UAV Vision CM160 User manual

CM160 Multi-Sensor
Operations Manual
Version 1.8.0
Doc#: 100-104
UAV Vision Pty Ltd 2013
Unit 2/10 Uralla Road, Port Macquarie,
NSW 2444,
Australia
Phone/Fax [phone]
[e-mail]
www.uavvision.com

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Version:1.8.0
Revision History
Document Version
Date
Page Number
Change Description
V1.0
NA
First release.
V1.1
12-17
Added, UAV Navigation and MicroPilot
Instructions
V1.2
11
12
13
Changed delay time, added sentence about current
draw
Added new Hookup Diagram
Added Current Recommendation, changed min max
for new gimbals
V1.3
01/10/2010
12
11
14
Updated to CM160-V2, added new cable
configuration + Voltages
Added new power requirements
Added new Systems Dimensions
V1.4
24/02/2011
11
Updated to new wiring diagram, to include BNC
Connections
V1.5
11/10/2011
Various
Updated address and contact details, packing
information, Test GUI (Vision System), minor
grammatical and spelling corrections
V1.6
03/11/2011
11
Updated diagram and table to include the maximum
allowable voltage when operating the CM160 with
HD sensors
V1.7
27/02/2012
13
Added Mounting caution
V1.8.0
11/06/2013
All
Ported previous document across to new file
template
References
References are specific to both the CM100 and CM160. Please refer only the documents which match
the model of gimbal you are operating.
Reference ID
Document Name
Document Description
[1]
UV400-101_CM160_GimbalPinOuts_2-0-4
CM160 Gimbal Pin Outs
[2]
UV100-103_GTI_QuickStartGuide_1-0-0
Gimbal Interface Quick Start
Manual
[3]
UV300-100_BenchKit_HookUpDiagram_1-0-0
Bench kit Hook-Up Diagram
You are required to read this manual thoroughly and pay attention to voltages and mounting
instructions.
All rights reserved. No part of this book may be reproduced, stored in a retrieval system, or
transcribed, in any form or by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission of UAV Vision.
The information in this manual is subject to change without notice and, except for the warranty, does
not represent a commitment on the part of UAV Vision. UAV Vision cannot be held liable for any
mistakes in this manual and reserves the right to make changes.

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Table of Contents
Revision History.......................................................................................................................................ii
References ................................................................................................................................................ii
1. Features ............................................................................................................................................ 5
1.1. Control Modes...........................................................................................................................5
1.1.1 Position Mode.....................................................................................................................5
1.1.2 Velocity Mode....................................................................................................................5
1.1.3 Gyro Mode ......................................................................................................................... 5
1.2. Daylight Camera Controls.........................................................................................................5
1.2.1 Zoom Velocity Set..............................................................................................................5
1.2.2 Focus Manual/Auto............................................................................................................6
1.2.3 Focus Set ............................................................................................................................6
1.2.4 Auto Exposure On/Off .......................................................................................................6
1.2.5 Iris Manual Mode...............................................................................................................6
1.2.6 Iris Set.................................................................................................................................6
1.2.7 Shutter Manual Mode.........................................................................................................6
1.2.8 Shutter Speed Set................................................................................................................6
1.2.9 Camera Gain Set.................................................................................................................6
1.2.10 Stabilize Lens On/Off.........................................................................................................7
1.2.11 Picture Invert On/Off..........................................................................................................7
1.3. IR Camera controls....................................................................................................................7
1.3.1 IR FFC Mode Select...........................................................................................................7
1.3.2 IR Do FFC..........................................................................................................................7
1.3.3 IR FFC Set Temperature Delta...........................................................................................7
1.3.4 IR Zoom In 2x....................................................................................................................7
1.3.5 IR Freeze Frame On/Off.....................................................................................................7
1.3.6 IR Video LUT .................................................................................................................... 7
1.3.7 IR Video Orientation..........................................................................................................8
2. Specifications ...................................................................................................................................8
3. Compatible Sensors..........................................................................................................................8
3.1.1 IR Cams:.............................................................................................................................8
3.1.2 Daylight Cams:...................................................................................................................8
3.1.3 Sensors................................................................................................................................8
4. Unpacking the Box........................................................................................................................... 8
5. Handling Instructions....................................................................................................................... 9
6. Powering the System........................................................................................................................9
6.1. Boot-up Sequence......................................................................................................................9

