Professional Documents
Culture Documents
User's Manual
Revision 1.8, Date of issue: 31/05/2014
Rudolf-Baschant-Straße 2
This User's Manual is a key part of the TH6D system and must be kept
throughout the life span of the product. Any supplements issued later by
Scansonic MI GmbH must be filed along with the User's Manual. The
abbreviation UM will be used throughout to specify the User's Manual.
Note Scansonic MI GmbH is not liable for the completeness or correctness of the
information found in this manual. Due to continued development of the
product, the contents of this manual are subject to change without prior
notice at the discretion of Scansonic MI GmbH. Every attempt has been
made to ensure that the information contained in this manual is complete
and correct at the time it is printed.
Reproduction / The contents of the User's Manual are the property of Scansonic MI GmbH.
Copyrights No person or other business divisions or departments of other companies
are permitted to reproduce, distribute or alter this manual in any way or by
any means unless prior written authorization has been given by Scansonic
MI GmbH. Furthermore, it is not permitted to use parts or the whole of this
manual to manufacture or sell anything.
Rudolf-Baschant-Straße 2
13086 Berlin, Germany
2. Protective..................................................................... 2-1
2.1 General Safety instructions ......................................................... 2-2
2.2 Laser safety .............................................................................. 2-4
2.2.1 Dangers posed by class-3R lasers ................................................ 2-4
2.2.2 Retro-reflection ......................................................................... 2-5
2.2.3 Laser aperture on the TH6D sensor head ...................................... 2-5
2.2.4 Operating the laser safely ........................................................... 2-5
2.3 Particular dangers...................................................................... 2-8
2.3.1 Master machines ....................................................................... 2-8
2.3.2 Excessive pressure and emitted substances .................................. 2-8
2.4 Protective safety measures during normal operation ...................... 2-9
2.5 Proper and intended usage ......................................................... 2-9
2.6 Warrantee and liability ............................................................. 2-10
2.7 Information and warning signs on the TH6D sensor head.............. 2-11
2.8 Disposal ................................................................................. 2-12
CAUTION!
You must read all relevant documentation and take additional training in order to
work with the TH6D system!
The user's manual contains the necessary information describing the installation, operation, and
maintenance for the following approved versions of the sensor system: Tracking Head 6
Dimensions:
TH6D-150-CFxx-yy
TH6D-150-KFxx-yy
The Tracking Head 6 Dimensions will be subsequently referred to as the TH6D in this document.
The illustrations in this manual do not always include all details and do not always depict the
latest components. They show only the most significant information for the reader.
The User's Manual is divided up into chapters arranged according to technical and training topics.
Abbreviations
Ex. Example
Fig. Figure
IP Internet protocol
L Direction of beam
MD Machinery directive
n Normal
SP Seam point
PU Polyurethane
r Direction of reflection
S0 Sensor origin
t Time
UM User's Manual
v Viewing angle
θr Angle of reflection
Units
kW Kilowatt
min Minute
ms Millisecond
m2 Square metre
nm Nanometre
s Second
W Watt
μm Micrometre
µs Microsecond
°C Degrees Celsius
ØA Outer diameter
ØI Internal diameter
Symbols
The following symbols and icons are used to identify sources of danger. They are in compliance
with the applicable standards at the time this manual was published and may occur at all warning
levels.
Warning for dangers in vicinity of the turning and reaching zone of the industrial
robot (W079)
DANGER!
This indicates particular dangers to life and limb. Failure to observe these notices will
lead to death or serious injuries.
WARNING
This indicates a situation that may be dangerous. Failure to observe these notices
can lead to death or serious injuries.
CAUTION!
This indicates a situation that may be dangerous. Failure to observe these notices
can result in slight injuries. In addition, there is a risk of considerable damage to
property.
NOTE!
This is used for notices which, if not observed, can lead to a disruption in operating
procedures.
TIP!
This is used for notices which can lead to an improvement in operating procedures if
observed.
