THORLABS KSG101 User manual

KSG101
Strain Gauge Reader
Kinesis User Guide
Original Instructions

2 HA0374T Rev Bk Aug 2022
Contents
Chapter 1 Safety ............................................................................................. 4
1.1 Safety Information .................................................................................. 4
1.2 General Warnings .................................................................................. 4
Chapter 2 Overview and Setup ..................................................................... 5
2.1 Introduction ............................................................................................. 5
2.2 Power Options ........................................................................................ 6
2.3 Kinesis Software Overview ..................................................................... 7
2.3.1 Introduction ......................................................................................................... 7
2.3.2 Kinesis Server .................................................................................................... 7
2.3.3 Software Upgrades ............................................................................................. 9
2.4 Install The Software. ............................................................................. 10
2.5 Mechanical Installation ......................................................................... 10
2.5.1 Environmental Conditions ................................................................................ 10
2.5.2 Mounting Options ............................................................................................. 11
2.5.3 Using the Baseplate ......................................................................................... 11
2.6 Electrical Installation ............................................................................. 12
2.6.1 Connecting a Strain Gauge Signal ................................................................... 12
2.6.2 Strain Gauge - General Information ................................................................. 12
2.6.3 Supply Voltage and Current Requirements ...................................................... 13
2.6.4 Front Panel ....................................................................................................... 14
2.6.5 Powering Down The Unit .................................................................................. 15
2.6.6 Connecting To A Standalone Power Supply .................................................... 15
2.7 Connect The Hardware ........................................................................ 16
2.8 Verifying Software Operation ............................................................... 17
Chapter 3 Standalone Operation ................................................................ 18
3.1 Introduction ........................................................................................... 18
3.2 Control Panel ....................................................................................... 19
3.2.1 Digital Display - Operating Mode ...................................................................... 19
3.3 Settings Menu ...................................................................................... 20
3.3.1 Menu Overview ................................................................................................ 20
3.3.2 Menu Option - Zeroing ..................................................................................... 21
3.3.3 Menu Option - Analogue Out ............................................................................ 22
3.3.4 Menu Option - Units Select .............................................................................. 23
3.3.5 Menu Option - Force Sensors .......................................................................... 24
3.3.6 Menu Option - Brightness ................................................................................. 25
Continued...

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K-Cube Strain Gauge Reader
Chapter 4 Operation - Tutorial .................................................................... 26
4.1 Introduction ........................................................................................... 26
4.2 Using the Kinesis Software ................................................................... 26
4.3 Closed Loop Piezo Operation ............................................................... 27
4.3.1 Electrical Connections and Software Settings - Hub Operation ....................... 28
4.3.2 Electrical Connections and Software Settings - Off Hub Operation ................. 31
4.4 Setting the Position Sensor Zero .......................................................... 33
4.5 Using The Strain Gauge Reader K-Cube with a Piezo Driver K-Cube 34
4.6 Using the Controller with a Force Sensor ............................................. 35
4.7 Setting Move Sequences ...................................................................... 36
4.8 Changing and Saving Parameter Settings ........................................... 36
Chapter 5 Software Reference .................................................................... 37
5.1 GUI Panel ............................................................................................. 37
5.2 Settings Panel ...................................................................................... 38
5.2.1 Persisting Settings to the Hardware ................................................................. 38
5.2.2 Settings Tab. .................................................................................................... 39
5.2.3 Panel/Triggering tab ......................................................................................... 42
Appendices
Appendix A Connector Pinout Details ....................................................... 45
Appendix B Preventive Maintenance ......................................................... 47
Appendix C Specifications and Associated Parts .................................... 48
Appendix D Piezo Operation - Background ............................................... 49
Appendix E Regulatory ................................................................................ 52
Appendix F Thorlabs Worldwide Contacts ................................................ 55

4
Chapter 1 Safety
1.1 Safety Information
For the continuing safety of the operators of this equipment, and the protection of the
equipment itself, the operator should take note of the Warnings, Cautions and Notes
throughout this handbook and, where visible, on the product itself.
The following safety symbols may be used throughout the handbook and on the
equipment itself.
1.2 General Warnings
Shock Warning
Given when there is a risk of injury from electrical shock.
Warning
Given when there is a risk of injury to users.
Caution
Given when there is a risk of damage to the product.
Note
Clarification of an instruction or additional information.
Warnings
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired. In particular,
excessive moisture may impair operation.
Spillage of fluid, such as sample solutions, should be avoided. If spillage does
occur, clean up immediately using absorbant tissue. Do not allow spilled fluid
to enter the internal mechanism.

