SICK Ranger E User manual

REFERENCE MANUAL
Ranger E/D
MultiScan 3D camera with Gigabit Ethernet (E)
3D camera with Gigabit Ethernet (D)

© SICK AG 2011-06-17
All rights reserved
Subject to change without prior notice.
Please read the complete manual before attempting to operate your Ranger.
WARNING
Turn off power before connecting
Never connect any signals while the Ranger unit is powered.
Never connect a powered Ranger E/D Power-I/O terminal or powered I/O signals to a
Ranger.
Do not open the Ranger
The Ranger unit should not be opened. The Ranger contains no user serviceable parts
inside.
Safety hints if used with laser equipment
Ranger is often supposed to be used in combination with laser products.
The user is responsible to comply with all laser safety requirements according to the laser
safety standards IEC 60825 – 1 and 21 CFR 1040.10/11 (CDRH) respectively.
Please read the chapter Laser Safety in Appendix B carefully.
Turn off the laser power before maintenance
If the Ranger is used with a laser (accessory), the power to the laser must be turned off
before any maintenance is performed. Failure to turn this power off when maintaining the
unit may result in hazardous radiation exposure.
ISM Radio Frequency Classification - EN55011 - Group1, Class A
Class A equipment is intended for use in an industrial environment. There may be potential
difficulties in ensuring electromagnetic compatibility in other environments, due to con-
ducted as well as radiated disturbances.
Explanations:
Group1 – ISM equipment (ISM = Industrial, Scientific and Medical)
Group 1 contains all ISM equipment in which there is intentionally generated and/or used
conductively coupled radio-frequency energy which is necessary for the internal function-
ing of the equipment itself.
Class A equipment is equipment suitable for use in all establishments other than domestic
and those directly connected to a low voltage power supply network which supplies build-
ings used for domestic purposes.
Class A equipment shall meet class A limits.
Note: Although class A limits have been derived for industrial and commercial establish-
ments, administrations may allow, with whatever additional measures are necessary, the
installation and use of class A ISM equipment in a domestic establishment or in an estab-
lishment connected directly to domestic electricity power supplies.
Please read and follow ALL Warning statements throughout this manual.
Windows and Visual Studio are registered trademarks of Microsoft Corporation.
All other mentioned trademarks or registered trademarks are the trademarks or registered trademarks of their
respective owner.
SICK uses standard IP technology for its products, e.g. IO Link, industrial PCs. The focus here is on providing
availability of products and services. SICK always assumes that the integrity and confidentiality of data and rights
involved in the use of the above-mentioned products are ensured by customers themselves. In all cases, the
appropriate security measures, e.g. network separation, firewalls, antivirus protection, patch management, etc.,
are always implemented by customers themselves, according to the situation.
a

Reference Manual
Ranger E/D
©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved 3
Contents
Contents
1Introduction ................................................................................................................................... 6
2Overview......................................................................................................................................... 8
2.1 Measuring with the Ranger ..................................................................................................... 8
2.2 Mounting the Ranger............................................................................................................... 9
2.3 Configuring the Ranger..........................................................................................................10
2.3.1 Ranger Studio ..........................................................................................................10
2.3.2 Measurement Methods ...........................................................................................11
2.4 Developing Applications ........................................................................................................17
2.5 Triggering ...............................................................................................................................18
3Mounting Rangers and Lightings...............................................................................................19
3.1 Range (3D) Measurement..................................................................................................... 20
3.1.1 Occlusion..................................................................................................................21
3.1.2 Height Range and Resolution.................................................................................. 21
3.1.3 Main Geometries......................................................................................................22
3.2 Intensity and Scatter Measurements ...................................................................................23
3.3 MultiScan ...............................................................................................................................23
3.4 Color Measurements .............................................................................................................24
3.5 Light sources for Color and Gray Measurements ................................................................25
3.5.1 Incandescent lamps.................................................................................................25
3.5.2 Halogen lamps .........................................................................................................25
3.5.3 Fluorescent tubes ....................................................................................................26
3.5.4 White LEDs ...............................................................................................................26
3.5.5 Colored LEDs............................................................................................................27
4Ranger Studio..............................................................................................................................28
4.1 Ranger Studio Main Window................................................................................................. 28
4.1.1 Visualization Tabs ....................................................................................................29
4.2 Zoom Windows ......................................................................................................................31
4.3 Parameter Editor ...................................................................................................................32
4.3.1 Flash retrieve and store of parameters ..................................................................33
4.4 Using Ranger Studio ..............................................................................................................33
4.4.1 Connect and Get an Image...................................................................................... 33
4.4.2 Adjust Exposure Time ..............................................................................................35
4.4.3 Set Region-of-Interest ..............................................................................................35
4.4.4 Collection of 3D Data............................................................................................... 36
4.4.5 Getting a Complete Object in One Image................................................................37
4.4.6 White Balancing the Color Data ..............................................................................37
4.4.7 Visualizing Color Images..........................................................................................39
4.4.8 Save Visualization Windows ....................................................................................39
4.4.9 Save and Load Measurement Data ........................................................................40
5Configuring Ranger E and D .......................................................................................................41
5.1 Selecting Configurations and Components..........................................................................41
5.2 Setting Region-of-Interest......................................................................................................42
5.3 Different Triggering Concepts ...............................................................................................43
5.4 Enable Triggering...................................................................................................................43
5.5 Pulse Triggering Using an Encoder .......................................................................................45
5.5.1 Triggering Scans.......................................................................................................45
5.5.2 Embedding Mark Data.............................................................................................46

