Summary of Contents for Erhardt+Leimer OL 80
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Page 1: Table Of Contents
Description B CCD array camera OptoLine OL 80.. 1. General instructions 2. Type references 3. Function 4. Camera controls 5. Assembly 5.1 Determining scanning direction 5.2 Determining camera mea s uring range and distance between camera and web 5.3 Determining the light transmitter size and distance M between the light transmitter and camera 5.4 Camera assembly 5.5 Light transmitter assembly 5.6 Determining the background 5.7 Mount support roller 6. Installation 7. Commissioning 7.1 Position camera... -
Page 2: General Instructions
CCD array camera OptoLine OL 80.. 1. General instructions 1.1 Description This description applies for all CCD array cameras in the OL 80.. se- ries. It explains the standard operation for width measuring and web guiding with one or two cameras on a moving web. Keep the description in a safe place, accessible to personnel at all times. The description is part of the package supplied and should be read carefully prior to assembly, operation and maintenance work. 1.2 Explanation of symbols ➜ jobs to be performed important information and instructions 1.3 Operation The CCD array camera Opto Line OL 80.. should only be operated by qualified personnel or suitably instructed persons. 2. Type references CCD array cameras in the OL 80.. series are only differentiated by their various lenses (measuring ranges). The function of the cameras is identical. The first two digits of the type reference indicate the cam- era resolution (80 = 8192), the third and fourth digits, the lens focal length. Example: OL 8028 focal length 28 mm B Page 2 BEA--220265-EN-04... -
Page 3: Function
CCD array camera OptoLine OL 80.. 3. Function The CCD array camera Opto Line OL 80.. was developed for con- tact-free position measuring. It detects the position of contrasts (edg- 3.1 Purpose es, lines, flutes or grooves) on a moving web. The measuring result can be used for width measuring, web guiding, following up actuators or tools such as cutters etc. . In this description the camera and standard operation for width mea- suring and web guiding with one or two cameras is explained. Spe- cialised applications designed by E+L are described separately in the system specifications or operating instructions. 3.2 Design A width measuring system consists of: - one or several cameras - a set of cables - one or two light transmitters - a DO 002. remote display A web guiding system consists of: - one or several cameras - a set of cables - one or two light transmitters - an E+L controller with command station 3.3 Operating principle Frontlighting Backlighting Scanning methodes... - Page 4 CCD array camera OptoLine OL 80.. With the backlighting method the light transmitter is positioned behind the object to be scanned, as seen from the scanned object. In the case of non-transparent materials, only the outer edges are detected. The following applies for both methods: Whether one or two cameras are used to establish the position de- pends on the resolution and web width required (see block diagram). What is important is that when width measuring or web guiding with one camera, both web edges are always in the camera visual range. When width measuring or web guiding with two cameras, one web edge each must be in the camera visual range. The centerpiece of the camera is a charge coupled device with 2048 pixels. The individual pixels convert the light shed into signal voltag- es. Contrast changes in the camera measuring range such as a web or printed line on a web cause a change in the voltage. The camera can detect up to 30 contrast changes in its measuring range, regardless of whether these are caused by one or several webs. See fig. on page 5. A maximum of 8 measuring values can be output on the basis of the positions recorded. A measuring value is a contrast position (e.g. the web edge position) or the center between two contrasts (e.g. the web or line center position). The built-in light controller makes the camera practically impervious to soiling caused by dust and environmental factors such as steam or ambient light fluctuations. All data to the camera (camera settings, measured value selection) and from the camera (measured value position, error messages, status information) are transferred via a CAN interface. The CAN controller is built into the camera. The in-house E+L protocol is used on the CAN bus. Coupling to other buses or unit interfaces is es- tablished via special interface modules that can be attached to the CAN bus. Two keys and a 16-bit LED display are available for basic operating functions, setting the CAN address, focusing the camera and displaying the measured value position. Further settings are per- formed via an E+L command station DO.. or RT.. . *CCD = Charge-Coupled-Device B Page 4 BEA--220265-EN-04...
