SICK InspectorP User manual

OPERATING INSTRUCTIONS
InspectorP Rack Fine Positioning
2D machine vision

2Operating Instructions | InspectorP Rack Fine Positioning 8024534 / 16UW / 2020-02-26
Subject to change without notice
Product described
InspectorP Rack Fine Positioning
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Trademarks
IBM is a trademark of the International Business Machine Corporation.
MS-DOS is a trademark of the Microsoft Corporation.
Windows is a trademark of the Microsoft Corporation.
Other product names in this document may also be trademarks and
are only used here for identification purposes.
Legal notes
This work is protected by copyright. The associated rights are reserved by SICK AG.
Reproduction of this document or parts of this document is only permissible within
the limits of the legal provisions of copyright law. Any modification, abridgment, or
translation of this document is prohibited without the express written permission of
SICK AG.
The trademarks mentioned in this document are the property of their respective
owners.
© SICK AG. All rights reserved.
Original document
This document is a translation of the original document from SICK AG.

ABOUT THIS DOCUMENT 1
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Contents
1About this document ............................................................................ 5
1.1 About these operating instructions..............................................................5
1.2 Explanation of symbols ................................................................................. 5
1.3 Further information .......................................................................................6
2Safety information ................................................................................ 7
2.1 Intended use .................................................................................................7
2.2 Improper use ................................................................................................. 7
2.3 Internet protocol (IP) technology ..................................................................7
2.4 Limitation of liability ...................................................................................... 8
2.5 Modifications and conversions .................................................................... 8
2.6 Requirements for skilled persons and operating personnel ......................8
2.7 Operational safety and specific hazards...................................................... 9
3Product description .............................................................................10
3.1 Scope of delivery .........................................................................................10
3.2 Function and use ........................................................................................10
3.3 Principle of operation..................................................................................11
3.4 Single deep applications.............................................................................12
3.5 Single and double deep applications.........................................................12
3.6 Positioning mark .........................................................................................12
4Installation............................................................................................14
4.1 Software installation ...................................................................................14
4.1.1 SICK AppManager............................................................................14
4.1.2 SOPASair (web server) .....................................................................15
4.1.3 Saving parameter set ......................................................................15
4.1.4 Installing firmware updates.............................................................16
4.2 Mounting......................................................................................................16
4.2.1 Mounting requirements ...................................................................16
4.2.2 Mounting procedure ........................................................................19
4.2.3 Mounting device...............................................................................19
4.3 Electrical installation...................................................................................20
4.3.1 Notes on electrical installation .......................................................20
4.3.2 Interfaces .........................................................................................20
5Commissioning and operation ..........................................................21
5.1 Establishing a connection: Ethernet ..........................................................21
5.2 Establishing a connection: PROFINET........................................................21
5.3 Parameterizing device with SOPASair........................................................22
5.3.1 SOPASair user interface ..................................................................22
5.3.2 Setting up user interface .................................................................22
5.3.3 Fine adjustment of the device.........................................................23

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5.3.4 Calibration of the device .................................................................24
5.3.5 Fine adjustment and calibration in single and double deep
applications......................................................................................25
5.3.6 Setting the evaluation mode...........................................................25
5.3.7 Adjusting the target region.............................................................. 27
5.3.8 Optimizing image brightness ..........................................................28
5.3.9 Setting up Ethernet interface..........................................................28
5.3.10 Additional parameters ................................................................29
5.3.11 Completing configuration............................................................29
5.4 Specification of the interface and interaction with the controller............29
5.4.1 Communication process .................................................................29
5.4.2 Interfaces .........................................................................................29
5.4.3 Commands from the controller to the device ................................31
5.4.4 Response from the device to the controller...................................33
5.4.5 Interpretation of the position correction values ............................34
5.4.6 Control via digital inputs and digital outputs .................................35
6Cleaning ................................................................................................38
7Annex ....................................................................................................39
7.1 Parameter....................................................................................................39
7.2 Licenses ...................................................................................................... 43

