Riftek RF1010SL Series User manual

3D Laser Measurement Machine, RF1010SL
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Contents
1. Safety precautions ....................................................................................................................3
2. Electromagnetic compatibility...................................................................................................3
3. Laser safety...............................................................................................................................3
4. General information ..................................................................................................................4
5. Structure and operating principle..............................................................................................4
6. Basic technical data..................................................................................................................5
7. Dimensions...............................................................................................................................6
8. Mounting and setup ..................................................................................................................6
9. Connection diagram..................................................................................................................8
9.1. Signal block.......................................................................................................................8
9.1.1. Connection diagram..................................................................................................8
9.1.2. LED indication...........................................................................................................9
9.1.3. Interface cables.........................................................................................................9
9.1.4. Input-output circuitry .................................................................................................9
10. Software..................................................................................................................................10
10.1. Scanning Control ............................................................................................................10
10.1.1. Machine Control......................................................................................................10
10.1.2. Calculations.............................................................................................................11
10.1.3. Input tolerances and setting calculation parameters..............................................13
10.1.4. Logging events and results.....................................................................................14
10.1.5. Calibrating the machine..........................................................................................14
10.2. Detail statistics viewer.....................................................................................................15
10.3. Signal block testing application ......................................................................................15
11. Intended use ...........................................................................................................................16
11.1. Preparation for use .........................................................................................................16
11.1.1. External inspection..................................................................................................16
11.1.2. Set up on a conveyer..............................................................................................16
11.1.3. Switching the machine............................................................................................16
11.1.4. Calibrating the machine..........................................................................................16
11.1.5. Checking the machine ............................................................................................16
11.2. Operating the machine....................................................................................................17
12. Maintenance............................................................................................................................17
12.1. General instructions........................................................................................................17
12.2. Safety precautions ..........................................................................................................17
12.3. Maintenance procedure..................................................................................................17
12.3.1. Daily maintenance work..........................................................................................17
12.3.2. Weekly maintenance work......................................................................................17
12.3.3. Yearly maintenance work .......................................................................................17
12.4. Operability test ................................................................................................................17
13. Routine repairs........................................................................................................................18
14. Warranty policy.......................................................................................................................18
15. Distributors..............................................................................................................................18

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1. Safety precautions
•Use supply voltage and interfaces indicated in the machine specifications.
•In connection/disconnection of cables, the machine power must be switched
off.
•Do not use machine in locations close to powerful light sources.
•To obtain stable results, wait about 20 minutes after machine activation to
achieve uniform scanner warm-up.
•Avoid metal chips getting into the machine body.
•Do not allow foreign objects to get between moving and stationary parts of the
measuring machine after turning it on.
•Do not obstruct the movement of moving parts of the machine.
•Friction parts of the ball screw assembly should be kept clean and be lubri-
cated.
•The machine should be grounded and connected to ground line via a sepa-
rate lateral line.
2. Electromagnetic compatibility
The machine has been developed for use in industry and meets the require-
ments of the following standards:
•EN 55022:2006 Information Technology Equipment. Radio disturbance char-
acteristics. Limits and methods of measurement.
•EN 61000-6-2:2005 Electromagnetic compatibility (EMC). Generic standards.
Immunity for industrial environments.
•EN 61326-1:2006 Electrical Equipment for Measurement, Control, and Labor-
atory Use. EMC Requirements. General requirements
3. Laser safety
The machine makes use of laser scanner. Laser scanner belongs to the 2M la-
ser safety class according to IEC 60825-1:2007.
The scanner makes use of an c.w. 660 nm wavelength semiconductor laser.
Maximum output power is 8 mW. The following warning label is placed on the laser
body:
The following safety measures should be taken while operating the scanners:
•Do not target laser beam to humans;
•Avoid staring into the laser beam through optical instruments;
•Do not disassemble the laser scanner;
•Do not place any objects that can cause reflection on the path of the laser radia-
tion.

