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Installation

3 Installation

3.1 Hardware installation

Basically the whole system consists of three main components:

▪

Temperature measuring system 1: 2 cameras with shutter (measurement from underneath)

▪

Glass breakage detection: high performance pyrometer (measurement from the side)

▪

Switch cabinet with complete electronic unit and remote control

Hardware and software recommendations:

▪

Computer with OS Windows 10 or higher

▪

i7 Processor 10th Generation with 2,6GHz or higher

▪

16 GB RAM or higher

Note:

•

The camera must be focused if the distance between the camera lens and the object
(see

Figure 7

: schematic representation of the distances) is not equal to 90cm.

•

After focusing the camera, the shutter must be adjusted (s.

Chapter 3.1.3

page

)

•

Note the distance between the cameras (see

Figure 10

and

Figure 7

: schematic

representation of the distances)

•

Consider the minimum distance of the selected optics.

•

For installation, the components must be detached from the profiles.

Summary of Contents for Bottom-Up GIS 450i G7

Page 1: ...Operators Manual Bottom Up GIS 640i G7 and 450i G7 Glass Inspection System ...

Page 2: ...Optris GmbH Ferdinand Buisson Str 14 13127 Berlin Germany Tel 49 30 500 197 0 Fax 49 30 500 197 10 E mail info optris global Internet www optris global ...

Page 3: ... contents Table of contents 3 1 General notes 6 1 1 Intended use 6 1 2 Warranty 7 1 3 Scope of supply 8 2 Technical Data 9 2 1 Bottom Up GIS 9 2 2 Factory default 14 2 3 Optical specifications 15 2 3 1 Camera 15 2 3 2 Pyrometer 19 ...

Page 4: ...26 3 1 3 Shutter adjustment 28 3 1 4 Installation control cabinet 29 3 2 Software Installation 33 3 2 1 Set up of the USB Server 33 3 2 2 Installation PIX Connect 33 3 2 3 Set up of the Software PIX Connect 34 3 2 4 Fine tuning of the Software PIX Connect 38 3 3 Electrical Installation 40 4 Operation 42 ...

Page 5: ...4 2 Glass breakage sensor CTL 4M 46 5 Basics of glass measurement 47 5 1 Reflection and transmission 47 5 2 Influence of different measuring wavelengths 49 5 3 Hardening of glass sheets 50 5 4 Angle dependency 50 Appendix A Control cabinet 52 ...

Page 6: ...ee analysis software PIX Connect and a predefined layout the system can be used directly Features Bottom Up system with additional breakage detection sensor Digital controlled lens protection system DCLP avoids additional air purge and protects the camera lens Automatic calculation of the glass surface Automatic Adjustment of the scan line Automatic Line Adjustment ALA Pre assembled system for eas...

Page 7: ...ges which result from misuse or neglect The warranty also expires if you open the product The manufacturer is not liable for consequential damage or in case of a non intended use of the product If a failure occurs during the warranty period the product will be replaced calibrated or repaired without further charges The freight costs will be paid by the sender The manufacturer reserves the right to...

Page 8: ...x 2x Shutter systems with mounting bracket and electronic box 2x USB Server Gigabit 2 0 and 1x Ethernet switch Control cabinet pre assembled and pre wired with 10m cable set and 24V Power supply 2x Industrial Process Interface PIF Remote control for trigger signal of shutter USB stick with Software Layout and calibration files Operators manual ...

Page 9: ...ager 7 9 µm Optical resolution 640x480 Pixel VGA Up to 1600 points line 382x288 Pixel Up to 955 points line Accuracy 2 C or 2 Frame rate Scan speed 32Hz 125 Hz 640x120 Pixel 80 Hz switchable to 27 Hz NETD Temperature resolution 80 mK 150 mK Ambient temperature camera 0 50 C 0 70 C Ambient temperature pyrometer 0 70 C Ambient temperature control cabinet 0 50 C ...

Page 10: ... Integrated TCP IP Ethernet interface via USB Server Environmental rating IP67 Dimensions Shutter 116 x 57 x 121 mm control cabinet 400 x 200 x 155 mm CTlaser 4M Pyrometer L 100mm Ø 55mm Weight complete system 16 5 kg Material Stainless steal Warm up time 10 min Table 1 Technical Data of Bottom Up GIS ...