Obligations of The TH6D system must only be mounted, operated and maintained by
the facility trained personnel. These personnel must be able to recognize possible
manufacturer, dangers or malfunctions based on pertinent experience gained from
operating operating automated production facilities. They must also have knowledge
company and of all applicable standards and safety measures.
personnel It is the responsibility of the laser safety officer to ensure that personnel
operating the laser system are sufficiently trained. Every person who
installs, operates or services the TH6D system must understand and follow
the contents of the manual. These regulations are also intended to prevent
accidents and must be followed:
Safety The operator of the system is responsible for labelling the system properly.
equipment The operator must also provide an adequate screening or perimeter to
prevent access to the danger zone. The proper measures should be taken
to ensure that no unauthorized personnel are allowed access to the danger
zone. Please observe the information found in point 5.3 in DIN EN ISO
11553-1 "Carrying out corrective measures" which pertains to safety
equipment. Ensure that automatic operation of the facility is impossible
when safety equipment is open or disabled. The prescribed safety
equipment required for operating this system must be available, installed
and ready for use. Faults and malfunctions, in particular those that impair
safety, must be rectified immediately. You must regularly check the
effectiveness of the safety mechanisms!
Initial The TH6D system should only be commissioned and used when it is in a
commissioning technically flawless condition (refer to Chapter 5, "Initial Commissioning
and operation and Operation"). Incorrect operation or misuse can result in danger to life
and limb. The efficient functioning of the TH6D system can also be
impaired. Damage to the TH6D system and to surrounding property is also
possible. No personnel should be located in the danger zone of the facility
during operations. Danger zones must be cordoned off and inaccessible.
When replacing cables or the protective glass on the TH6D sensor head,
allow the processing head to cool down after the work process or be sure
to wear protective gloves.
Maintenance Always be sure that the power supply is disconnected before starting any
and repair maintenance procedures. Also be sure that it cannot be accidentally
switched on during maintenance. This will reduce the risk of dangers such
as laser light, unanticipated robot movements or crushing hazards.
Damaged components or safety glass may have sharp edges. Be very
careful when replacing these parts. Use only genuine (original) spare parts
and genuine expendable (wearing) parts. There is no guarantee that parts
from third-party suppliers will meet construction specifications with regard
to load capability or safety. When ordering parts, specify the exact name,
the article number according to the spare parts list and the serial number
of your device! Follow the information regarding maintenance and repair
found in the DIN EN ISO 11553-1:2009-03 standard.
Laser class For the purposes of accident prevention regulations, a laser device's class
indicates the radiation-related risk posed by the accessible laser beam.
The following TH6D sensor types are classified as laser equipment in laser
class 3R, according to DIN EN 60825-1 (VDE 0837-1): 2008-05.
TH6D-150-CFxx-yy
TH6D-150-KFxx-yy
The TH6D sensor heads use laser diodes with a maximum power of
40 mW at a wavelength of 660 nm. For measuring purposes, they project
three laser lines onto the work piece being processed. The actual output of
the emitted radiation may be reduced depending on the mode of
operation.
Overview When operating the TH6D system, specific hazards may be present based
on how the laser beam is used.
CAUTION!
Please refer to the instructions about accident
prevention regulation found in BGV B2 "Laser
safety" (section 2.1).
Dangers from It is dangerous to look directly into the laser beam or into the beam's
laser radiation reflection (see also section 2.2.2). Your eyes could be permanently
damaged. It is essential that you wear safety goggles and maintain a safe
distance from the maximum permissible radiation areas. In order to avoid
accidents, work safety measures must be implemented and followed. The
dangers posed by diffuse reflection from laser radiation are relatively low.
However you should avoid exposure to longer periods of diffuse reflection
(longer than 10 seconds). You should also avoid observation distances
under 13 cm. Work pieces, optical lenses or mirrors which lie in the
beam's path can narrow the beam and actually increase the danger of
directed or reflected laser beams. Make sure that such components do not
lie in the beam's path!
2.2.2 Retro-reflection
General hazards
DANGER
Danger from reflected laser beams!
Position The laser aperture is located at the bottom of the TH6D sensor head. (See
Figure 1.) This location is marked with a warning label.
Aperture
Overview Laser devices which are supplied as components for a system are not
subject to IEC 60825-1, since the final product itself is subject to this
standard. If the laser system can be removed and operated separately
from a facility, then the requirements of IEC 60825-1 pertain to the
stand-alone component.
