SICK Free Flow Profiler User manual

OPERATING INSTRUCTIONS
FREE FLOW PROFILER
Proling systems

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Product described
Product name: Free Flow Profiler
Document identification
Title: Operating instructions for Free Flow Profiler
Part number: 8020776/12AX
Status: 2019-05-31
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.
Original documents
The German version 8020775/12AX of this document is an original
SICK AG document.
SICK AG does not assume liability for the correctness of any unauthorized
translation.
In case of doubt, contact SICK AG or your local agency.
Legal notes
Subject to change without notice
© SICK AG. All rights reserved

CONTENTS
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Contents
1About these operating instructions................................................................................7
1.1 Described software versions ...............................................................................7
1.2 Purpose of this document....................................................................................7
1.3 Target group .........................................................................................................7
1.4 Information depth ................................................................................................8
1.5 Abbreviations used...............................................................................................8
1.6 Symbols used .......................................................................................................9
2On safety......................................................................................................................... 10
2.1 Qualified safety personnel................................................................................ 10
2.2 Applications of the system................................................................................ 10
2.3 Intended use...................................................................................................... 11
2.4 General safety notes and protective measures .............................................. 12
2.4.1 Safety notes and symbols ................................................................. 12
2.4.2 General safety notes.......................................................................... 13
2.4.3 Potential hazardous points................................................................ 14
2.5 Protecting the environment .............................................................................. 17
3System description ........................................................................................................ 18
3.1 The measurement site ...................................................................................... 19
3.1.1 Typical layout of the measurement site............................................ 19
3.1.2 Possible layouts ................................................................................. 20
3.2 The system components in detail .................................................................... 24
3.2.1 2D LiDAR sensors .............................................................................. 24
3.2.2 Traffic Controller FPS ......................................................................... 24
3.3 System operating principle ............................................................................... 25
3.3.1 Operating principle of vehicle detection ........................................... 25
3.3.2 Operating principle of the function for calculating the vehicle
dimensions ......................................................................................... 27
3.3.3 Operating principle of the vehicle classification function................ 29
3.3.4 Operating principle of the vehicle axle counting function ............... 30
3.3.5 Emission of object location messages.............................................. 32
3.3.6 Data processing in the Traffic Controller FPS................................... 33
3.3.7 Output data ........................................................................................ 34
3.4 System interfaces.............................................................................................. 36
3.4.1 Integration into existing IT infrastructure ......................................... 37
3.4.2 Site view in TEMS Manager ............................................................... 38
3.4.3 Plug-ins for saving and downloading the vehicle data..................... 39
3.4.4 Downloading log files......................................................................... 41
3.5 Project planning ................................................................................................ 42
3.5.1 General system requirements ........................................................... 42
3.5.2 Requirements for vehicles................................................................. 42
3.5.3 General requirements at the measurement site.............................. 43
3.5.4 Requirements for mounting the vehicle detection
components........................................................................................ 43
3.5.5 Requirements for mounting the axle counting components ........... 44
3.6 Status indicators ............................................................................................... 48
3.6.1 Status indicators for the 2D LiDAR sensors ..................................... 48
3.6.2 Status indicators and controls on the Traffic Controller FPS .......... 48

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4Mounting .........................................................................................................................49
4.1 Mounting 2D LiDAR sensors .............................................................................49
4.1.1General advice ....................................................................................49
4.1.2 Mounting positions of the 2D LiDAR sensors ...................................50
4.1.3 Mounting accessories for the LMS511 2D LiDAR sensor................52
4.2 Mounting the Traffic Controller FPS..................................................................55
4.3 Mounting the Ethernet switch ...........................................................................55
5Electrical installation.....................................................................................................56
5.1 General advice ...................................................................................................56
5.2 Wiring overview ..................................................................................................56
5.3 Connecting the Traffic Controller FPS...............................................................57
5.3.1 Connections on the Traffic Controller FPS ........................................57
5.3.2 Connecting to the voltage supply.......................................................58
5.3.3 Connection to Ethernet switch ...........................................................59
5.3.4 Connecting to the customer interface ...............................................59
5.4 Connecting the Ethernet switch to the voltage supply ....................................60
5.5 Connecting the 2D LiDAR sensors ....................................................................60
5.5.1 Connections on the 2D LiDAR sensor................................................60
5.5.2 Connecting to the voltage supply.......................................................61
5.5.3 Connection to Ethernet switch ...........................................................62
5.6 SICK connecting cables .....................................................................................63
6Commissioning ...............................................................................................................64
6.1 Starting the profiling system .............................................................................64
6.2 Connecting to TEMS Manager...........................................................................64
6.3 Configuring the IP address of the Traffic Controller FPS .................................65
6.4 Setting up the site configuration with the wizard.............................................68
6.4.1 Selecting components ........................................................................69
6.4.2 Specifying the measurement site layout ...........................................70
6.4.3 Selecting a region ...............................................................................71
6.4.4 Defining the classification system .....................................................72
6.4.5 Completing site configuration ............................................................73
6.5 Working in TEMS Manager ................................................................................74
6.5.1 The user interface...............................................................................74
6.5.2 Displaying the measurement site ......................................................77
6.6 Adapting system functions to the measurement site......................................80
6.6.1 Configuring the measurement site ....................................................80
6.6.2 Configuring system functions for vehicle detection..........................83
6.6.3 Configuring system functions for axle counting ................................90
6.7 Working in expert mode.....................................................................................93
6.7.1 Displaying the system parameters and system status.....................93
6.7.2 Displaying system functions for vehicle classification .....................95
6.7.3 Working with the Axle Overruler.........................................................96
6.7.4 Configuring plug-ins ............................................................................96
6.8 Running the configuration .............................................................................. 100
6.8.1 Checking operational readiness ..................................................... 101
6.8.2 Displaying measurement points ..................................................... 103
6.8.3 Displaying the device status ........................................................... 104
6.8.4 Switching back to editing mode...................................................... 104
6.8.5 Saving the configuration on the hard drive .................................... 105

