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optris Bottom-Up GIS 640i G7 Operator's Manual

Glass inspection system
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Operators Manual
Bottom-Up GIS
640i G7 and 450i G7
Glass Inspection System

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Summary of Contents for optris Bottom-Up GIS 640i 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: Table Of Contents

    Table of contents Table of contents Table of contents ............................3 General notes ............................6 Intended use ............................ 6 Warranty ............................7 Scope of supply ..........................8 Technical Data ............................9 Bottom-Up GIS ..........................9 Factory default ..........................14 Optical specifications ........................15 2.3.1 Camera ..........................
  • Page 4 Installation ............................21 Hardware installation ........................21 3.1.1 Scan line and FOV ......................23 3.1.2 Camera positioning ......................26 3.1.3 Shutter adjustment ......................28 3.1.4 Installation control cabinet ....................29 Software Installation ........................33 3.2.1 Set up of the USB-Server ....................33 3.2.2 Installation PIX Connect .....................
  • Page 5 Table of contents Maintenance ..........................45 Glass breakage sensor CTL 4M ....................46 Basics of glass measurement ......................47 Reflection and transmission ......................47 Influence of different measuring wavelengths ................49 Hardening of glass sheets ......................50 Angle dependency ......................... 50 Appendix A –...

  • Page 6: General Notes

    1 General notes 1.1 Intended use ® Thank you for choosing the optris Bottom Up Glass Inspection System (BUGIS). This compact system is ideal for measuring glass and can be used for process control in glass tempering machines. This system consists of several components which are already pre-wired and ready for immediate use.

  • Page 7: Warranty

    General notes 1.2 Warranty Each single product passes through a quality process. Nevertheless, if failures occur please contact the customer service at once. The warranty period covers 24 months starting on the delivery date. After the warranty is expired the manufacturer guarantees additional 6 months warranty for all repaired or substituted product components.

  • Page 8: Scope Of Supply

    1.3 Scope of supply ▪ 2x PI 640i G7 with 90° FOV or 2x PI 450i G7 with 80° FOV ▪ CTLaser 4M pyrometer for the breakage detection with electronic box ▪ 2x Shutter systems with mounting bracket and electronic box ▪...

  • Page 9: Technical Data

    Technical Data 2 Technical Data 2.1 Bottom-Up GIS System 640i G7 450i G7 Temperature range 150-900°C or 200-1500°C Spectral range breakage sensor: 2,2-6 µm Imager: 7,9 µm Optical resolution 640x480 Pixel VGA 382x288 Pixel Up to 1600 points/line Up to 955 points/line Accuracy ±...
  • Page 10 In- and Outputs 0-10 V Inputs, digital input, 3x 0/4-20 mA output or alarm- /Relais outputs Interface 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...
  • Page 11 Technical Data Figure 1: Dimensions [mm], shutter system...
  • Page 12 Figure 2: Dimensions [mm], control cabinet...
  • Page 13 Technical Data Figure 3: Dimensions [mm], CTL 4M...

  • Page 14: Factory Default

    2.2 Factory default The CTL 4M pyrometer is delivered with the following factory settings: Emissivity 1,00 Exposure time (90%) [µs] Averaging (AVG) inactive Lower limit temperature range [°C] Upper limit temperature range [°C] alarm limit (AL2) [°C] Alarm source and alarm mode Tproc - normally open Temperature unit °C...

  • Page 15: Optical Specifications

    Technical Data 2.3 Optical specifications 2.3.1 Camera Make sure that the focus of thermal channel is adjusted correctly. If necessary, focus the thermal imaging camera with the optics (Figure 4). The turning out of the optics leads to the focus setting "near"...
  • Page 16 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 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.
  • Page 18 * Note: The accuracy of measurement can be outside of the specifications for distances below the defined minimum distance.

  • Page 19: Pyrometer

    As an alternative to the optical diagrams, the spot size 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 20 CTL 4M (FF optics) Figure 5: spot size diagram...