Sensor safety According to DIN EN 60825-1 (VDE 0837-1): 2008-05, every class-3R
laser systems must have a key-operated main switch. The key for the
switch must be removable. It must not be possible to switch on the laser
beam when the key switch is deactivated.
The TH6D sensor head has no dedicated key switch. The TH6D sensor
head has a separate power supply for the diode laser so that the laser can
operate safely. Thus the voltage for the laser diodes (24V_LSK) is only
applied when the laser safety circuit is closed, when the key is turned in
the switch and when safe operations are ensured. The laser safety circuit
has a safety lock function. No laser radiation is emitted when there is no
laser power supply.
Two redundant orange LEDs are used to signal when the laser power
supply is applied to the TH6D sensor head. (Refer to section 3.5.1.) This
warning LED indicates that laser radiation is being emitted or that the
system is ready to emit laser radiation.
The wavelength of the warning LED is 606 nm. When selecting safety
goggles, ensure that you can still see the warning LED clearly with the
goggles on. It the operating personnel cannot see the warning light visible
from their secure positions, then additional acoustic or visual warning
signals should be attached during the installation of the TH6D sensor
system.
When installing the sensor heads listed in section 1.1, make sure that the
laser beam cannot inadvertently expose the skin or eyes over the
allowable limits as specified in EN 60825-1 (VDE 0837-1): 2008-05.
Safety measures Possible safety precautions include setting up supervised access areas and
implementing personal protective measures. Contacts made to the laser
safety circuit (for monitoring the area in which hazardous laser radiation is
present) must be fail-safe or redundant. The installer or commissioning
engineer is responsible for ensuring safe operation for the TH6D system in
compliance with DIN EN 60825-1 (VDE 0837-1): 2008-05.
The safety clearance gap (with respect to the range of the unhindered
laser beam) is 3 metres.
A gap of 3 metres must also be maintained from reflected beams that
could come from any other objects. Focusing optical elements may not
intersect the beam path, since this would increase the minimum safety
gap required.
Design measures were carefully integrated into the construction of the TH6D system so that
dangers posed by emitted substances ("media") and voltages would be minimized.
Your own health and the health of others should be your primary consideration. Ensure that all
voltage sources have been switched off to the facility during set-up or maintenance procedures.
The TH6D sensor system should be switched off and the pneumatic systems should be de-
pressurized. Make sure that the facility cannot be turned on again unintentionally.
DANGER!
There is a risk of injury from the master machines!
Do not stay in the swivel range of master machines when they are turned on!
Disconnect the power supply before working on any processing device!
Depending on the particular application, the TH6D sensor head may be moved under the control
of master machines. Serious injury or even death can result from being in the swivel range of a
master machine. It is very dangerous and prohibited to work in the operating range of the
master machine (e.g., when setting up the process). You should pay special attention to the
instruction manuals of the other devices in use and their relation to the operation and safety of
the master machines.
WARNING
Excessive pressure in the media lines can lead to eye and ear damage or
other injuries!
Always wear the proper protective eye glasses, ear protection, and clothing
when changing pressurized lines and hoses!!
Forbidden, excessive pressure leads to an increased risk of injury. Follow the pressure
specifications given in the Technical Specifications section in Chapter 8.
Extremely loud noises can occur when changing the pressurized media-supply hoses. Damage to
hearing could result. Always wear proper ear protection while making the change.
Pressurized lines can whip back and forth after they are disconnected. This can lead to eye or
bodily injuries. Always wear proper eye protection and protective clothing while making the
change.
Overview The lifespan of the integrated laser diode may be shortened if you are
operating with an enclosure temperature that exceeds the specified
operating temperature. Make sure the temperature stays in the specified
range. Operations outside of the specified temperatures will lead to a
temperature-related decrease in the absolute measurement accuracy.
DANGER!
Follow the proper and intended use guidelines!
Proper and The TH6D system is used exclusively as a module that is installed as part
intended usage of a production facility. The TH6D system is an optical measuring system
that automatically detects the shape of work pieces. It represents state-
of-the-art technology.