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6.2. Recommended Operating Conditions........................................................................................9
6.3. Cable Configuration.................................................................................................................10
6.4. Absolute Maximum Ratings....................................................................................................10
7. Cleaning the CM160 ......................................................................................................................10
8. Gimbal Test Interface software...................................................................................................... 11
9. Bench Kit........................................................................................................................................11
10. Acceptance Tests.........................................................................................................................12
10.1. Video Quality.......................................................................................................................12
10.2. Position Controller Test....................................................................................................... 12
10.3. Gyro Stabilization................................................................................................................ 12
10.4. Feature Test..........................................................................................................................12
11. System Dimensions.....................................................................................................................13
12. UAV NAVIGATION with the CM160.......................................................................................14
12.1. CFG Tab:..............................................................................................................................14
12.2. Payload Tab..........................................................................................................................14
12.3.....................................................................................................................................................15
13. MicroPilot with the CM160 ........................................................................................................ 16
13.1. Horizon GCS Configuration:............................................................................................... 16
13.2. Setup for Camera in the autopilot:.......................................................................................17
13.2.1 Control Camera by Position............................................................................................. 17
13.2.2 Control Camera by Velocity.............................................................................................17
13.2.3 Hybrid. Autopilot Controls Position, Joystick Control Velocity. ....................................17
13.3. Autopilot Fields for VD170 / GD170 and CM160 Cameras............................................... 18
13.3.1 Hybrid Mode Setup:.........................................................................................................19
14. Contact.........................................................................................................................................20
14.1. Support.................................................................................................................................20
14.2. Sales..................................................................................................................................... 20
14.3. General Enquiries................................................................................................................. 20
14.4. Phone Contact...................................................................................................................... 20

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1. Features
This section will present the features for the UAV Vision CM160 gimbals.
Pan and Tilt operation is super smooth with our internal controller, you can pan the system continuously and
tilt from +90 though 0 to -90 degrees.
The gyro sensors are being read and filtered at 3khz giving us great vibration smooth data enabling us to
provide you with the best stabilization possible.
The CM160 can be fitted with multiple sensors, as default we fit the SONY FCB-EX980SP and the FLIR
TAU 2 336 with a 35mm lens. This gives us great characteristics for search and rescue, amongst others.
We have fitted two 5megapixel video cameras for a particular project and have fantastic tracking results.
1.1. Control Modes
The CM160 Gimbal has three operational modes:
1.1.1 Position Mode
This mode allows a user to demand pan/tilt position. The CM160 will move to the demanded position in the
direction that is quickest for the system to arrive at it.
The velocity of movement toward the demanded position will be determined by the distance away from the
demanded position.
The position demands are capable of demanding the system to one of 32768 positions in pan, corresponding
to the full 3600rotations. The 32768 positions result in a position resolution for the system of 0.0110
(360/32768) in both the pan and tilt axis. The tilt axis is limited by the end stops programmed into the
system, with an effective travel of ±900from the centre position.
1.1.2 Velocity Mode
The pan and tilt can be controlled via a velocity, this being an absolute system pan or tilt velocity to the
CM160.
This velocity is the actual velocity (in degrees per second) that the system will move at. The velocity limit
demands are ±1550/sec and in 0.010/sec increments for both pan and tilt.
1.1.3 Gyro Mode
The CM160 is delivered with gyros. The CM160 gimbal performs excellently on moving platforms. This
feature gives us the ability to hold an image still even through adverse movements.
When the CM160 is in Stabilization Mode, the user can demand velocities on both Pan and Tilt which are
relative to the ‘World’. For example, the platform which is carrying the CM160 is rotating at +100/sec and
the user would like to continue to pan the image slowly at -20/sec then the internal calculations will pan the
system at -120/sec, relative to the CM100 but a smooth -20/sec relative to the image/world.
The CM160 is capable of streaming its current angle at 40Hz, therefore giving the user the ability to close
the loop on a hybrid position control manually. This can be activated in all three modes.
1.2. Daylight Camera Controls
1.2.1 Zoom Velocity Set
The CM160 is fitted with the Sony FCB-EX980SP as standard and as such comes with an incredible 26x
optical continuous zoom; the Sony protocol allows us to demand 6 levels that the user can demand the zoom
velocity. The numbers are from 2 to 7, with 2 being the slowest zoom speed and 7 the highest. The user can
choose to zoom in or out at any of these speeds.