Reference Manual
Ranger E/D
4©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved
Contents
5.6 Setting Exposure Time...........................................................................................................47
5.7 Range Measurement Settings ..............................................................................................49
5.8 Details on 3D Profiling Algorithms........................................................................................ 50
5.9 Color Data Acquisition ...........................................................................................................54
5.9.1 White Balancing .......................................................................................................54
5.9.2 Color Channel Registration...................................................................................... 55
5.10 Calibration.............................................................................................................................. 56
5.10.1 Calibrated Data ........................................................................................................57
5.10.2 Rectified Images ...................................................................................................... 57
5.10.3 Physical Setup.......................................................................................................... 58
5.10.4 Calibration and 3D Cameras ...................................................................................59
6Ranger D Parameters .................................................................................................................61
6.1 System settings .....................................................................................................................61
6.2 Ethernet Settings...................................................................................................................61
6.3 Image Configuration ..............................................................................................................62
6.4 Measurement Configuration .................................................................................................63
7Ranger E Parameters..................................................................................................................67
7.1 System settings .....................................................................................................................67
7.2 Ethernet Settings...................................................................................................................67
7.3 Image Configuration ..............................................................................................................68
7.4 Measurement Configuration .................................................................................................70
7.5 Measurement Components ..................................................................................................72
7.5.1 Horizontal Threshold (HorThr) .................................................................................72
7.5.2 Horizontal Max (HorMax) .........................................................................................76
7.5.3 Horizontal Max and Threshold (HorMaxThr) ...........................................................77
7.5.4 High-resolution 3D (Hi3D)........................................................................................79
7.5.5 High-resolution 3D (Hi3D COG) ...............................................................................80
7.5.6 Gray ..........................................................................................................................83
7.5.7 HiRes Gray................................................................................................................ 84
7.5.8 Scatter ......................................................................................................................85
7.5.9 Color and HiRes color ..............................................................................................86
8iCon API ....................................................................................................................................... 89
8.1 Connecting to an Ethernet Camera ......................................................................................90
8.2 Retrieving Measurement Data.............................................................................................. 92
8.2.1 IconBuffers, Scans, Profiles and Data Format .......................................................92
8.2.2 Accessing the Measurement Data ..........................................................................93
8.2.3 Polling and Call-back ...............................................................................................95
8.2.4 Handling Buffers ......................................................................................................95
8.2.5 Mark Data.................................................................................................................96
8.3 Changing Camera Configuration...........................................................................................97
8.3.1 Using Parameter Files.............................................................................................. 97
8.3.2 Setting Single Parameter Values.............................................................................97
8.4 Error Handling........................................................................................................................98
8.5 Calibration and Post Processing of Buffers.......................................................................... 99
8.5.1 Filter Classes............................................................................................................99
8.5.2 Extraction Filter ......................................................................................................100
8.5.3 Calibration Filter.....................................................................................................100
8.5.4 Rectification Filter..................................................................................................101
8.5.5 Color Registration filter..........................................................................................101
8.5.6 Color Generation Filter...........................................................................................103

