SICK AS30 Prime Edge Manual

TECHNICAL INFORMATION
AS30
Application and Tricks

1 Introduction
The AS30 Application Service package was developed to aid in identification of applica‐
tions that could be solved using the AS30 Array sensor. In this document we will elabo‐
rate on the applications as well as giving a step by step configuration for these applica‐
tions. Keep in mind that this is not an instruction manual on how to do an initial setup
of the device. This information is available in the Device operating instructions. This
document is application based setup, optimization and trouble shooting.
As products become more versatile, they also become more complex. This document
aids in bridging this gap. Information not in this document is available on the SICK Inter‐
nal Intranet and includes AS30 product training, application and setup videos, trou‐
bleshooting guide, firmware information and PLC integrations training Videos.
1 INTRODUCTION
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Contents
1 Introduction........................................................................................ 2
2 Getting startet.................................................................................... 4
3 Edge detection of a grid................................................................... 7
4 Guide line detection in print industry............................................. 9
5 Foil control in battery manufacturing............................................. 11
6 Glue line tracking in furniture manufacturing............................... 13
7 Bottle inspection - roundness.......................................................... 15
8 Object diameter measurement....................................................... 17
9 Control of spray jets.......................................................................... 19
10 Detection of spring............................................................................ 22
11 Tool positioning.................................................................................. 24
12 Troubleshooting................................................................................. 26
CONTENTS
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2 Getting startet
First steps
1. Type selection
2. Power connection
3. Connection analog output
1 2 - 3 4 5 6 7 8 9 10 11 12 13 14
AS 30 - W B M 5 3 4 I 2 2 0 A 00
Keyposition Performance Scanning
width
Scanning Dis‐
tance
Control Panel Core /
Prime classi‐
fication
3E = Edge
W = Width
P = Position
63 = 30 mm
4 = 45 mm
5 = 50 mm
71 = 25 mm
3 = 100 mm
10 1 = LEDs &
Buttons
2 = TFT Graph‐
ics
11 1 = Core
2 = Prime
3 = Pro
Type selection
Selecting between Core and Prime:
Table 1: Control Panel
Figure 1: TFT Graphic
Figure 2: LEDs & Buttons
AS30 Core AS30 Prime Applications hints
Configuration via Con‐
trol panel
push buttons & LED TFT display more comfortable
2 GETTING STARTET
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AS30 Core AS30 Prime Applications hints
Repeatability 0.2 mm 30/50 µm Higher precision
Edge guiding yes yes Choosing E type
Width measurement no yes Choosing W type
Position teach yes yes Single point & window
mode
Enhanced functions fix smoothing adjustable smoothing for smoothing rugged
edges time based
analog scale fix scalable analog range adjustment of mea‐
surement field
Both Core and Prime:
Default Analog scale
Default direction
NOTE PLEASE TAKE CARE:
Reading direction is inverse to slide-in direction!
mA values can be adjusted in Prime version
Table 2: Connection
Pin Color Code Description
1 BN = brown + (L+) Supply plus
2 WH =white Qa Analog output 4 ... 20 mA
3 BU = blue M Supply minus
4 BK = black Q (C) Switching output or IO-Link communication
5 GY = gray MF Multifunction control input
GETTING STARTET 2
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Pin Color Code Description
12
5
4 3
Settings via display
The most comprehensive way to configure is via SOPAS as not all settings are available
via the display.
Example for changing to reflector mode:
If a reflector calibration is needed, Sopas will be needed:
2 GETTING STARTET
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3 Edge detection of a grid
Task:
During the manufacturing of metal
grids, the customer wants to maintain
the alignment of the product on the
conveyor. As the target product is not a
solid target, a suitable product in an
acceptable price category has not been
found. The customer has considered
analog inductive sensors, photoelectric
arrays and camera systems with mini‐
mal success.
How to ... (Setup and configuration)
The AS30 can be configured as normal to Edge guiding.
Within the Sopas settings, a smoothing adjustment will resolve the issue of the object
not being solid.
