SICK VMS4400 CV User manual

O P E R A T I N G I N S T R U C T IO NS
VMS4400 Contour Verification
Track and trace systems

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Subject to change without notice
Described product
VMS4400 Contour Verification
Document No.
8025816
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
www.sick.com
Legalnotes
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. All rights reserved
Original documents
This document is an original document from SICK AG.

CONTENTS
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Contents
1About this document ................................................................................................ 5
1.1 Limitation of liability..................................................................................... 5
1.2 Purpose of this document ........................................................................... 5
1.3 Target groups................................................................................................ 5
1.4 Further information...................................................................................... 6
1.5 Other relevant technical documentation/information............................. 6
1.6 Document conventions................................................................................ 6
2Safety information..................................................................................................... 7
2.1 Intended use ................................................................................................. 7
2.2 General safety notes.................................................................................... 7
2.3 Requirements for the qualification of personnel ..................................... 8
2.4 Protective devices........................................................................................ 8
2.5 Sources of danger........................................................................................ 8
2.6 Warranty......................................................................................................... 9
2.7 RoHS Directive.............................................................................................. 9
2.8 Safety conventions....................................................................................... 9
2.9 Warning symbols on the system components........................................10
2.10 Mandatory symbols....................................................................................10
3System description.................................................................................................11
3.1 Scope of delivery ........................................................................................11
3.2 System components...................................................................................12
3.2.1 LMS4x21 2D LiDAR sensors.....................................................13
3.2.2 Trigger photoelectric sensor......................................................14
3.2.3 Incremental encoder..................................................................15
3.2.4 Cabinet.........................................................................................16
3.3 Operating principle.....................................................................................18
3.3.1 Automated operating mode ......................................................18
3.3.2 Recording of measured values and data processing............20
3.3.3 Data output.................................................................................23
3.3.4 Expanding the system with a reading and
weighing station..........................................................................24
3.4 System requirements.................................................................................25
3.4.1 Requirements on the ambient conditions...............................25
3.4.2 Requirements on the conveying equipment...........................26
3.4.3 Object requirements...................................................................26
3.4.4 Mounting requirements.............................................................27
4Mounting...................................................................................................................28
5Electrical installation.............................................................................................29
6Commissioning........................................................................................................31
7Maintenance and repair.........................................................................................32
7.1 Monitoring and cleaning work ..................................................................33
7.1.1 Control measurements..............................................................33
7.1.2 Visual control...............................................................................33
7.1.3 Cleaning the 2D LiDAR sensors................................................34
7.1.4 Cleaning the photoelectric retro-reflective sensor.................35
7.1.5 Checking the incremental encoder components...................35
7.1.6 Cleaning the cabinet..................................................................36

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7.2 Replacing components..............................................................................37
7.2.1 Replacing the 2D LiDAR sensor................................................37
7.2.2 Replacing the system controller...............................................39
7.2.3 Replacing the battery in the system controller.......................40
7.2.4 Replacing the dimensioning controller....................................41
7.2.5 Replacing the power supply unit ..............................................42
7.2.6 Replacing the photoelectric retro-reflective sensor...............44
7.2.7 Replacing the incremental encoder components..................45
8Fault diagnosis........................................................................................................46
8.1 Response to errors.....................................................................................46
8.2 Fault indications of the components .......................................................47
8.2.1 Fault indication on the LMS4x21.............................................47
8.2.2 Fault indication on the system controller................................48
8.2.3 Fault indication on the trigger photoelectric
retro-reflective sensor................................................................49
8.3 Fault indication during operation .............................................................50
8.3.1 Checking the triggering..............................................................50
8.3.2 Checking the incremental encoder..........................................51
9Technical data..........................................................................................................52
10 Disposal.....................................................................................................................53

ABOUT THIS DOCUMENT 1
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1About this document
This document about the multi-dimensional VMS4400Contour Verification measurement
system (short VMS4400 CV):
Contains informationthat is required during the life cycle of the system.
Must be made available to all those who workwith the system.
Should be read through carefully, and the contents fully understood before working
with the system.
1.1 Limitation of liability
Applicable standards and regulations, the latest technological developments, and
our many years of knowledge and experience haveall been taken into account when
assembling the data and information contained in this document.
The manufacturer accepts no liability for damage caused by:
Failure to observe this document.
Non-compliancewith notes and regulations.
Unauthorizedmounting and installation.
Unauthorizedtechnical and other changes.
Use of unauthorized spare parts, wear and tear parts, and accessories.
Unauthorizedchanges, adjustments, and/or manipulations of software.
Failure to perform and document regular maintenance work.
The actual scope of delivery may differ from the features and illustrations shownhere
where special variants are involved, if optional extras have been ordered, or as a result
of the latest technical changes.
1.2 Purpose of this document
This document describes the multi-dimensional VMS4400 CV measurement system.
1.3 Target groups
This document is intended for qualified persons who operate the VMS4400 CV.

