SICK TriSpector1000 User manual

OPERATING INSTRUCTIONS
TriSpector1000
3D Vision

Described product
TriSpector1000
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
2011/65/EU
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Contents
1 About this document........................................................................ 7
1.1 Information on the operating instructions.............................................. 7
1.2 Explanation of symbols............................................................................ 7
1.3 Further information................................................................................... 8
2 Safety information............................................................................ 9
2.1 Intended use............................................................................................. 9
2.2 Improper use............................................................................................. 9
2.3 Laser safety............................................................................................... 9
3 Product description........................................................................... 10
3.1 System overview....................................................................................... 10
3.2 Scope of delivery....................................................................................... 10
3.3 System requirements............................................................................... 11
3.4 TriSpector1000 variants.......................................................................... 11
3.5 Dimensional drawings.............................................................................. 11
3.5.1 TriSpector1008........................................................................ 12
3.5.2 TriSpector1030........................................................................ 12
3.5.3 TriSpector1060........................................................................ 13
3.6 LED indicators........................................................................................... 13
4 Transport and storage....................................................................... 15
4.1 Transport................................................................................................... 15
4.2 Transport inspection................................................................................. 15
4.3 Storage...................................................................................................... 15
5 Mounting............................................................................................. 16
5.1 Mounting instructions............................................................................... 16
5.1.1 Mounting a microSD memory card......................................... 16
5.2 Field of view diagrams.............................................................................. 17
6 Electrical installation........................................................................ 18
6.1 Prerequisites for the safe operation of the device in a system............. 18
6.2 Connection diagram................................................................................. 19
6.3 Encoder..................................................................................................... 19
6.4 Pin assignment......................................................................................... 20
7 Operation............................................................................................ 22
7.1 Commissioning......................................................................................... 22
7.1.1 Installing SOPAS....................................................................... 22
7.1.2 Connecting the hardware........................................................ 22
7.1.3 Connecting the TriSpector1000 to SOPAS ET........................ 22
7.2 Description of the user interface............................................................. 23
7.2.1 Menus....................................................................................... 24
7.2.2 Image handling controls.......................................................... 24
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7.2.3 Image view modes................................................................... 25
7.2.4 Image view options.................................................................. 26
7.2.5 Image view controls................................................................. 27
7.3 Handling jobs and configurations............................................................ 27
7.4 Workflow steps.......................................................................................... 28
7.5 Image workflow step.................................................................................. 29
7.5.1 Scanning an object.................................................................. 29
7.5.2 Setting the field of view........................................................... 30
7.5.3 Adjusting the image settings................................................... 30
7.5.4 Configuring the trigger settings.............................................. 31
7.5.5 Recording images.................................................................... 32
7.6 Task workflow step..................................................................................... 32
7.6.1 Using the tools......................................................................... 32
7.6.2 Setting the region of interest.................................................. 33
7.6.3 Tool groups............................................................................... 34
7.6.4 Shape tool.................................................................................. 34
7.6.5 Blob tool.................................................................................... 35
7.6.6 Edge tool.................................................................................... 36
7.6.7 Plane tool................................................................................... 37
7.6.8 Fix Plane tool.............................................................................. 38
7.6.9 Peak tool.................................................................................... 38
7.6.10 Point tool................................................................................... 39
7.6.11 Area tool.................................................................................... 39
7.6.12 Distance tool.............................................................................. 40
7.6.13 Angle tool................................................................................... 40
7.6.14 Application example: Counting chocolates............................ 41
7.7 Results workflow step................................................................................ 43
7.7.1 Result handling........................................................................ 43
7.7.2 Tool result output..................................................................... 43
7.7.3 Decision model........................................................................ 44
7.7.4 Conditions................................................................................ 44
7.7.5 Digital outputs.......................................................................... 46