  • Page 21: Installation

    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: ▪...
  • Page 22 All components must be correctly positioned for the first commissioning of the entire system. Since all components are already pre-wired, they only have to be brought 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.

  • Page 23: Scan Line And Fov

    Installation After leaving the furnace, the glass must be cooled down after a relatively short time. The annealing furnace follows the heating furnace at a very short distance. Since glass is coated on the top size in most cases, a measurement from below has advantages.
  • Page 24 The width of the glass surface or the width of the oven should be covered by the scan line completely. The maximum width of 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 –...
  • Page 25 Installation The following diagram 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.

  • Page 26: Camera Positioning

    3.1.2 Camera positioning For the positioning of the cameras, the following diagram (see Figure 10) showing the distance between the cameras (d in Figure 7) depending on the chosen system (640i G7 vs. 450i G7 or horizontal vs. diagonal setup) and the distance ground to object (a+A in Figure 7) is used. Once the cameras are positioned, they must be focused to the object.
  • Page 27 Installation Figure 10: camera distance...

  • Page 28: Shutter Adjustment

    3.1.3 Shutter adjustment 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.
  • Page 29 Installation 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. Figure between shutter and lens...

  • Page 30: Installation Control Cabinet

    3.1.4 Installation control cabinet Now the control cabinet (Figure 14) must be moved to a suitable position. The individual cable lengths are 10 m. Therefore, make sure that the switch cabinet is no further than 10 m from the cameras or breakage sensor.
  • Page 31 Installation To dismantle the cables on the shutter box, loosen the four screws on the shutter box housing (it is not necessary to loosen the screws completely). Remove the cover of the shutter housing by tilting it backwards and pulling upwards.
  • Page 32 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.

  • Page 33: Software Installation

    Installation 3.2 Software Installation After having connected your Hardware, you can start with the configuration in the PIX Connect software. The steps in chapters 3.2.1 to 3.2.3 are mandatory and the steps in chapter 3.2.4 are optional and is only used to calculate the produced glass area.

  • Page 34: Set Up Of The Software Pix Connect

    After the installation the software can be opened. When using the camera for the first time, the calibration files must be downloaded from the Internet. This happens automatically, your PC hast to be connected to the internet. Alternatively, they can also be downloaded from the USB stick.
  • Page 35 Installation Start the software PIX Connect and load the layout BUGIS_Setup. Now the cameras can be fine-tuned. To do this, place a hot object in the center of the merged image so that the overlap of the two cameras captures that object.
  • Page 36 Now start the layout BUGIS_Operation. The shutters must be open for this step. To do this, go to the Line scanner configuration via Tools - Line scanner mode - Line scanner settings under the tab General click on the Continuous mode. After the fine adjustment set the Line scanner configuration mode back to External triggered.
  • Page 37 Installation Take care to position of the scan line between the rollers of the conveyor system to avoid possible reflections. You can use the Automatic Line Adjustment (ALA) function. The scan line is automatically set over the temperature for the entire scan width. There must be a hot object (e.g., glass) on the rollers in the scan line field.

  • Page 38: Fine Tuning Of The Software Pix Connect

    3.2.4 Fine tuning of the Software PIX Connect If you want to use the area calculation of the glass surfaces via the PIX Connect software or your thermal image of the glass is distorted, some modifications to the PIX Connect software are necessary. Rectification of the IR image The linescan is displayed in a metric format.
  • Page 39 Installation Calculation of produced glass area With the new specification of these values, the calculated produced glass area must still be adjusted. This indicates how much material is generated in one scan pass. To do this, go to Tools and Configuration in the menu.

  • Page 40: Electrical Installation

    3.3 Electrical Installation The delivered glass system is already pre-wired and is ready for operation without additional electrical installation. To integrate the input signal from the furnace with 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.
  • Page 41 Installation Designation 1. Ground 2. Shutter Status LED 3. Not assigned 4. Analog Input for the shutters – remote control 5. Analog Input for the shutters – external trigger 6. to 9: 24 V DC Power supply 10. to 13: Ground Figure 23: Terminal block The wiring of the furnace signal on the control cabinet is done under connection 5 (Input) and connection 10 (ground).