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4. General information
The measuring machine is designed for non-contact measurement of geomet-
rical parameters of objects, specifically suspension arms, and is a standalone software/
hardware system.
Technical characteristics of the machine can be changed for a specific task.
5. Structure and operating principle
The work of the machine is based on the principle of 3D laser scanning of object/
objects with subsequent construction of a 3D computer model and determination of ge-
ometrical parameters from the model.
The machine structural design is illustrated in Figure 1 (machine with cover re-
moved).
The machine comprises two columns 1,2, closed with the guide 3. The carriage
4, carrying the laser scanner 5, is mounted on the guide 3. Mounted on the column 1 the
stepping motor 6 is connected to the ball screw (not shown) that drives the carriage 4. In
the extreme positions of the carriage 4 limit switches (not shown) are mounted. There
are a signal block 7 and a power supply 8 on the column 2.
Laser scanner 5 radiation is formed in a line and is projected onto the controlled
object 9. The resulting image of the contour (cross-sectional profile) 10 of the object is
analyzed by a signal processor of the scanner which calculates the distance to the object
(Z coordinate of points) for each of a plurality of points along the laser line on the object
(X coordinate of points).
Figure 1
The machine operates as follows.
The laser scanner mounted on the carriage moves along the object, the direction
of the movement being the coordinate Y. The laser scanner determines the coordinates
of the object profile points (X, Z) at fixed regular linear intervals along the Y coordinate
defined by the stepper motor drive, fig. 2.

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Figure 2
The result is a 3D computer model of the object in the form of Point Cloud with
established profile coordinates (X,Y,Z). An example of the model is shown in Figure 3.
The required geometrical parameters are calculated from the resulting object model.
Figure 3
6. Basic technical data
Parameter
Value
Scanning range Y-axis, mm
370
Scanning range, Z-axis, mm
135
Scanning range Х(start of measurement, Z-axis), mm
45
Scanning range Х(end of measurement Z-axis), mm
70

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Measurement accuracy, X,Z axes, um
±50
Measurement accuracy, Y axis, um
±20
Sampling rate, profiles/s
250
Speed, mm/s
Parameters under control
see point 10.1.2.
Dimension, mm
730х415х180
Weight, kg
40
Power supply
alternating-currentmains with sampling rate
(50 ± 1) Hz, nominal power 220 with allowa-
ble stress ±10 %.
Power consumption, W
300
Environment conditions
Environmenttemperature:+1..+350С
Relative humidity25
-
65%
7. Dimensions
The dimensions of the machine are shown in the figure 4.
Figure 4
8. Mountingand setup
To reduce the volume of adjustment work measuring machine is delivered fully
assembled.
Installation of the machine on a conveyer belt is made as follows.
In the conveyer frame screw holes (M5-7H) are made as per the scheme. Mark-
ing the holes is made from pallets, located in the measurement area, according to the
figures 5 and 6.

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Figure 5
Figure 6
At the measuring station mounting screws are loosened, providing horizontal
motions of the support bracket, fig. 7,9.
Figure 7
Figure 8

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Next is the station installation on the conveyer frame using M5 screws. After the
station is installed it should be located at the distance from the conveyer according the
installation dimensions, figure 4.
9. Connection diagram
Connection diagram is shown in Fig. 9.
Figure 9
Where 1 – power supply; 2 – limit switches; 3 – laser scanner; 4 – signal block;
5 – network router; 6 - terminal (PC); 7 – stepper motor; 8 – switching unit; 9 – synchro-
nization and signaling machine condition cable.
9.1. Signalblock
All interface connections to the machine are implemented via the signal block. 3
LEDs duplicating digital output status are located on the panel of signal block.
9.1.1. Connection diagram.
Connection to signal block is shown in Figure 10.
Figure 10

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Where 1 – stepper motor to laser scanner connection (cable entry); 2 -synchro-
nization and machine condition digital outputs connection; 3 – power and limit switches
connection (cable gland); 4 – network interface of the laser scanner connection (cable
gland); 5 - network interface to the router scanner connection (connector); 6 – signal
block network interface to the router connection (connector).
9.1.2. LED indication
LED indicators, located on the signal block characterize the current state of the
measuring machine and the result of measurement:
Machine condition
Indication
System is ready
Green
Measurement process
Yellow
Failure
Red
Valid detail
Flashing green
Rework
Flashing yellow
Waste
Flashing red
9.1.3. Interface cables
System signals cable 9 is shown in the Figure 11.
Figure 11
Laser scanner connection cable is shown in the Figure 12.
Figure 12
9.1.4. Input-output circuitry
Trigger input stage is shown in Figure 13. Synchronization input is designed to
alarm of object on the measuring position.