Page 11: ... Technical Data 11 Figure 1 Dimensions mm shutter system ...

Page 12: ... 12 Figure 2 Dimensions mm control cabinet ...

Page 13: ... Technical Data 13 Figure 3 Dimensions mm CTL 4M ...

Page 14: ...Averaging AVG inactive Lower limit temperature range C 0 Upper limit temperature range C 500 alarm limit AL2 C 300 Alarm source and alarm mode Tproc normally open Temperature unit C Baud rate kBaud 921 6 You can change the settings either directly with the CompactPlusConnect software or via the programming keys on the electronics box ...

Page 15: ... the focus setting near and the turning in of the lens to the focus setting infinity Note The focus of the optics is set at the factory to an object distance of 90 cm camera lens to measurement object A in Figure 7 The optics only must be focused if the distance is not equal to 90 cm When refocusing the optics the shutter must also be adjusted see chapter 3 1 3 on page 28 Figure 4 Focusing by turn...

Page 16: ...s available Wide angle lenses have a radial distortion due to their large opening angle the software PIX Connect has an algorithm which corrects this distortion As an alternative to the tables below the optics calculator can also be used on the optris website or via the optris calculator app The app can be downloaded for free from the Google Play Store see QR code ...

Page 17: ... Technical Data 17 Note The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance ...

Page 18: ... 18 Note The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance ...

Page 19: ... on the Optris website or via the Optris calculator app The app can be downloaded for free from the Google Play store see QR code D Distance from front of the sensing head to the object S Spot size The size of the measuring object and the optical resolution of the infrared thermometer determine the maximum distance between sensing head and measuring object In order to prevent measuring errors the ...

Page 20: ... 20 CTL 4M FF optics Figure 5 spot size diagram ...

Page 21: ...uter with OS Windows 10 or higher i7 Processor 10th Generation with 2 6GHz or higher 16 GB RAM or higher Note The camera must be focused if the distance between the camera lens and the object see A in Figure 7 schematic representation of the distances is not equal to 90cm After focusing the camera the shutter must be adjusted s Chapter 3 1 3 on page 28 Note the distance between the cameras see Fig...

Page 22: ...t into the correct position A suitable position for glass measurement is between the furnace and the immediately following annealing furnace In most cases there is a small slot there which allows a contactless temperature measurement The glass is transported on horizontal rollers Figure 6 shows a classical glass tempering process Figure 6 Process of glass production ...

Page 23: ... are required to display the individual glass sheets in a complete image This is positioned on the floor as shown in Figure 6 More about this in chapter 5 Basics of glass measurement The software PIX Connect uses the Linescan and the Merge function to display a complete image although only one line is scanned 3 1 1 Scan line and FOV The scan line is an important tool to display the thermal image a...

Page 24: ... the scan line depends on the distance between the camera lens and the measurement object A in Figure 7 and on the selected configuration diagonal or horizontal setup The diagonal setup increases your scan line black line in Figure 8 and your field of view FOV Filed of View Figure 8 camera setup left diagonal right horizontal ...

Page 25: ...am shows the maximum scan line width as a function of the distance from the ground to the object a distance from the ground to the camera lens a in Figure 7 of 155mm was assumed and depending of a chosen system Figure 9 maximum line width ...

Page 26: ...ground to object a A in Figure 7 is used Once the cameras are positioned they must be focused to the object Focusing is not required at the object distance camera lens to measurement object A in Figure 7 of 90cm this distance is factory focused As soon as the camera has been focused the shutter must be readjusted see Chapter 3 1 3 on page 28 The fine adjustment of the camera position is carried ou...

Page 27: ... Installation 27 Figure 10 camera distance ...

Page 28: ...Open the shutter via the remote control If necessary readjust the focus Loosen the screws on both sides of the shutter housing see pictures on the right and left It is not necessary to unscrew these screws completely Lift the shutter housing and close the shutter via the remote control above the lens ...

Page 29: ...allation 29 Figure 13 Gap between shutter and lens Sink the shutter housing above the lens and tighten the screws There must not be any gap between lens and shutter see Figure 13 Now the shutter is adjusted ...