- Page 5 CCD array camera OptoLine OL 80.. CCD-camera Light transmitter CCD camera visual range Edge Printed line (dark) Web (light) Background Scan on oscilloscope 1 Edge 2/3 Line 2048 Scanning direction Pixel 1 Frontlighting principle BEA--220265-EN-04 B Page 5...
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Page 6: Camera Controls
Other settings by the E+L Setup Editor. The setup editor is a software tool for calibrating and con- figuring E+L CAN modules such as camera OL 80.. . In setup mode parameters can be displayed and some changed as well. Setup mode is accessed via a command station DO .. -
Page 7: Assembly
CCD array camera OptoLine OL 80.. 5. Assembly Please observe the locally applicable and professional safety and accident prevention regulations. Assembly procedure: 5.1 Determine scanning procedure 5.2 Determine camera measuring range and distance between camera and web 5.3 Determine the size of the light transmitter and the maximum distance between the light transmitter and camera 5.4 Assemble camera 5.5 Assemble light transmitter 5.6 Determine background, mount black screen as required 5.7 Mount support roller as required Select frontlighting to scan lines or transparent webs, edges on 5.1 Determining scanning opaque webs should be scanned using backlighting. In border cases, direction the suitable scanning process should be selected by trial and error. 5.2 Determining camera mea- suring range and distance The distance K between the camera and web influences the camera... -
Page 8: Determining The Light Transmitter Size And Distance M Between The Light Transmitter And Camera
CCD array camera OptoLine OL 80.. 5.2.1 Systems with one camera: * Depending on the application, a safety measuring range = max. web width + max. web movement ** + safety * clearance of 50-100 mm must be al- lowed for in each case. 5.2.2 Systems with two cameras: **On applications with an a ctuating element, e.g. pivoting frame, the stroke measuring range = max. web width - min. web width + max. web movement ** + safety * must be taken into account with regard to web movement. The web must never lie outside the camera measuring range. 5.3 Determining the light The E+L light transmitter is available with one fluorescent tube transmitter size and dis- (FS 16.1) and with two fluorescent tubes (FS 16.2). If sufficient tance M between the light space is available, the light transmitter should always be used with... -
Page 9: Camera Assembly
CCD array camera OptoLine OL 80.. The following table lists the maximum distance of standard E+L transmitters to the camera. Light transmitter length Light transmitter h Maximum mounting distance camera - light transmitter M FS 16.1 FS 16.2 operational range OL 8024 OL 8028 OL 8050 665 mm 685 mm 450 mm 400 mm 460 mm 830 mm 1275 mm 1295 mm 1050 mm 900 mm 1050 mm 1880 mm 1575 mm 1595 mm 1350 mm 1150 mm 1340 mm 2400 mm The longer the light transmitter, the greater the gap will be. The maxi- mum mounting distance can be calculated as follows: M = Max. mounting dist. camera - light transmitter M in mms f (a+b) a = Light transmitter operational range in mms b = CCD element length = 28,67 mm f = Lens focal length (24, 28 or 50 mm) 5.4 Camera assembly If the camera looks down on the web from above, it should be mount-... -
Page 10: Determining The Background