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R1
1 KOm
VD2
BAT54
VD1
BAT54 D1
BZX84C3V3
C1
470 pF
MCU
IN
Figure 13
The output stage of the machine condition output is shown in the Figure 14. The
outputs are used to connect external alarm and actuators.
R1
11 KOm
R2
5,1 KOm
BC847 DRV
OUT
24V
Figure 14
10. Software
The software is implemented to run on the operating system Windows XP, Vista,
7. Qt-library version 4.8.0 Microsoft redistributable package 2010 is used in the software.
Software consists of 4 components:
•Scan control RFScanDetail.exe,
•Statistics details viewer RFStatViewer.exe
•Signal block testing TestSignalBlock.exe
•Scanner setup and test rf620et-sp.exe
Additional applications that may be needed to set up and debug the scanner:
•Wireshark network analyzer
•DHCP server
10.1. ScanningControl
The scanning control application provides:
•control of the machine in working process and debug modes
•receiving data from scanner and three-dimensional detail model construction
•detail model mathematical calculation
•input tolerances and setting calculation parameters
•assessment of detail state and comparison with tolerances
•logging events and results
•machine status control
•signal block management
•calibration of the machine
10.1.1. Machine Control
Operating window of the application is shown in the figure below. Control buttons
are located in the right part of the window.

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Being started the application automatically searches for the devices of the
measuring machine in the network and connects to them. If the devices aren’t connected
to the network when the application is started, the process can be started forcedly by
pressing the Connect button.
If all the devices are found, the scanning session starts automatically. Scanning
session can be stopped via pressing the Stop button.
The machine state is displayed in the title bar of the application: Working -
scanning session is started, Stopped - scanning session is stopped. If the session is
stopped the measuring process can only be started forcibly from the app via the Forci-
bly scanningbutton.
The scanning session can be started again via the Scanning session start but-
ton. When the scanning session is disabled the system calibration can be performed
via the Calibration button.
Measurement parameters can be configured at any time while the application is
working via the Parameters Settings button. But the changes will take effect only after
restarting the application.
The basic devices (namely, scanner movement drive, signal block, laser scanner
and counter of measured items) status is displayed in the central part of the window.
In the bottom part of the window the calculation results of the last scanned detail
and validity evaluation (namely, valid, spoilage and rework) are displayed.
10.1.2. Calculations
The scanning control application performs the next set of calculations:
•Calculation of the axis displacement in the XY-plane as

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deviation of the central elbow axis position from the axis connecting centers of the two
extreme elbows, mm.
•Calculation ofthe axis displacement in the XZ-plane as
maximum angle (in degrees) between the lines that run along the upper landing of the
three elbows,. That is, the angle difference is calculated pairwise between the three lines
taken. Displacement of the axis is the maximum difference of the angles.
•Detailwidth calculation in A,B and C positions
Detail width in A and C positions is calculated according to the calibration data.
The calculation is based on the line passing through the center of the visible part of the
calibration block. The height of the A and C elbows is compared with the height of the
calibration block at A and C points. Then from the nominal value of the calibration stand-
ard height the difference between the elbow height and the calibration standard height is
subtracted. The obtained result is the elbow height.
The elbow width in B position is calculated on the basis of the widths of the elbow
A and C. The central axis of the detail is reproduced on the basis of the A and C widths.
The width of the elbow B is calculated from the central axis and the height of the elbow
B.
•Distances AB, BC and AC calculation

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The distances between the axes A, B and C in XY-plane are calculated.
•Detailtwisting calculation
The maximum angle between the lines running along the upper landing of three elbows
perpendicular to the detail axis is calculated, degrees. That is, the difference between
the angles of these three lines is calculated pairwise. Detail twisting is the maximum dif-
ference of the angles.
10.1.3. Input tolerances and setting calculation parameters
To enter the setup mode press the Parameter Setting button in the main win-
dow of the application. The settings window contains several tabs.
Tab General Settings.
•turn on the reverse scanning when scanner movement direction need to be
reversed
•folder for temporary files – set the pass to store temporary files if necessary
•displacement step, number of measurements, divisor, number of microsteps –
factory defaults are shown
The other tabs are designed for the input of tolerances. The logic of the signaling
LEDs and the logic output of the synchronization unit will comply with the established
tolerances.
Tabs Axis offset and Width

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Tabs Center distance and Twisting
10.1.4. Logging events and results
During operation of the machine the scanning control application conducts event
logging to the files system[index] in the /Log/folder. The file title contains an index,
when exceeding the current file size a new log file with the index for 1 bigger than the
previous is created.
The results of processing the model of the detail as well as the accidents are
logged to the database. The database is implemented on the basis of splite. Database
files are stored in [month].sqlite files, where month is the number of the current month.
That means all entries in a month are stored in a single file. All database files are stored
in the folders form /[year]/, where year is the number of current year. All the data be-
longing to the particular year measurements are in the same appropriately named folder.
According to these data the statistics viewer builds statistical reports. All data can be
transferred for analysis to another computer preserving the folder structure.
When the application is working the initial scanning data three-dimensional
models in the *bin format are recorded in the temporary directory /tmp/. The address of
the temporary folder is specified in the program settings. The files formed in this folder
can be used for detailed analysis of the calculation faults, development of the new and
correction of the existing calculations.
10.1.5. Calibrating the machine.
To calibrate the machine install the calibration block (supplied rectangular speci-
fied sizes block) in the control position, see the Figure below.

