Sensopart RailPilot FR 85-2 ILLG-POL5 User manual

RailPilot – optical anti-collision sensors
System manual FR 85-2 ILLG-POL5 | FR 85-2 ILLG-S1L5
Optical sensors Ultrasonic sensors Inductive sensorsVision sensors and systems

RailPilot system manual
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RailPilot system manual
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Copyright
No part of this document may be reproduced, published or stored in information retrieval systems or data
bases in any manner whatsoever, nor may illustrations, drawings and the layout be copied without prior
written permission from SensoPart Industriesensorik GmbH.
We accept no responsibility for printing errors and mistakes which occurred in drafting this manual. Subject
to delivery and technical alterations.

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Contents
1RailPilot FR 85 anti-collision sensor..............................................................................................................4
1.1 RailPilot FR 85 sensor technology......................................................................................................5
1.1.1 Aligning RailPilot in a conveyor system (EMS)...................................................................................5
1.2 RailPilot versions.................................................................................................................................6
1.2.1 FR 85-2 ILLG – POL5 .........................................................................................................................7
1.2.2 FR 85-2 ILLG – S1L5 ..........................................................................................................................8
1.3 Example of change-over of safety ranges ..........................................................................................9
1.4 Installation / Mounting suggestion.......................................................................................................9
2Setting FR 85 with PC software ..................................................................................................................10
2.1 Serial communication FR 85-2 ILLG-S1L5 .......................................................................................10
2.2 PC-Software FR85-2 ILLG protocol tester ........................................................................................11
2.3 FR 85-2 ILLG – POL5 .......................................................................................................................12
2.4 Programming with ProgSensor .........................................................................................................13
2.4.1 System requirements ........................................................................................................................13
2.4.2 Installation .........................................................................................................................................13
2.4.3 Explanation ProgSensor ...................................................................................................................14
2.4.4 Symbols button bar ...........................................................................................................................15
2.4.5 Procedure for programming FR 85-2 ILLG with settings from another sensor.................................15
3Order informationen ....................................................................................................................................15
3.1 Accessories.......................................................................................................................................15

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1 RailPilot FR 85 anti-collision sensor
The sensor’s task is to prevent the collision of vehicles on rail-mounted tracks, primarily suspension tracks;
RailPilot is the reliable solution for this task. Breaking distances and distances between vehicles differ
according to the type of goods being carried and the speed of travel. This requires a flexible adjustment of
switching distances. Constantly changing objects around the vehicles and the presence of other sensors do
not impair RailPilot’s reliable anti-collision function.
In order to maintain the reliable anti-collision function and ensure accurate switching points regardless of the
surroundings and conditions of the vehicles themselves, a reflector is fitted to the rear of every vehicle
present in the installation. RailPilot is fitted to the front of each vehicle and thus always points at the reflector
on the vehicle ahead. Should the vehicle come closer than the currently selected breaking distance, the
breaking system is activated and the vehicle slows down. Should the vehicle come closer than the stopping
distance, it comes to a complete standstill. Once the vehicle in front moves further away, the signals are
enabled one after the other and the vehicle travels forward again.
When using vehicles of variable length, e.g. due to overhanging loads, the distances maintained in the
installation can be varied. This RailPilot function enables optimum use of congested areas.

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1.1 RailPilot FR 85 sensor technology
Railpilot FR 85 works on the principle of optical time-of-flight measurement.
Distance measurement uses the physical principle that light always spreads at a constant speed of
c=299,792 kilometres per second.
In other words, light travels a distance of 1 m in 3.335 ns (0.000,000,003,35 s).
RailPilot uses the principle of pulsed time-of-flight measurement:
With pulsed time-of flight-measurement, a very short light impulse is emitted, reflected and registered by the
receiver; measured time is stopped at that very same moment.
The emitted impulse triggers a clock which is stopped by the received impulse. The time elapsed
(time of flight) is always proportional to the optical path length.
Use of this physical principle makes RailPilot ideal for optical anti-collision distance measurement.
1.1.1 Aligning RailPilot in a conveyor system (EMS)
Reflector Sensor Reflector
EMS vehicle

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1.2 RailPilot versions
RailPilot is available in three versions:
FR 85-2 ILLG-POL5 2x Q
FR 85-2 ILLG-S1L5
FR 85-2 ILLG-S1L5
RS485, 57.6 kB
RS485, 62.5 kB
Their sensor technology is virtually identical, as each version only detects reflectors within its detection
range. Machines or rail components which may also be in the field of vision do not affect the RailPilot.
Close-up at distances of less than 0.3 m, the RailPilot detects every object. This function is used for
detecting obstacles directly in front of the sensor.
The sensor versions differ in signal function and detection range.