7.7.6 Ethernet output string............................................................. 46
7.7.7 Image logging........................................................................... 47
7.7.8 Functions and operators......................................................... 47
7.8 Interfaces workflow step............................................................................ 50
7.8.1 Configuring the digital in- and outputs................................... 50
7.8.2 Using the command channel.................................................. 50
7.8.3 Sending an output string......................................................... 50
7.8.4 Logging images to an FTP server............................................ 51
7.8.5 Enabling the web interface..................................................... 51
7.8.6 Setting parameters of the serial interface............................. 52
7.8.7 Logging images to a microSD memory card.......................... 52
7.8.8 Selecting jobs via digital inputs.............................................. 54
7.8.9 Fieldbuses................................................................................ 54
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7.9 Using the SOPAS ET emulator.................................................................. 54
7.9.1 Starting the emulator.............................................................. 54
7.9.2 Controlling the emulator.......................................................... 55
7.9.3 Selecting images to be used................................................... 56
7.9.4 Copying a configuration from the emulator........................... 56
7.10 Exporting and importing data.................................................................. 56
8 Maintenance...................................................................................... 58
8.1 Cleaning..................................................................................................... 58
8.2 Upgrading the firmware............................................................................ 58
8.3 Data backup and restoration................................................................... 58
9 Troubleshooting................................................................................. 59
9.1 General faults, warnings, and errors....................................................... 59
9.2 Repairs...................................................................................................... 60
9.3 Returns...................................................................................................... 60
9.4 Disposal..................................................................................................... 60
10 Technical data.................................................................................... 61
10.1 Features.................................................................................................... 61
10.2 Ambient data............................................................................................. 61
10.3 Interfaces.................................................................................................. 61
10.4 Mechanics and electronics...................................................................... 62
10.5 Input switching levels............................................................................... 62
10.6 Output switching levels............................................................................. 63
10.7 Performance............................................................................................. 63
11 Accessories........................................................................................ 64
12 Appendix............................................................................................. 65
12.1 Declarations of conformity....................................................................... 65
12.2 Licenses.................................................................................................... 66
12.3 Available commands for command channel........................................... 67
12.3.1 Sending a command............................................................... 67
12.3.2 Command examples................................................................ 67
12.3.3 General commands................................................................. 67
12.3.4 Tool commands........................................................................ 69
12.4 Connecting TriSpector1000 to CDF600-2200....................................... 72
12.5 Setting up a TriSpector1000 to communicate via EtherNet/IP............. 73
12.5.1 Interfacing TriSpector1000 with an Allen Bradley/Rockwell
Programmable Controller........................................................ 73
12.5.2 Input and Output Data Assemblies - TriSpector1000........... 74
12.5.3 Inside the Programmable Controller...................................... 77
12.5.4 Triggering a TriSpector1000.................................................... 80
12.5.5 Switching Jobs.......................................................................... 82
12.5.6 TriSpector1000 EtherNet/IP Compatibility............................ 84
12.6 TriSpector1000 Result Output Function Block....................................... 85
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12.6.1 About this document............................................................... 85
12.6.2 Overview................................................................................... 86
12.6.3 TriSpector1000 configuration................................................. 86
12.6.4 PLC Configuration.................................................................... 87
12.6.5 Modify the Function Block to fit your output.......................... 94
12.6.6 Troubleshooting....................................................................... 100
12.6.7 Function block differences...................................................... 102
CONTENTS
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1 About this document
1.1 Information on the 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 before starting any work on the device, in
order to familiarize yourself with the device and its functions.
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 operat‐
ing instructions of the specific machine.
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, per‐
sonal injury, and material damage.
DANGER
… 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.
CAUTION
… indicates a potentially dangerous situation, which may lead to minor/slight injuries if
not prevented.
NOTICE
… indicates a potentially harmful situation, which may lead to material damage if not
prevented.
ABOUT THIS DOCUMENT 1
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NOTE
… highlights useful tips and recommendations as well as information for efficient and
trouble-free operation.
1.3 Further information
NOTE
Further documentation for the device can be found on the online product page at:
www.sick.com/TriSpector1000
The following information is available for download there:
■Model-specific online data sheets for device variants, containing technical data,
dimensional drawings and diagrams.
■EU declaration of conformity for the product family.
■Dimensional drawings and 3D CAD dimension models in various electronic for‐
mats.