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In the main window of the application click Calibrate. After the block is scanned
the machine is ready for operation.
10.2. Detailstatisticsviewer
To view the statistics of measurements run RFStatViewer.exe. The main window
of the application is shown in the Figure below.
The application allows to generate statistical reports for a given period of time.
10.3. Signalblocktesting application
To test the signal block run TestSignalBlock.exe. The main window of the appli-
cation is shown in the Figure below.

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Condition Group enables to test the logic outputs, LEDs Group tests LED
performance. To test the movement system set the number of steps and click Move. To
return the carriage in the initial position click Ini Position. The other parameters are
shown informative.
11. Intended use
11.1. Preparationforuse
Preparation the machine includes:
•external inspection;
•set up on a conveyer;
•switching the machine;
•calibrating the machine;
•checking the machine.
11.1.1. External inspection
Before operating it is needed to ensure of the serviceability of the equipment,
check the cables, ground wires. Check the condition of output windows of the scanner
and, if necessary, wipe them with a soft cloth.
11.1.2. Set up on a conveyer
Install the machine on a conveyer according to the Paragraph 8 of this manual.
Make the electrical connections in accordance with the Paragraph 9.
11.1.3. Switching the machine
11.1.4. Calibrating the machine
Calibrate the machine according to the Paragraph 10.1.5. Setting calibration
should be held on a daily basis before the work shifts.
11.1.5. Checking the machine
To check the functionality of the machine conduct a full cycle control of the geo-
metrical parameters of the control sample detail. It is recommended to conduct at list one
functional test of the machine at the beginning or during the shift.

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11.2. Operatingthe machine
The geometric parameters measurement cycle is fully automated and operation
of the machine is reduced to the work with the program.
•run the machine control application
•add/control the tolerances according to the Paragraph 10.1.3
•when getting the synchronization signal the machine performs the scanning of
the detail, calculation of the geometrical parameters and grading
•after the scanning the carriage automatically returns to the starting position
and the machine waits for the next synchronization signal
12. Maintenance
12.1. Generalinstructions
Maintenance of the machine is carried out to ensure constant-ready status and
continued availability of its work and to prevent premature failure. Maintenance includes
preventive measures aimed at identification and elimination of defects and to ensure the
normal operation while installation and working. It is recommended to conduct the daily,
weekly and annual maintenance work.
12.2. Safetyprecautions
During the installation maintenance security measures outlined in the Paragraph
1 should be observed.
12.3. Maintenanceprocedure
12.3.1. Daily maintenance work
Daily maintenance includes:
•visual inspection of the machine,
•checking of completeness,
•inspection of the units and elements that make up the machine,
•checking for any damage of the structural elements, power and instrument
cables, indicators and connectors,
•weakening of screw connections and insulation failures,
•before starting work, it is necessary to wipe the input and output laser scanner
windows with a soft dry cloth.
12.3.2. Weekly maintenance work
Weekly maintenance includes:
•cleaning of laser scanner windows with a dry soft lint-free cloth from
contamination of dirt;
•checking of free movement of the carriage.
12.3.3. Yearly maintenance work
Authenticated calibration of the laser scanner should be made once a year
12.4. Operabilitytest
It is recommended to conduct the functional test at least once at the beginning or
during the shift, for what it is necessary to complete full cycle control of the geometrical
parameters of the control sample (not supplied).

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13. Routine repairs
Possible troubles and trouble-shooting instructions are given in the following ta-
ble.
Troubles Possible cause Corrective actions
Incorrect measure-
ments
The influence of an external illumination
source Remove the external source or protect the controlled item from its influence.
Wet surface of the detail with the drops of
coolant and water Remove the drops of coolant and water
Laser scanner window pollution Clean the scanner window
Malfunctions of the software Reboot the computer
The detail is unsuitable for the control
Remove any external objects or coat- ings from the surface of the detail
Scanner displacement Calibrate the machine
Other Contact the manufacturer
14. Warranty policy
Warranty assurance for the 3D Laser measurement machine RF1010SL – 24
months from the date of putting in operation; warranty shelf-life - 12 months.