ABOUT THIS DOCUMENT 1
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1About this document
1.1 About these operating instructions
These operating instructions provide important information on how to use devices
from SICK AG.
Prerequisites for safe work are:
•Compliance with all safety notes and handling instructions supplied.
•Compliance with local work safety regulations and general safety regulations for
device applications.
The operating instructions are intended to be used by qualified personnel and
electrical specialists.
NOTE
Read these operating instructions carefully to familiarize yourself with the device
and its functions before commencing any work.
The instructions constitute an integral part of the product and are to be stored in the
immediate vicinity of the device so they remain accessible to staff at all times. Should
the device be passed on to a third party, these operating instructions should be
handed over with it.
These operating instructions do not provide information on operating the machine
or system in which the device is integrated. For information about this, refer to the
operating instructions of the specific machine.
Related publications
The following related publications must be read:
Part no.
Publication
8019946
InspectorP63x Flex C-mount and S-mount Operating Instructions
8018486
Technical Information for Ring Illumination Unit VI55I
1.2 Explanation of symbols
Warnings and important information in this document are labeled with symbols. The
warnings are introduced by signal words that indicate the extent of the danger. These
warnings must be observed at all times and care must be taken to avoid accidents,
personal injury, and material damage.
HAZARD
… indicates a situation of imminent danger, which will lead to a fatality or serious
injuries if not prevented.
WARNING
… indicates a potentially dangerous situation, which may lead to a fatality or
serious injuries if not prevented.

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CAUTION
… indicates a potentially dangerous situation, which may lead to minor/slight
injuries if not prevented.
IMPORTANT
… indicates a potentially harmful situation, which may lead to material damage if
not prevented.
NOTE
… highlights useful tips and recommendations as well as information for efficient
and trouble-free operation.
1.3 Further information
NOTE
Other documentation for the device can be found on the online product page at:
•www.sick.com/InspectorP_Rack_Fine_Positioning
There, additional information has been provided depending on the product, such
as:
•Model-specific online data sheets for device variants, containing technical
data, dimensional drawing, and specification diagrams
•These device operating instructions, available in English and German, and in
other languages if applicable
•Other publications related to the devices described here
•
Publications dealing with accessories

SAFETY INFORMATION 2
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2Safety information
2.1 Intended use
InspectorP Rack Fine Positioning is suited for storage and conveyor applications in
which precise positioning of automated storage and retrieval systems is required when
putting goods into and taking them out of storage.
The management, commissioning and operation of the device is done on a computer
by using the SICK AppManager and SOPASair software. The device sends results to
a higher-level control (e.g. PLC) in order to coordinate further processing via the host
interface.
SICK AG assumes no liability for losses or damage arising from the use of the product,
either directly or indirectly. This applies in particular to use of the product that does
not conform to its intended purpose and is not described in this documentation.
2.2 Improper use
Any use outside of the stated areas, in particular use outside of the technical
specifications and the requirements for intended use, will be deemed to be incorrect
use.
•The device does not constitute a safety component in accordance with the
respective applicable safety standards for machines.
•The device must not be used in explosion-hazardous or corrosive areas or under
extreme ambient conditions.
•Any use of accessories not specifically approved by SICK AG is at your own risk.
WARNING
Danger due to improper use!
Any improper use can result in dangerous situations.
Therefore, observe the following information:
•Device should be used only in accordance with its intended use.
•
All information in these operating instructions must be strictly observed.
2.3 Internet protocol (IP) technology
NOTE
SICK uses standard IP technology in its products. The focus is on availability of
products and services.
SICK always assumes the following prerequisites:
•The customer ensures the integrity and confidentiality of the data and rights
affected by its own use of the aforementioned products.
•In all cases, the customer implements the appropriate security measures,
such as network separation, firewalls, virus protection, and patch
management.

