Riftek RF096-440 Series User manual

Certified according to ISO 9001:2015
FINE COAL BURNER INNER
SURFACE INSPECTION MACHINE
22, Logoisky tract, Minsk
220090, Republic of Belarus
tel/fax: [phone]
[email protected]
User's manual
www.riftek.com
RF096-440/1440-2000 Series

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Fine Coal Burner Inner Surface Inspection Machine
RF096-440/1440-2000 [Revision 1.0.0] 11.11.2022
Contents
.............................................................................................................................................31. Safety precautions
.............................................................................................................................................32. CE сompliance
.............................................................................................................................................33. Laser safety
.............................................................................................................................................34. General information
.............................................................................................................................................35. Basic technical data
.............................................................................................................................................46. Main functions of the software
.............................................................................................................................................47. Structure and operating principle
........................................................................................................................................... 5
7.1. Laser scanning module
........................................................................................................................................... 6
7.2. Installation frame
........................................................................................................................................... 7
7.3. Guide and centralizer
........................................................................................................................................... 7
7.4. Tablet
.............................................................................................................................................88. Complete set to be supplied
.............................................................................................................................................99. Example of item designation when ordering
.............................................................................................................................................910. Preparation for use
.............................................................................................................................................1011. Service program
........................................................................................................................................... 10
11.1. System requirements
........................................................................................................................................... 10
11.2. Desktop PC setup
........................................................................................................................................... 14
11.3. Tablet setup
........................................................................................................................................... 15
11.4. Starting the service program
........................................................................................................................................... 15
11.5. Main window
........................................................................................................................................... 16
11.6. Selecting the user interface language
........................................................................................................................................... 17
11.7. Connecting and disconnecting the machine
........................................................................................................................................... 17
11.8. Manual control of the motion system
........................................................................................................................................... 17
11.9. Machine calibration
.............................................................................................................................................1712. Scanning an object
.............................................................................................................................................1813. Viewing the data
.............................................................................................................................................2014. Saving, reading and exporting data
.............................................................................................................................................2015. Using the reference model
........................................................................................................................................... 20
15.1. Saving the current scan as a zero model
........................................................................................................................................... 20
15.2. Loading a zero model
........................................................................................................................................... 21
15.3. Aligning the zero model and the scanned model. Manual mode
........................................................................................................................................... 22
15.4. Aligning the null model and the scanned model. Semi-automatic mode
........................................................................................................................................... 23
15.5. Viewing the difference between the zero model and the scanned model
.............................................................................................................................................2416. Technical support
.............................................................................................................................................2417. Warranty policy
.............................................................................................................................................2418. Revisions
.............................................................................................................................................2419. Distributors

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1. Safety precautions
· Do not use the machine in locations close to powerful light sources.
2. CE сompliance
The machine has been developed for use in industry and meets the
requirements of the following Directives:
· EU directive 2014/30/EU. Electromagnetic compatibility (EMC).
· EU directive 2011/65/EU, “RoHS“ category 9.
3. Laser safety
The machine makes use of a c.w. 660 nm wavelength semiconductor laser.
Maximum output power is 1 mW. The machine belongs to the 2 laser safety class
according to IEC/EN 60825-1:2014. The following warning label is placed on the
housing:
The following safety measures should be taken while operating the machine:
· Do not target laser beam to humans.
· Do not disassemble the laser sensor.
· Avoid staring into the laser beam.
4. General information
The machine is designed to measure the geometric parameters of the inner
surface of the fine coal burner.
5. Basic technical data
Parameter
Value
Inner diameter measurement range, mm
440...1440
Inner diameter measurement error, mm
±0.5
Scan resolution, points/turnover
2008
Scanning depth range, mm
0...2000
(programmable parameter)
Minimum distance between measured sections, mm
1
(programmable parameter)
Linear displacement error, mm
±0.1
Maximum sampling frequency, Hz
9400
Light source
red semiconductor laser,
660 nm wavelength
Output power, mW
<1
Laser safety class
2 (IEC60825-1)
Interface
WiFi
Power supply, V
Batteries 12V
Weight, kg
77