1 ABOUT THIS DOCUMENT
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1.4 Further information
Special local conditions
The local laws, regulations, technical rules and internal companyoperating instructions
at the usage site must be observed.
Storage of documents
This document and other relevant technical documentation/information:
Must be kept available for reference.
Must be handed over to new system operators/new specialist personnel.
1.5 Other relevant technical documentation/information
Technical system documentation
Technical data
Connection diagram
Terminal diagram
Operating instructions for the following system components:
Operating Instructions
Manufacturer
LMS4000 2D LiDAR sensor operating instructions
SICK
Depending on system variant
SIM2000 modular system controller
SIM Eco modular system controller
MSC800 modular system controller
SICK
WL27-3 photoelectric retro-reflective sensor (optional)
SICK
DFV60 (optional)
SICK
1.6 Document conventions
▸Instructions
Result of action
Reference to another document.
All measurement units used in this document are metric.
Subject to change without notice.
NOTE! Illustrations may differ from the actual design.

SAFETY INFORMATION 2
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2Safety information
2.1 Intended use
The multi-dimensional VMS4400 CV measurement system is used for automated
deformationdetection of cuboid objects on flat conveyingsystems.
Four 2D LiDAR sensors determine the smallest cuboid that fully encloses an object
regardless of its shape, and then use this to derive the length, width and height of the
object.
The system detects dents and bulges on flat areas and edges based on the determined
box volume. You can set the accuracy of the deformation detectionusing parameters.
If the deformation is above the tolerance zone, a respective error code is output via
the central control unit to a downstream host computer for further processing.
The multi-dimensional VMS4400CV measurement system ensures compatibility with
existing solutions from SICK and enables adaptations to customer-specific applications
such as identification systems or dynamic scales. They enable full status control,
thereby improving process transparency.
NOTE! Intended use also includes observance of these operating instructions,
in particular the safety notes and repair and maintenance requirements as well
as proper installation.
2.2 General safety notes
▸Please read this document through carefully and observe all the safety notes and
information before working on the VMS4400 CV.
▸Only qualified persons from the relevant departments are permitted to work on the
VMS4400 CV.
▸Follow operating processes.
▸Follow local regulations.
▸Follow all local regulations relating to working with electrical components.
Only authorized persons are permitted to access the VMS4400 CV.
System damage/transport damage
Damage to the individual components can lead to malfunctions of the system as a whole.
▸Do not ignore any damage caused to system components during transport.
▸In case of damage, contact SICK Service.

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2.3 Requirements for the qualification of personnel
Only qualified persons with the relevant technical expertiseare permitted to work on
the system.
Qualified persons have the specialist training, skills, and experience, as well as
knowledge of the relevant regulations and standards, to be able to perform work
assigned to them and to identify and avoid any potential dangers independently.
Electricians have the professional training, skills and experience, and knowledge of
the relevant standards and provisions to work on electrical systems and to detect
and avoid any potential dangers independently.
2.4 Protective devices
The multi-dimensional measurement systemis designed in a way that allows for safe
operation. Protective devices reduce potential risks to the maximum possible extent.
Laser protective cover for the 2D LMS4x21LiDAR sensor
2.5 Sources of danger
The VMS4400 CV works with class 2 lasers.
The human eye is not at risk when briefly exposed to the radiation for up to 0.25 seconds.
Exposure to the laser beam for longer periods of time may cause damage to the retina.
The laser radiation is harmless to human skin.
▸Never look directly into the laser beam.
▸Never point the laser beam at people’s eyes.
▸During commissioning or maintenancework, suitable eye protection must be worn.
▸Avoid laser beam reflections caused by reflectivesurfaces. In particular during
mounting and alignment work.
▸Do not open the housing.
▸Current national regulations regarding laser protection must be observed.
Touching live devices, which may still be energized, can lead to death, burns or electrical
shock.
▸Electrical work may only be performed on the system by qualified specialist personnel.
▸Before working on electrical components, observe the five safety rules:
▸Disconnect.
▸Secure against being switched back on.
▸Ensure that there is no voltage.
▸Ground and short-circuit.
▸Cover or enclose live parts in the vicinity.
▸Never enter the area under suspended loads.
▸Pay close attention when lifting loads.
▸Comply with lifting instructions to preventinjuries and accidents.
▸Use suitable, undamagedlifting tools.
▸Wear personal protective equipment (safety helmet, safety shoes).
Optical radiation:
Laser class 2
Electrical voltage
Suspended loads