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1.2.2 Focus Manual/Auto
Occasionally you will need to set the focus to manual. This is sometimes needed according to the
surroundings. If you are looking backwards and an undercarriage leg is in view the camera will focus on
that, while you will probably wish to have the focus set to the surroundings. The easiest way to achieve this
is to move the image away from the foreground and focus on the background, press manual focus and it will
lock the focus to the background, then you can move back to the previous position and the foreground will
now be blurry. You can now concentrate on the background without the camera “pumping” in and out of
focus.
User Tip
An alternative method, if you are at a constant altitude, is to zoom in to an object and let the camera focus,
press manual focus and zoom out. Now everything at that distance will be in focus and you will even be able
to zoom and keep the focus.
1.2.3 Focus Set
Alternatively you can manually set the focus with a simple numeric command.
1.2.4 Auto Exposure On/Off
There will be times when there will be a difference in light between what you are trying to recognize and the
surrounding light, which can cause issues with the auto setting. You will need to turn the auto exposure
control of the camera off. When the control is off it allows the user to control the iris, shutter, and gain
manually with the manual commands listed below.
1.2.5 Iris Manual Mode
If the iris manual mode is turned on the iris can be controlled manually, but the camera shutter and gain
controls will still be automatic.
1.2.6 Iris Set
The iris may be set manually if you have turned off the auto exposure control or if you have enabled the iris
manual mode.
1.2.7 Shutter Manual Mode
If you are having difficulties getting enough light on the subject you may have to set all/one of these settings
to manual, and control the amount of light yourself. Our communications protocol allows you to control
every available command that the Sony provide. The Shutter Manual Mode can assist to get either a video
sync, if there are any other TV’s or Monitors you are pointing at, or in extreme light conditions and you
don’t want the gain to creep causing a grainy picture. Bear in mind that the slower the shutter speed the
better the illuminations, but you may suffer from a jumpy image.
If the shutter manual mode is turned on, the shutter can be controlled manually, but the camera iris and gain
controls will still be automatic.
1.2.8 Shutter Speed Set
The shutter may be set manually if you have turned off the auto exposure control or if you have enabled the
shutter manual mode.
1.2.9 Camera Gain Set
The camera gain can be set manually only if you have turned off the auto exposure control. Bear in mind
the higher the gain the worse the picture quality.

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1.2.10 Stabilize Lens On/Off
Along with the internal gyros of the CM160 the Sony FCB-EX980SP is fitted with an optical image
stabilizer, the image stabilizer works extremely well under harsh vibrations and smoothes the whole picture
making it a viewable image for recognition however there are a couple of downfalls, 1, image resolution and
2, if you are trying to locate an object via Geo-pointing then this can push your object off by a few degrees.
This may or may not be useful depending on the application, but is worth experimenting with to determine if
it is useful.
1.2.11 Picture Invert On/Off
This is used to invert the image streamed from the system.
1.3. IR Camera controls
The CM160 can be fitted with a FLIR IR camera and as such a select number of commands have been
implemented in our software to control the FLIR TAU 2 range of Infrared cameras and are listed below.
1.3.1 IR FFC Mode Select
The IR camera we are using is Un-cooled and as such has to regularly perform an FFC (Flat Field
Correction) whereby the camera internally places a Flat plate over it’s sensor and recalibrates for a uniform
temperature sensing. This happens upon a certain temperature change listed below, or can be commanded as
and when you would like it to happened. The disadvantage of the auto setting is it can disturb your image at
the wrong time, as when this occurs your image will freeze for approximately 1 second. The manual setting
is generally used for this purpose, although we have set the default value to Auto for basic use. The user is
able to switch between the automatic and manual modes for FFC.
1.3.2 IR Do FFC
Once in manual FFC mode, the user can send the Do FFC command to the IR camera.
1.3.3 IR FFC Set Temperature Delta
This is used as described earlier to set the temperature delta. The range is from 0-1000C.
1.3.4 IR Zoom In 2x
The TAU 2 has a prime lens, which is a set zoom and focus lens. Therefore to get a zoom out of it you need
to do it digitally, the IR camera is capable of 2x Digital zoom.
1.3.5 IR Freeze Frame On/Off
Another neat feature is freeze frame. The user can freeze the current frame and then resume to the default
real time video stream after reviewing the frozen frame, without the need for a DVR.
1.3.6 IR Video LUT
In certain instances you will need to change the LUT of the IR camera. In some weather conditions you will
find that you will need to alternate the LUT to locate heat sources. When looking for a vehicle from above
the White hot is from our opinion the best setting. Please experiment with what works for you, the Fusion is
very good on close-up human images. The user can control the video LUT (intensity transform) output of
the camera. The available options are:
White hot (default);
Black hot;
Fusion; and
Rain.

