Pepperl+Fuchs EtherCAT PGV F200A-B21-V1D Series Manual
  1. Manuals
  2. Brands
  3. Pepperl+Fuchs Manuals
  4. Industrial Equipment
  5. EtherCAT PGV F200A-B21-V1D Series
  6. Manual
Pepperl+Fuchs EtherCAT PGV F200A-B21-V1D Series Manual

Pepperl+Fuchs EtherCAT PGV F200A-B21-V1D Series Manual

Data matrix positioning system
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
PGV...-F200A-B21-V1D
Data Matrix
Positioning System
Manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the EtherCAT PGV F200A-B21-V1D Series and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Pepperl+Fuchs EtherCAT PGV F200A-B21-V1D Series

Summary of Contents for Pepperl+Fuchs EtherCAT PGV F200A-B21-V1D Series

  • Page 1 PGV...-F200A-B21-V1D Data Matrix Positioning System Manual...
  • Page 2 Phone: +49 621 776 - 0 E-mail: info@de.pepperl-fuchs.com North American Headquarters Pepperl+Fuchs Inc. 1600 Enterprise Parkway Twinsburg, Ohio 44087 Phone: +1 330 425-3555 E-mail: sales@us.pepperl-fuchs.com Asia Headquarters Pepperl+Fuchs Pte. Ltd. P+F Building 18 Ayer Rajah Crescent Singapore 139942 Phone: +65 6779-9091 E-mail: sales@sg.pepperl-fuchs.com https://www.pepperl-fuchs.com...

  • Page 3: Table Of Contents

    PGV...-F200A-B21-V1D Contents Introduction........................ 6 Content of this Document ................6 Target Group, Personnel ................6 Symbols Used ....................7 Trademarks..................... 7 Product Description ....................8 Use and Application ..................8 LED Indicators and Operating Elements........... 12 Accessories....................14 Planning........................15 Plant Design ....................
  • Page 4 PGV...-F200A-B21-V1D Contents Read Head ....................74 4.2.1 Mounting the Read Head ....................75 4.2.2 Aligning the Read Head ....................77 Electrical Connection ..................81 Setting up Windows Network Communication between the Read Head and a PC/Laptop ..............82 Configuration with TwinCAT® ..............84 Operation and Communication ................98 EtherCAT®...
  • Page 5 PGV...-F200A-B21-V1D Contents Maintenance......................140 Maintenance ....................140 Testing......................140 Cleaning...................... 141 Repair......................141 Disposal........................142 Appendix ........................ 143 ASCII Table ....................143...

  • Page 6: Introduction

    PGV...-F200A-B21-V1D Introduction Introduction Content of this Document This document contains information required to use the product in the relevant phases of the product life cycle. This may include information on the following: • Product identification • Delivery, transport, and storage •...

  • Page 7: Symbols Used

    PGV...-F200A-B21-V1D Introduction Symbols Used This document contains symbols for the identification of warning messages and of informative messages. Warning Messages You will find warning messages, whenever dangers may arise from your actions. It is mandatory that you observe these warning messages for your personal safety and in order to avoid prop- erty damage.

  • Page 8: Product Description

    Figure 2.1 Schematic structure of the positioning system The read head forms part of the positioning system in the Pepperl+Fuchs incident light pro- cess. The read head includes a camera module and an internal illumination unit. The read head uses these features to detect a colored tape stuck to the floor or a painted colored lane to track the lane.
  • Page 9 PGV...-F200A-B21-V1D Product Description Maximum Data Matrix Code Tape Length Resolution of the Reader [mm] Maximum Length of the Code Tape [km] The code tape length of up to 100 km is sufficient even for very large applications. It offers suf- ficient reserves for extensions or systems with several branches and parallel conveyor routes.
  • Page 10 PGV...-F200A-B21-V1D Product Description Colored Lane Tracking The colored lane painted or glued on the floor serves as a visual guide for auto-guided trans- port systems. The specified path is automatically followed and the y-position and angle of rota- tion of the AGTS are continuously reported back. Data Matrix control codes are used for additional information, e.g., when the lane changes color.
  • Page 11 PGV...-F200A-B21-V1D Product Description Data Matrix tags In addition to lane tracking, the read head can be used in tag mode. The read head detects Data Matrix tags, which are typically glued onto the floor in a grid. The individual Data Matrix tags are numbered (number range: 1 to 99.999.999) and contain position information.

  • Page 12: Led Indicators And Operating Elements

    PGV...-F200A-B21-V1D Product Description LED Indicators and Operating Elements To ensure reliable device operation, the read head is equipped with 7 LEDs, which can be used for visual function control and quick diagnosis. The LEDs indicate the current status of the read head and can help you quickly detect and correct errors or problems.
  • Page 13 PGV...-F200A-B21-V1D Product Description LED Indica- Item Designation LED color Meaning Green Device is in the "Initialization" RUN/ERROR state (normal state after switch- ing on or after a restart). Flashing Device is in the "Pre-Opera- tional" state (configuration of the EtherCAT® network). Easy to light Device is in the "Safe-Opera- tional"...

  • Page 14: Accessories

    If products are used in harsh ambient conditions, appropriate Pepperl+Fuchs accessories can be used to extend the service life of these products.

  • Page 15: Planning

    Before selecting and using the product, the plant designer must evaluate whether this product is suitable for the intended application. Pepperl+Fuchs has no influence on the selection and use of this product. The warranty therefore only covers the consistent quality of the product.
  • Page 16 PGV...-F200A-B21-V1D Planning Note Priority Data Matrix code tapes and Data Matrix tags have priority over colored tapes or colored lanes. If the read head detects a Data Matrix code tape or Data Matrix tags in the field of view, colored tapes or colored lanes in the field of view are ignored.