5
Chapter 2 Overview and Setup
2.1 Introduction
The K-Cube Strain Gauge Reader (KSG101) is a new very compact single channel
reader, providing immediate 'out of the box' operation. For non-PC use the unit is
equipped with an OLED Display to indicate position, together with a settings menu to
change the display units and set the zero position point. The unit is also equipped with
a SMA position monitor output generating an analog voltage (0-10V) proportional to
the strain gauge signal.
Furthermore, when operated together with the new K-Cube Piezo Driver unit
(KPZ101) on the K-Cube Controller Hub (see over), high precision closed loop
positioning is possible using the complete range of feedback equipped piezo
actuators available from Thorlabs.
The unit can also be placed into Force Sensing mode, to allow operation with
Thorlabs Force Sensor products (FSC102 and FSC103). High sensitivity force
sensing is possible down to mN levels.
For convenience the footprint of this unit has been kept to a minimum, measuring only
60mm x 60mm x 47mm (2.36” x 2.36” x 1.85”) and with the facility to directly mount
to the optical table close to the device under control. Table top operation also allows
minimal drive cable lengths for easier cable management. All manual controls are
located on the top face of the unit – very convenient when monitoring positions using
the easy to read display (with brightness adjustment).
Fig. 2.1 K-Cube Strain Gauge Reader (KSG101)
A low voltage output connector allows for easy monitoring of the strain gauge signal.
Zero to 10V represents a Strain gauge signal (position or force) from 0 to full scale.

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Chapter 2
USB connectivity provides easy 'Plug and Play' PC controlled operation - multiple
units can be connected to a single PC via standard USB hub technology or by using
the new K-Cube Controller Hub (see over) for multi-axis motion control applications.
Coupling this with the very user friendly Kinesis software (supplied) allows the user to
very quickly get up and running in a short space of time. Custom automated strain
gauge reader applications can be developed using the extensive ActiveX®
programming environment also supplied. This programming library is compatible with
many development tools such as LabView, Visual Basic, Visual C++, C++ Builder,
LabWindows/CVI, Matlab and Delphi.
See Section 2.3. for a full description of the Kinesis system software.
In the remainder of this handbook, the Tutorial section (Chapter 4) provides a good
initial understanding on using the unit, and the reference section (Chapter 5) covers
all operating modes and parameters in detail.
2.2 Power Options
For power, a compact two-way power supply unit (TPS002) is available from Thorlabs
allowing up to 2 K-Cube Strain Gauge or Piezo Driver units to be powered from a
single mains outlet. This power supply unit is also designed to take up minimal space
and can be mounted to the optical table in close proximity to the driver units,
connected via short power leads.
As a further level of convenience when using the K-Cube Controllers Thorlabs also
offers the 3-channel and 6-channel K-Cube Controller Hubs (KCH301 and KCH601).
These products have been designed specifically with multiple K-Cube operation in
mind in order to simplify issues such as cable management, power supply routing,
multiple USB device communications and different optical table mounting scenarios.
The K-Cube Controller Hub comprises a slim base-plate type carrier with electrical
connections located on the upper surface to accept the K-Cubes.
Internally the Controller Hub contains a fully compliant USB 2.0 hub circuit to provide
communications for all K-Cubes – a single USB connection to the Controller Hub is
all that is required for PC control. The Controller Hub also provides power distribution
for the K-Cubes, requiring only a single power connection.