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2.4 Limitation of liability
Relevant standards and regulations, the latest technological developments, and our
many years of knowledge and experience have all been taken into account when
compiling the data and information contained in these operating instructions. The
manufacturer accepts no liability for damage caused by:
•Non-compliance with product documentation (e.g. operating instructions)
•Improper use
•Use of untrained staff
•Unauthorized conversions
•Technical modifications
•Use of unauthorized spare parts, consumables, and accessories
The actual scope of delivery may differ from the features and illustrations shown here
where special variants are involved, if optional extras have been ordered, or as a result
of the latest technical changes.
2.5 Modifications and conversions
IMPORTANT
Modifications and conversions to the device may result in unforeseeable
dangers.
Interrupting or modifying the device or SICK software will invalidate any warranty
claims against SICK AG. This applies in particular to opening the housing, even as part
of mounting and electrical installation.
2.6 Requirements for skilled persons and operating personnel
WARNING
Risk of injury due to insufficient training!
Improper handling of the device may result in considerable personal injury and
material damage.
•
All work must only ever be carried out by the stipulated persons.
This product documentation refers to the following qualification requirements for the
various activities associated with the device:
•Instructed personnel have been briefed by the operating entity about the tasks
assigned to them and about potential dangers arising from improper action.
•Skilled personnel have the specialist training, skills, and experience, as well as
knowledge of the relevant regulations, to be able to perform tasks assigned to them
and to detect and avoid any potential dangers independently.
•Electricians have the specialist training, skills, and experience, as well as
knowledge of the relevant standards and provisions, to be able to carry out work on
electrical systems and to detect and avoid any potential dangers independently.
The electrician must comply with the provisions of the locally applicable work safety
regulation.

SAFETY INFORMATION 2
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The following qualifications are required for various activities:
Activities
Qualifications
Mounting, maintenance
•Basic practical technical training
•Knowledge of the current safety regulations in
the workplace
Electrical installation, device
replacement •Practical electrical training
•Knowledge of current electrical safety regulations
•Knowledge of the operation and control of the
devices in their particular application
Commissioning, configuration
•Basic knowledge of the WindowsTM operating
system in use
•Basic knowledge of the design and setup of the
described connections and interfaces
•Basic knowledge of data transmission
•Knowledge of the programming of image-
processing systems and network components
Operation of the device for the
specific application •Knowledge of the operation and control of the
devices in their particular application
•Knowledge of the software and hardware
environment for the particular application
concerned
2.7 Operational safety and specific hazards
You can find more detailed safety information in the product documentation of the
InspectorP63x Flex C-mount and S-mount. The product documentation is available in
the Internet as a download at www.sick.com/8019946.

3PRODUCT DESCRIPTION
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3Product description
3.1 Scope of delivery
The scope of delivery includes the following components:
No. of
units
Component
Remarks
1
Device in the version ordered
V2D63xP-xMxSCxx (single deep
applications)
or
V2D63xP-xMxSExx (single and double
deep applications)
2
Sliding nut with 5.5 mm-deep M5
threaded mounting hole
Positioned in the slot on the right side of
the device on delivery.
Alternative mounting option for the device
instead of tapped blind hole. Use in pairs.
1
Hexagon key WAF 2
For manual actuation of the focus screw.
4
Label (round, self-adhesive)
Protects the focus setting when using an
S-mount lens. Adjustment is performed
using the manual focus screw. The label
is stuck over the access opening for the
focus screw on the top of the device.
1
Printed safety notes, multilingual
Brief information and general safety
notes.
3.2 Function and use
Temperature-, load- and steel construction-dependent influencing variables generate
varying geometric conditions at transfer points in the storage and conveyor technology.
These conditions make safe automated positioning of automated storage and retrieval
systems more difficult when putting in and removing load carriers from storage.
InspectorP Rack Fine Positioning supports precise positioning when putting in and
removing load carriers from storage. In doing so, positioning processes can be
controlled both for single deep applications as well as combined applications with
single and double deep racks. The device is mounted to the automated storage and
retrieval system. The device takes pictures when putting goods into and taking them
out of storage and detects a hole or a round reflector as a positioning mark in the rack.
Using this positioning mark, the device sends a deviation of the current position of the
Figure 1: Negative influencing variables during automated positioning processes

