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Appendix A

– Control cabinet

Figure 35: Control box of shutter (opened)

Power supply:

12-24 V

Upper terminal screw

Connection for Process

Interface (PIF)

Switch

for different operation modes:

S1:

Switching between switch operation and pulse

operation

S2:

Activation/deactivation 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 (S1)

IN 2:

Currently no usage

IN 3:

Trigger input for fast-closing mode (S2)

Содержание Bottom-Up GIS 450i G7

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

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

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

Страница 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 ...

Страница 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...

Страница 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 ...

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

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

Страница 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 ...

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

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

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

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

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

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

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