•Use the device in Reflector Mode
•Consider a Tilt angle
•Adjust the Smoothing in Sopas
•Use the sensor as normal
Sopas
Smoothing for moving targets.
Setting in Sopas:
Adjust the Smoothing length in accor‐
dance to the speed of the movement
and the size of the openings
EDGE DETECTION OF A GRID 3
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3 EDGE DETECTION OF A GRID
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4 Guide line detection in print industry
Task:
In large printing houses, the alignment
of the paper is extremely important. On
many occasions, a printing alignment
line is also used. With this line, the
paper edge and the printing edge are
both measured to ensure alignment of
printer head and paper. Camera sys‐
tems have been used to manage this
task, but due to lighting and different
print line colors, repeated setup is
often needed. The customer requires
an accuracy of 0.1 mm with the dis‐
tance from Line to edge calibrated to
13 mm.
How to ... (Setup and configuration)
Using Sopas, the AS30 can be configured to width measurement. Also ensure that the
sensitivity is set to Fine.
On the target, select an Easy Teach-in to detect the first two edges in edge search direc‐
tion.
Select Advanced Teach-in to select the preferred edges.
Sopas
In the Teach-in Wizard, select the Teach-in snapshot and then select the preferred edge.
GUIDE LINE DETECTION IN PRINT INDUSTRY 4
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Click to the selected preferred edge
In Process data, select Width Measure‐
ment and Sensitivity Fine.
Selecting a window mode and set-points, you can set the tolerance window.
Within the Process data the width mea‐
surement is visible in reference to the
two selected edges. This value can be
measured with an analogue value as
well as a standard switching output.
4 GUIDE LINE DETECTION IN PRINT INDUSTRY
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5 Foil control in battery manufacturing
Task:
During the manufacturing of Lithium-
Ion batteries, layers of different materi‐
als including copper and aluminum foil
are used. During the application, it is
required to monitor that the Cathode
electrode film is accurately applied to
the copper film. The customer currently
uses cameras, but due to lighting and
reflection, regular re-programming is
needed. The camera also need to be
re-programmed to every different layer‐
ing process, which requires program‐
mers and downtime.
How to ... (Setup and configuration)
Using the AS30, we can easily configure the required detection edge. Doing so, we can
configure the AS30 to detect that the layers are evenly aligned.
An IO-Link, analog out or a simple switching output can be used to align using the
rollers or give an output as soon as a predetermined tolerance level has been
breached.
•Mount the unit at a slight angle to
avoid reflections
•Select edge guidance
•Use Sopas if the reflection influ‐
ences the measurement
FOIL CONTROL IN BATTERY MANUFACTURING 5
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Sopas
Using Advanced Teach-in
for the edge detection,
you could pick up addi‐
tional reflections as per
image 1. Tilting the sen‐
sor by a few degrees
(Image 2) can clean up
the detection as per
image 3.
Choose needed edge
Ensure that the sensitivity
is set to Coarse due to
material reflections.
Select your preferred out‐
put configuration
5 FOIL CONTROL IN BATTERY MANUFACTURING
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6 Glue line tracking in furniture manufacturing
Task:
In a furniture manufacturing plant, the
customer has an automated gluing sta‐
tion. There is no inspection for the glue
and the customer wishes to add one.
As the gluing takes place in a straight
line, the inspection will also be in a
straight line. However, if a blockage
occurs, the glue jet can be partially
clogged, causing less glue to run or the
glue to run out at an angle that would
lead to quality failure.
How to ... (Setup and configuration)
Using the AS30, we can easily config‐
ure the required detection area. You
can set an area that would trigger a
switching output when the glue is
applied in the correct area. From the
analog value you can determine the
continuous thickness of the applied
glue.
•Using Sopas, do an easy Teach-in
•In the Configuration Qint, set your
two set points in window mode
•In the Process setup, you can select
Process data as width measure‐
ment.
NOTE
You can also monitor the diameter and
position using IO-Link
Sopas
GLUE LINE TRACKING IN FURNITURE MANUFACTURING 6
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The Width is displayed in Sopas and
the output based on 4-20 mA is sent
via Pin 2.