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6.9 Checking that measuring mode is working properly ..................................... 106
6.9.1 Displaying vehicles with measured values .....................................106
6.9.2 Saving vehicle data .......................................................................... 108
6.9.3 Accessing detailed information about a vehicle ............................108
6.10 Downloading log files ......................................................................................117
6.11 Updating the TEMS Recorder and packages .................................................120
6.11.1 Displaying information on the TEMS Recorder...............................120
6.11.2 Updating the TEMS Recorder ..........................................................121
6.11.3 Updating packages ..........................................................................122
6.12 Using the TEMS Info interface ........................................................................ 123
6.13 Installing the security certificate for the HTTPS connection .........................125
6.13.1 Uploading the supplied HTTPS certificate ...................................... 125
6.13.2 Uploading your own HTTPS certificate ............................................ 127
6.14 Extending/changing the site........................................................................... 128
6.14.1 Adding system components ............................................................128
6.14.2 Adding a second road ......................................................................132
6.14.3 Configuring an additional LMS Length in an offset position .........134
6.14.4 Using a configuration file to load system parameters ................... 136
7Maintenance ................................................................................................................137
7.1 Overview of maintenance tasks .....................................................................137
7.2 Maintenance during operation .......................................................................138
7.2.1 Visual inspection .............................................................................. 138
7.2.2 Cleaning the 2D LiDAR sensors ......................................................139
7.3 Replacing components ...................................................................................140
7.3.1 Basic procedure ............................................................................... 140
7.3.2 Replacing the 2D LiDAR sensors ....................................................141
7.3.3 Replacing the Traffic Controller FPS ...............................................141
7.3.4 Updating the measurement site .....................................................142
8Fault diagnosis ............................................................................................................ 146
8.1 SICK Support ................................................................................................... 146
8.2 Fault indicators at component level............................................................... 147
8.2.1 Fault indicator for the 2D LiDAR sensors ....................................... 147
8.2.2 Traffic Controller FPS fault indicators ............................................. 147
8.3 Fault indicators at system level...................................................................... 148
8.3.1 Fault diagnosis in TEMS Manager................................................... 149
8.3.2 Fault diagnosis via the TEMS Info interface ...................................154
8.3.3 Detecting system errors using log files...........................................154
8.3.4 Providing raw data to help Support................................................. 154
8.3.5 Sensor component failures .............................................................156
8.4 Typical fault situations ....................................................................................157
9Annex ............................................................................................................................ 159
9.1 Technical data .................................................................................................159
9.1.1 FPS data sheet .................................................................................159
9.1.2 Excerpt from the Traffic Controller FPS data sheet........................159
9.1.3 Excerpt from the LMS511 SE data sheet .......................................159
9.2 Dimensional drawings..................................................................................... 160
9.2.1 Dimensional drawing for LMS511 SE 2D LiDAR sensor................ 160
9.2.2 Dimensional drawings for the Traffic Controller FPS ..................... 163

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9.3 Category systems............................................................................................ 164
9.3.1 European region .............................................................................. 164
9.3.2 North American region .................................................................... 167
9.3.3Brief overview of grouped category systems.................................. 169
9.4 Terminology relating to statistical measurement accuracy.......................... 170
9.5 Users and authorizations................................................................................ 171
9.5.1 Overview ........................................................................................... 171
9.5.2 Changing default passwords........................................................... 172
9.5.3 Creating users .................................................................................. 173
9.5.4 Change password ............................................................................ 174
9.5.5 User data for accessing the FTP server of the Traffic
Controller.......................................................................................... 174
9.6 IP addresses.................................................................................................... 175
10 Disposal ........................................................................................................................ 176