SAFETY INFORMATION 2
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2.6 Warranty
No warranty claims will be accepted if:
▸The safety notes and measures in this document are not observed.
▸Parts or components of the VMS4400 CV havebeen installed, mounted or modified
without authorization.
▸The VMS4400 CV has been altered or modified.
▸The software has been modified, customized, and/or tampered with without
authorization.
2.7 RoHS Directive
This product has been designed for specific applications in large industrial plants
according to Article 2 (4) e, RoHS 2011/65 / EU, and must therefore only be used
in such plants.
The product is neither suitable nor approved for use outsideof these plants. SICK
therefore cannot provideany warranty or accept any liability whatsoever for such use.
2.8 Safety conventions
The warnings used in this manual have the following meanings:
DANGER
Identifies an imminent danger, which will lead to death or serious injuries if not
prevented.
WARNING
Identifies a situation presentingdanger, which will leadto death or serious injuries
if not prevented.
CAUTION
Identifies a possibly hazardoussituationwhich may lead to minor or moderate
bodily injuries or material damage if not prevented.
NOTE
Important information and useful notes.

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2.9 Warning symbols on the system components
Warning labels must not be removed or coveredup. If labels are missing, these must be
affixed. Damaged labels must be replaced.
Symbol
Meaning
Hazardous point warning
Hazardous electrical voltage warning
Warning of laser light
Suspended load warning
2.10 Mandatory symbols
Symbol
Meaning
Read document
Use head protection
Use foot protection
Disconnect before maintenance or repairs

SYSTEM DESCRIPTION 3
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3System description
3.1 Scope of delivery
NOTE!
▸After delivery, inspect the system for transport damage and report any such damage
immediately.
▸Check that the delivery includes all components listed on the deliverynote.
System components
Cabinet with system controller, dimensioning controller, power supply module, and
Ethernet switch
Four LMS4x21 2D LiDAR sensors with laser protective cover and connecting cables
Optional
Incremental encoder (optional), e.g., DFV60
Photoelectric retro-reflective sensor (optional), e.g., WL27-3
Aluminum profiles for setting up the frame (application-dependent as per the order)
Mounting kits for the cabinet and sensors

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3.2 System components
Fig. 1: Components of the VMS4400 CV
Legend
1
2D LiDAR sensors
2
Photoelectric retro-reflective sensor (optional)
3
Incremental encoder (optional)
4
Cabinet with system controller, dimensioning controller, power supply
unit, and Ethernet switch
The system components are mounted on a customer-specific frameas per the
technical drawing.
Devices
Mounting

SYSTEM DESCRIPTION 3
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3.2.1 LMS4x21 2D LiDAR sensors
Fig. 2: LMS4x21 2D LiDAR sensors
Legend
1
LMS4x21 2D LiDAR sensor
2
Laser protective cover
The VMS4400 CV comprises four LMS4x21 2D LiDAR sensors with laser protective
covers.
Two 2D LiDAR sensors are mounted below the conveyor belt. The laser scanner beam
is guided through the seam between two conveyor belts.
They detect the bottom as well as the right and left side of the object.
Two 2D LiDAR sensors are mounted above the conveying equipment.
They detect the top as well as the front and rear side.
The four 2D LiDAR sensors span a measuring field and detect the contours of objects
transported into the field.
The acquired measurement points are transmitted to the dimensioning controller for
further processing.
Features
Function