CCD array camera OptoLine OL 80.. Background Background Light transmitter assembly with frontlighting principle When using frontlighting the following should be observed: - when scanning the edges of transparent webs, mount the light transmitter so that the mirror surface reflects the light sent from the transmitter into the camera (see illustration above left). - when detecting lines and colour contrasts on transparent and opaque webs, mount the light transmitter so that a diffuse reflec- tion is produced. Surface glare is avoided and a clear image is produced (see illustration above right). When frontlighting, please ensure that the light transmitter is not in the camera visual range. 5.6 Determining the back- A uniform contrast-free dark background is required for frontlighting. ground You may have to mount a matt black panel behind the web, in the camera visual range. This optimum contrast to the web guarantees efficient web edge scanning, influences from external light sources are avoided. 5.7 Mount support roller It must be guaranteed that the web does not form folds or creases and that the edges do not turn up as otherwise the light is reflected at... -
Page 11: Installation
CCD array camera OptoLine OL 80.. 6. Installation ➜ Run electrical leads according to the attached wiring diagram and EMC instructions. ➜ Protect and run CAN bus lines away from noisy or heavy current- carrying leads. Ensure that: insulation is not damaged and the leads properly secured and protected. the total length of the CAN bus line is limited to 200 m and may not exceed this. a terminating resistor connector is attached to both ends of the CAN bus line. -
Page 12: Position Camera
CCD array camera OptoLine OL 80.. 7.1 Position camera Example: Backlighting ➜ Set the camera visual range (CCD array) at a 90° angle to the web surface and web center. Ensure when measuring with two cameras, that both are set at the same distance A from the web. ➜ For frontlighting, align the camera and light transmitter with one another (see illustration on top of page 10). ➜ S ee wiring diagram. 7.2 Check wiring Check wiring 7.3 Check supply voltage ➜ See wiring diagram. 7.4 Set camera CAN address The camera has a CAN address by which it can be reached via the bus. The CAN address consists of a group and device number. The (Group) number refers to which control loop the device belongs, the (Device) number to the specific device in the control loop. On systems designed by E+L the CAN address is works set. The CAN address is specified on the type plate along with the module reference and is listed in the system block diagram. -
Page 13: Position The Web Edge In The Camera Visual Range
7.6 Set the camera aperture ➜ Screw off the protective cylinder on the lens. and focusing The aperture on OL 80 cameras is focused like a normal camera by adjusting the front ring, the aperture on the right behind. See fig. opposite. Aperture If the lens is secured against twisting by an O-ring, the latter Focusing should be moved to the side during setting procedure. - Page 14 CCD array camera OptoLine OL 80.. The camera must be precision set for difficult (poor) con- trasts via parameter 27. To do so, proceed as follows: ➜ call up setup editor. ➜ enter the camera device number in parameter 0. ➜ enter the camera group number in parameter 1. ➜ call up parameter 26 *data rate(, note value in parameter 26. ➜ c all up parameter 27, value in parameter indicates set aperture exposure time. ➜ set camera aperture so that the exposure time is between the minimum exposure time (0.9 msec) and the value of parameter 26 (default value 5,0 msec). ➜ wait approx. 1 minute after setting until setup mode is terminated. 7.6.2 Focusing the camera 7.6.2.1 On the camera ➜ Press the GRP key on the camera control field until LED 0 and 1 above the GRP key light up alternately (approx. 10 seconds).
- Page 15 CCD array camera OptoLine OL 80.. 7.6.2.4 Retaining settings ➜ Turn the ring or lens for setting the focusing depth until the as- cending or descending flank is depicted by as few pixels as pos- sible, see illustration below. ➜ Retain the settings with an O-ring or enclosed adhesive plate (mat. no. 231411). Adhesive plate Sharply defined edge Unclear egde Unclear edge Sharply defined edge Camera visual range Camera visual range 2.25 ms 2.25 ms Schematic sketch: descending flank Function diagram: ascending flank Oscilloscope, focusing the camera BEA--220265-EN-04 B Page 15...