PRODUCT DESCRIPTION 3
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automated storage and retrieval system from the target position to a higher-level
control (e.g. PLC), which initiates rack fine positioning of the automated storage and
retrieval system. This prevents load carriers from colliding with the racks.
3.3 Principle of operation
Rack fine positioning takes place with a positioning mark on the rack. Positioning is
possible over holes (recommended hole diameter: 13 mm) and round reflectors as
positioning marks. A distinction is also made between single and double deep racks.
In single deep racks, the shelf has space for a storage unit. In double deep racks, two
storage units are operated one behind another, whereby the shelf is twice as deep.
The device can handle both applications. Depending on the application (type of
positioning mark, rack depth), there are differences in system design such as the
selection of the lens focal length and the use of lighting filters.
The positioning mark (hole or reflector) is typically placed in the center of the camera
image and defined as the target region during alignment and rack fine positioning of
the device. The target region typically corresponds to the area around the center point
of the image. If necessary, the target region can be moved into another area of the
image using the operating software. The device detects the current position of the
positioning mark during operation and forwards the deviation from the target region to
the control. Using the information provided by the device, the control initiates rack fine
positioning of the automated storage and retrieval system. If the positioning mark is
located in the target region, goods may be put onto and taken off the rack. If the
positioning mark is outside the target region, the relative position in relation to the
target region is displayed using ambient sectors.
Figure 2: Detection and output related to the target region (example)
(1) Ambient sector (blue)
(2) Positioning mark (red)
(3) Target region (green)

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3.4 Single deep applications
Single deep applications can be used in the following cases:
Positioning mark
Rack depth
Working distance
Drill hole
Single deep rack
100 mm … 350 mm
1)
Reflector
Single deep rack
150 mm … 700 mm 1)
1) Measured from the viewing window of the device to the rack. Depends on the application.
This application has a large field of view at close range.
3.5 Single and double deep applications
Combined applications with single and double deep racks can be used in the following
cases:
Positioning mark
Rack depth
Working distance
Drill hole
Combination of single and
double deep racks
200 mm … 1,950 mm 1)
Drill hole
Single deep rack
200 mm … 1,950 mm 1)
1) Measured from the viewing window of the device to the rack. Depends on the application.
3.6 Positioning mark
The accuracy and tolerance when detecting the positioning mark and in the sub-
sequent position correction depends on the working distance, the sensor resolution,
and the ambient conditions. Each specific application situation must be considered
individually.
Only relevant for single deep applications: The type of positioning mark (hole or
reflector) can be set in SOPASair in the Setup window using the Preconfiguration
application parameter.
Applications with holes
Holes as positioning marks can be used both for single deep applications as well as
combined applications with single and double deep racks.
When using holes as positioning marks, please note:
•Recommended diameter of the hole: 8 mm … 15 mm (typically 10 mm … 13 mm).
•Surface characteristics of the steel around the hole: diffuse, lightly reflective.
Recommendation: hot-dip galvanized steel.
•Ensure that there are no fully reflective surfaces behind the hole. Reduce the effect
of any fully reflective surfaces with matt black spray paint or cover them with
adhesive tape.

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Applications with reflectors
Round reflectors as positioning marks can only be used for single deep applications.
The surface characteristics of the steel around the reflector will have only a minor
effect on the application and can be ignored.
NOTE
The following reflectors are recommended:
•PL22-1 (part number: 1003546)
•PL22-2 (part number: 1003621)
•PL22-3 (part number: 1004488)
•PL22-4 (part number: 5327829)
You can find the reflectors as accessories in the Internet at www.sick.com by
entering the respective part number into the search field.

