No additional
software is required on your laptop or mobile device.
Cell phone
network
Direct
connection to
FiX1 Wi-Fi
access point
Figure 5 Wi-Fi access point mode
Figure 6 Connection using the cell phone network

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2.2.3 Scanning and results
Once fully mobilised, the FiX1 runs a laser scan across the area of interest. This can take place at scheduled times,
or on demand. When carrying out a scan, the body of the FiX1 rotates horizontally at a relatively slow speed, while
at the same time the laser head rotates vertically at a higher speed. The laser itself is firing constantly at a pre-
determined rate.
The result of this scanning action is a pattern of radial scan lines which form a dense point cloud covering the area
of interest beneath the FiX1.
Figure 7 FiX1 Scan action
Figure 8 FiX1 running radial scan lines over the targeted area

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After each scan, automated intelligence onboard the FiX1 processes the raw point cloud to filter the data, eliminate
spurious points and form a gridded 3D surface model. This model is compared to the uploaded base surface and
the volume between the two surfaces is computed.
The volume is reported on the FiX1’s web application and is visible, along with historical data, to anyone logging on
to the system.
Reports of all volumes are available to download, if required.
Figure 9 Gridded surface created from the raw point cloud
Figure 10 FiX1 web application (left) and volume report (right)

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If necessary, the scan data can also be viewed online in the integrated 3D viewer.
For troubleshooting or record keeping, raw point cloud data can also be downloaded for further analysis in third
party software. This is not required for normal day-to-day operations.
If network access to the FiX1 is available, Carlson offers remote support and system upgrades.
2.3 Single and multiple unit installations
Many sites will have stockpiles located in a relatively restricted area which can be adequately covered by a scan
from a single, strategically positioned FiX1. However, other sites may have stockpiles spread out over larger areas.
In this case some parts of the stockpiles may be obscured from the line-of-sight of a single FiX1 unit, or some parts
of the site may be beyond its maximum range.
In such situations, multiple FiX1 units are required. This is a hub-and-spoke installation: an integrated network of
strategically positioned units can ensure full, uninterrupted coverage of the area of interest.
When multiple FiX1 units are first installed on a single site, they must all be surveyed in place relative to each other.
One unit in the network is designated the ‘hub’ and all others are the ‘spokes’. All units must be connected to the
local area network. If required, they may use different methods to connect to the network.
The user communicates only with the hub. When a scan is requested, the hub instructs all the spokes to conduct a
simultaneous scan. On completion of the scan, the spokes send their gridded data back to the hub. At the hub, a
single volume is computed and reported back to the web application.
The correct installation and geo-location of the FiX1 units in a hub-and-spoke installation is essential. Thereafter,
just as with a single unit setup, the system is automated and requires no user intervention.
Figure 11 3D point viewer embedded in the FiX1 web application

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LOCAL AREA NETWORK
HUB SPOKE
SPOKE
Figure 12 Three FiX1 units in a hub-and-spoke installation

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3 FiX1 components
The hardware components of a FiX1 system are described below.
3.1 FiX1 unit
The FiX1 consists of a laser head which pivots vertically on the body of the unit which in turn pivots horizontally on
the FiX1 base.
The FiX1 base houses all connectors and processing capacity.
The base plate allows attachment of the FiX1 to the mounting plate which is attached to the site superstructure.
Mounting
plate
FiX1
baseplate
LED strip
Ethernet
connector
Power
connector
Laser head
shield
Vertical
pivot
Horizontal
pivot
Laser head
FiX1 base
FiX1 body
Serial
number
sticker
Figure 13 FiX1 unit

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3.1.1 Laser head
The laser head is where the FiX1’s laser is housed. The laser head spins vertically on the vertical pivot, by which it
is attached to the FiX1 body.
The measuring laser is an infra-red ‘time of flight’ device.
Laser pulses are fired through the transmitting optics. The laser pulses hit the targeted surface where they are
scattered. A tiny fraction of the scattered pulse reflects back into the FiX1’s receiving optics. The measured range
is derived from the time taken for the pulse to return to the laser, multiplied by the speed of light.
The laser measures between 5,000 and 15,000 points per second. The maximum distance that the laser can
measure is 250 m. Typically, ranges are measured to an accuracy of 1 cm.
The laser head rotates vertically on the vertical pivot which joins the laser head and the FiX1 body. Avoid placing
strain on the vertical pivot when handling the unit.
The laser head is surrounded by a sun shield which protects the body of the laser from direct sunlight.
3.1.2 FiX1 body
The FiX1 body rotates on the horizontal pivot which joins the FiX1 body and base.
The FiX1 body is connected to the laser head by the vertical pivot.
Vertical
pivot
Sun shield
Transmitting
optics
Receiving
optics
Figure 14 FiX1 laser head