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Page 16: Camera Configuration
CCD array camera OptoLine OL 80.. 7.7 Camera configuration A camera may be regarded as eight sensors in an enclosure. When configuring the camera, a CAN address must be assigned and properties defined for each sensor that is to output a measured value. Properties include the sensor measuring range (parameter 10/11), operating mode (parameter 6/7/8) and emergency guiding (parameter 9). Direction of web travel CAN address 0.1 Left edge = value 2 Right edge = value 1 CAN address 0.2 CAN address 0.1 (web guider, sensor on left) (Web guider, sensor on right ) Mode 1 in parameter .6 Mode 1 in parameter 6 Contrasting edge 1 in parameter 7 Contrasting edge 1 in parameter 7 Left line = value 4 Right line = value 3 CAN address 1.2 CAN address 1.1 (Width measuring, left sensor) - Page 17 CCD array camera OptoLine OL 80.. The measuring range of each sensor may be set individually. It may correspond to the entire camera scanning range (2048 pixels) or only a part of it. The measuring range is set in parameters 10 and 11. The following rules should thereby be observed: - Camera pixels are used as the unit of measurement (max. 2048). Web plane The values are always in reference to the physical camera scan- ning direction. - If the values in parameters 10 and 11 exceed the physical length limited measuring of the camera scanning range (start + length > 2048), the measur- range ing range setting is not effective, i.e. the entire measuring range is 200 1848 used. - A separate measuring range may be set for each sensor. - If a 0 is set in both parameters for sensors 2 to 7, the measuring total measuring range range of these sensors will be limited to that set for sensor 1. - The measuring range setting is also effective during the calibration 0 2048 process. The camera is calibrated to the measuring range set in sensor 1. Array camera measuring range - Default setting for sensor 1: Parameter 10 = 0, Parameter 11= 2048 Value of parameter 22 x value of parameter 11 set measuring range (mm) = 2048 The sensor operating mode (parameter 6) determines whether the sensor should output the position of a contrasting edge (operating mode 1) or the center between two contrasting edges (operating mode 2). Once the operating mode is set, the contrasting edges in the camera scanning range from which the position is to be output must be specified (parameter 7/8).
- Page 18 CCD array camera OptoLine OL 80.. 7.7.1 Configuring the first measured value: A CAN address should be set for each measured value to be output. The CAN address of the first measured value is usu- ally the address specified on the module reference on the camera or in the block diagram.
- Page 19 CCD array camera OptoLine OL 80.. 7.7.2 Configuring the 2nd measured value: 7.7.2.1 Setting the CAN address ➜ Call up the setup editor. ➜ Enter the camera device number in parameter 0. 1 for measured value 1 (right sensor) ➜ Enter the camera group number in parameter 1. 0 for measured value 1 ➜ Enter the device and group number for the second measured value in parameter 47 (sub address). 0.2 in parameter 47 for measured value 2 (left sensor) ➜ Enter a 1 in parameter 3 (reset), then change parameters to initi- ate the reset.
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Page 20: Camera Calibration
CCD array camera OptoLine OL 80.. 7.7.3 Configuring the 3rd to 8th measured values: Proceed as for configuring the 2nd measured value for all fur- ther measured values that are to be output. First enter the camera CAN address, then set one sub ad- dress (parameters 48 to 53) and initiate a reset. Finally, set the operating mode of the new measured value. - Page 21 CCD array camera OptoLine OL 80.. ➜ Enter camera device number in Parameter 0. ➜ Enter camera group number in Parameter 1. ➜ Check parameter 17. To ensure that the camera is properly cali- brated, make sure that the correct lens size is selected: 1 = 24 mm (OL 8024) 2 = 28 mm (OL 8028) 3 = 50 mm (OL 8050) ➜ Enter the template width in Parameter 18. ➜ Enter a 6 (standard calibration) in parameter 3 then change pa- rameters to initiate the calibration routine. During calibration, both halves of the LED bar on the array camera will flash alternately (approx. 5 secs). During calibration two red LEDs on the sensor key will light up on E+L command device DO 10.. . - If calibration is not successful, every second LED will flash on the camera LED bar. In addition, an error message will be displayed in parameter 5. - If calibration is successful, a reset will be initiated automatically. Then the LED bar on the array camera indicates the position of the web in the measuring range. The two red LEDs on the sensor key of E+L command device DO 10.. go out. ➜ Check parameter 5 additionally. ..5. errorcode error code:: Units indicate exposure errors ..0 = optimum exposure ..1 = soiled ..2 = under-exposed ..3 = over-exposed Tens indicate camera operating status .1. = emergency guiding .2. = no result .3. = Calibration ok .4. = calibration error: no edge .5. = calibration error: only one edge Hundreds indicate camera calibrating status 1.. = not calibrated ➜ If calibration is not successful, (error code .4. or .5.), clear the er- ror and repeat calibration.