Reference Manual
Ranger E/D
©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved 5
Contents
9Hardware Description .............................................................................................................. 105
9.1 Sensor ..................................................................................................................................105
9.1.1 Light Sensitivity ......................................................................................................105
9.1.2 Color Filter Layout ..................................................................................................106
9.1.3 High-resolution Rows .............................................................................................107
9.1.4 Color response .......................................................................................................107
9.1.5 Standard and high-resolution color differences ...................................................109
9.2 Electrical Connections.........................................................................................................110
9.3 Technical Data .....................................................................................................................112
9.4 Dimensional Drawing ..........................................................................................................114
Appendix............................................................................................................................................ 115
ARanger E and D Models.......................................................................................................115
BLaser Safety .........................................................................................................................116
CRecommended Network Card Settings ..............................................................................117
DRecommended Switches.....................................................................................................118
EiCon Device Configuration...................................................................................................118
FConnecting Encoders...........................................................................................................119
GRanger E/D Power-I/O terminal ..........................................................................................121
HLaser Safety Key Box (ICT-B) ...............................................................................................123

Chapter 1 Reference Manual
Ranger E/D
6©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved
Introduction
1Introduction
The Ranger is a high-speed 3D camera intended to be the vision component in a machine
vision system. The Ranger makes measurements on the objects that passes in front of the
camera, and sends the measurement results to a PC for further processing. The meas-
urements can be started and stopped from the PC, and triggered by encoders and photo-
electric switches in the vision system.
Figure 1.1 – The Ranger as the vision component in a machine vision system.
The main function of the Ranger is to measure 3D shape of objects. Depending on model
and configuration, the Ranger can measure up to 35 000 profiles per second.
In addition to measure 3D – or range – the Ranger can also measure color, intensity and
scatter:
Range measures the 3D shape of the object by the use of laser triangulation. This can
be used for example for generating 3D images of the object, for size rejection
or volume measurement, or for finding shape defects.
Intensity measures the amount of light that is reflected by the object. This can for
example be used for identifying text on objects or detecting defects on the ob-
jects’ surface.
Color measures the red, green, and blue wavelength content of the light that is
reflected by the object. This can be used to verify the color of objects or to get
increased contrast for more robust defect detection.
Scatter measures how the incoming light is distributed beneath the object’s surface.
This is for example useful for finding the fiber direction in wood or detecting
delamination defects.

Reference Manual Chapter 1
Ranger E/D
©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved 7
Introduction
Figure 1.2 – 3D (left), intensity (top right), and scatter (bottom right) images of a blister
pack with one damaged blister and two empty blisters.
There are four different models of the Ranger available:
Ranger C Connects to the PC via CameraLink.
Ranger E Connects to the PC through a Gigabit Ethernet network.
ColorRanger E Combines the function of a Ranger E camera and a three-color line scan
camera.
Ranger D A low-cost, mid-performance version of the Ranger E, suitable for meas-
uring 3D only in applications without high-speed requirements. The
Ranger D can measure up to 1000 profiles per second.
The Ranger C, E and ColorRanger E models are MultiScan cameras, which mean that they
can make several types of measurements on the object in parallel. This is achieved by
applying different measurement methods to different parts of the sensor.
By selecting appropriate illuminations for the different areas of the measurement scene,
the Ranger can be used for measuring several features of the objects at the very same
time.
Figure 1.3 – Measuring several properties of the objects at once with MultiScan, using
multiple light sources.
Field-of-vie
w
Scatte
r
3D measurement
Grayscale
White light
Lasers

Chapter 2 Reference Manual
Ranger E/D
8©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved
Overview
2Overview
2.1 Measuring with the Ranger
Each time the Ranger makes a measurement, it measures along a cross-section of the
object in front of it. The result of a measurement is a profile, containing one value for each
measured point along the cross-section – for example the height of the object along its
width.
For the Ranger to measure an entire object, the object (or the Ranger and illumination)
must be moved so that the Ranger can make a series of measurements along the object.
The result of such a measurement is a collection of profiles, where each profile contains
the measurement of a cross-section at a certain location along the transportation direc-
tion.
Figure 2.1 – Measuring the range of a cross-section of an object.
For some types of measurements, the Ranger will produce more than one profile when
measuring one cross-section. For example, certain types of range measurements will
result in one range profile and one intensity profile, where the intensity profile contains the
reflected intensity at each measured point.
In addition, the Ranger C, Ranger E and ColorRanger E models – being MultiScan cameras
–can also make parallel measurements on the object. This could for example be used for
measuring surface properties of the objects at the same time as the shape. If the Ranger
is configured for MulitScan measurements, the Ranger may produce a number of profiles
each time it makes one measurement – including multiple profiles from one cross-section
of the object, as well as profiles from parallel cross-sections.
In this manual, the term scan is used for the collection of measurements made by the
Ranger at one point in time.
Note that the range measurement values from the Ranger are not calibrated by default –
that is:
Range values (z coordinates) are given as row – or pixel – locations on the sensor.
The location of a point along the cross-section (x coordinate) is given as a number
representing the column on the sensor in which the point was measured.
The location of a point along the transport direction (y coordinate) is represented by for
example the sequence number of the measurement, or the encoder value for when the
scan was made.
Profiles
z
(range)
x
(width)
Transportation
y