The TH6D sensor head was designed to be mounted on a master machine
(for example, a robot). It may also be used in facilities where the
processing head is fixed in position and the work pieces move. The TH6D
system was designed and manufactured in accordance with recognized
technical safety regulations. The TH6D system should be used for its
intended purpose only.
Proper and Incorrect usage or incorrect operation can lead to danger of death or
intended usage serious damage to health and property. Improper or incorrect usage
- continued absolves the manufacturer from all liability! The TH6D system must only
be operated when in perfect technical condition. During the initial
commissioning, all necessary safety measures must be taken in
accordance with applicable regulations.
You must observe the safety instructions and notices contained in this
manual. The user must read and understand the manual before working
with the TH6D system. We recommend that you take additional Scansonic
training.
CAUTION!
Please observe the warrantee and liability claims description!
Warrantee and liability claims for personal injury and damage to property are not possible if they
are attributable to one or more of the following causes:
Operating the TH6D system when safety equipment is defective or not properly
installed, or operating the module when safety and protective devices are not
functioning,
NOTE
Always maintain the signs so that they are in a good, readable condition.
S/N: 14xxxxxx
1 Manufacturing date 20xx/xx
3
3
4 Labelled connections
4
2.8 Disposal
Note The TH6D system can be returned free of charge to Scansonic IPT GmbH
for disposal (excluding delivery charges).
3.1 Overview
The TH6D system is an optical measuring system that can detect and measure the shape of work
pieces. It is designed for seam tracking during the joining process, but can be used for other
measurement tasks. When integrated in a welding facility with other master machines and
robots, this system can track the seam joint. The TH6D system can also measure the gap width,
the edge offset and the distance of the joint line from the work pieces being welded or soldered.
In addition, the TH6D system measures the orientation of the sensor head over the work piece
surface (the push/drag angles, the workl angle, the angle of rotation and the vertical axis). These
measurements are used to automatically guide the production facility. The sensor system records
any variations in the work pieces and positions. The weld seam can then be automatically
corrected with high precision and reliability.
The measurement The laser stripe sensors in the TH6D series provide no-contact detection
mechanism and measurement of work pieces using the principle of laser triangulation.
(As shown in Figure 3.)
1
2
3
4 5
1 Laser diode
2 Collimator optics
3 Projection optics
7 Light detector
+z
Direction Direction of process feed
S0 along the X
axis:
-y +x
Direction Lateral correction
along the Y
axis
Overview The possible usages for optical seam tracking systems are limited by the
physical environmental conditions present during the welding process. The
reflective properties of the work piece's surface are a major factor, since
all measurements are deduced from the reflected beam pattern. Since the
sensor head works in the immediate vicinity of the welding process,
interference emitted by the process should not be able to impair the
sensor functionality. Welding spatter, smoke, flickering light and EMC
interference are all secondary effects of arc welding.
Overview When using optical sensors for weld-seam tracking, a good understanding
of surface reflectivity is required in order to optimally adjust the laser
brightness and sensor orientation. When working with an ideal reflective
surface (as shown in Figure 4 on left), the light source (a diode laser) is
directed at the work piece surface at an angle of incidence θL so that the
laser beam is completely reflected at the reflection angle θr. No light is
emitted in the direction "n" towards the camera, so there are no laser lines
visible in the camera image. However, for very smooth and shiny work
piece surfaces, only a small fraction of the emitted light is diffusely
reflected (as shown in Figure 4 on right), so that laser lines are faintly
visible (when working with stainless steel and aluminium, for example).
Possible solutions There are two possible ways to improve this situation. The laser output
can be increased or the mounted position of the sensor head can be
changed.
Increasing the laser More powerful laser output is not always available and results in unwanted
output stray light on the work piece and the surrounding clamping mechanisms.
Changing the If the sensor head is tilted slowly in the direction of travel, the angle θL is
mounting position reduced and thus the maximum of the reflection lobe moves toward the
camera window. The result is a pronounced change in brightness of the
measured lines when the slope of the sensor changes.