  • Page 17: Positioning Targets

    The self-adhesive colored tapes are applied to the floor and are used for lane tracking with a read head. Pepperl+Fuchs colored tapes are available in different colors. This allows you to choose the appropriate color for your circumstances and requirements.
  • Page 18 If you are having trouble selecting the color of the colored tape, use the color analysis in the Vision Configurator to help. If you are having trouble selecting the color of the colored tape, get in touch with your contact at Pepperl+Fuchs.
  • Page 19 PGV...-F200A-B21-V1D Planning Basics The read head detects a colored tape on a floor as a lane. The width of the colored tape must be between 10 mm and 40 mm; the default width is 18 mm. The zero point is in the center of the colored tape (y = 0 level).
  • Page 20 PGV...-F200A-B21-V1D Planning Branches • The read head detects one lane at the lower edge of the field of vision and two lanes at the upper edge of the field of vision; the reader therefore indicates this as a branch. • The read head detects two lanes at the lower edge of the field of vision and one lane at the upper edge of the field of vision;...
  • Page 21 PGV...-F200A-B21-V1D Planning Intersections The colored lanes may cross. However, the angle must be observed. The read head detects the angle in relation to the tracked lane with a resolution of 1° (corre- sponds to a value range of 0 to 360). The angle is specified relative to the position marker. The read head moves over the blue lane A with a read head alignment of 0°...
  • Page 22 PGV...-F200A-B21-V1D Planning Crossing with Data Matrix tag Because a colored tape contains no direction information and the angle to lane B is 90° (or 270°), lane B would normally be ignored. However, by placing a Data Matrix tag exactly in the middle of the intersection of the two lanes, it is possible to make the read head turn right at the intersection and follow the new lane B.
  • Page 23 PGV...-F200A-B21-V1D Planning Color Change If, as in this scenario, the read head changes from the blue lane to the red lane, the position of the color change must be marked with a control code, for example. The configured color must be changed at this point, otherwise the red lane will be ignored.
  • Page 24 PGV...-F200A-B21-V1D Planning Parallel Colored Lanes • The two colored lanes of different colors can be laid parallel to each other. Note here a minimum distance of  0 mm between the two colored lanes of different colors. D 0 mm Figure 3.8 Colored lane arrangement in parallel Note...

  • Page 25: Data Matrix Code Tape

    PGV...-F200A-B21-V1D Planning 3.3.2 Data Matrix Code Tape In addition to lane tracking on a colored tape, the Data Matrix code tapes enable the exact posi- tioning of auto-guided transport systems. The read heads continuously report the detected position, speed, and rotation angle of the AGTS so that reliable goods transport is guaranteed at all times.
  • Page 26 PGV...-F200A-B21-V1D Planning Characteristics of the Data Matrix Codes The position marks in the code tape contain information about the absolute position of the tape, and serve as reference points for the read head. The read head uses its camera to capture the image of the code and uses the information contained in the position marks to determine the exact position of the code in the camera image.
  • Page 27 PGV...-F200A-B21-V1D Planning Code Redundancy As soon as at least one single Data Matrix code is detected in the field of view, the position out- put can be performed. The system therefore offers the highest possible pollution tolerance, and can also bridge expansion joints or gaps without losing position. 0000.0 m PGV-CA25 Figure 3.10 Code redundancy...
  • Page 28 PGV...-F200A-B21-V1D Planning Note A maximum of 2 Data Matrix code tapes in the reading window The maximum number of Data Matrix code tapes in the reading window is limited to 2 and one control code. Basics Distances The distance D between the lanes should be selected so that the lanes are always in the read- ing window (see chapter 3.6) of the read head.
  • Page 29 PGV...-F200A-B21-V1D Planning Δx > 1 m Note Loss of information Make sure that Data Matrix codes are not glued over each other at a branch or intersection, as this could result in a loss of information.
  • Page 30 PGV...-F200A-B21-V1D Planning Branch with Control Code Figure 3.12 Branch with control code Branches/Lane Change by Direction Decision or Control Logic Normally, the AGTS is controlled at branches by the direction decision. The direction deci- sion affects whether the position information is output from the right or left code tape. As long as the control logic keeps the vehicle in the lane only, the vehicle will follow the right or left lane.
  • Page 31 PGV...-F200A-B21-V1D Planning To avoid losing the position when changing lanes, the position marks must be in the reading window of the read head at the same time (B). In this case, the read head has several position markers in its field of view that serve as reference points. Since the lane selection here cannot be made via the direction decision, it must be assumed that the read head randomly outputs the position based on one of the reference points.
  • Page 32 PGV...-F200A-B21-V1D Planning Determining the Position of Ambiguous Position Markers If several lanes run in parallel and the specifications for branches are adhered to, the direction decision can be used to decide whether the position information for the right or left lane is out- put.

  • Page 33: Operation Using Control Codes

    PGV...-F200A-B21-V1D Planning 3.3.3 Operation Using Control Codes When positioning systems are used, certain processes (= events) must be started at fixed posi- tions in many applications. In addition to the colored tapes, position code tapes are also required to precisely define the exact positions. For lane tracking, it is advisable to mark branches using control codes to make it easier for the controller to make the direction decision.
  • Page 34 PGV...-F200A-B21-V1D Planning Order Information (Example) Control code numbers from 150 to 199 are required. The order is placed using the start num- ber for the number range and the end number for the number range. This results in the order designation PGV-CC25-150-050-SET.
  • Page 35 PGV...-F200A-B21-V1D Planning Bit1 Bit0 Bit1 Bit0 Orientation Orientation Side Side 1. Data Matrix position code 2. Data Matrix control code Bit1 Bit0 Bit1 Bit0 Orientation Orientation Side Side 1. Data Matrix position code 2. Data Matrix control code...