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K-Cube Strain Gauge Reader
2.3 Kinesis Software Overview
2.3.1 Introduction
The K-Cube range of controllers share many of the benefits. These include USB
connectivity (allowing multiple units to be used together on a single PC), fully featured
Graphical User Interface (GUI) panels, and extensive software function libraries for
custom application development.
The Kinesis software suite provides a flexible and powerful PC based control system
both for users of the equipment, and software programmers aiming to automate its
operation.
The User Interface allows full control of all settings and operating modes enabling
complete ‘out-of-box’ operation without the need to develop any further custom
software. It provides all of the necessary system software services such as generation
of GUI panels, communications handling for multiple USB units, and logging of all
system activity to assist in hardware trouble shooting. The Kinesis server is also used
by software developers to allow the creation of advanced automated positioning
applications very rapidly and with great ease. The server is described in more detail
in the following section.
2.3.2 Kinesis Server
Kinesis controls are re-usable compiled software components that supply both a
graphical user interface and a programmable interface. Many such Controls are
available for Windows applications development, providing a large range of re-usable
functionality. For example, there are Controls available that can be used to
manipulate image files, connect to the internet or simply provide user interface
components such as buttons and list boxes.
With the Kinesis system, .Net Controls are deployed to allow direct control over (and
also reflect the status of) the range of electronic controller units, including the Piezo
K-Cube. Software applications that use .Net Controls are often referred to as 'client
applications'. A .Net Control is a language independent software component.
Consequently the controls can be incorporated into a wide range of software
development environments for use by client application developers. Development
environments supported include Visual Basic, Labview, Visual C++, C++ Builder,
HPVEE, Matlab, VB.NET, C#.NET and, via VBA, Microsoft Office applications such as
Excel and Word.

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Chapter 2
Consider the control supplied for a KSG101 Strain Gauge K-Cube unit.
This Control provides a complete user graphical instrument panel to allow the Strain
Gauge unit to be manually operated, as well as a complete set of software functions
(often called methods) to allow all parameters to be set and Strain Gauge control
operations to be automated by a client application. The instrument panel reflects the
current operating state of the controller unit to which it is associated (e.g. such as
Strain Gauge reading). Updates to the panel take place automatically when a user
(client) application is making software calls into the same Control. For example, if a
client application instructs the associated Strain Gauge Control to zero the position
sensor, progress is monitored automatically by changing position readout on the
graphical interface, without the need for further programming intervention.

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K-Cube Strain Gauge Reader
Note that the The Kinesis Controls collection provides a rich set of graphical user
panels and programmable interfaces allowing users and client application developers
to interact seamlessly with the Kinesis hardware. Each of the Kinesis controllers has
an associated .Net Control and these are described fully in the handbooks associated
with the controllers.
Fig. 2.2 System Architecture Diagram
Refer to the main Kinesis Software online help file, for a complete programmers
guide. This is available either by pressing the F1 key when running the Kinesis server,
or via the Start menu, Start\Programs\Thorlabs\Kinesis\Kinesis Help.
2.3.3 Software Upgrades
Thorlabs operate a policy of continuous product development and may issue software
upgrades as necessary. The latest software can be downloaded from the ‘services’
section of www.thorlabs.com.

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Chapter 2
2.4 Install The Software.
DO NOT CONNECT THE CONTROLLER TO YOUR PC YET
1) Go to Services/Downloads at www.thorlabs.com and download the Kinesis
software.
2) Run the .exe file and follow the on-screen instructions.
2.5 Mechanical Installation
2.5.1 Environmental Conditions
Location Indoor use only
Maximum altitude 2000 m
Temperature range 5oC to 40oC
Maximum Humidity Less than 80% RH (non-condensing) at 31°C
To ensure reliable operation the unit should not be exposed to corrosive agents or
excessive moisture, heat or dust.
If the unit has been stored at a low temperature or in an environment of high humidity,
it must be allowed to reach ambient conditions before being powered up.
Note
This section is applicable only if the K-Cube is to be used with a PC. If your
application consists only of local operation via the K-Cube front face, proceed
to Section 3.1.
When operating via a PC, direct user interaction with the strain gauge reader
is accomplished through intuitive graphical user interface panels (GUIs),
which expose all key operating parameters and modes. The user can select
multiple panel views displaying different information about a particular
hardware unit. The multitasking architecture ensures that the graphical
control panels always remain live, showing all current hardware activity.
Caution
Some PCs may have been configured to restrict the users ability to load
software, and on these systems the software may not install/run. If you
are in any doubt about your rights to install/run software, please consult
your system administrator before attempting to install.
If you experience any problems when installing software, contact
Thorlabs on [phone] and ask for Technical Support.
Warning
Operation outside the following environmental limits may adversely affect
operator safety.