Rough surface
Welding spatter, Very strong interference can occur in the sensor camera's field of view
smoke which can then harm the imaging. Welding splashes, smoke and intense
brightness caused by the arc can interfere with the camera's image. The
bright lines visible in Figure 6 represent spatter (molten welding metal)
that extends radially in all directions from the welding process. Metal balls
which have cooled are already present on the surface of the work piece.
Solution In the TH6D system, the image is recorded using a camera with an
C-MOS camera extremely broad range of light sensitivity. The brightest areas of the
image can be portrayed equally well as the darkest areas. The master
controller associated with the CCD camera is no longer needed with the
TH6D system. Arc and laser welding tests carried out with the TH6D
system clearly show that the C-MOS technology is superior for these
applications.
Figure 7: MIG process – the inert gas nozzle is clearly visible on the right
Accessibility Another constraint on the use of the TH6D system is the unavoidable look
ahead distance to the TCP. Especially during arc welding processes, this
represents a significant constraint for the robot programming. Without the
TH6D sensor head, the torch can be moved in any direction. With the
TH6D sensor head, the welding torch is forced in a forward direction.
Figure 9 illustrates this restriction using the example of a laser welding
optics with the TH6D sensor head. Since there is a forward-leading sensor
head, the weld seam cannot be processed all the way up to the vertical
wall of the work piece. A closer approach to such a wall is only possible if
the welding optics are put into an increasingly limited stabbing position.
Overview Problematic applications may limit the seam tracking system; such limits
can be worked around by changing the position or alignment of the
sensor.
Problem Figure 11 illustrates a recorded measurement from the TH6D system. The
measured area is divided visually into two sections (left and right); the
three laser lines depict the step made by a lap joint. Visually, the number
of laser lines changes from three to six. In this limit case, the step height
of the lap joint is so large that laser lines 2 and 3 (at left) coincide with
laser lines 1 and 2 (at right).
left right
1
2 1
3 2
Solution By changing the drag angle slightly by five degrees, this unfavourable
situation can be resolved so that reliable detection is again possible. (As
shown in Figure 12.)
left right
1
2 1
3 2
Figure 12: Limit case – the lap joint is too large – the solution
3.2.6 Influence of the sensor's orientation in relation to the work piece surface
Overview The mounted position of the TH6D sensor head on the tool must be
flexible since the tool itself has precedence over priority positioning. Thus,
the TH6D sensor head may need to be aligned at an angle lateral to the
joint or at a drag angle. For this work angle, limitations to the mounting
positions are imposed by the diminishing reflection, particularly when
working with smooth or specular surfaces. Field-tested work angles are in
the range from 15 to 20 degrees. Other angles may be possible depending
on the shape of the work piece (its T-joint). The TH6D sensor head is
mounted in a push or drag angle of ± 40 degrees perpendicular to the
work piece. The software will not function if the positioning angle is
outside of this range.
Overview For a butt joint, the lower limit of the gap is dependent on the quality of
the surface, with the following dimensions:
Overview Limitations imposed by the operating voltage are necessary for the proper
functioning of the TH6D system.
NOTE!
Make sure that you are using VDE-compliant and certified
power supplies!
1 2
9
8
3
6 5 4
Figure 13: The TH6D sensor head
Overview The standard protective glass unit uses an extra plastic protective glass to
cover the protective glasses that are built into the TH6D sensor head. This
additional protective glass protects against long-term contamination from
welding spatter and deposits. Thus it is difficult to clean and designed as a
replaceable wearing part.
Increasing the Spatter and deposits reduce the life of the plastic protective glass. This life
life span span can be increased by using clean purge air. A hose for purge air can
be connected to the X1 interface for this purpose (refer to section 4.4.9).
The purge air should be turned on and off in a way that prevents
excessive contamination. You may want to have lead time and follow time
for the purge air. This can be useful when you are using a long supply
hose and because deposits and steam require some time to remove.
Construction The protective glass unit consists of a protective plate and the receptacle
which holds the protective glass. (Refer to Figure 14.) The protective plate
shields the unit from radiation coming in from the sides.
3 4
Adjusting the
CAUTION!
protective plate
Do not bend the tabs on the protective plate into the
measurement field.
Overview The controller for the TH6D system runs on the TH6D process computer.