The width and positioning is available
within IO-Link as an integer value.
6 GLUE LINE TRACKING IN FURNITURE MANUFACTURING
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7 Bottle inspection - roundness
Task:
During the manufacturing of glass bot‐
tles, quality inspections are done.
Depending on the need of the company
and their customers, the inspection
could consist of several cameras for
overall inspection, or a roundness
inspection. The roundness inspection
is important for the bottle to be suit‐
able for labelling and branding. Here
we can offer a solution to replace a
camera or camera set with our AS30.
How to ... (Setup and configuration)
Using the AS30, we can set two fields. One field would be the required accuracy toler‐
ance and the second, a confirmation that a bottle is detected. These two signals com‐
bined will set a switching output on pin 4.
The measurement value can also be monitored using the analogue output or IO-Link.
•Set up the sensor with REF-AX-002
reflector
•Do a reflector teach in Sopas
•Run an advanced teach and based
on the transparency of your bottle,
select your sensitivity. For a clear
transparent bottle, consider Course.
•In the Configuration Qint, set your
tolerance values in window mode
•For Qint 2, set your broader detec‐
tion window
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Sopas
During the inspection, the bottle is cen‐
tered on a rotation plate.
The following states of the internal
markers will determine the signal out
put QL1.
Under the tab Smart tasks, set the “AND” function between Qint.1 and Qint.2. Under
this tab you can also add time delays functions if needed.
7 BOTTLE INSPECTION - ROUNDNESS
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8 Object diameter measurement
Task:
In a Bearing manufacturing plant it
happens that balls of incorrect sizing
fall into the mix. The customer wants
do differentiate between one to two
sizes as some bearings use two differ‐
ent sizes. The application is very fast
and an accuracy of 0.5mm needs to be
detected.
How to ... (Setup and configuration)
Using the AS30, we can set two fields. One field would be the correct ball and the sec‐
ond for the second size. If only one is needed, only configure one.
The measurement value can also be monitored using the analogue output or IO-Link for
more variables. With IO-Link, you can have four pre-configured sizes.
•Run an easy teach to evaluate the
first result
•Run an advanced teach and based
on the reflectivity of the ball, select
your sensitivity. In our case “Fine”
was suitable
•In the Configuration Qint, set your
tolerance values in window mode
and output to QL1
•For Qint 2, set your broader detec‐
tion window if a second size is
needed and set the output to QL2
Sopas
First steps
1. Using a set background ( conveyor or slide), do a standard setup of the device. Use
a single teach (Image 1) for each of your sizes to establish the sizing based on the
mounted distance.
2. Set your window to an acceptable tolerance (Image 2).
3. Re-evaluate your sensitivity and teach-in tolerance to the most robust detection.
OBJECT DIAMETER MEASUREMENT 8
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8 OBJECT DIAMETER MEASUREMENT
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9 Control of spray jets
Task:
The customer has primer coating spray
jets that get clogged from time to time.
This clog can cause a reduction in
quantity of primer or an unequal
amount over certain areas being
applied. The customer has been trying
photoelectric sensors, but with limited
success. The customer needs a simple
pass or fail solution.
How to ... (Setup and configuration)
Set up the AS30 for Centre Determination in the Process setup using the device with a
Reflector in reflector mode.
The measurement value can also be monitored using the analogue output or IO-Link for
more variables. With IO-Link, you can have four pre-configured tolerances.
•Run a reflector teach, followed by an
easy teach to evaluate the first
result
•Run an advanced teach and based
on the reflectivity and transparency
of the spray, select your sensitivity.
In our case “Middle” was suitable
•In the Configuration Qint, set your
tolerance values in window mode
and output to QL1
CONTROL OF SPRAY JETS 9
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Sopas
Scanning the center position of a spray
jet,
Qint1 = 1>good
Qint1 = 0>bad
Spray jet can be transparent
Only the center of the spray jet is con‐
sidered, not the diameter
Please consider the Minimum
Detectable Object value:
100 mm version MDO = 0.5 mm
25 mm version MDO = 0.2 mm
9 CONTROL OF SPRAY JETS
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