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K-Cube Strain Gauge Reader
2.5.2 Mounting Options
The K-Cube Strain Gauge Reader is shipped with a baseplate, for use when fitting the
unit to a breadboard, optical table or similar surface.
For multiple cube systems, a 3-channel and 6-channel K-Cube Controller Hub
(KCH301 and KCH601). ) are also available - see Section 2.2. for further details. Full
instructions on the fitting and use of the controller hub are contained in the handbook
available at www.thorlabs.com
2.5.3 Using the Baseplate
The baseplate must be bolted to the worksurface before the K-Cube is fitted, as
shown below. The K-cube is then located on two dowels in the baseplate and secured
by two clips.
Fig. 2.3 Using The Baseplate
Cautions
When siting the unit, it should be positioned so as not to impede the
operation of the control panel buttons.
Ensure that proper airflow is maintained to the rear of the unit.

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Chapter 2
2.6 Electrical Installation
2.6.1 Connecting a Strain Gauge Signal
Fig. 2.4 Rear Panel Connections
STRAIN GAUGE I/P (9 Pin DIN connector) – This connector receives the signal from
the strain gauge to provide the feedback for the control loop - see Section A.1. for pin
out details. Thorlabs supply cabling to connect from this D-type connector to the full
range of strain gauge equipped piezo actuators and force sensors.
MONITOR – This output can be connected to an oscilloscope, allowing the strain
gauge output to be monitored.
2.6.2 Strain Gauge - General Information
Typically, the KSG101 is used with strain gauges in a full bridge configuration
(Wheatstone). The resistance of each arm of the bridge should be around 350 
since there is a trade-off between resolution and heating of the gauges through too
much current. The gauge factor should be about ‘2’.
Note
Thorlabs supply a variety of SMA to BNC and SMC to BNC adaptor and
extension cables. Please visit www.Thorlabs.com for further details.
MONITOR STRAIN GAUGE I/P
0 - 10V
12345
6789

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K-Cube Strain Gauge Reader
A typical bridge circuit and strain gauge layout is shown below.
Fig. 2.5 Typical Circuit and Strain Gauge Layout
2.6.3 Supply Voltage and Current Requirements
Supply Minimum Maximum Max Operating Current
+15V +14.5V +15.5V 220 mA
-15V -14.5V -15.5V 50 mA
+5V +4.9V +5.1V 350 mA
Red
Black
Blue
Yellow
GAUGE A GAUGE B
R2
R1
R4
R3
Vo
R4
(active)
R2
(dummy)
R1
(active)
R3
(dummy)
VEX
Bridge Excitation
Blue (+ve)
Yellow (-ve)
Red Black
V0= Output voltage of full bridge
VEX = Excitation voltage
Note. R2 and R3 (dummy) are for
thermal compensation due to
temperature changes. They are
not affected by changes in the
strain signal.
-ve+ve
Ident Mark
Ident Mark

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Chapter 2
2.6.4 Front Panel
Fig. 2.6 Front Panel
POWER - Eight pin connector for connecting the unit to a regulated DC power supply
of the rating detailed in Section 2.6.3.
USB - USB port for system communications.
ON - Power ON/Standby switch - see Section 2.6.5.
TRIG 1 and TRIG 2 - SMA connectors for use with external trigger output signals (5V
TTL levels). The function is set to trigger IN or OUT via the settings panel - see
Section 5.2.3.
Warning
The unit must be connected only to a DC supply as detailed in Section 2.6.3.
Connection to a supply of a different rating may cause damage to the unit and
could result in injury to the operator.
Caution
Ensure the power switch on the front panel of the unit is switched off
before connecting power to the K-Cube. Always power up the K-Cube unit
by its ON switch. DO NOT connect the K-Cube unit to a 'live' external
power supply. Doing so (i.e. “hot plugging”) carries the risk of
PERMANENT damage to the unit. Similarly, to power down the unit, turn
the power switch off before disconnecting the power supply.
Note
The USB cable length should be no more than 3 metres unless a powered
USB hub is being used.
TRIG 1 TRIG 2
USB
+5V TTL +5V TTL
ON
P
O
W
E
R