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6. Main functions of the software
The software is intended for:
· parameterization of the system and control of the scanning process,
· system calibration,
· formation of a 3D model of an object based on the data obtained during
scanning,
· viewing a 3D model,
· comparison of models obtained at different points in time,
· comparison of the obtained model with the reference,
· calculation of shape deviation values (surface wear) of selected models,
· calculation of the circle parameters in any cross section of the object, namely
the diameter (average, maximum, minimum), ovality, roundness,
· saving, reading and exporting data.
7. Structure and operating principle
The operation of the machine is based on the principle of scanning the inner
surface of the product by a rotating triangulation laser sensor.
The main components of the machine are shown in the figure, where 1 -
installation frame, 2 - guide, 3 - centralizer, 4 - laser scanning module, 5 - burner
surface; the tablet is not shown.
The frame (1) is attached to the end of the burner (5). The guide (2) is located
along the axis of the burner and rests on the frame (1) on one side and on the
centralizer (3) on the other. The centralizer is installed on the conical surface of the
burner. The laser scanning module (4) is installed on the guide (2).
The machine operates as follows.
On command from the tablet, the laser sensor starts to rotate and the scanning
module (4) moves along the guide (2). The laser sensor measures the distance to the
burner surface. The polar coordinates of the burner surface points (distance to the
surface measured by the laser sensor and the sensor rotation angle measured by the
built-in encoder), synchronized with the linear position of the module, are transmitted to
the computer. The program builds a 3D model of the inner surface, according to which
the required geometric parameters and the wear are calculated. Video demonstration:
https://www.youtube.com/watch?v=O87vvxaJuMY

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7.1. Laser scanning module
The main components of the laser scanning module and its overall dimensions
are shown in the figures below.
Designations:
1 - Sleeve.
2, 3 - Wheel systems mounted on the sleeve (1). One of the wheels is equipped
with an encoder (not shown) to control the linear position of the module.
4 - Linear motion module.
5 - Rotation module.
6 - Laser sensor (installed on the rotation module).
7, 8 - Batteries of modules 4 and 5, respectively.
9, 10 - Battery charge indicators.
11, 12 - Battery indicator control buttons.
13, 14 - Power buttons.
15, 16 - Wi-Fi antennas.
17, 18 - End sensors.
19, 20 - Carrying handles.

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7.2. Installation frame
The main components of the installation frame are shown in the figure below.

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Designations:
1 - Folding legs.
2 - Screws for fastening to the end of the burner.
3 - Screw for adjusting the upper part of the split prism for installing the guide.
4 - Four screws for fixing the scanning module.
5, 6 - Calibration blocks.
7 - Removable slipway.
8 - Slipway fixing screw.
7.3. Guide and centralizer
The guide is assembled from three elements. The centralizer is installed at the
end of the guide. The assembly principle is illustrated in the figure:
7.4. Tablet
Parameter
Value
Architecture
CPU
Intel cherry trail Z8350 1.44Ghz-1.92GHz
OS
Windows 10 pro
RAM/ROM
4GB+64GB
Display
Size
10,1"
Resolution
1920x1200
Touch panel type
Capacitive
Interfaces
Type-A
USB2.0 x1
Type-A
USB.0 x1
MicroUSB
x1
RJ45 Ethernet
10/100/1000M x1
DB9 RS232
9-pin serial port x1
DC power interface
DC 12V 2A x1
Environmental
resistance
Enclosure rating
Waterproof IP65 but in fact is IP67 design.
Drop 1.2m, 6 sides
Certification standards
Military 810G. EU CE, US FCC