■These operating instructions.
■The device quickstart, in English and German.
■Other publications related to the device described here.
■Publications dealing with accessories.
1 ABOUT THIS DOCUMENT
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2 Safety information
2.1 Intended use
The TriSpector1000 is an industrial 3D sensor that uses laser triangulation on objects
to produce 3D images. Embedded 3D image analysis tools are applied to the 3D
images. The results are sent to a control system via external interfaces.
The TriSpector1000 series is primarily designed for use in industrial and logistics areas,
and it meets the requirements for industrial ruggedness, interfaces and data process‐
ing.
2.2 Improper use
Any use outside of the stated areas, in particular use outside of the technical specifica‐
tions and the requirements for intended use, will be deemed to be incorrect use.
•The device does not constitute a safety-relevant device according to the EC
Machinery Directive (2006/42/EC).
•The device must not be used in explosion-hazardous areas, in corrosive environ‐
ments or under extreme ambient conditions.
•Any use of accessories not specifically approved by SICK AG is at your own risk.
2.3 Laser safety
The TriSpector1000 is equipped with a Class 2 laser according to EN/IEC
60825-1:2014 (Class 2M according to EN/IEC 60825-1:2007). It complies to 21 CFR
1040.10 except for deviations pursuant to Laser Notice No.50, dated June 24, 2007.
The legal regulations on laser safety for the laser class of TriSpector1000 must be
adhered to.
CAUTION
Optical radiation: Laser class 2
The human eye is not at risk when briefly exposed to the radiation for up to 0.25 sec‐
onds. Exposure to the laser beam for longer periods of time may cause damage to the
retina. The laser radiation is harmless to human skin.
■Do not look into the laser beam intentionally.
■Never point the laser beam at people's eyes.
■If it is not possible to avoid looking directly into the laser beam, e.g., during com‐
missioning and maintenance work, suitable eye protection must be worn.
■Avoid laser beam reflections caused by reflective surfaces. Be particularly careful
during mounting and alignment work.
■Do not open the housing. Opening the housing will not switch off the laser. Open‐
ing the housing may increase the level of risk.
■Current national regulations regarding laser protection must be observed.
NOTICE
If the TriSpector1000 is mounted in a system or a casing, so that the laser safety notice
signs are hidden, additional signs must be placed beside the exit aperture of the laser
beam on the system or casing. Additional signs are not included in the delivery.
SAFETY INFORMATION 2
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3 Product description
3.1 System overview
The TriSpector1000 uses laser triangulation on objects to produce 3D images. Embed‐
ded 3D image analysis tools are applied to the 3D images. The results are sent to a
control system via external interfaces.
Laser triangulation means that the object is illuminated with a laser from one direction,
and the camera acquires an image of the laser line from another direction. Each
acquired image contains a height profile, which corresponds to a cross-section of the
object. By making a scan, which means collecting height profiles across the object
while it moves, a complete 3D image can be acquired.
21
Figure 1: Laser triangulation principle
1Field of view
2Laser
Figure 2: Height profile Figure 3: 3D image
3.2 Scope of delivery
The delivery of the device includes the following components:
■TriSpector1000 series sensor
■Printed quickstart in English and German
■Printed safety notes
Accessories
Accessories, such as brackets and connecting cables, are only supplied if ordered sep‐
arately.
3 PRODUCT DESCRIPTION
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3.3 System requirements
For adequate SOPAS ET performance, use a PC with Intel Core I5 540M (2.53 GHz, 4
GB RAM) or better, and a screen resolution of at least 1024x768.
Graphics card: Intel® HD Graphics video card (or NVIDIA® NVS 3100M 512MB
GDDR3), or better. Make sure to use the latest graphic card drivers.
Ethernet connection is required, 100 Mbit/s or better. 1 Gbit/s or faster is recom‐
mended for best performance during configuration of the device via SOPAS ET.
Operating systems: Windows 7 or Windows 10 (64 bit is recommended).
SOPAS ET version: 2018.2 or higher
Hard drive: Minimum 550 MB.