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3.1.3 FiX1 base
The blue metal base of the FiX1 incorporates all connectors.
The main power connector accepts the supplied power cable. The power must originate from a stable 90-240 V ac
mains supply.
Above the power connector is the fuse cover. Unscrew the fuse cover to access the cartridge fuse. The rating of
the fuse is T3.15AH250V.
On the adjacent side of the FiX1 base are arranged:
•The serial connector: available for external accessories to connect with the FiX1.
•The USB connector: available for external accessories to connect with the FiX1.
•The Ethernet connector: allows a wired network connection using a standard Ethernet cable with an RJ45
connector.
On the side of the base opposite the power connector are arranged:
•Wi-Fi antenna connection: an SMA coaxial RF connector to fit the supplied Wi-Fi antenna.
•Cell antenna connection: an SMA coaxial RF connector to fit the supplied cell antenna.
•A protective cover for the SD card / SIM card port: this can be unscrewed for access, if required.
All connectors on the FiX1 base are environmentally protected to a rating of IP67.
The serial number sticker is also located on the FiX1 base, next to the fuse cover. Quote the serial number during
any contact you have with Carlson concerning your FiX1 unit.
Figure 15 FiX1 base connections - i
Fuse cover
Power connector
with cable
attached
Ethernet
connector with
cable attached
USB connector
Serial connector
Serial number
sticker
FiX1 base

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3.1.4 SD card
A 64GB Micro SD card is supplied installed into every FiX1 unit. There should be no reason to remove or change
the card. However, in case this is required, the card must be formatted to Linux's ext4 file system.
3.1.5 SIM card
For use on a cellular network, a SIM card is required. Supplying a SIM card appropriate for your region is the
responsibility of the end user. See section 5.8.6.
SD / sim
card cover
Wi-Fi and Cell
antenna
connections
SD / SIM card
cover -
unscrewed
SD card
SIM card
Figure 17 SD / SIM card cover unscrewed
Figure 16 FiX1 base connections - ii

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3.1.6 LED strip
Above the FiX1 baseplate is the LED strip. During operations the LED strip displays different colour combinations
depending on the current state of the FiX1.
3.1.7 FiX1 baseplate
The FiX1 baseplate is at the base of the FiX1 Unit. The baseplate attaches to the separate mounting plate which,
in turn, is directly attached to the building superstructure.
FiX1 state
LED display
Booting up Green solid
Powered on, idle Green – blinking
Initialising before a scan Blue – solid
Scanning Blue – chasing around base
Processing after a scan Blue – blinking
Error Red - solid
Holes to
secure unit to
mounting plate
FiX1
baseplate
Guide holes for
guide pins on
mounting plate
Figure 19 FiX1 baseplate
FiX1
baseplate
LED strip
FiX1 mounting
plate
Figure 18 FiX1 LED strip

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3.2 Mounting plate
The mounting plate is designed to be permanently or semi-permanently fixed to the site superstructure. The FiX1
can then be easily attached once the mounting plate is in place. The FiX1 can also be easily detached from the
mounting plate, if required for site operations or for servicing.
The centre of the mounting plate is marked with an etched cross. To ensure that all FiX1 data is correctly
georeferenced, use traditional survey techniques to survey in the FiX1 reference point on the local site coordinate
system.
The long axis of the etched cross provides a reference line to indicate the heading of the FiX1. Use traditional survey
techniques to survey in the FiX1 reference line on the local site coordinate system.
Twelve holes – for size M8 bolts – are positioned in a circle, at 30° intervals. These provide options for attaching
the mounting plate to the site superstructure.
Four threaded holes – also size M8 – are positioned with two at either end of the mounting plate. These line up with
holes in the FiX1 baseplate and are used to directly attach the FiX1 unit to the mounting plate.
Two guide pins ensure that the FiX1 can be held in place while the unit is screwed onto the mounting plate.
See section 5 for details on installing the mounting plate, surveying the system into a site coordinate system, and
attaching the FiX1 unit to the mounting plate.
Threaded holes for
attachment to FiX1
base plate
Guide pins to
insert into guide
holes on baseplate
Reference line for
heading control
Holes to attach the
mounting plate to
site infrastructure
Survey reference
point
Figure 20 FiX1 mounting plate

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3.3 Ethernet cable
The Ethernet cable supplied is a standard Cat-5e cable with RJ45 connectors.
The Ethernet cable is 2 m long and can be used for testing the system before it is mounted. When the FiX1 is in
position on-site, you will usually require a much longer Ethernet cable. The length will depend on where the FiX1 is
mounted in relation to the nearest network connection point.
See section 5.8 for information on data connections.
3.4 Power cable
A 2 m power cable is supplied with a mains power plug.
Variants of the power cable are available for different mains plugs found in different regions of the world.
Extension cables will probably be required onsite to reach to your 110 or 240 V dc mains power supply.
See section 5.7 for information on connection power to the FiX1.
3.5 USB and serial cable
USB and serial ports are incorporated into the FiX1 to allow accessories to be added to the system.
These ports are not currently active, so no cables are supplied to connect to these ports.
Carlson continues to update and expand the functionality of the FiX1 and will soon be activating these ports to
increase the unit’s capabilities.
Please contact Carlson for further information.
Figure 21 FiX1 power cable (Europe version)