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Parameter
Value
Operating temperature
-20°С...60°С
Built-in battery
Battery type
Built-in removable Li-ion polymer battery
Rated capacity
10500 mAh
Dimensions
See the figure below
8. Complete set to be supplied
Name
Quantity
Laser scanning module
1
Industrial tablet with built-in Wi-Fi modules
1
Charger for industrial tablet
1
Installation frame
1
Screw for adjusting the upper part of the split prism for installing the guide
1
Screw for fixing the scanning module
4
Removable slipway
1
Slipway fixing screw
1
Front element of the guide
1
Middle element of the guide
1
Rear element of the guide
1
Centralizer
1
Centralizer fastening nut
1
Batteries Bosh GBA 12V 3.0 Ah
4
Charger Bosh GBA 12V 3.0A
1
Converter Dayton THG-150S
1
Protective case 670x508x355
1
Protective case 1189x405x160
1
Wooden box 825x725x200
1
Wooden box 1300x500x220
1

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Name
Quantity
Open-end wrench 19 mm
1
Open-end wrench 13 mm
1
Hex key 4 mm
1
Hex key 5 mm
1
User's manual
1
Wi-Fi-USB adapter (option for PC)
2 (option)
The software contains the following packages:
RF096740_Desktop_Win64_v1_11_2022_11_03*
Service program for desktop PC. A full-featured
version designed to control the system, view and
process data. NOTE: control from a PC is only
possible with Wi-Fi-USB adapters.
RF096740_Tablet_Win64_v1_11_2022_11_03*
Service program for the tablet. An adapted version
designed to control the system, collect and view
measured data.
CDM v2.12.36.4 WHQL Certified
FTDI driver for virtual COM port.
* When updating the software, the version number and date are different from
those above.
9. Example of item designation when ordering
RF096.Burner-IDmin/IDmax-L
Symbol
Description
IDmin/IDmax
Measurement range (inner diameter), mm
L
Scanning depth, mm.
NOTE: The measurement error should be discussed with the manufacturer.
10. Preparation for use
Preparing the machine for operation consists in assembling its components and
placing it in the burner for scanning. Assembly procedure:
1. Fix the installation frame to the end of the burner using 4 screws.
2. Fasten the slipway to the installation frame.
3. Place the scanning module on the slipway.
4. Fix the scanning module to the frame with 4 screws.
5. Remove the slipway.
6. Slide the first element of the guide through the support prism of the
installation frame and the sleeve of the scanning module.
7. Fix the centralizer at the end of the first element.
8. Attach the second element of the guide and slide the guide deep into the
burner body.
9. Attach the third element and slide the guide until the centralizer is in the
conical surface.
10. Fix the guide in the prism by lowering the top of the prism and tightening it
with the screw.
11. Release the scanning module by unscrewing the four screws securing it to
the installation frame.
12. Turn on the rotation module and the linear motion module.
13. Check the battery charge level. Install freshly charged batteries if necessary.
The machine is ready for operation.

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11. Service program
11.1. System requirements
Operating system
Windows 10 and later
RAM
at least 8 GB
Display resolution
at least 1280x1024
OpenGL
version 4.0 and later
USB
two free USB 2.0 slots
11.2. Desktop PC setup
1. Install the service program. To do this, unzip the following archive:
RF096740_Desktop_Win64_v1_11_2022_11_03.zip.
2. Configure virtual COM ports for Wi-Fi adapters (if any). To do this, insert the
adapters one by one into free USB ports and follow these steps:
a. Unzip the CDM v2.12.36.4 WHQL Certified.zip archive into a temporary
folder.
b. Start Device Manager.
c. Right-click on Other Devices > USB Serial Port and select Update driver.
d. Select Browse my computer for drivers.

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e. Click the Browse... button, select the path to the temporary folder where
the FTDI driver was unzipped, and click Next.
f. When the FTDI driver installation is complete, click Close.

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g. Right-click on the appropriate port in the Ports (COM & LPT) group and
select Properties.
h. Go to the Port Settings tab and click the Advanced... button.

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i. Set Latency Timer to 1, Receive and Transmit to 4096, and click OK.
j. Close the USB Serial Port (COM5) Properties window by clicking the OK
button.