  • Page 36: Colored Tapes And Data Matrix Code Tapes In Combination

    PGV...-F200A-B21-V1D Planning 3.3.4 Colored Tapes and Data Matrix Code Tapes in Combination Note Note the following conditions: • Data Matrix code tapes and Data Matrix tags have priority over colored tapes or colored lanes. • If the read head detects a Data Matrix code tape or Data Matrix tags in the reading range, colored tapes or colored lanes are ignored.
  • Page 37 PGV...-F200A-B21-V1D Planning Branches Note If no other command is stored in the control logic, the read head always follows the Data Matrix code band when lanes made from colored tape and Data Matrix codes are mixed at branches or intersections. However, you can store the position of the branch at which a lane change is to take place in the controller.
  • Page 38 PGV...-F200A-B21-V1D Planning Figure 3.17 Mixture of lanes with colored tape and Data Matrix codes Distances Parallel distance The distance between a colored tape and a Data Matrix control code must be between 0 mm and 5 mm. Data Matrix control codes are used in tandem with the colored tape or Data Matrix position code.
  • Page 39 PGV...-F200A-B21-V1D Planning Vertical distance A lane can switch from a colored tape to a Data Matrix code tape and back again as often as required. The distance between the colored tape and the edge of the Data Matrix code must be between 0 mm and 10 mm Figure 3.19 Distance: 0 mm ...

  • Page 40: Data Matrix Tags

    PGV...-F200A-B21-V1D Planning 3.3.5 Data Matrix Tags In addition to lane tracking, the read head can be used in tag mode. The read head detects Data Matrix tags, which are typically glued onto the floor in a grid. The individual Data Matrix tags are numbered (number range: 1 to 99999999) and contain position information.

  • Page 41: Metal Code Bars

    PGV...-F200A-B21-V1D Planning 3.3.6 Metal Code Bars The metal code bar system consists of rugged Data Matrix metal code bars and profile rails. It is especially resistant to mechanical stress. This property makes the system particularly suit- able for heavily used plant areas, such as busy intersections. Note A separate assembly guide is available for installing the metal code bar system.
  • Page 42 PGV...-F200A-B21-V1D Planning Metal Data Matrix Tags The metal Data Matrix tags made of anodized aluminum are used for the evaluation of control and position information. Figure 3.24 Profile Plates The profile plates are used for mounting the tags. Depending on the application, these are mounted on the floor as drive-over profile plates or used as countersunk profile plates in a floor groove.
  • Page 43 PGV...-F200A-B21-V1D Planning Curved Areas Note When the metal code bars are bent in curved areas, there is a jump in the angle of the position data. The angle jump must be tolerated by the auto-guided transport system. Recommendations: • The length of the metal code bars selected must be adapted to the curve radius. •...
  • Page 44 PGV...-F200A-B21-V1D Planning Curves with Drive-Over/Countersunk Profile Rails To create curves, separable corners are removed from the profile rails to create curved areas. For left curves, the left separating corners are removed, and vice versa for right curves. By removing the corners, a maximum angle of 18° between two consecutive drive-over or counter- sunk profile rails can be achieved.

  • Page 45: Angle And Distance Output

    PGV...-F200A-B21-V1D Planning Angle and Distance Output The read head detects the angle of the colored tape and the Data Matrix code tape and passes this value on to the controller. The output value is different for colored tapes and Data Matrix code tapes.
  • Page 46 PGV...-F200A-B21-V1D Planning 60° 60° 6 6 0 0 ° 60° 60° 0° 0 Figure 3.29 For example: Angle (60°) outside the permissible range...
  • Page 47 PGV...-F200A-B21-V1D Planning Distance Output for Colored Tape The read head detects the distance to the zero point in the y-direction and passes this value on to the controller. The output value differs for colored tapes and Data Matrix code tapes because colored tapes do not have the x-position.
  • Page 48 PGV...-F200A-B21-V1D Planning Angle Output for Data Matrix Code Tape The read head detects the absolute angle in relation to the tracked lane with a maximum reso- lution of 0.1°. The angle is specified as an absolute value relative to the tracked lane, as a Data Matrix code tape contains direction information.
  • Page 49 PGV...-F200A-B21-V1D Planning α 0000.0 m PGV-CA25 PGV-CA25 www.pepperl-fuchs.com www.pepperl-fuchs.com Figure 3.32 Absolute angle at 130°...
  • Page 50 PGV...-F200A-B21-V1D Planning Distance Output for Data Matrix Code Tape The read head records the distance to the zero point of the read head of a Data Matrix code tape and passes this value on to the controller. The read head outputs the vertical distance relative to the Data Matrix code tape. α...

  • Page 51: Direction Decision

    PGV...-F200A-B21-V1D Planning Direction Decision The read head has several ways of following colored tapes and Data Matrix code tapes depending on the parameterization. Depending on the input signal, the read head follows the right-hand lane, the left-hand lane, or the better lane. To ensure that the read head does not report any error messages after being switched on, a direction decision must be specified.
  • Page 52 PGV...-F200A-B21-V1D Planning Following the Lane with Better Quality You can parameterize the read head so that it follows the colored lane with better quality. Example Figure 3.35 Better colored lane Poorer colored lane Following the Lane with More Detailed Position Information You can parameterize the read head so that it follows the Data Matrix code tape that continues the current location information.

  • Page 53: Reading Range Of The Read Head

    PGV...-F200A-B21-V1D Planning Reading Range of the Read Head The reading range is the part of the read head's field of view in which Data Matrix codes can be decoded or colored lanes detected. It must be ensured that the Data Matrix code or colored lane is completely within the field of view.

  • Page 54: Read Head Orientation

    PGV...-F200A-B21-V1D Planning Read Head Orientation The read head offers reliable code detection from any angle. For optimal results, we recom- mend setting the alignment of the read head to 0° or 180° to the Data Matrix code tape or col- ored lane.

  • Page 55: Aligning The Read Head With The Data Matrix Code Tape

    PGV...-F200A-B21-V1D Planning Aligning the Read Head with the Data Matrix Code Tape 3.8.1 Horizontal Tolerance – Read Distance z The head offers a high depth of field at different reading distances. If the read head is mounted too close or too far away on the Data Matrix code tape, a warning message is issued. We rec- ommend that the read head always be mounted at a nominal distance of 100 mm to ensure the highest possible availability of the system (due to resolution and code redundancy).