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K-Cube Strain Gauge Reader
2.6.5 Powering Down The Unit
2.6.6 Connecting To A Standalone Power Supply
1) Using the front panel connector as shown above, connect the unit to a regulated
DC power supply of the rating detailed in Section 2.6.3.
2) Switch on the Power Supply unit, then switch on the KSG101.
3) The Version number of the embedded software is displayed for a few seconds.
Thorlabs offers a compact, two-way power supply unit (TPS002), allowing up to
two piezo driver K-Cubes to be powered from a single mains outlet. However, if
an third party supply is to be used, see Appendix A.1 for power supply
connector pin out details
Warning
Always be use the front panel ON switch to power down the unit. When in the
ON position, the unit is fully powered up. When the switch is turned to the
Standby position, the unit initiates a controlled power down sequence, saving
all user-adjustable parameters to non-volatile memory before turning off the
power. For the first few seconds, the shutdown can be cancelled by turning the
switch on again, in which case the unit will save the parameters but will remain
powered up. In a powered down (Standby) state, the logic circuits are powered
off and the unit will draw only a small quiescent current.
Warning
The unit must be connected only to a DC supply of the rating detailed in
Section 2.6.3. Connection to a supply of a different rating may cause
damage to the unit and could result in injury to the operator.
Caution
Ensure the power switch on the front panel of the unit is switched off
before connecting power to the K-Cube. Always power up the K-Cube unit
by its ON switch. DO NOT connect the K-Cube unit to a 'live' external
power supply. Doing so (i.e. “hot plugging”) carries the risk of
PERMANENT damage to the unit. Similarly, to power down the unit, turn
the power switch off before disconnecting the power supply.
Caution
If a third party power supply is used, ensure that the 3 supply voltages are
turned on and off simultaneously. Applying the supply voltages with a
large (more than 1 second) time delay between them can result in the strain
gauge cube showing an incorrect reading during subsequent operation.

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Chapter 2
2.7 Connect The Hardware
1) Perform the mechanical installation as detailed in Section 2.5.
2) Install the Kinesis Software.
3) Connect the Controller unit to your PC.
(Note. The USB cable should be no more than 3 metres in length. Communication
lengths in excess of 3 metres can be achieved by using a powered USB hub).
4) Connect the strain gauge to the Controller unit - see Section 2.6.1.
5) Connect the Controller unit to the power supply - see Section 2.6.3.
6) Connect the PSU to the main supply.
7) Switch ‘ON’ the unit using the switch on the front panel.
The unit takes about 5 seconds from power application until warm up is finished,
during which time the software revision is displayed. WindowsTM should detect the
new hardware. Wait while WindowsTM installs the drivers for the new hardware..
Caution
During items (3) to (6) the instructions should be followed strictly in the
order stated. Problems may occur if the process is not performed in the
correct sequence.
Caution
During item (4) ensure the power supply unit is isolated from the mains
before connecting to the K-Cube unit. Always power up the K-Cube unit
by connecting its power supply to the mains. DO NOT connect the K-Cube
unit to a 'live' external power supply. Doing so (i.e. “hot plugging”) carries
the risk of PERMANENT damage to the unit. Similarly, to power down the
unit, disconnect the power suply from the mains before disconnecting
the K-Cube unit.
Note
If any problems are encountered during the connection and power up
process, power cycle the unit, which should clear the error.
Thorlabs KSG101
SwRev 010001
Stage Travel:
100 μm