5
2 4
3
Figure 15: TH6D process computer
Overview The TH6D process computer and the TH6D sensor head require a separate
power supply unit to supply power from the mains.
TH6D process A power supply unit is included in the delivery and is used to supply power
computer to the TH6D process computer. Section 4.4.12 describes the connections.
The TH6D sensor A separate mains power supply (separated from the TH6D process
head computer) should be used for the TH6D sensor head. A suitable mains
power supply is available from Scansonic.
NOTE!
For more information on power supplies, please contact
Scansonic or your local service representative.
3.3.5 Cable
Overview The TH6D system comes with a set of cables. This set consists of one
cable each for the:
Ethernet connection (see Figure 16)
Power supply (see Figure 17)
The cable set can be configured to lengths of 10, 15 or 25 metres. The
number of your cable configuration can be found in the list in section 8.3.
Cable for the An Ethernet connection is used as the data link from the TH6D sensor
head to the TH6D process computer.
Ethernet
connection It supports 100BASE-T Ethernet (Fast Ethernet).
Section 4.4.7 describes this cable connection.
Power supply A separate power supply unit is used to supply power to the TH6D sensor
cable head. This power supply is built into the production facility. Section 4.4.8
describes this cable connection and pin assignments.
Usage The cooling module can be used under the following application
conditions:
An ambient temperature above 45°C (seasonal / location)
When the workpieces are preheated before welding (must be
verified)
Longer welding times and with multi-layer welding
ATTENTION!
Refer to section 8.4 for more information on ambient
conditions.
Construction of The cooling module consists of a heat shield and a cooling block used for
the cooling connecting the cooling liquid. (Refer to Figure 18) The heat shield is used
module to shield against lateral radiation and to dissipate the heat. The facility's
cooling circuit is used as the heat exchange mechanism.
1 4
3
2
Overview The following auxiliary modules are available for the TH6D system:
Analogue-digital interface
Calibration plate
Network cable (patch cable for Ethernet)
Analogue-digital The analogue-digital interface (ADF) allows setting and receiving of signals
interface – ADF going to or from the TH6D system. A WAGO bus terminal is used for the
ADF. An Ethernet bus coupler is used to communicate with the TH6D
system.
Signal input Process parameters are permanently assigned to the analogue outputs in
through the the TH6D system. This means that a particular analogue output is always
facility controller represented by the same process parameter. The user needs to integrate
signals in the production facility's controller which are maintained there as
process records.
Information Section 4.5.1 includes a description of the types of bus terminals and the
ADF connection. Section 8.2 contains more information about the
input/output assignments.
Calibration plate The calibration plate is used for tool calibration for various machine
interfaces. The TH6D sensor head is aligned to the tool and the sensor
coordinate system is aligned with the machine coordinate system.
Information Section 5.14 contains more information about setting up and calibrating
the tool.
Overview Network cables (patch cables) are used by the following system
components for Ethernet communications.
Analogue-digital interface (ADF) to TH6D process computer
Robot interface to TH6D process computer
THxDView (user PC) to TH6D process computer
The ADF auxiliary module is delivered with a 0.5 metre cable. Network
cables of varying lengths can be ordered from Scansonic for extensions or
re-positioning.
Overview
NOTE!
The status LEDs on the TH6D sensor head display
information about the state of the TH6D system.
The LEDs on the TH6D sensor head display the status of the sensor and
the Ethernet connection.
Functions The P1 through P4 LEDs have following functions (refer to Figure 22):
No. Description
P3 POWER indicator
P2
P1
P3
P4
Status display The P1 and P2 LEDs only show the status of the supply voltage. The P3 and
P4 LEDs have the following additional functions:
Green Laser is ON
rapidly flashing The status is identical for both the
light automatic and set-up modes
Overview
NOTE!
The status LEDs display information about the state
of the TH6D process computer.
The available LEDs display the following functions for the TH6D process
computer.
1 3 5
7
2 4 6
Status indication The LEDs on the TH6D process computer differ according to their status:
Control
NOTE!
The TH6D sensor head is designed with reversed
voltage protection. It is allowed to connect with
existing power supplies.