Supported web browsers: Google Chrome (recommended due to advanced support of
WebGL and WebSockets) and Microsoft Edge.
SD memory card (optional): SICK microSD memory card (part no 4051366 or
4077575).
A mouse with at least three buttons (or a scroll wheel) is recommended.
3.4 TriSpector1000 variants
TriSpector1000 is available with three different field of view (FoV) sizes and two differ‐
ent window materials. PMMA is a plastic material used as an alternative material to
glass in food processing environments.
Table 1: TriSpector1008 (Small FoV)
Window material No.
Glass 1075604
PMMA 1060426
Table 2: TriSpector1030 (Medium FoV)
Window material No.
Glass 1072923
PMMA 1060427
Table 3: TriSpector1060 (Large FoV)
Window material No.
Glass 1075605
PMMA 1060428
3.5 Dimensional drawings
See chapter 3.5.1, chapter 3.5.2 and chapter 3.5.3 for dimensional drawings for all
three TriSpector1000 variants. The dimensional drawings can also be downloaded as
CAD files from the TriSpector1000 device page at www.sick.com/TriSpector1000.
PRODUCT DESCRIPTION 3
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3.5.1 TriSpector1008
61.9 (1.26)
27.9
(1.10)
2
(0.08)
34
(1.34)
38
(1.50)
18.5
(0.73)
136 (5.35)
145.9 (5.74)
9.9
(0.39)
5.6
(0.22)
24 (0.94)
24 (0.94)
18
(0.71)
82 (3.23)
83.3 (3.28)
45
(1.77)
7.4
(0.29)
47
(1.85)
94 (3.70)
21
(0.83)
á ß à
4 5 6 7 8
9
32
1
M12 x 1
M12 x 1
M12 x 1
1Connector Encoder (thread inside)
2Connector Gigabit Ethernet (Gig E)
3Connector Power I/O (thread outside)
4LED: On
5LED: State
6LED: Link/Data
7LED: Result
8LED: Laser
9Fastening threads (M5x8.5 length)
ßOptical receiver (center)
àOptical sender (center)
áSD-card
3.5.2 TriSpector1030
1
2
4
á ß à
5 6 7 8
9
3
61.9 (2.44)
27.9
(1.10)
114.5 (4.51)
217 (8.54)
226.9 (8.93)
18.5
(0.72)
2
(0.08)
34
(1.34)
M12 x 1
M12 x 1
M12 x 1
45
(1.77)
7.4
(0.29)
61.5 (2.42)94 (3.70)
9.9
(0.39)
5.6
(0.22)
83.3 (3.28)
47 (1.85)
3 PRODUCT DESCRIPTION
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1Connector Encoder (thread inside)
2Connector Gigabit Ethernet (Gig E)
3Connector Power I/O (thread outside)
4LED: On
5LED: State
6LED: Link/Data
7LED: Result
8LED: Laser
9Fastening threads (M5x8.5 length)
ßOptical receiver (center)
àOptical sender (center)
áSD-card
3.5.3 TriSpector1060
61.9 (1.26)
27.9
(1.10)
205.5 (8.09)
307 (12.09)
316.9 (12.48)
2
(0.08) 34
(1.34)
18.5
(0.73)
45
(1.77)
7.4
(0.29)
47
(1.85)
94 (3.70)
106.5
(4.19)
9.9
(0.39)
5.6
(0.22)
24 (0.94)
24 (0.94)
18
(0.71)
82 (3.23)
83.3 (3.28)
á ß à
1
2
4 5 6 7 8
3
9
M12 x 1
M12 x 1
M12 x 1
1Connector Encoder (thread inside)
2Connector Gigabit Ethernet (Gig E)
3Connector Power I/O (thread outside)
4LED: On
5LED: State
6LED: Link/Data
7LED: Result
8LED: Laser
9Fastening threads (M5x8.5 length)
ßOptical receiver (center)
àOptical sender (center)
áSD-card
3.6 LED indicators
Name Color Function
On Green Power on
State Green Ready for trig input and image acquisition
Link/Data Green Gigabit Ethernet (Gig E)
Link: LED on
Activity: LED blink
PRODUCT DESCRIPTION 3
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Name Color Function
Result Green Overall result: Pass
Red Overall result: Fail
Blue Result not found
No light Result invalid or neutral
Laser Green Laser on
3 PRODUCT DESCRIPTION
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4 Transport and storage
4.1 Transport
For your own safety, please read and observe the following notes:
NOTICE
Damage to the product due to improper transport.