Reference Manual Chapter 2
Ranger E/D
©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved 9
Overview
To get calibrated measurements – for example coordinates and heights in millimeters –
you need to transform the sensor coordinates (row, column, profile id) into world coordi-
nates (x, y, z). This transformation depends on a number of factors, for example the dis-
tance between the Ranger and the object, the angle between the Ranger and the laser,
and properties of the lens. You can do the transformation yourself, or you can use the
3D Camera Coordinator – a tool that performs the transformation from sensor coordinates
(row, column) to world coordinates (x, z). The world coordinate in the movement direction
(y) is obtained by the use of an encoder. For more information about the Coordinator tool,
see the 3D Camera Coordinator Reference Manual.
In a machine vision system, the Ranger acts as a data streamer. It is connected to a PC
through either a CameraLink connection (Ranger C) or a Gigabit Ethernet network (Ran-
ger D & E). The Ranger sends the profiles to the computer, and the computer runs a
custom application that retrieves the profiles and processes the measurement data in
them. This application can for example analyze the data to find defects in the objects and
control a lever that pushes faulty objects to the side.
Before the Ranger can be used in a machine vision system, the following needs to be
done:
Find the right way to mount the Ranger and light sources.
Configure the Ranger to make the proper measurements.
Write the application that retrieves and processes the profiles sent from the Ranger.
The application is developed in for example Microsoft Visual Studio, using the APIs that
are installed with the Ranger development software.
Figure 2.2 – Profiles are sent from the Ranger to a PC, where they are analyzed by a
custom application.
2.2 Mounting the Ranger
Selecting the right way of illuminating the objects to measure, and finding the right way in
which to mount the Ranger and lightings are usually critical factors for building a vision
system that is efficient and robust.

Chapter 2 Reference Manual
Ranger E/D
10 ©SICK AG • Advanced Industrial Sensors • www.sick.com • All rights reserved
Overview
The Ranger must be able to capture images with good quality of the objects in order to
make proper measurements. Good quality in vision applications usually means that there
is a high contrast between the features that are interesting and those that are not, and
that the exposure of the images does not vary too much over time.
A basic recommendation is therefore to always eliminate ambient light – for example by
using a cover – and instead use illumination specifically selected for the measurements to
be made.
The geometries of the set-up – that is the placement of the Ranger, the lightings and the
objects in relation to each other – are also important for the quality of the measurement
result. The angles between the Ranger and the lights will affect the type and amount of
light that is measured, and the resolution in range measurements.
Chapter 3'Mounting Rangers and Lightings' contains an introduction to factors to con-
sider when mounting the Ranger and lightings.
2.3 Configuring the Ranger
Before the Ranger can be used in a machine vision application, the Ranger has to be
configured to make the proper measurements, and to deliver the profiles with sufficient
quality and speed. This is usually done by setting up the camera in a production-like
environment and evaluating different ways of mounting, measurement methods and
parameter settings until the result is satisfactory.
2.3.1 Ranger Studio
The Ranger Studio application – which is a part of the Ranger development software – can
be used for evaluating different set-ups of the camera, and for visualizing the measure-
ments. With Ranger Studio, you can change the settings for the camera and instantly see
how the changes affect the measurement result.
Once the Ranger has been set up to deliver measurement data that meets the require-
ments, the settings can be saved in a parameter file from the Ranger Studio. This parame-
ter file is later used when connecting to the Ranger from the machine vision application.
Figure 2.3 – Configuring the Ranger with Ranger Studio.