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Here are the most important distinguishing features of the two versions:
1.2.1 FR 85-2 ILLG – POL5
•Detection range 0 … 6 m
•Aperture angle horizontal ± 7.5 degrees; vertical ± 3.5 degrees
•Two PNP N.C. outputs Q1, Q2
•One "range change"input
The FR 85-2 ILLG – POL5 sensor is connected to the vehicle control system via the two PNP switching
outputs; one switching signal (Q1) can thus be used to change the speed of travel to slow, the second
switching signal (Q2) acts as a stop signal.
It is possible to switch between two pre-set pairs of switching distances for Q1 and Q2 via the E1 "range
change"input.
This function is of help when positioning vehicles carrying greatly overhanging loads. The vehicles can thus
travel close up when unloaded but keep to a greater distance when loaded.
Both signal outputs are N.C. so that there is protection from breakage in the connection cable.
The four signal points (close / far for both Q1 and Q2) are programmed via a set-up box (part no.
533-11016).
The set-up box is connected between the RailPilot and connection cable for sensor programming and has a
serial RS232 interface. Distance values for switch points can be programmed using parameter software
available for PC (Windows). This software is available free of charge.
Advantages:
It is very easy to integrate it in existing installations.
Sensor settings are easy to reproduce and can be recorded.
Sensors can be easily pre-set outside the installation (short commissioning time).
Connection example:

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1.2.2 FR 85-2 ILLG – S1L5
•Detection range 0 … 6 m
•Aperture angle horizontal ± 7.5 degrees; vertical ± 3.5 degrees
•RS485 serial interface
Der FR 85-2 ILLG – S1L5 only communicates with the vehicle control system via the RS485 interface.
For this purpose, the vehicle control software must have implemented the protocol of the
FR 85-2 ILLG - S1L5.
(Control systems with this function are currently available from DETO and LJU).
In this application, RailPilot acts as an actual value indicator for the distance to the vehicle in front. The
control system continuously interrogates the sensor for the distance to the reflector in front. If the reflector is
within detection range, RailPilot sends the distance value to the control system, otherwise the signal sent
indicates "no reflector detected".
Aufgrund dieser Information kann die Fahrzeugsteuerung das Fahrzeug an den gewünschten Positionen
platzieren.
Based on this information, the vehicle control system can position the vehicle as.
Advantages:
parameter settings are carried out via the control system. Should it be necessary to replace the RailPilot, no
sensor adjustments are required.
Connection example:
Fahrzeugsteuerung
+24V
Gnd
B(+)RS485
A(-)RS485
+UB
B(+)RS485
A(-)RS485
GND
n.c.
5
3
4
2
1
Magnetrastschalter
beladen / unbeladen
FR85-2ILLG-S1L5
Eingang
beladen/
unbeladen
Vehicle control
Magnetic switch
loaded/unloaded
Input
l
oaded
/
unloaded

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1.3 Example of change-over of safety ranges
Bi-stable magnetic switches are commonly used for switching between close/far safety ranges.
Schematic diagram of change-over using bi-stable magnetic switches
1.4 Installation / Mounting suggestion
The illustrated frame protection prevents damage occurring to sensors and reflectors when the EMS vehicles
are pushed up close together during service interventions.
EMS track
Magnetic
switches
Magnets

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2 Setting FR 85 with PC software
2.1 Serial communication FR 85-2 ILLG-S1L5
FR 85-2 ILLG – S1L5 only communicates with the vehicle control system via the RS485 interface.
When installing with a suitable vehicle control system (currently DETO and LJU), it is merely necessary to
set the correct baudrate.
The factory setting is 57.6 kBaud.
This setting makes the FR 85-2 ILLG – S1L5 sensor suitable for immediate use with the DETO control
system. When used with the LJU control system, the baudrate must be set to 62.5 kBaud
(see transmission protocol data sheet and description of test software).
Test of FR 85-2 ILLG – S1L5 on a PC with FR85ILL_tester.exe software
RailPilot FR 85-2 ILLG – S1L5 can be connected to a PC for test and adjustment purposes via a RS485 –
RS232 interface converter den.
The sensor is available with preset baudrate:
Type / order reference Baudrate Suitable for control system Part no.
FR 85-2 ILLG-S1L5 62.5 kB LJU 529-11014
FR 85-2 ILLG-S1L5 57.6 kB DETO 529-11008

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2.2 PC-Software FR85-2 ILLG protocol tester
The software must first be successfully installed on the PC.
RailPilot FR 85-2 ILLG – S1L5 is connected to the PC as previously described.
Once the software has been started-up, the following
window appears:
Once the software has been started-up, the following
window appears.
Then the ComPort number must be set to that of the
ComPort in use.
The following windows appears when the "Send"menu is selected:
Special feature:
There is the problem that it is possible to set a baud-
rate which cannot be processed on a PC.
In order to bypass this problem, the following
function has been integrated in RailPilot
FR 85-2 ILLG – S1L5:
Once the power supply has been switched on, the
sensor monitors its RS485 interface with a baudrate
of 57.6 kBaud for 100 ms and tries to receive
the command "C".
If the command "C"is received within 100 ms, the
sensor knows that it is connected to a system which
operates with 57.6 kBaud. The sensor maintains the
baudrate of 57.6 kBaud.
If the command "C"is not received within 100 ms,
the sensor knows it is not connected to a system
operating with 57.6 kBaud. It then switches to its
pre-set baudrate.
In order to create a serial connection to RailPilot FR 85-2 ILLG – S1L5, proceed as follows:
1. Disconnect FR 85-2 ILLG – S1L5 from the power supply.
2. Activate the "continuous"button (the command "C"is continuously sent).
3. Reconnect FR 85-2 ILLG – S1L5 to the power supply.
Should no connection be made, repeat steps 1 … 3.
1. Enter the number of the
ComPort in use here.
2. Activate the "Zuweisen"
button.
3. It is then possible to switch to
the “Send“ menu.