ABOUT THESE OPERATING INSTRUCTIONS 1
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OPERATING INSTRUCTIONS|Free Flow Profiler
1About these operating instructions
Please read through this chapter carefully before you use the documentation and work
with the Free Flow Profiler profiling system (also abbreviated to FPS in these operating
instructions).
1.1 Described software versions
Software
Function
Status
TEMS Info interface
Profiling software for recording and processing
measurement data
V 2.0
TEMS platform
Profiling software
V 2.8
Tab. 1: Software versions
1.2 Purpose of this document
These operating instructions are designed to give technical personnel instructions on
the safe mounting, configuration, electrical installation, commissioning, operation, and
maintenance of the profiling system.
These operating instructions do not provide information on operating the customer
system into which the profiling system has been or is going to be integrated. More
information on this can be found in the customer documentation.
1.3 Target group
These operating instructions are intended for persons integrating and operating the
profiling system. They are also intended for the planners and integrators of the customer
system, as well as the operating entity with responsibility for it.
Target group
Activities
Entity operating the customer system
System user
Operating the system: site view and display of the measurement
results in TEMS Manager

The system user reports faults to the system manager.
System manager
Mounting, electrical installation, maintenance, and replacement
of system components.
The system manager submits support requests to SICK.
SICK
SICK service technician
Commissioning, configuration, and support.
Tab. 2: Target group

1ABOUT THESE OPERATING INSTRUCTIONS
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1.4 Information depth
These operating instructions contain information about the following topics related to the
profiling system:
•System description
•Mounting
•Electrical installation
•Commissioning
•Operation
•Maintenance and care
•Fault diagnosis and troubleshooting
•Technical data and dimensional drawings
When planning and using profiling systems, technical skills are required that are not
covered by this document.
The official and legal regulations for operating the system must always be complied with.
Further information about the device components used in the profiling system can be
found in the accompanying operating instructions.
1.5 Abbreviations used
The 2D cross-sections recorded by the 2D LiDAR sensors during the measurement
process are merged together to form a 3D point cloud. The point cloud is used as the
basis for calculating the vehicle dimensions and for vehicle classification.
Free-flow profiling system = a system for measuring and classifying vehicles in free-
flowing traffic
File Transfer Protocol = a network protocol for transferring data between different systems
Laser measurement scanner = 2D LiDAR sensor from SICK AG
Simple Network Management Protocol = a protocol for managing and controlling networks
Traffic Enhanced Measurement System
Customer side of the TEMS Info interface
TCP/IP interface for communication with the TEMS Recorder
Configuration software for the profiling system
Profiling software on the Traffic Controller FPS; it processes the data from the 2D LiDAR
sensors and outputs the results
Entering a UNC path (Universal Naming Convention) allows a path in a network to be
accessed without the need for a drive letter. The UNC path does not need to be visible in
Windows Explorer. Windows shared folders can also be used as UNC destinations.
Uninterruptible Power Supply
Note
3D point cloud
FPS
FTP
LMS
SNMP
TEMS
TEMS Info client
TEMS Info interface
TEMS Manager
TEMS Recorder
UNC
UPS

ABOUT THESE OPERATING INSTRUCTIONS 1
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1.6 Symbols used
Recommendations are intended to help you make a decision regarding the use of a
particular function or technical feature.
Notes provide information about the features of a device, application tips, or other useful
information.
Instructions that must be carried out in the described order are referred to as step-by-step
instructions and are indicated by numbered lists. Carefully read and follow the
instructions for action.
Instructions requiring specific action are indicated by an arrow. Carefully read and follow
the instructions for action.
LED icons describe the status of a diagnostics LED.
The LED is illuminated continuously.
The LED is flashing.
The LED is off.
Display symbols show the status of the 7-segment display:
 Constant display of characters, e.g., U
Flashing display of characters, e.g., 8
 Alternating display of characters, e.g., L and 2
Recommendation
Note
1. / 2. ...
step by step

Action
, 

,


2ON SAFETY
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2On safety
This chapter provides information that concerns your own safety as well as the safety of
the plant operator.
▸Please read this chapter carefully before you begin working with the profiling system.
2.1 Qualified safety personnel
The profiling system must only be mounted, commissioned, and maintained by properly
qualified safety personnel.
A person is considered qualified safety personnel if he/she
•Has sufficient skills in the field of the respective equipment based on his/her technical
training and experience and
•Has been instructed by the manufacturer on system operation and all applicable safety
guidelines and
•Is familiar with all relevant country-specific occupational safety regulations, work safety
regulations, guidelines, and generally accepted technical rules and standards (e.g.,
DIN standards, VDE regulations, country-specific rules) to such an extent that he/she is
able to evaluate the safe condition of the power-driven machinery and he/she
•Has access to and has read the operating instructions.
2.2 Applications of the system
The Free Flow Profiler profiling system is designed for automated measurement of vehicle
dimensions using eye-safe laser scanners. The system takes the measurements
automatically in free-flowing traffic without any need for manual operation.
The profiling system is designed for use in multi-lane, free-flowing traffic and stop-and-go
traffic as part of electronic toll systems. It can also be used for traffic management and
analysis.
The modules available for the profiling system support the system functions described
below:
System function for measuring vehicle dimensions
The Dimension Measurer system function can be used to identify the following vehicle
data (depending on the system variant): length, width, height, speed, measurement start
and end times, 3D measuring points for the vehicle including – where applicable – excess
dimensions.