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k. Close Device Manager.
11.3. Tablet setup
ATTENTION.
The manufacturer of the machine has made all the necessary settings for
the included tablet.
The user does not need to make any additional settings.
If the tablet has been reset to factory settings, you need to configure the tablet
as follows:
1. Install the service program. To do this, unzip the following archive:
RF096740_Desktop_Win64_v1_11_2022_11_03.zip. Create a shortcut and
copy it to the desktop.
2. Configure virtual COM ports (see Desktop PC setup).
3. Install the latest Microsoft Visual C++ Redistributable Package
(https://learn.microsoft.com/en-US/cpp/windows/latest-supported-vc-redist?
view=msvc-170).
4. Enable image rotation lock (Display Settings, Rotation Lock = On).
5. Turn off the automatic screen lock and sleep timers:
a. Personalize - Lock Screen - Screen Timeout settings - On Battery Power,
turn off after = Never;
b. Personalize - Lock Screen - Screen Timeout settings - On Plugged in, turn
off after = Never;
c. Personalize - Lock Screen - Sleep - On Battery Power, PC goes to sleep
after = Never;
d. Personalize - Lock Screen - Sleep - On Plugged in, PC goes to sleep after
= Never;
6. It is recommended to set the hibernation mode when pressing the tablet
power button.

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11.4. Starting the service program
On a desktop PC, run RF096740_DesktopDemo.exe.
On the tablet, run RF096740_TabletDemo.exe.
11.5. Main window
All functions of the service program are available in the main window.
There are two versions of the service program - Desktop version and Tablet
version.The Desktop version is designed to work on a personal computer with a large
monitor and provides all the options for viewing and processing measurements. In
addition, the Desktop version can also be used to control the system when two Wi-Fi-
USB adapters are connected to a PC. The main window of the Desktop version of the
service program:
The Tablet version is adapted for installation on a tablet. It provides full control
over the measurement process and a preview of the scan results. The main window of
the Tablet version of the service program:

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The main window is divided into the following groups:
1. Language. Selecting the user interface language.
2. Device. Connecting/disconnecting the service program to/from the system.
3. Motion. Manual control of the linear motion system.
4. Measure. Setting scan parameters and controlling the measurement process.
5. Session. Saving, loading and exporting scan data in various formats.
6. Measurement list. Displaying a list of completed measurements and
selecting a single measurement for detailed viewing.
7. Status. The current operating mode of the service program.
8. Cross section. Displaying a cross section at a given position.
9. Longitudinal section. Displaying a longitudinal section of an object by a
given plane.
10. 3D View. Displaying a 3D model.
Control commands are activated by clicking the corresponding button. Some
buttons are protected from accidental clicking. Before clicking such a button, you need
to remove the protection. As an example, the screenshots below show the Disconnect
button with the protection not removed (a) and with the protection removed (b).
a) b)
11.6. Selecting the user interface language
Select the user interface language from the drop-down list in the Language
group, as shown in the screenshot below. The service program saves the selected
language. The next time you start the service program, the user interface will be
displayed in the selected language.

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11.7. Connecting and disconnecting the machine
To establish a connection between the service program and the machine, do the
following:
1. Turn on the machine and the tablet.
2. Make sure both USB connectors are plugged into the USB slots of the tablet.
3. Run RF096740_TabletDemo.exe.
4. Click Connect.
To disconnect the service program from the machine, do the following:
1. Tick the checkbox and click Disconnect.
2. Turn off the machine.
11.8. Manual control of the motion system
After scanning is completed, the service program automatically moves the
scanning module to the initial position. In some cases, for example, after an emergency
shutdown, this does not happen. Since the control algorithms exclude the possibility of
spontaneous movement of any parts of the system, the user must generate a command
to move the scanning module to the initial position. To do this, follow these steps:
1. Connect the service program to the machine (see Connecting and
disconnecting the machine).
2. Tick the checkbox and click the Move to Initial Position button.
11.9. Machine calibration
The calibration is performed automatically before each measurement.
12. Scanning an object
Follow these steps:
1. Prepare the machine for operation (see Preparation for use).
2. Connect the service program to the machine (see Connecting and
disconnecting the machine).
3. Make sure the scanning module is in the initial position (see Manual control of
the motion system).
4. If you need to continue a previously saved session, then it is necessary to
load it (see Saving, reading and exporting data).