4INSTALLATION
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4Installation
4.1 Software installation
4.1.1 SICK AppManager
Installation of the SICK AppManager is required to perform the following tasks:
•Reading out and changing the IP address
•Saving (backing up) currently valid parameter set on the computer or a microSD
memory card in the device (cloning)
•Installing firmware updates
Installing SICK AppManager
To install SICK AppManager, open the installation file (*.exe) and follow the instructions
on the screen.
SICK AppManager user interface
(1) Device window (window name changes depending on the connected device)
(2) Device Search window
(3) Firmware window
NOTE
The current version of SICK AppManager can be downloaded in the Internet at:
www.sick.com/SICK_AppManager
Figure 3: SICK AppManager user interface

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4.1.2 SOPASair (web server)
The device is set up and parameterized using the SOPASair operating software.
You can call up the operating software with a web browser (recommendation: Google
Chrome). No installation of software is required. The device must be supplied with
voltage and connected to the computer via the Ethernet interface in order to use
the SOPASair web server.
Starting SOPASair
1. Start web browser (recommendation: Google Chrome).
2. Enter the device IP address into the address line.
The SOPASair user interface appears.
4.1.3 Saving parameter set
The currently valid parameter set can be backed up using SICK AppManager.
The complete environment of the device is then available if support is necessary.
Saving on the computer (backup)
1. In the SICK AppManager, in the Device window, click on the Backup button.
The Backup Apps and Data window opens.
2. Fill out the Name, Version and Filename fields.
3. Select the path for data backup.
4. Select all available options.
5. To run the backup, click on the Backup button in the Backup Apps and Data
window.
Saving on a microSD memory card (cloning)
IMPORTANT
Risk of damage to the memory card!
▸To avoid damaging the memory card, make sure the device is
de-energized when you insert or remove the card. For this purpose,
disconnect the device from the supply voltage accordingly.
Figure
4: “Backup Apps and data” window

4INSTALLATION
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The card slot for the microSD memory card is located at the top of the device at the
rear under the hinged cover.
1. Switch off the supply voltage to the device.
2. Undo the screws on the hinged cover.
3. Open the cover.
4. Insert the microSD memory card.
5. Close the hinged cover. Make sure that the cover is completely flush with the
housing.
6. Tighten the screws on the hinged cover again.
7. Switch on the supply voltage for the device.
8. In the SICK AppManager, in the Device window, click on the Clone button.
From now on, the device will back up the current parameter set on the
microSD memory card.
4.1.4 Installing firmware updates
To install firmware updates using SICK AppManager:
1. Pull the file with the firmware update into the Firmware window with drag and
drop.
2. Select the file you want to install.
3. Click on the Install button in the lower right section of the window to install the
update.
4.2 Mounting
4.2.1 Mounting requirements
General mounting requirements
•Distance from the device to the positioning mark (hole or reflector):
100 mm … 1,995 mm. The distance depends on the device type and type of
positioning mark.
•The user can locate the positioning mark anywhere in the field of view of the device
to suit the application situation. Recommendation: Locate the positioning mark at
the center point of the image.
•The positioning mark must be within the area that is visible to the device in single
and double deep applications when mounted at a permissible working distance.
•An algorithm is available to classify and ignore multiple positioning marks within the
field of view of the device.
Mounting requirements: holes as positioning marks
•Ensure that no objects or contamination with distinct contours, or with a similar
diameter or surface as the hole are present in the field of view.
•Ensure that there are no light sources mounted behind the hole.
•Ensure that the beams of the high-bay rack system are not heavily contaminated in
the area of the hole. If necessary, clean the area around the hole.

INSTALLATION 4
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Mounting requirements: reflector as positioning mark
•Ensure that there are no light sources in the field of view of the device.
•Ensure that the reflector is not contaminated. A reflection must be ensured.
If necessary, clean the reflector.
•During rack fine positioning with round reflectors, lights structures are searched
for on darker surfaces. Use a polarizing filter to prevent total reflection of the
illumination. The polarizing filter hides the total reflecting light from the surface.
Do not use the polarizing filter for applications with holes.
NOTE
You can find the the polarizing filter (part number: 2088229) as an accessory in
the Internet at www.sick.com by entering the part number into the search field.