■The device must be packaged for transport with protection against shock and
damp.
■Recommendation: Use the original packaging as it provides the best protection.
■Transport should be performed by trained specialist staff only.
■The utmost care and attention is required at all times during unloading and trans‐
portation on company premises.
■Note the symbols on the packaging.
■Do not remove packaging until immediately before you start mounting.
4.2 Transport inspection
Immediately upon receipt in Goods-in, check the delivery for completeness and for any
damage that may have occurred in transit. In the case of transit damage that is visible
externally, proceed as follows:
■Do not accept the delivery or only do so conditionally.
■Note the scope of damage on the transport documents or on the transport com‐
pany's delivery note.
■File a complaint.
NOTE
Complaints regarding defects should be filed as soon as these are detected. Damage
claims are only valid before the applicable complaint deadlines.
4.3 Storage
Store the device under the following conditions:
■Recommendation: Use the original packaging.
■Do not store outdoors.
■Store in a dry area that is protected from dust.
■So that any residual damp can evaporate, do not package in airtight containers.
■Do not expose to any aggressive substances.
■Protect from sunlight.
■Avoid mechanical shocks.
■Storage temperature: see "Ambient data", page 61.
■Relative humidity: see "Ambient data", page 61.
■For storage periods of longer than 3 months, check the general condition of all
components and packaging on a regular basis.
TRANSPORT AND STORAGE 4
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5 Mounting
5.1 Mounting instructions
Mount the TriSpector1000 in a position above the surface to be scanned. See "Field of
view diagrams", page 17 for field of view diagrams and mounting distances. The
default scan direction is shown in figure 4. If a scan is performed in the opposite direc‐
tion, the acquired image will be mirrored.
Figure 4: Mounting position
For optimal performance:
■Observe the ambient conditions for the operation of the TriSpector1000 (for exam‐
ple, ambient temperature and ground potential). See "Technical data", page 61
for specifications.
■Ensure adequate heat transfer from the device, for example, via the mounting
bracket to the mounting base, or by means of convection.
■Use a stable bracket with sufficient load bearing capacity and suitable dimensions
for the TriSpector1000.
■Minimize shock and vibration.
■Ensure a clear view of the objects to be detected.
5.1.1 Mounting a microSD memory card
NOTICE
If the TriSpector1000 is powered on, click the Eject button in the SD Card section under
the Interfaces workflow step before removing the microSD memory card.
NOTICE
The screws for the microSD memory card lid must be tightened with a torque of 0.3 Nm
to keep the IP65 classification.
Follow the steps below to insert or remove a microSD memory card to or from the
TriSpector1000. The microSD memory card slot is located next to the inspection win‐
dow.
1. Release the two screws to remove the lid.
2. Insert or remove the microSD memory card.
3. Re-mount the lid and tighten the screws with a torque of 0.3 Nm.
For a specification of supported microSD memory cards, see "System requirements",
page 11.
5 MOUNTING
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5.2 Field of view diagrams
The maximum guaranteed image acquisition area in mm (inch) for each TriSpector1000
variant is shown in figure 5. The brighter areas represent typical image acquisition
areas.
56
(2.20)
60
(2.36)
75
(2.95)
H
W
65 x 15
(2.56 x 0.59)
40
(1.57)
TriSpector1008
291
(11.46)
800
(31.50)
660
(25.98)
H
W
540 x 200
(21.26 x 7.87)
180
(7.09)
TriSpector1060
141
(5.55)
400
(15.75)
330
(12.99)
H
W
270 x 100
(10.63 x 3.94)
90
(3.54)
TriSpector1030
Y
X
TriSpector1000
Y = Max. height range
X = Width at max.
working distance
Typical field of view
TriSpector1008
TriSpector1030
TriSpector1060
Figure 5: Field of view diagrams
MOUNTING 5
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6 Electrical installation
6.1 Prerequisites for the safe operation of the device in a system
WARNING
Risk of injury and damage due to electrical current!