Page 30: ... it should be easily accessible because the trigger signal from the oven must be connected here Figure 14 Control cabinet The cables of the cameras the pyrometer and the shutter boxes can be disassembled for easier cable laying The cables on the cameras and pyrometer are screwed and can be easily unscrewed for disassembly When reassembling the cables make sure that the master and slave of the came...

Page 31: ...er the cover and pull out the slide Figure 15 in blue Now you can unscrew the shutter cable and after laying the cable reassemble it in the reverse order Now that the three main components have been successfully assembled two connections must be connected The first connection is the Ethernet cable to a computer or switch The second connection is the power supply The entire system is supplied with ...

Page 32: ...ecessary to align the devices This can only be done when the shutters are open When the system is powered the yellow LED is on and the shutters are closed When the button is pressed the shutters are opened and the LED goes off Figure 16 Remote control Further notes and information on glass measurement can be found in chapter 5 Basics of glass measurement ...

Page 33: ...e USB Server But before you start the PIX Connect you must first set up the USB server On the supplied USB stick in the folder USB Sever you will find two software programs WuTility and USB Redirector that are required for the installation of the whole system Detailed instructions for setting up the server can be found in the folder Documentation Manuals ACPIUSBSGB QSG Dxxxx xx x 3 2 2 Installatio...

Page 34: ...ontain all the necessary settings To load them you must first import them from the stick into the software In the menu go to Tools Layouts Layots import export Layouts import and select the two pre configured layouts from the stick The software already contains two predefined layouts called BUGIS_Operation BUGIS_Demo and BUGIS_Setup You can load these layouts in the menu under Tools and Load layou...

Page 35: ... correctly and is not distorted or duplicated In this setup the merged image from the two cameras with an overlap of 12 pixels is shown Figure 17 Layout BUGIS_Setup The scan line can also be used as an aid to aligning the cameras to the glass between the rollers Later the scan line has to be set in the BUGIS_Operation layout The scan line in the layout BUGIS_Setup is used for orientation and camer...

Page 36: ...onfiguration mode back to External triggered Now a few settings have to be made The scan line must be positioned correctly The scan line can be moved in the lower right window line scanner live view in the specified 5 points by clicking and dropping Alternatively coordinates can also be entered via the line scan camera configuration via Line scanner configuration Make absolutely sure that the widt...

Page 37: ...n width There must be a hot object e g glass on the rollers in the scan line field Detailed instructions for setting up the line scanning function can be found in the folder Documentation Manuals PIX Connect MA E20xx xx X pdf The system is now ready and can be operated Additional settings described in 3 2 4 are required for the correct and undistorted display of the glass surfaces and the calculat...

Page 38: ... means that the length and width of the furnace must be specified in the software To do this go to the menu Tools Line scanner mode and select Line scanner settings A new window opens Under the tab Presentation the parameters can be entered see Figure 20 Under Width Length of line and Length of scan the two parameters can be entered To obtain an undistorted representation of the product at the end...

Page 39: ...ow much material is generated in one scan pass To do this go to Tools and Configuration in the menu In the tab Measuring area click on the measuring area Area On the right side under Total area you can enter the new value Figure 21 setup the of the calculation area Now you can use the system and start your temperature measurement and calculation of produced glass area ...

Page 40: ...hout any additional electrical installation To integrate the input signal from the furnace with the glass inspection system you must open the control cabinet On the left side is a terminal block which is connected to different colors of wires These are labeled as follows Figure 23 Figure 22 Control cabinet open ...

Page 41: ...und The wiring of the furnace signal on the control cabinet is done under connection 5 Input and connection 10 ground The input voltage range is 0 max 24 V An open input is interpreted as a high signal The signal must be switched to ground 0 V If your system provides an open input as a low signal the alarm mode must be changed from normally open to normally closed on the CTL 4M via CompactPlusConn...

Page 42: ...cess starts The software starts the linescan with 125 Hz and builds up the image line by line In the end a complete image of the product is created and automatically saved as a snapshot Since each pixel is saved as a temperature value an exact analysis can be performed afterwards In addition to maintaining the correct temperature the software also displays the temperature distribution as a profile...