  • Page 56: Vertical Tolerance - Height Tolerance Y

    PGV...-F200A-B21-V1D Planning 3.8.2 Vertical Tolerance - Height Tolerance y If the read head moves along the Data Matrix code tape (X-axis) in the Y-direction and leaves the zero line (Y = 0), a no-position message is output from a defined limit value. The read head continuously measures its position in relation to the Data Matrix code tape and compares the current limit value.
  • Page 57 PGV...-F200A-B21-V1D Planning Target Range The read head is in an optimal position with respect to the Data Matrix code tape. +y₀ -y₀ Figure 3.39 Green: recommended range 1: Data Matrix code tape No-Position The read head is too low in relation to the Data Matrix The read head is positioned too low in relation to the Data Matrix code tape and loses the posi- tion.

  • Page 58: Inclination Angle

    PGV...-F200A-B21-V1D Planning 3.8.3 Inclination Angle Inclination angle of ± 30° possible. It should be noted that the extreme tolerances do not apply in total. Simultaneous tilting possible in both x and y directions. Note Simultaneous tiltings in the x and y directions are allowed. It is important to note that tilting the sensor shifts the reading window.

  • Page 59: Gaps/Interruptions

    PGV...-F200A-B21-V1D Planning Gaps/Interruptions To compensate for length changes in plant structures, expansion joints are usually required for longer tracks. If a Data Matrix code tape is applied at such locations, we recommend that you interrupt the code tape at the edge of the expansion joint and continue with a fully readable Data Matrix code tape.
  • Page 60 PGV...-F200A-B21-V1D Planning Maximum Gap Width (D) Read distance (Z) Max. gap width (D) 80 mm 26 mm 100 mm 46 mm 120 mm 56 mm Maximum Gap for Read Head Orientation 90°/270° PGV-CA25 www.pepperl-fuchs.com www.pepperl-fuchs.com 15 mm 15 mm 2 mm 2 mm Figure 3.44 Expansion Joints / Gaps...
  • Page 61 PGV...-F200A-B21-V1D Planning Examples of the Gap Width for Consecutive Missing Data Matrix Codes The read head expects Data Matrix codes with an ascending number sequence in a predefined grid. A new code every 20 mm. This grid should be adhered to as far as possible at the inter- ruptions to avoid position jumps.
  • Page 62 PGV...-F200A-B21-V1D Planning Cutting Rule The code tape is laid in ascending order of position, whereby the distances between the codes are defined by the pattern of the code tape. 000 000.0 m PGV-CA25 www.pepperl-fuchs.com 2 mm 2 mm Figure 3.45 •...
  • Page 63 PGV...-F200A-B21-V1D Planning Case 2 - Continuous Continuation Glue the Data Matrix code tape up to the gap and cut out the codes in the area of the gap. Con- tinue the code tape at the continuous component. Advantage: In the case of extremely wide gaps, the Data Matrix code tape can be optimally mounted along the mechanical gap.
  • Page 64 PGV...-F200A-B21-V1D Planning Case 4 - Gap is too Large For a short period of time, the read head outputs the message "No Position." 110 cm 120 cm 000 000.0 m PGV-CA25 www.pepperl-fuchs.com Figure 3.49 Y offset To ensure successful detection of Data Matrix codes on a code tape, the offset V between the position codes must not be so large that the actual codes lie outside the reading window.
  • Page 65 PGV...-F200A-B21-V1D Planning Thermal Expansion of the Surface Note Thermal expansion coefficient The thermal expansion coefficient of the attached code tape depends on the thermal expansion coefficient of the surface. When planning the system, consider the worst-case scenario that can be caused by thermal expansion of the surface and adjust the Data Matrix code tape to fit the expansion joint accord- ingly.

  • Page 66: Real-Time Positioning

    PGV...-F200A-B21-V1D Planning 3.10 Real-Time Positioning The read head with timestamp and sync output function ensures extremely accurate synchroni- zation and chronological assignment of image captures and the associated position data. These functions make the read head a reliable component for demanding real-time applica- tions in industrial automation.
  • Page 67 PGV...-F200A-B21-V1D Planning Synchronization Output (Sync Output) The read head has two configurable switching outputs. The default setting is recorded on the datasheet. If the switching output is set to "Sync out," a synchronization pulse will be supplied at the switching output. The pulse is synchronized with image capture. The control signal of the image capture (exposure/shutter speed) is supplied with zero latency at the output and extended to a pulse duration of 1 ms.
  • Page 68 PGV...-F200A-B21-V1D Planning Example of Timestamp and Sync Output • The read head captures images at a scan rate of 25 frames per second (every 40 ms). • The latency time required by the read head for image processing and position value cal- culation is 60 ms.

  • Page 69: Quality Grades

    PGV...-F200A-B21-V1D Planning 3.11 Quality Grades If you have created a project with your read head in TwinCAT®, you can display the quality grades of the read head. Quality Grades at a Glance The permanent monitoring of the quality grades enables an early reaction to damage or con- tamination of the code tape or the camera during commissioning and during operation.
  • Page 70 PGV...-F200A-B21-V1D Planning Number of Codes Detected: 1 and quality grade: 5 Figure 3.56 Code tape damaged Note An evaluation that indicates poor quality as the outcome can be due to a misalignment, an incorrect measuring distance, or because the code tape has been affixed incorrectly. The information in the following chapters must be observed, see chapter 3 and see chapter 4.
  • Page 71 PGV...-F200A-B21-V1D Planning Quality Description of grade the grade Action Poor Immediately inspect any positions that are graded  5 for dirt and damage; where necessary, clean or repair them directly. Not acceptable Immediately inspect any positions that are graded  5 for dirt and damage;...

  • Page 72: Installation And Commissioning

    The self-adhesive colored tapes are applied to the floor and are used for lane tracking with a PGV read head. Pepperl+Fuchs colored tapes are available in different colors. This allows you to choose the appropriate color for your circumstances and requirements.
  • Page 73 PGV...-F200A-B21-V1D Installation and Commissioning Apply the self-adhesive protective film PGV25M-CD*-CLEAR To increase the durability of the colored tapes, we recommend applying a protective film to the colored tapes. We recommend using the versions PGV25M-CD100-CLEAR and PGV25M- CD160-CLEAR. Applying Protective Film Clean the surface.