4INSTALLATION
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The following graphic shows step-by-step mounting of the polarizing filter:
(1) Scope of delivery of polarizing filter kit (part number: 2088229): Polarizing filter disk.
(2) Turn optics cover counterclockwise.
(3) Remove optics cover.
(4) Turn spacer ring counterclockwise.
(5) Remove spacer ring.
(6) Clip on the polarizing filter disk. Make sure the alignment is correct: Centering ring downwards,
recesses over retaining clips.
(7) Put on optics cover.
(8) Turn optics cover clockwise.
Figure 5: Polarizing filter mounting

INSTALLATION 4
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4.2.2 Mounting procedure
The device is delivered with pre-mounted illumination, pre-focused optics, pre-installed
software and pre-configured defaults. This enables quick and easy commissioning.
The optics are already pre-focused at a distance which is suitable for most applica-
tions. It might be necessary to adjust the focus position in rare cases, see Figure 8:
Manual focus screw, page 24.
The procedure for mounting the device is divided into the following steps:
•Mount the device with a view to the positioning mark
•Connect the device to interfaces and supply voltage
•Align the device using the laser alignment aid
4.2.3 Mounting device
Install the device to the mechanics with the bracket so that the device points vertically
to the positioning mark on the rack.
NOTE
It should be mounted so that it is exposed to as little shock and vibration as
possible. Ensure that the position of the device is not moved by vibrations during
operation.
After switching on the supply voltage, the Continuous measurement parameter in the
device is activated by default. The device immediately goes into measurement mode.
Press the arrow button to switch the laser alignment aid on and off. The laser
alignment aid helps align the device. The device projects two red laser points on the
rack, signaling the viewing direction of the camera. The center of the image is between
the two points. Align the device so that the positioning mark on the rack is between
the two laser points and is therefore in the center of the image.
In a combined application with single and double deep racks, first align the device on
the single deep rack. Then adjust the position of the device for the double deep rack, if
applicable.
Figure
6: Mounting example

4INSTALLATION
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4.3 Electrical installation
4.3.1 Notes on electrical installation
NOTE
For detailed information on device connection, see the operating instructions of
the InspectorP63x Flex C-mount and S-mount at www.sick.com/8019946.
4.3.2 Interfaces
The device offers both an Ethernet interface and digital inputs and digital outputs for
communicating with the control. Parallel use of the two interfaces for communicating
with the control is not recommended.
Ethernet interface
The user can parameterize the device via the Ethernet interface using the SOPASair
operating software. Furthermore, the device transfers the deviation between the
actual and the target position of the automated storage and retrieval system to the
control via the Ethernet interface.
In doing so, the device precisely forwards the deviation between the actual position
and the target position to the control using X- and Y-values. Based on these values,
the control initiates position correction of the automated storage and retrieval system.
The necessary communication protocol (PROFINET, TCP/IP or UDP) is set using the
SOPASair operating software, see 5.3.9 Setting up Ethernet interface, page 28.
Digital inputs and digital outputs
The device is triggered via the digital input. The device outputs the position results
using 4 digital outputs.
The device only delivers information on the direction (up, down, left, right) via the
digital outputs. The automated storage and retrieval system approach the target
position step-by-step based on this direction information. A quantitative statement
about the deviation between the actual and the target position of the automated
storage and retrieval system is not transmitted.
Use the following pins to use the digital inputs and digital outputs:
•Pin 10: Sensor 1, digital input, IN 1 (switch continuous measurement on and off)
•Pin 15: Sensor 2, digital input, IN 2 (activate and deactivate double deep mode)
•Pin 13: IN/OUT 3 (direction specification: up)
•Pin 14: IN/OUT 4 (direction specification: down)
•Pin 16: IN/OUT 5 (direction specification: right)
•Pin 17: IN/OUT 6 (direction specification: left)
For further information on digital inputs and digital outputs, see 5.4.6 Control via digi-
tal inputs and digital outputs, page 35.