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K-Cube Strain Gauge Reader
2.8 Verifying Software Operation
The Software should be installed (Section 2.4.) and the hardware connected (Section
2.7.) before software operation can be verified.
1) Run the software and check that the Graphical User Interface (GUI) panel appears
and is active.
Fig. 2.7 Gui panel showing jog and ident buttons
2) Click the ‘Ident’ button. The digital display on the front panel of the associated
controller flash for a short period. This is useful in multi-channel systems for
identifying which channel is associated with which GUI.
Follow the tutorial described in Chapter 4 for further guidance on basic operation.
Caution
In applications requiring the highest level of accuracy and repeatability, it
is recommended that the controller unit is powered up approximately 30
minutes before use, in order to allow the internal temperature to stabilize.

18
Chapter 3 Standalone Operation
3.1 Introduction
The Strain Gauge Reader K-Cube has been designed specifically to operate with the
extensive range of Thorlabs piezo-actuated feedback equipped opto-mechanical
products. It is also compatible with Thorlabs force sensor products, FSC102 and
FSC103 providing high-sensitivity force and touch probe sensing.
For non-PC use the unit is equipped with an OLED Display to indicate position,
together with a settings menu to change the display units and set the zero position
point. These parameters can also be set via the Kinesis Server software - see Chapter
4. Parameters can be saved to the unit to allow “out of the box” operation with no
further “set up” required.
The unit is also equipped with a SMA position monitor output generating an analogue
voltage (0-10V) proportional to the strain gauge signal (position or force).
Furthermore, when operated together with the new K-Cube Piezo Driver unit
(KPZ101) on the K-Cube Controller Hub, high precision closed loop positioning is
possible using the complete range of feedback equipped piezo actuators available
from Thorlabs.
The following brief overview explains how the front panel controls can be used to
perform a typical series of operations.
In conjunction with this chapter, it also may be useful to read the background on piezo
operation contained in Appendix D .
Caution
The unit will always output the strain gauge feedback signal on the
external SMA connector on the rear panel. This means that the unit can
be used out-of-the-box, without any software setup. However, before the
unit is operated it is advisable to read the section on Setting The Position
Sensor Zero (Section 4.4.) and either Using with a Piezo Controller
(Section 4.5.) or Using with a Force Sensor (Section 4.6.).

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K-Cube Strain Gauge Reader
3.2 Control Panel
Fig. 3.1 Panel Controls and Indicators
Controls - These controls allow all motor moves to be initiated.
Wheel - The wheel/joystick is an infinite turn potentiometer, which is used to select
different parameters and values in the settings menu - see Section 4.4.
Digital Display - The display shows the menu options and settings, accessed via
the menu button - see Section 3.3. When the Ident button on the associated GUI
panel is clicked, the display will flash for a short period.
MENU - used to access the settings menu - see Section 3.3.
3.2.1 Digital Display - Operating Mode
During normal operation, the top line of the digital display shows the current units
applied, Voltage (V), Position (µm) or Force (N). The bottom line shows an indicator as
to whether the unit has been zeroed (Z = Zeroed, N = Not Zeroed), the max travel of the
piezo actuator connected, and the signal routing for the KCHxxx hub (Ch:1 or Ch:2)..
Fig. 3.2 Digital Display - Normal Operation
Strain Gauge Reader
MENU
Strain Gauge Reader
Pos: 50.026 μm
N 100 μm Ch:1

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Chapter 3
3.3 Settings Menu
3.3.1 Menu Overview
Press the MENU button
Use the wheel to scroll through the menu options
Press the MENU button to enter a particular option
Zeroing the Position Sensor - see Section 3.3.2.
Set the KCHx01 hub comms channel - see Section 3.3.3.
Set the display units - see Section 3.3.4.
Set the type of force sensor used - see Section 3.3.5.
Set the display brightness - see Section 3.3.6.
Set the display timeout period - see Section 3.3.7.
Menu options
Use wheel
Menu options
1 Zeroing
Menu options
2 Analogue out
Menu options
3 Units select
Menu options
4 Force Sensors
Menu options
5 Brightness
Menu options
6 Disp.Timeout
MENU
Pos: 50.026 μm
N 100 μm Ch:1