- Page 22 CCD array camera OptoLine OL 80.. 7.8.2 Template calibration Template calibration is designed for camera implementation in lami- nation processes. With template calibration, the resolution of two cameras (as with standard calibration) and the distance of the cam- eras to one another may be simultaneously calibrated. Calibration template, E+L mat. no. 226896 consists of a metal strip with two slots. For calibration purposes the center of the template must be aligned according to a freely selected reference point, e.g. the machine center. One slot each must be located in the measuring range of each camera. ➜ Align template. ➜ Call up the setup editor. ➜ Calibrate the first camera as follows: Template calibration with E+L template (mat.no. 226896) ➜ Enter the camera device number in parameter 0. ➜ Enter the camera group number in parameter 1. ➜ Check parameter 17. To assure that the camera may be correctly calibrated, it is important that the right lens focal distance is set: 1 = 24 mm (OL 8024) 2 = 28 mm (OL 8028) 3 = 50 mm (OL 8050) ➜ Enter the length of the calibrating template slot in parameter 18. ➜ Enter the distance of the slot (inner edge) to the reference point, e.g. machine center in parameter 19. ➜ Calibration: enter a 7 in parameter 3 for this purpose, then change parameter to initiate the calibration routine. During calibration, the two halves of the LED bar on the CCD camera flash alternately (approx. 5 secs). During calibration, the two red LEDs on the sen- sor key of E+L command device DO 10.. light up. - If calibration is not successful, every second LED on the camera LED bar flashes. In addition, an error message is displayed in pa- rameter 5. - If calibration is successful, a reset is initiated automatically. Then the LED bar on the array camera indicates the position of the web in the measuring range. The two red LEDs on the sensor key of E+L command device DO 10.. go out.
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Page 23: Width Measuring Function Calibration
CCD array camera OptoLine OL 80.. 7.9 Width measuring function If the web width is measured by two cameras, the distance calibration between these two must be calibrated once each camera has been calibrated individually. Calibration can only be performed on command station DO 002. A template is required to calibrate the width measuring function. It is inserted in the measuring range of both cameras in place of the web. - Page 24 CCD array camera OptoLine OL 80.. ➜ Enter value 1 in parameter 41 (send mount position). 1 = send mount position 0 = do no send mount position ➜ Check the "send mount position" parameters of interface DI.. and module DM.. if necessary enter value 0 (do not send mounting po- sition). Only one device in the CAN network may send the mount- ing position. 7.10.2 Set the type of exposure control With some applications it may be beneficial if the exposure control is switched off from time to time or all together. The setting should then only be changed if satisfactory results cannot be obtained with the standard setting. The exposure control operating mode is set in parameter 28. 0 = exposure control active (standard) 1 = exposure control is only active if no web is in the camera measur- ing range. As soon as the web is located in the camera measur- ing range, operation is with the most recently established expo- sure value. This setting should be selected if the light conditions on the moving web change so much that the exposure control must be continually readjusted. 2 = exposure control off. The exposure is fixed at a value set in pa- rameter 29. This setting may be advantageous when scanning edges with a poor contrast. 7.10.3 Setting the type of contrasting edge evaluation On some applications, it may be beneficial to change the evaluation of the contrasting edges. This change should only be made when no satisfactory results could be achieved with the standard setting. The evaluation of the contrasting edges is set in parameter 32, the limit values in parameters 33 and 34.
- Page 25 CCD array camera OptoLine OL 80.. Parameter 34, lower limit value: Parameter 32 = 0: minimum height of a valid negative flank Parameter 32 = 1: grey scale threshold below which a valid negative flank must not drop Grey scale threshold that must be exceeded by a valid positive flank Minimum height of valid positive/nega- tive flank Grey scale threshold below which a valid negative flank must not drop Flank height Grey scale threshold Example: contrasting edge evaluation BEA--220265-EN-04 B Page 25...