Page 43: ...pshots are saved after each scan and can subsequently be evaluated in terms of temperature and the produced glass area Figure 25 Digital display group Another component of the system is the remote control With this unit the shutters can be opened and closed again During the first installation it is necessary to align the devices This can only be done when the shutters are open When the system is p...

Page 44: ... 44 Figure 27 Linescan in PIX Connect software customized Layout ...

Page 45: ... a complete opening and closing of the shutters These points must be observed as they have a direct influence on the temperature measurement Figure 28 Shutter open camera Figure 29 Shutter closed camera Figure 30 breakage sensor Never use cleaning compounds which contain solvents neither for the lens nor for the housing The lens surface can be cleaned with a soft humid tissue moistened with water ...

Page 46: ...en the rollers If a glass breaks into pieces and these fall between the rollers the pyrometer recognizes this because of the ultra fast reaction time of 90 µs and gives the shutters a signal to close The shutters are operated here in the so called fast mode so that the closing time is approx 100ms This prevents broken glass from damaging the camera lens Furthermore a signal can be output that a gl...

Page 47: ...ollowing points should be considered Angle of view Emissivity Coatings Correct sensors Heat and dust Also pay attention to the measuring depths 1 0 to 3 9 µm for deep layers 5 0 and 7 9 µm for surface 5 1 Reflection and transmission Reflection and transmission must be considered For long wavelength devices 8 14 µm LT the emissivity ε is about 0 85 ...

Page 48: ...reflectivity ρ Figure 31 Representation of the emissivity over the wavelength for different glass types The figure shows how the dependence of the emissivity of different types of glass behaves with respect to the wavelength A good emissivity is present in the wavelength range 5 0 µm and 7 9 µm and is preferred for measurements on glass ...

Page 49: ...0 Low temperature uncoated glass 7 9 µm PI 640i G7 CTlaser G7 High temperature coated glass 5 0 µm CTlaser G5 1 0 µm PI 1M molten glass looking in through glass The table gives an overview for which purpose which wavelength and therefore which sensor must be used This depends among other things on the material the temperature and the coating ...

Page 50: ...heating cooling degree depending on the temperature distribution 5 4 Angle dependency The angle dependence is another important factor to be considered when measuring temperature On the uncoated side the values are constant up to an angle of 45 On the coated side low E the 60 optics is preferred since the influence of the emissivity change is negligible here The following two figures show the emis...

Page 51: ... Basics of glass measurement 51 Figure 32 Angle dependency of Low E glass coated surface Figure 33 Angle dependency of Low E glass uncoated surface ...

Page 52: ... 52 Appendix A Control cabinet Figure 34 Wiring diagram of control cabinet ...

Page 53: ...n of fast closing mode S3 Only for factory calibration Switch must be at Normal S4 Switching between mV or mA input The S4 position is on the control box shutter 1 on 1 and on the control box shutter 2 on 2 Lower screw terminal Connection for power supply Inputs Start Stop signal and Motor Inputs Start Stop signal max 24 V input is active LOW open input HIGH IN 1 Trigger input for normal operation...

Page 54: ... Pin assignment PIF electronic box industrial process interface Figure 36 Connections of the industrial Process Interface PIF GREY Interrupt GREEN SCL I2 C YELLOW SDA I2 C WHITE 3 3 V BROWN GND SHIELD GND ...

Page 55: ... open closed green LED on 0 30 V 400 mA 1 depending on supply voltage for 0 20 mA on the AO the PIF has to be powered with min 5V 1 5 working resistance 0 021 24 V Example RLoad 500 ohm Umin 1 5 500 0 021 12 V RLoad 100 ohm Umin 1 5 100 0 021 3 6 V min 5 V 2 the AI is designed for max 24 V the voltage level above 10 V is not interpreted 3 active if AO1 2 or 3 is are programmed as alarm output The ...

Page 56: ...uts OUT AMB Analog output head temperature mV OUT TC Analog output thermocouple J or K OUT mV mA Analog output object temperature mV or mA F1 F3 Functional inputs AL2 Alarm 2 Open collector output 3V SW 3 VDC switchable for laser sighting tool GND Ground 0 V for laser sighting tool BROWN Temperature probe head WHITE Temperature probe head GREEN Detector signal YELLOW Detector signal ...

Page 57: ...Bottom Up GIS MA E2022 04 A ...

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