  • Page 42: Operation

    4 Operation After successful hardware and software configuration and electrical installation, the operation of the system is very simple. With the existing layout and the signal of the furnace, the system runs autonomously. The process procedure is as follows: The glass system gets the signal from the furnace: the signal opens the two shutters and the actual process starts.
  • Page 43 Operation Furthermore, the amount of glass produced can be displayed in the software. In this way, it is possible to see how much glass has been produced in a linescan pass. This information can be found in the digital display group. It is also possible to get the value of the calculated glass area via the analog output.
  • Page 44 Figure 27: Linescan in PIX Connect software (customized Layout)

  • Page 45: Maintenance

    Operation 4.1 Maintenance The system requires a maintenance check at regular intervals. Here, it should be checked whether the optics of the camera are clean, correctly focused and whether the shutter systems still function properly. This includes a complete opening and closing of the shutters. These points must be observed, as they have a direct influence on the temperature measurement.

  • Page 46: Glass Breakage Sensor Ctl 4M

    4.2 Glass breakage sensor CTL 4M To protect the cameras, the glass inspection system is delivered with a glass breakage detection. For this purpose, the pyrometer CTL 4M is set up just below the scan line between 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.

  • Page 47: Basics Of Glass Measurement

    Basics of glass measurement 5 Basics of glass measurement In general, non-contact temperature measurement on glass is very suitable. However, the following points should be considered: • Angle of view • Emissivity • Coatings • Correct sensors • Heat and dust Also pay attention to the measuring depths: •...
  • Page 48 • For devices with a wavelength range of 5.0 µm (G5) or 7.9 µm (G7) the emissivity ε is > 0.90 and there is a low angular dependence of the reflectivity ρ Representation of the emissivity over the wavelength for different glass types Figure 31: The figure shows how the dependence of the emissivity of different types of glass behaves with respect to the wavelength.

  • Page 49: Influence Of Different Measuring Wavelengths

    Basics of glass measurement 5.2 Influence of different measuring wavelengths Spectral range Sensor (Examples) Purpose 8 - 14 µm PI 640i, Xi 400 Low temperature, uncoated glass 7.9 µm PI 640i G7, CTlaser G7 High temperature, coated glass 5.0 µm CTlaser G5 molten glass, 1.0 µm...

  • Page 50: Hardening Of Glass Sheets

    5.3 Hardening of glass sheets • Temperature has a direct influence on glass quality • Testing for the heating profile (temperature distribution) Linescan function (line scanning) with PI camera from below. Direct effects: Defective or inhomogeneous surfaces can be detected by the measurement. Tempering: Change of the 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.
  • Page 51 Basics of glass measurement Figure 32: Angle dependency of Low-E glass, coated Figure 33: Angle dependency of Low-E glass, surface uncoated surface...

  • Page 52: Appendix A - Control Cabinet

    Appendix A – Control cabinet Figure 34: Wiring diagram of control cabinet...
  • Page 53 Appendix A – Control cabinet 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 Figure 35: Control box of shutter (opened)
  • Page 54 Pin assignment PIF electronic box (industrial process interface) GREY Interrupt GREEN SCL (I YELLOW SDA (I WHITE 3,3 V BROWN SHIELD Figure 36: Connections of the industrial Process Interface (PIF)
  • Page 55 Appendix A – Control cabinet The industrial process interface provides the following inputs and outputs: Name Description max range / status A IN 1 / 2 Analog input 1 and 2 0-10 V D IN 1 Digital input 24 V (active-low = 0…0,6 V) AO1 / 2 / 3 Analog output 1, 2 and 3...
  • Page 56 Designation CT electronic box +8…36 VDC Power supply Ground (0 V) of power supply Ground (0 V) of internal in- and outputs 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 Alarm 2 (Open collector output)

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