Incorrect grounding of the device can result in equipotential bonding currents between
the device and other grounded devices in the system. This can lead to the following
dangers and faults:
•Hazardous voltages are applied to the metal housings.
•Devices will malfunction or sustain irrepairable damage.
•Cable shieldings are damaged by overheating and cause cable fires.
Remedial measures:
•Only qualified electricians should be permitted to carry out work on the electrical
system.
•Install the grounding for the sensor and the system in accordance with national
and regional regulations.
•Ensure that the ground potential is the same at all grounding points.
•If the cable insulation is damaged, disconnect the voltage supply immediately and
have the damage repaired.
Observe the following safety measures:
■Only skilled electricians with appropriate training and qualifications are permitted
to perform electrical installation.
■Standard safety requirements must be met when working in electrical systems.
■Electrical connections between the TriSpector1000 and other devices may only be
made or disconnected when there is no power to the system. Otherwise, the
devices may be damaged.
■Where connecting cables with one end open are concerned, make sure that bare
wire ends do not touch each other (risk of short circuit when the supply voltage is
switched on). Wires must be appropriately insulated from each other.
■Wire cross sections of the supply cable from the customer's power system should
be designed and protected in accordance with the applicable standards.
■If the supply voltage for the TriSpector1000 is not supplied via the CDB650-204
connection module, the TriSpector1000 must be protected by a separate slow-
blow fuse with a max. rating of 2.0 A. This fuse must be located at the start of the
supply circuit.
■All circuits connected to the TriSpector1000 must be designed as SELV circuits
(SELV = Safety Extra Low Voltage).
6 ELECTRICAL INSTALLATION
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6.2 Connection diagram
Power I/O
Gig E
Encoder On
State
Link/Data
Result
Laser
PC
24 V DC
Encoder
Photoelectric
switch
1
2
34
Figure 6: Connection diagram
1Encoder
2PC/Network
3Photoelectric switch
424 V DC, voltage supply
6.3 Encoder
NOTICE
It is strongly recommended to use an encoder for measuring applications, such as
shape measuring and volume measuring. If no encoder is used, analysis results may be
inaccurate due to object traversing speed variations.
The encoder must fulfill the following requirements:
■The encoder must be an incremental encoder.
■The encoder must have a RS-422/TTL interface. In the case of strong magnetic
fields in proximity to the TriSpector1000 a recommended encoder (no. 1068997)
must be used to ensure optimal performance.
■The connection requires two encoder channels (A/A¯ and B/B¯) to keep track of
movement and direction.
ELECTRICAL INSTALLATION 6
8021808/12ID/2019-01 | SICK O P E R A T I N G I N S T R U C T I O N S | TriSpector1000 19
Subject to change without notice

6.4 Pin assignment
Encoder I/O
4
3
6
5
7
8
1
2
Figure 7: M12 female connector, 8-pin A-coded
Pin Signal
1 A/ - RS-422 inverted input
2 A - RS-422 non-inverted input
3 B/ - RS-422 inverted input
4 B - RS-422 non-inverted input
5 (Not connected)
6 (Not connected)
7 GND (Power / Signal)
8 24 V Voltage supply output
Gigabit Ethernet
4
3
6
5
7
8
1
2
Figure 8: M12 female connector, 8-pin X-coded
Pin Signal
1 GETH_L1+
2 GETH_L1-
3 GETH_L2+
4 GETH_L3+
5 GETH_L3-
6 GETH_L2-
7 GETH_L4+
8 GETH_L4-
6 ELECTRICAL INSTALLATION
20 O P E R A T I N G I N S T R U C T I O N S | TriSpector1000 8021808/12ID/2019-01 | SICK
Subject to change without notice