  • Page 74: Data Matrix Code And Data Matrix Tag

    PGV...-F200A-B21-V1D Installation and Commissioning 4.1.2 Data Matrix Code and Data Matrix Tag The following description provides general guidance for applying Data Matrix tags or Data Matrix codes. Please note that the exact specifications may vary depending on the application. Note Butt edges If you attach another Data Matrix code tape at the end of a previous Data Matrix code tape, the code pattern of 20 mm must be retained.
  • Page 75 PGV...-F200A-B21-V1D Installation and Commissioning Marking the Code Tape Section The marker head (PCV-LM25) is available to make it easier to apply the Data Matrix code tape. The marker head is used to indicate the position of the Data Matrix code tape on the traverse path.

  • Page 76: Replacement Tape

    PGV...-F200A-B21-V1D Installation and Commissioning 4.1.3 Replacement Tape In the event of a repair, the code tape generator is available to you for a short-term interim solu- tion. This provides the option to create and print code tape segments online to replace defec- tive, heavily soiled, or missing pieces.

  • Page 77: Read Head

    PGV...-F200A-B21-V1D Installation and Commissioning Read Head The read head consists of a camera system with a built-in illumination unit and powerful signal processing. The read heads are very rugged and compact at the same time, so that they can be perfectly accommodated even in the smallest auto-guided transport systems (AGTS). Powerful LED lighting makes the read heads insensitive to environmental influences.

  • Page 78: Mounting The Read Head

    PGV...-F200A-B21-V1D Installation and Commissioning 4.2.1 Mounting the Read Head The mounting and alignment of the read head for detecting Data Matrix codes requires precise fine adjustment of the read head. The PCV-MB1 mounting bracket is suitable for this purpose. It enables flexible and precise adjustment of the read head.
  • Page 79 PGV...-F200A-B21-V1D Installation and Commissioning Mounting the Read Head on the Mounting Bracket Before installing the read head, ensure that a stable and secure mounting fixture is provided. Mount the read head so that the optics of the read head with ring light and camera module point toward the Data Matrix code tape.
  • Page 80 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.3 Schematic diagram for mounting the read head Note A guide pin is located in the center of the terminal block. This ensures that the read head is guided through the slots.

  • Page 81: Aligning The Read Head

    PGV...-F200A-B21-V1D Installation and Commissioning 4.2.2 Aligning the Read Head Since the vehicle follows the lane and compensates for deviations in the y-direction by steering movements, the read head does not have to be aligned exactly with the lane. However, some systems require uniform alignment of all read heads to ensure that all vehicles are positioned equally.
  • Page 82 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.5 Distance y Note y orientation: • The optical axis of the read head is too low in relation to the center of the code tape: yellow LED 5 lights up. • The optical axis of the read head is too high in relation to the center of the code tape: yellow LED 5 goes out •...
  • Page 83 PGV...-F200A-B21-V1D Installation and Commissioning Fine-Tuning the Read Head To ensure that all vehicles are aligned equally, a system-specific alignment procedure is required. The following steps are for guidance only. 1. Before fine-tuning the reading head, make sure that the vehicles are mechanically posi- tioned as evenly as possible.
  • Page 84 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.8 Image View...

  • Page 85: Electrical Connection

    PGV...-F200A-B21-V1D Installation and Commissioning Electrical Connection The electrical connection of the read head is established via connector plugs on the side of the housing. The read head is connected to the field environment via the "Main" connector along with "EC IN" and "EC OUT" for the EtherCAT connection. Caution! Damage to the device Connecting an alternating current or excessive supply voltage can damage the device or cause...
  • Page 86 PGV...-F200A-B21-V1D Installation and Commissioning Connection for inputs/outputs and power supply Power Connection Connector plug, M12, 8-pin, A-coded Ground Output 3 EtherCAT IN and OUT EtherCAT connection EC IN, EC OUT Connection Connector socket, M12, 4-pin, D-coded Tx + Rx + Rx - Shielding Connection Lines The shielding of cables is required to suppress electromagnetic interference.

  • Page 87: Setting Up Windows Network Communication Between The Read Head And A Pc/Laptop

    PGV...-F200A-B21-V1D Installation and Commissioning Setting up Windows Network Communication between the Read Head and a PC/Laptop The read head has a fixed IP address 192.168.2.2 when connected via EoE (Ethernet over EtherCAT). To enable communication within the network, the network settings of your PC/lap- top must be synchronized with the read head and may need to be adjusted.
  • Page 88 PGV...-F200A-B21-V1D Installation and Commissioning The Properties window for the TCP/IP protocol opens. Select the "General" tab. Select the input function "Use the following IP address." Enter the IP address of the read head, but only the first three segments of the IP address. The last segment must be different from the read head's IP address.