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3.2.2 Trigger photoelectric sensor
Fig. 3: Photoelectric retro-reflective sensor and reflector
Legend
1
Photoelectric retro-reflective sensor (e.g., WL27-3)
2
Reflector
Photoelectric retro-reflective sensor trigger available as an option.
Used for the optical, non-contact detection of objects.
A reflector is required for it to function.
The emitted light signal is reflected back by a reflector.
Sender and receiver are arranged parallel to one another in the housing of the
photoelectric retro-reflective sensor.
If the light beam is interrupted by an object, a switching signal is output to the system
controller.
Supplies the trigger signal to the system controller in systems with triggered
measurement.
The trigger signal activates the sensors and opens the internal reading gate.
The trigger signal, together with the incremental signal, are required to determine the
position of the object on the conveying equipment and thereby correctly assign the
measured values and read results.
NOTE! Alternatively, the trigger signal can also be supplied by the customer via the PLC.
Features
Function

SYSTEM DESCRIPTION 3
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3.2.3 Incremental encoder
Fig. 4: DFV60 incremental encoder
Legend
1
Measuring wheel
2
Spring-loaded mounting arm
Optionally available measuring wheel system mountedbelowthe conveying equipment.
Large spring travel and pivot range of the spring arm compensates for unevenness
on measurement surface.
Measurement of linear movements.
Detection of position and speed directly on the running surface of the conveyor using
a precision measuring wheel.
The incremental signal, together with the customer-supplied trigger signal, are required
to determine the position of the objects on the conveying equipmentand thereby
correctly assign the measured values and read results.
NOTE! Alternatively, the speed signal can also be supplied by the customer via the
controller.
Properties
Function

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3.2.4 Cabinet
Fig. 5: Components in the cabinet
Legend
1
Air inlet for cooling (with filter mat and cooler)
2
Terminals for mains voltage IN (230 VAC, 50 Hz)
3
System controller (examplein the image: SIM2000)
4
Power supply units
5
Terminals (24 V DC) and fuse module OUT
6
RCD (residual current device) for protective contact plug
7
Air outlet for cooling (with filter mat)
8
Circuit breaker for power supply unit modules
9
Air outlet for cooling (with filter mat)
10
Dimensioning controller (example in the image: APU8520)
11
Ethernet switch
12
Air inlet for cooling (with filter mat and fan)

SYSTEM DESCRIPTION 3
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The power supply units supply the voltage to the controllers and connected sensors.
The dimensioning controller receives the measurement points from the 2D LiDAR
sensors.
It calculates a three-dimensional model with the relevant object dimensions from the
distance data of the 2D LiDAR sensors and, based on this data, determines whether
or not any deformation is present.
The measurement results are transmitted to the system controller via CAN bus.
The system controller coordinates all the connected sensors. It processes the trigger
and encoder signals and, via its digital inputs and outputs, provides all the relevant
information for calculating the object dimensions.
The system controller receives the measurement results from the deformation check
of the dimensioning controller and outputs these to the customer systemin a defined
host telegram.
Function

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3.3 Operating principle
3.3.1 Automated operating mode
The VMS4400 CV runs fully automatically after startup. No manual intervention by the
operator is required.
Fig. 6: Transport conditions - singulated measurement
Legend
1
Rotational angle of the objects on the conveyor belt: up to ± 45°
2
Required minimum distance > max. object height
The VMS4400 CV detects singulated cuboidobjects on flat conveying systems such
as conveyor belts.
Objects are singulated by the customer.
The objects must pass the VMS4400 CV with a defined separation distance larger
than the max. object height (distance between rear edge and leading edge).
The minimum distancemust ensure that there is always only one object in the
measuring range.
Object rotations of up to ± 45° are detected.
Transport conditions

SYSTEM DESCRIPTION 3
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Fig. 7: No touching, no side-by-side
Legend
1
The objects must not be located side-by-side*.
2
The objects must not be touching*.
* Otherwise the track and trace system will not deliver plausible measurement results.
Not allowed!

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3.3.2 Recording of measured values and data processing
Fig. 8: Measuring point determination of the VMS4400 CV
The measurement process is activated via the trigger signal.
The two 2D LiDAR sensors mounted belowand above the conveying equipment span
a two-dimensional measuring range and perform a non-contact scan of the surface
of the object on the conveying equipment.
The 2D LiDAR sensors transmit the acquired measurement points to the dimensioning
controller.
Fig. 9: 3D model generation in the dimensioning controller
There, a spatial model is created taking into consideration the detected conveyor
speed and the specific position of the object on the conveying equipment.
The dimensioning controller calculates the volume of the smallest cuboid that
fully encloses the object and uses this to derive the length, width and height.