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1.3.7 IR Video Orientation
As with the Daylight camera the user is able to switch the video output between normal, inverted, revert
(horizontal flip) and invert/revert.
2. Specifications
Gimbal Specs
Units
Position Resolution
0.011°
Position Accuracy
0.005°
Stabilization Accuracy
0.05°
Elevation
+- 120°
Azimuth
360° Continuous
Slew Rate
155°/sec
(2.7 rad/s)
Slew Acceleration
100°/s/s
Power
5w/20w
Voltage
12-36V
Physical
Weight
1450 g
Dimensions
160mm x 250mm
3. Compatible Sensors
3.1.1 IR Cams:
FLIR TAU 2 336/640 up to a 50mm lens
Thermoteknix 110k/307k up to a 50mm lens
Opgal 320 and 640 up to a 50mm lens
3.1.2 Daylight Cams:
Sony FCB-EX Series block cameras
Gigabit Cameras
Firewire Cameras
3.1.3 Sensors
Laser Range Finder
4. Unpacking the Box
The CM160 is well protected and packaged. It is provided in a hard ruggedised case, to provide additional
protection when it is removed from the platform or needs to be transported. The case has a foam insert
which the gimbal is stored in, along with associated cables and accessories.
When removing the CM160 take care not to apply pressure upon the actual ball section. Once the CM160 is
free of the box place it on a soft surface. Do not place the gimbal on anything which could damage the
gimbal surface.

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Inside the box you will find a USB Key with a copy of UAV Vision’s Gimbal Test Interface software and
digital copies of the operational manuals. The cables required for operation may also be included. It is
important to note voltage and power requirements before plugging any of the cables in.
5. Handling Instructions
Please note that the CM160 is fitted with an anti-backlash device, which also doubles up as a torque limiter.
This device enables us to give you perfect gear alignment for years to come. You should never suffer from
backlash.
The CM160 should not be moved manually at any time, permanent damage will occur. The CM160
can be handled via the outer shell. Try to avoid handling the system via the ball.
6. Powering the System
Note: before powering the system ensure that you are powering within the limits of the CM160 as
specified, taking particular notice of the minimum current draw/limit.
All new customers should have purchased a test bench. Please ensure that the CM160 is free from any
obstructions, and is mounted using the supplied Test Bench in a hanging configuration. The CM160 will
move in a predetermined manner during initialisation and indexing. The operator cannot control the unit
during this process.
Please note it is good practise to power the CPU supply before the Motor Supply, however there is no
restriction on the order when applying power. The two supplies may also be connected together and
powered from the same supply, if the supply is suitable.
6.1. Boot-up Sequence
Due to the high-resolution gyros and digital optical encoders the CM160 has to go through a boot-up
sequence, this being as follows:
Pan and Tilt The CM160 will pan and tilt to find it’s index positions. The Pan will drive to find
the index and then return to it’s initial offset position known as it’s ‘0’ and in a
similar manner the Tilt will tilt upside down and then point directly down or up
depending on the mounting configuration.
Please note that this happens at quite a high speed and the unit must be fixed to a solid platform and remain
stationary for the initial 6 seconds.
Once the boot-up sequence has finished you will have full control over the system.
6.2. Recommended Operating Conditions
Symbol
Characteristic
Min
Typical
Max
Unit
VCC Supply
Main Supply Voltage
9
18
36
V
VCC Supply
Main Supply Current Limit
4
4
-
A
Temperature
Ambient Temperature
0
25
50
C

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6.3. Cable Configuration
A cable configuration and pin out diagram will be provided with your gimbal. The document name and
description is listed in the related documents table. Please refer to it for pin outs, power, and serial
communications. [1]
6.4. Absolute Maximum Ratings
Symbol
Characteristic
Min
Max
Unit
VCC Motor Supply
Main Power Supply*
12.50
36.00
V
CPU VCC
CPU Power Supply*
5.50
36.00
V
MSOUT Control
Service Transmit Line
-15
+15
V
MSIN Control
Service Receive Line
-15
+15
V
TTL Lines
System Board Boot Bypass (Service ONLY)
0
3
V
Comms IN (RX)
System Communications Receive Line
RS232
-15
+15
V
Comms Out (TX)
System Communications Transmit Line
RS232
-15
+15
V
VIDEO Signal 2
IR Camera Video Signal
0
1
Vp-p
VID Screen
Video Screen (Both Outputs)
0
0
V
VIDEO Signal 1
Day-light Camera Video Signal 1(switchable)
0
1
Vp-p
Motor Power
Current Draw
1350
4000
mA
CPU Power
Current Draw
200
900
mA
Temperature
Ambient Temperature
-10
40
C
* Important Note: The maximum voltage when using an HD sensor is 18 volts
7. Cleaning the CM160
The CM160 is finished with a fairly robust coating, as used on the DC3’s in Australia. The coating is
scratch resistant and solvent resistant.
The lenses are also resistant to most solvents. The IR lens is Germanium but with a Diamond Like Coating
on the external surface, giving you a lens which can withstand finger prints and even Acetone.
Please clean the CM160 with window cleaning solution and avoid cleaning with solvents although they
shouldn’t damage it.