  • Page 89: Configuration With Twincat

    PGV...-F200A-B21-V1D Installation and Commissioning Configuration with TwinCAT® The configuration of a read head using the "TwinCAT®" project planning and development environment from Beckhoff Automation GmbH is described below as an example. Offline and Online Read Head Configuration There are two options for configuring the EtherCAT® read head: •...
  • Page 90 PGV...-F200A-B21-V1D Installation and Commissioning Note It is always possible to use TwinCAT® "locally" or "remotely." If the TwinCAT® system including the user interface is installed on the respective controller (local), TwinCAT® can be used "locally." In this example, TwinCAT® is used locally. Integrate the controller in TwinCAT®...
  • Page 91 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.13 Configure the IP address for the selected device in the "Address Info" area. Add a communication route to the device by clicking on the "Add Route" button and confirm without entering a password. Save the connection settings and confirm the selection. In the left-hand working area of "Solution Explorer", switch to the option "I/O."...
  • Page 92 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.14 The "Insert Device" selection window opens. Select "EtherCAT® Master" and confirm with "OK." Figure 4.15 The EtherCAT® controller is created in the "Solution Explorer" project tree with the designa- tion "Device 1 (EtherCAT®)." In the "Solution Explorer" project tree, select the controller with the designation "Device 1 (EtherCAT®)"...
  • Page 93 PGV...-F200A-B21-V1D Installation and Commissioning The properties page opens on the right side of the window. Click the "Adapter" tab, followed by "Search..." to select the port for your controller. Figure 4.16 In the "Device Found At" dialog, select the port for your controller; in this example, the "Ethernet (TwinCAT-Intel PCI Ethernet adapter (Gigabit))"...
  • Page 94 PGV...-F200A-B21-V1D Installation and Commissioning Adding the Read Head to the Project To add the read head to the controller, right-click on "Device 1 (EtherCAT®)" in the project tree. Activate the "Scan" function with the left mouse button. Figure 4.18 All EtherCAT® nodes are read in and automatically added to the I/O configuration. The PGV-F200 read head appears in the project tree below the EtherCAT®...
  • Page 95 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.19 Click on the "Box 1 (PGV-F200)" entry with the left mouse button. The menu "TwinCAT Project 1" is displayed. To configure the process data, go to the "Process Data" (1) tab.
  • Page 96 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.20 In the "Sync Manager" section, click on the "Inputs" (2) option and select your input PDOs in the "PDO Assignment" area. For example, disable the checkbox "0x1A04" (3) if no tag number should be transmitted to the EtherCAT®...
  • Page 97 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.21 Confirm the message "Load I/O Devices" with "OK." The message "Activate Free Run" appears. Confirm the dialog with "Yes" to allow the processing of input data within the "Config Mode." The read head is in operating mode, but does not yet output any data (ERR LED lights up red). Select one of the two "Lane"...
  • Page 98 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.22 Go to the "Online" tab (1) and click on the "Pre-Op" button (2). Figure 4.23 The read head is in the "Pre-Operational" state.
  • Page 99 PGV...-F200A-B21-V1D Installation and Commissioning Activating EoE In general, the EtherCAT read head cannot be connected directly to the Vision Configurator. First, the reading head must be configured via TwinCAT in such a way that EoE is possible. In the "Solution Explorer", select the "Device (EtherCAT)" controller (1) in the left work area and click on "EtherCAT (2) >...
  • Page 100 PGV...-F200A-B21-V1D Installation and Commissioning Figure 4.25 The "Advanced Settings" selection window (3) opens. Navigate to "Mailbox > EoE." Figure 4.26 Enable the "Virtual Ethernet Port" option.
  • Page 101 PGV...-F200A-B21-V1D Installation and Commissioning Note MAC Addresses Each read head has a unique MAC ID that is assigned by the manufacturer. The MAC ID cannot be changed by the user. This MAC ID has no function for EtherCAT®. For EoE (Ethernet over EtherCAT®), the read head is assigned a virtual MAC address.
  • Page 102 PGV...-F200A-B21-V1D Installation and Commissioning Vision Configurator - Auto Detect The Auto detect (TCP/IP only) function is available in Vision Configurator. This function allows you to view all connected TCP/IP Ethernet devices. In the output window, you can dis- play the device you are looking for. Auto Detect Select the "Auto detect (TCP/IP only)"...

  • Page 103: Operation And Communication

    PGV...-F200A-B21-V1D Operation and Communication Operation and Communication EtherCAT® Communication Methods Ethernet over EtherCAT® - EoE In an EtherCAT® network, only communication via the EtherCAT® protocol is permitted. Any Ethernet-based communication that is not EtherCAT® (e.g., TCP/IP, UDP/IP, etc.) is tunneled through the EtherCAT®-SubDevice using the EtherCAT®...
  • Page 104 PGV...-F200A-B21-V1D Operation and Communication Device Description File—ESI File With EtherCAT®, all process data and the parameters are described in objects. The compila- tion of all the process data and parameters (the object directory) is stored in an EtherCAT® description file (ESI file, EtherCAT® SubDevice Information File). This ESI file contains all objects with index, subindex, name, data type, data access, and the value range with minima, maxima, and default value.
  • Page 105 PGV...-F200A-B21-V1D Operation and Communication Data Transmission by the SyncManager The PDOs and SDOs are read from the EtherCAT telegram by the SyncManager (Receive Parameter) or inserted into the EtherCAT telegram (Transmit Parameter). Four sync channels are available for data transmission. SyncManager channel Function...
  • Page 106 Modular device profile See "0xF000 Modular Device Profile" on page 105 Manufacturer-specific objects 0x3000 Pepperl+Fuchs Serial Number ro See "0x3000 Pepperl+Fuchs Serial Number" on page 105 For the tables below, the following applies: ro (= read only) means read-only access...
  • Page 107 PGV...-F200A-B21-V1D Operation and Communication 0x1008 Manufacturer Device Name This object specifies the manufacturer-specific device name. Index Subindex Object name Access Default Description 0x1008 0x00 Manufacturer Device name Device Name 0x1009 Manufacturer Hardware Version This object specifies the status of the hardware version of the read head. Index Subindex Object name Access...
  • Page 108 PGV...-F200A-B21-V1D Operation and Communication 0x1C00 SyncManager Communication Type This object displays the assignment of the four sync channels. Index Subindex Object name Access Default Description 0x1C00 0x01 Subindex 001 0x01 (1 Channel 1: Mailbox write per- mission 0x02 Subindex 002 0x02 (2 Channel 2: Mailbox read per- mission...
  • Page 109 PGV...-F200A-B21-V1D Operation and Communication 0x1C13 SyncManager TxPDO Assignment Object 1C13h can be used to configure a PDO for the sync channel. The sync channel is per- manently intended for sending transmit PDOs (read head for control). In this object, the number of PDOs assigned to this sync channel must be set under sub-index 0.
  • Page 110 Index distance of the objects of distance the individual channels 0x02 Maximum 0x0001 (1 ) Number of channels. Only one number of active channel is supported modules 0x3000 Pepperl+Fuchs Serial Number Pepperl+Fuchs standard serial number. Index Subindex Object name Access Default Description 0x3000 0x00 Pep-...