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Once a connection is made, the following windows appear:
Here communication can be tested by holding an object less than 30 cm in front of the sensor; the distance
value displayed alters accordingly (only reflectors are detected beyond 30 cm).
Once a connection exists, all the protocol commands can be tested.
The following functions are available in the FR 85 ILLG "protocol tester":
Input boxes for command
and parameters (command
in ASCII; parameters in hex)
Automatic setting of baudrate
for LJU control systems
FR 85-2 ILLG-S1L5
Displays the last strings sent
by FR 85 ILLG – S1L5; in
bytes in dec and hex
Automatic setting of baudrate
for DETO control systems
FR 85-2 ILLG-S1L5
Displays the last string sent
by the PC; in bytes in dec
Automatic delay of 300 µs
between the sensor receiving a
command and sending a reply
2.3 FR 85-2 ILLG – POL5
Switch points are programmed via PC.
RailPilot parameter software must be successfully installed on the appropriate device and a SensoPart
FR 85 set-up box is required.
The FR 85 setup box is connected to a PC via RS232 interface.
The "ProgSensor"software is available for download at www.sensopart.com.

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2.4 Programming with ProgSensor
2.4.1 System requirements
A PC with WINDOWS XP or higher installed and running. A free serial interface is required (COM).
SensoPart’s "ProgSensor"software was developed exclusively for the setting of parameters on SensoPart
sensors. SensoPart assumes no responsibility for damage which may occur when installing or operating the
ProgSensor programme.
2.4.2 Installation
In order to use ProgSensor software, it must be installed under Windows. Installation is started by starting
the "setup.exe"programme in the installation file.
Follow the instructions on the screen until installation has been completed.
Once it has been successfully installed, the programme can be started e.g. via the Windows "Start button".
Double click here to
start installation

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2.4.3 Explanation ProgSensor
In order to programme settings on the FR85-2 ILLG, ensure that the sensor
1. is connected to the power supply,
2. is connected to a free COM interface on the PC using the SensoPart programming adapter,
3. "ProgSensor"is installed on the PC.
Only sensors with a baudrate of 57.6 kBaud are automatically recognized.
Once setup.exe has started, the main window appears:
Clicking the sensor symbol opens the submenu for
parameterization of FR 85.
The menu bar oft the submenu consists basically of
following elements:
•File – Open and close files. Quit closes the
program.
•Sensor – Select the connected sensor type.
The choice ist between "automatic"or "manual"*.
•Sensor data– Read current sensor settings; send
settings from software to FR 85-2 ILLG. Start online
mode of sensor. In online mode, the sensor
cyclically transmitts measuring data which are then
indicated in the display. If the option "continously"
is not activated, only one measuring value is sent.
•Language – Select "German"or "English".
•
Help –
Displays the version number of the software.
* For "manual"FR 85-2ILLG hast o be set as follows:
Normally it is sufficient to define the ComPort.
Use of ProgSensor is based on the usual functions of Microsoft Windows and is thus mainly
intuitive. Alterations in appearance are thus possible at any time in the course of an update or as the
result of other Windows adjustments.

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2.4.4 Symbols button bar
Open parameter file
Save settings
Automatically search connected sensor
Read current settings from sensor or write to sensor
Read measurement values
Qiut program
2.4.5 Procedure for programming FR 85-2 ILLG with settings from another sensor
(Concerning part number 529-11010: An interface adapter 533-11016 is required)
1. Connect sensor with required setting using serial connection
2. Carry out automatic sensor search
3. Read-out setting from sensor
4. Disconnect sensor that has been read and connect sensor to be programmed in its place
5. Transfer parameters to sensor
(Steps 4 and 5 can be repeated as many times as required without reconnecting sensor to be read)
3 Order informationen
Type / order reference Switching output / interface Part-No.
FR 85-2 ILLG-POL5 2x Q 529-11010
FR 85-2 ILLG-S1L5 RS485, 57,6 kB 529-11008
FR 85-2 ILLG-S1L5-62,5kB RS485, 62,5 kB 529-11014
3.1 Accessories
Type / order reference Description Part-No.
L5-2m-G-PUR 2 m, straight, a-coded, PUR, IP 65 / IP 67 / IP 68 902-51652
R10/2 (2 x R10) reflector in housing 100 x 100 x 9 mm 904-51636
Setup Box FR 85-2 ILLX Setup box for FR 85 RailPilot system 533-11016

068-13813 21.01.2020-06
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