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Page 26: Operation
CCD array camera OptoLine OL 80.. 8. Operation 8.1 Specify set position value for guiders Direction of web travel CAN address 0.1 Left edge = measured value 2 Right edge = measured value 1 CAN address 0.2 CAN address 0.1 (web guider, left sensor) (web guider, right sensor) set position in parameter 13 set position in parameter 13 Example: specify set position of mea- If cameras are implemented on web guiding systems, before guiding sured values is begun the set position of the measured values must be specified. If a measured value deviates from the set position, the guider corrects the position of the web. 8.1.1 Specify set position value on command device DO 1... -
Page 27: Camera Start-Up Response
CCD array camera OptoLine OL 80.. Example 2 , see illustration at the bottom of page 26: The web is to be guided by the right web edge. For this purpose, the set value of measured value 1 must be stored. ➜ Before guiding, the web should be placed in the camera measur- ing range so that the right web edge is positioned at the set point. ➜ Store the set position of measured value 1 (right web edge). To do so, first press the SETUP key on E+L command device DO 1... then the key which you used to select the right sensor on your command device, or... -
Page 28: Paramter List (Excerpt)
CCD array camera OptoLine OL 80.. 10. Paramter list See the excerpt below of the most important camera parameters. All camera parameters are described in the attached parameter lists. (Excerpt) Name Default Access Description ..0. edit device Select device number, See block diagram for device numbers. ..1. edit group Select group number, See block diagram for group numbers. ..2. reset settings Works settings 0 = no function 1 = E+L basic settings 2 = internal value specification (default) ..3. start service Start a function 0 = no function 1 = reset guider 2 = save parameter 3 = save standard functions 4 = define guiding criterion (photo mode) 6 = standard calibration 7 = template calibration... - Page 29 CCD array camera OptoLine OL 80.. Name Default Access Description .1.4. position -32768 32767 Output measured value (contrasting edge set position) .17. lens type Define lens Lens Linearisation 0 = undefined off 1 = 24 mm 2 = 28 mm 3 = 50 mm .18. template width 3250.0 Width of calibrating template in mm .19. template offset -3000.0 3000.0 Distance from ref. point to tem. inner edge (e.g. machine center - template inner edge) .21. calibration pixels 32677 Total measuring range in sub pixels .22. calibration width 32677 Total measuring range in mm exp. adjust type Type of exposure control .28.
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Page 30: Error Messages
CCD array camera OptoLine OL 80.. 11. Error messages 11.1 Error messages on the The two outer LEDs are flashing: LED display on the No web in the measuring range. camera controls The measuring result on the LED display is flashing: Guiding criterion is not available, the camera detects the position of the emergency guiding criterion. Every second LED is flashing: Camera is under-exposed. Every second LED stays on permanently: Camera is over-exposed. -
Page 31: Maintenance
CCD array camera OptoLine OL 80.. 12. Maintenance ➜ Clean the glass of the camera protective cylinder and the glass cover of the light transmitter regularly with ordinary domestic cleaning agent. Random soiling of the light transmitter or camera causes incorrect measurements. As homogenous soiling builds up, the camera and light transmitter receive less and less light until the camera be- comes under-exposed. ➜ Replace the fluorescent tubes once a year. When ordering spares, please specify the length of the fluorescent tubes. 13. Technical data Lens 1:2.8 / 24 mm 1:2.8 / 28 mm 1:1.8 / 50 mm Lens connection M 42 x 1, bayonet Measuring range depends on lens and distance to lens Resolution measuring range / 8192 Scanning rate max. 700 Hz Pixel frequency 1.33 MHz Pixel count 2048 Pixel size 14 x 14 µm Active chip length 2048 x 14 µm = 28.67 mm Spectral maximum 500 nm Exposure controller 20 to 700 Hz Operating frequency 200 Hz... - Page 32 L+ L- PE Back-up fuse max. 6 A 3 x 1,5 mm See block diagram See block diagram On-site shutdown via for wiring for wiring main machine switch -X 5 -X 11 -X 4 :1 :2 :3 :1 :2 :3 :4 :5 :1 :2 :3 :4 :5 -X 2 :1 :2 Power card CN 0201 Camera evaluator card CL 0201 CCD chip control CP 0201 OL 80-- Technical data subject to modification without notice...
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