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5. Enter the scan parameters (Begin position, End position, Step), unlock and
click the Start button.
6. After clicking the Start button, the machine turns on the sensors and first
scans the calibration blocks, and then the object in accordance with the
entered parameters. The service program displays the scanning process in
the main window.
7. After the scanning process is completed, the service program adds the
measurement data to the current session. The navigation panel will display
the corresponding line containing the date and time of scanning, as well as
the user's comment.
8. If necessary, perform a new scan by repeating steps 5-7.
9. After completing all measurements, save the session to a file (see Saving,
reading and exporting data).
10. Disconnect the service program from the machine.
13. Viewing the data
The navigation panel displays the scan result of the current session.
The graphical part of the main window displays the 3D model of the scanned
object in three views:
1. Longitudinal section. Horizontal axis - coordinates along the object, vertical
axis - coordinates in the radial direction.
2. Cross section. The object profile section is shown in the radial coordinate
system. It also shows the measurement results, namely the average diameter
(Dave), minimum diameter (Dmin), maximum diameter (Dmax), ovality,
circularity.
3. 3D view.

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The service program provides the following options for viewing data:
1. To select a specific measurement, right-click on the corresponding line in the
navigation bar.
2. To view a fragment of a 3D model bounded by two sections, use the mouse to
move the left and right display boundaries to the desired position in the
Longitudinal Section window.
3. To change the viewing angle of the 3D model, move the mouse cursor over
the 3D View window, right-click and move the mouse cursor until the model is
rotated to the desired angle.
4. To view the cross section of an object at a given position, use the mouse
cursor to move the cross section line in the Longitudinal Section window to
the desired position.
5. To view the longitudinal section of an object along a specific plane in the
Cross Section window, rotate the longitudinal section line with the mouse
cursor to the required angle.
6. To automatically view the longitudinal section and the cross section at any
point, move the mouse cursor to the required point in the 3D View window
and double-click the left mouse button.
7. Use the checkboxes at the top of the 3D View window to select:
a. Points. The 3D image will be displayed as a point cloud.
b. Zero model. The reference surface will be displayed.
c. Difference. The difference between the current measurement and the
reference model will be displayed in colour.
Navigation in the 3D View window is done with the mouse:
1. To zoom in, rotate the mouse wheel away from you.
2. To zoom out, rotate the mouse wheel towards you.
3. To rotate the image, move the mouse cursor with the left button pressed.
4. To move the image along the axis of rotation, move the mouse cursor with the
right button pressed.

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14. Saving, reading and exporting data
The Session group contains buttons used to manage scan data.
1. To save the session, click the Save button and select the path to the session
file. The service program saves the session data to a binary file (rfs).
2. To view the saved session or to continue measurements, unlock and click the
Load button, and select the path to the required file.
3. To delete all measurements in the current session, unlock and click the Clear
button. Be careful, deleted data cannot be recovered if it has not been saved
to a file.
4. To export the current measurement to a CSV file, click the Export to CSV
button and select the path to the file.
5. To export the current measurement to an STL file, click the Export to STL
button and select the path to the file. Note that the outer surface of the object
will be saved to the _outer.stl file and the inner surface will be saved to the
_inner.stl file.
15. Using the reference model
The following models can be used as a reference:
1. models created in computer-aided design systems (for example, SolidWorks),
2. models obtained by scanning with this machine.
The reference model must be saved to an STL file.
15.1. Saving the current scan as a zero model
To save the current scan as a zero model, do the following:
1. In the Longitudinal Section window, set the 3D Display boundaries (see
Viewing the data).
2. Save the selected area as a zero model by clicking the Export to STL button
(see Saving, reading and exporting data).
15.2. Loading a zero model
1. Perform a measurement or open a previously saved one.
2. Click the Open button in the Select zero model group, specify the file (STL
format), tick the Zero Model checkbox in the Show group.
3. In the 3D View window, the zero model will be displayed in gray.