  • Page 111: Process Data Objects (Pdos)

    PGV...-F200A-B21-V1D Operation and Communication Process Data Objects (PDOs) PDO Frame The process data objects (PDOs) are used for the cyclic transfer of process data between the controller and read head. They must be configured by the controller in the "Pre-Operational" state before the read head is operated.
  • Page 112 PGV...-F200A-B21-V1D Operation and Communication 0x1A00 Status Subin- Object Data Data Index name Type size Offset Description 0x6000 0x01 Error Error message, see Error Codes 0x02 No Posi- No absolute position tion 0x03 Warning BIT Warnings present; see Warning Module 0x04 Control Control code recognized Code...
  • Page 113 PGV...-F200A-B21-V1D Operation and Communication 0x1A04 Tag Number Object Descrip- Index Subindex name Data Type Data size Offset tion 0x6004 0x01 Tag Number UDINT Tag number 0x1A05 Data Matrix Control Code Subin- Object Data Data Index name Type size Offset Description 0x6005 0x01 Position of a Data Matrix...
  • Page 114 PGV...-F200A-B21-V1D Operation and Communication 0x1A06 Warning Bits Subin- Object Data Data Index name Type size Offset Description 0x6006 0x01 Warning A code with content that does not belong to the PCV read head was found. 0x02 Warning Read head too close to code tape 0x03 Warning Read head too far from code tape...
  • Page 115 PGV...-F200A-B21-V1D Operation and Communication 0x1A08 Quality Information Subin- Object Data Data Index name Type size Offset Description 0x6008 0x01 Quality USINT Quality grade of the scene Index being viewed 0x02 Number USINT Number of decoded codes decoded Codes 0x1A09 Timestamp Object Descrip- Index...
  • Page 116 PGV...-F200A-B21-V1D Operation and Communication Configuration Parameters The configuration data is used to set the basic parameters of the read head. This data can be defined via the controller and serves as an initial configuration that is loaded when the read head is started.

  • Page 117: Firmware Update Via The "File Access Over Ethercat®" (Foe) Protocol

    Access over EtherCAT®" (FoE). This makes it possible to load the firmware onto the read head via the EtherCAT® controller, provided that it supports this function. A firmware update should only be carried out after consultation with Pepperl+Fuchs Support. Note The current firmware version can be downloaded from our website: www.pepperl-fuchs.com.
  • Page 118 PGV...-F200A-B21-V1D Operation and Communication Figure 5.1 State Machine—Bootstrap The "State Machine" menu opens. Click the "Bootstrap" button (2). The read head changes to the "BOOT" status (3). To download the new firmware from the directory, click the "Download" button (4). A new window opens in which you can search for your firmware file.
  • Page 119 PGV...-F200A-B21-V1D Operation and Communication Click the "Init" button (1). Figure 5.3 State Machine—Init The update is in progress. When the update is complete, the read head switches to the nor- mal operating mode.

  • Page 120: Vision Configurator

    4.5). Installing Vision Configurator Installing Vision Configurator The following describes how to obtain the installation file from the Pepperl+Fuchs homepage and install it. Go to the Pepperl+Fuchs homepage at http://www.pepperl-fuchs.com and enter the product designation or item number in the search function. You can find the Vision Configurator software in the Software section of the device's product detail page.

  • Page 121: Connecting The Read Head To The Pc

    PGV...-F200A-B21-V1D Vision Configurator Connecting the Read Head to the PC Connecting the Read Head to the PC The read head is connected to the PC as follows: EC IN EC OUT Main Figure 6.1 Connect the read head to a power supply (24 V DC). Establish an Ethernet connection between the PC system and read head.

  • Page 122: Getting Started

    Sensor configuration Create users at same level or below View all information User User Sensor configuration Create users at same level or below Admin View all information Sensor configuration Create and delete users PFAdmin Access only for Pepperl+Fuchs service personnel...
  • Page 123 PGV...-F200A-B21-V1D Vision Configurator Selecting a Device Family (2) The device family is selected in the Device family screen as follows: Left-click on the "Vision" device family. A list of the available sensor types is displayed. Selecting the Sensor Type (3) Left-click on the "PGV"...

  • Page 124: Application Window Structure

    PGV...-F200A-B21-V1D Vision Configurator Application Window Structure The application screen opens after you log in. Note The number of menu items depends on the selected sensor; not all menu items will be available. Only those menu items required to configure the sensor will be displayed. Figure 6.3 The application screen The software is designed to be similar to most Windows applications.

  • Page 125: Menu Bar

    PGV...-F200A-B21-V1D Vision Configurator Image Display • Displays images or diagrams • Used for layout and arrangement of information • The tab in the foreground is the active one • A varying number of tabs can be displayed depending on which sensor is connected •...

  • Page 126: View Menu

    PGV...-F200A-B21-V1D Vision Configurator 6.5.2 View menu Figure 6.6 View menu Show standard buttons Show and hide the buttons in the toolbar (see chapter 6.6). Show device data Show and hide the device data in the display window (see chap- ter 6.7). Displayed message Opens a selection window in which the following display windows types...

  • Page 127: Image Menu

    PGV...-F200A-B21-V1D Vision Configurator 6.5.4 Image Menu Figure 6.8 Image menu Opens the folder in which images are currently saved Open image folder Save image Saves the image currently displayed on the PC Copy image to clipboard Loads an image file to the clipboard Show graphic Switches display data sent from the sensor on and off in the image.

  • Page 128: Toolbar

    PGV...-F200A-B21-V1D Vision Configurator Toolbar The toolbar can be used to select various functions. Selecting the Connect button establishes a connection between the PC and the read head. The connection between the PC and the read head is discon- nected. A read head configuration stored on the PC is loaded. Note: Configuration is overwritten by the controller.

  • Page 129: Image Display

    PGV...-F200A-B21-V1D Vision Configurator Image Display The image display [Image View] (1) allows you to view the current capture of the read head. As an example, you can move the read head into difficult mounting positions and display the cap- ture. This allows you to detect the alignment of the read head with the Data Matrix code and readjust it.
  • Page 130 PGV...-F200A-B21-V1D Vision Configurator Toolbar The toolbar is located on the left side under the Image View tab. The toolbar contains several useful functions that are used to further process recorded images. The following functions are available. Figure 6.14 Toolbar Item Designation Function Magnifier +...

  • Page 131: Color Analysis Of The Colored Lane

    PGV...-F200A-B21-V1D Vision Configurator 6.8.1 Color Analysis of the Colored Lane The following chapter shows how an accurate color analysis is performed in the Vision Config- urator, taking into account the dependence on the colored lane and the background in particu- lar.
  • Page 132 PGV...-F200A-B21-V1D Vision Configurator Figure 6.17 Note This function can be used on-site to find the appropriate colored lane for a specific floor. Detection of Reflections/Overexposure The image display area shows surface reflections on the floor or on the colored tape. This can, for example, help to identify and avoid potential errors at an early stage during plant planning.
  • Page 133 PGV...-F200A-B21-V1D Vision Configurator Example of contaminated colored tape Figure 6.19 Contaminated area Clean area Note Lane detection is still possible with this type of contamination. Example of a shiny colored lane Figure 6.20 No colored tape detected Reflections on the colored tape Colored tape detected...

  • Page 134: Position Display

    PGV...-F200A-B21-V1D Vision Configurator Position Display The "Position View" (1) can be used to display the recorded x-absolute position, the y-offset, the angle output, and various status values. In addition, direction decisions can be made using "Lane selection" and "Color selection." The display is started with the "Start request" button and stopped with the "Stop request"...
  • Page 135 PGV...-F200A-B21-V1D Vision Configurator Position Data [Line Data] The display of the position information is started with the "Start request" button. Display Description X value x position in mm Y value y position in mm Angle Value Scaled angle of the code relative to the read head Lane 1 The position information of the Data Matrix code tape is displayed.
  • Page 136 PGV...-F200A-B21-V1D Vision Configurator Controller [Control] Figure 6.23 The read head has several ways of following colored tapes and Data Matrix code tapes depending on the setting. Lane Selection Spur Description Select left lane Follow left-hand lane Select right lane Follow right-hand lane Select first lane found The first lane that appears in the reading window is assumed as the direction of travel.

  • Page 137: Configuration Window

    PGV...-F200A-B21-V1D Vision Configurator 6.10 Configuration Window Various parameters are specified in the configuration window. The individual parameters depend on the current authorization level and are therefore not always all visible. Some fea- tures are available in different versions only. Depending on the parameters set, some fields will be grayed out.

  • Page 138: Common Tab

    PGV...-F200A-B21-V1D Vision Configurator 6.10.2 Common Tab Two menu items are available under the Common tab. The purpose of this section is to present the menu items in more detail. Input/Output Menu Item This section contains editable parameters for configuring the digital inputs, digital outputs, and read head inputs/outputs.
  • Page 139 PGV...-F200A-B21-V1D Vision Configurator Figure 6.27 Designation Function Type Output 3 The connection is identified as an output Input 3 The connection is identified as an input Input - Function No function The "No function" setting deactivates the input or output. Left lane selector The read head follows the left lane.
  • Page 140 PGV...-F200A-B21-V1D Vision Configurator Designation Function Output - Function No function The "No function" setting deactivates the input or output. Overspeed "Overspeed" activates the output if the speed is exceeded. Warning "Warning" activates the output if a warning occurs. Error "Error" activates the output if the error bit is set. Dirty "Dirty"...
  • Page 141 PGV...-F200A-B21-V1D Vision Configurator Output 1 Figure 6.28 Designation Function Type Output 1 The connection is identified as an output Function No function The "No function" setting deactivates the input or out- put. Overspeed "Overspeed" activates the output if the speed is exceeded.

  • Page 142: Measurement Tab

    PGV...-F200A-B21-V1D Vision Configurator Internal Menu Item Figure 6.29 Internal parameter Designation Function Timelock Defines after what time without parameterization activity the time lock of the read head is locked. Entered in seconds as an integer value. 0 means that this functionality is inactive and the read head can always be parameterized.
  • Page 143 PGV...-F200A-B21-V1D Vision Configurator Position behavior Figure 6.31 No Position X-Value Defines the x value if no Data Matrix code tape is visible. No position x Designation Function Last valid position The last valid x position is output with "Last valid position." Specified position "Specified position"...
  • Page 144 PGV...-F200A-B21-V1D Vision Configurator Angle Value Behavior at No Position Defines the angle output when a position is no longer detected. No position angle Designation Function Last valid value The last valid position angle is output with "Last valid value." Specified value "Specified value"...

  • Page 145: Code Tape And Optics Tab

    PGV...-F200A-B21-V1D Vision Configurator 6.10.4 Code Tape and Optics Tab One menu item is available under the Codeband and optics tab. This section explains the menu item in more detail. Code tape Figure 6.32 Code tape Designation Function PGV lane width Specify the width of the colored tape 10 mm to 40 mm Default value: 18 mm...

  • Page 146: Maintenance

    Replacing Damaged or Destroyed Data Matrix Code Tape The operator is responsible for replacing dirty or destroyed sections of Data Matrix code tape with original Data Matrix code tape. Replacement sections can be obtained from Pepperl+Fuchs. Note Replacing the Read Head If there is a defect, always replace the read head with an original device.

  • Page 147: Cleaning

    PGV...-F200A-B21-V1D Maintenance Cleaning Caution! Material damage due to improper cleaning Treating surfaces with the wrong cleaning agents and liquids can damage the surface and therefore disrupt the function of the read head or make the Data Matrix codes illegible. Cleaning the Read Head Check that the components are securely mounted and that optical surfaces are clean.

  • Page 148: Disposal

    PGV...-F200A-B21-V1D Disposal Disposal The device, built-in components, packaging, and any batteries contained within must be disposed in compliance with the applicable laws and guidelines of the respective country.

  • Page 149: Appendix

    PGV...-F200A-B21-V1D Appendix Appendix ASCII table ASCII hex ASCII ASCII hex ASCII Space " & < >...
  • Page 150 Pepperl+Fuchs Quality Download our latest policy here: www.pepperl-fuchs.com/quality www.pepperl-fuchs.com © Pepperl+Fuchs · Subject to modifications / DOCT-9137...

Table of Contents