X3
X2
X1
X5
X4
No. Description
X4 Power supply
Air cooling
CAUTION!
The enclosure for the TH6D sensor head is made
of aluminium. Never allow water to run through
the cooling channels: this could lead to corrosion!
NOTE!
When using air to cool the TH6D sensor head, you may
use a branch line with reduced pressure as purge air for
the protective glass (refer to the specifications in section
8.3).
Cooling air outlet Optional connection to the interface X3 (cooling air outlet)
Exhaust outlet for the used cooling air
Power supply
NOTE!
The negative terminal for the system supply and laser
supply voltage (0 V) is electrically isolated from the
system ground.
Connection to interface X4
Connection The following connections are available on the TH6D process computer.
overview
1 2 3 4 5 6 7
Rear side
8 9 10 11 12 13 14
Figure 25: Connection overview for the TH6D process computer, rear side
Front side
15
Figure 26: Connection overview for the TH6D process computer, front side
8 Not used
Communication The following interfaces are available for communicating with the
production facility (especially for the robot and system controls):
Ethernet TCP/IP
Analogue/digital/voltage/current interface (ADF)
Information More information about connecting and configuring the machine interfaces
can be found in sections 4.5 and 5.9.
Setting parameters
Monitoring processes
Communication Ethernet is used for the communication link between the TH6D
system and THxDView.
Information
NOTE!
Depending on your particular configuration, your TH6D
system may differ from the TH6D system described here.
The ordering documentation sent to you contains a more
detailed overview of your TH6D sensor system
configuration.
Optional Calibration plate (if required for connecting to ABB or KUKA robots)
Power supply unit for the TH6D sensor head (Scansonic
recommends using a separate power supply)
Machine-based auxiliary components (interface hardware that is
specific for your facility: ADF, converter, serial ports, repeaters,
network cables, etc.)
Cooling module
Wearing parts (protective glases)
Inspection Check your delivery to confirm that it is undamaged and complete based
on the delivery receipt.
Transportation In the event that there is damage or any discrepancies, please first
damages, etc. contact the shipper.
Storage or Keep the original packaging for storage or for the event that you need to
disposal of send the device back to Scansonic.
packaging If you cannot keep the packaging, please dispose of it in accordance with
the relevant national environmental regulations.
4.2 Returns
Information
WARNING!
Hazardous residues!
Be sure to package the TH6D system safely when returning it for service
or repair. Proper packaging will protect service and shipping personnel
from any hazardous residual gases.
Cleaning If the TH6D system is extremely dirty, clean it and all its cable thoroughly.
Overview
DANGER
Danger to life and limb!
Leave the TH6D By maintaining your Scansonic product in its original condition, you help
system in its us to replace or reproduce it more quickly. Operational malfunctions can
original result when additional components are installed on the TH6D system
condition which deviate from the approved configuration. We recommend avoiding
such additions!
Any structural changes made to the TH6D system will result in the
termination of Scansonic's warranty and liability!
Routing the Make sure that you preserve the motion capabilities of the TH6D system
cables and and master machine when routing the connecting cables and media lines.
media lines
Overview
DANGER
Danger from laser radiation!
CAUTION!
When operating in a humid environment, make sure that
the built-in protective glasses do not fog up.
Overview
CAUTION!
Before each use of the TH6D system, make sure that the
Protective glass unit is securely mounted to the TH6D
sensor head and that it is fitted with a clean protective
glass!
NOTE!
As the quality of the seam detection decreases, the
likelihood increases that the optical elements will get dirty.
Dirty optical elements on the TH6D sensor head decrease the quality of
the seam detection. Only use sensor systems with clean built-in protective
glasses. Only use clean glass in the protective glass unit!
Important Contact customer service if the protective glasses built into the TH6D
sensor head become dirty. Only Scansonic service technicians are
authorized to clean and repair the internal sensor modules.
Information The display showing the status of the measurement process (refer to
section 5.8) also provides information about the contamination on the
TH6D sensor head. A lower percentage indicates poorer quality seam
detection and dirtier optical elements.
Function The set-up and installation check-list contains starting points for inspecting
the TH6D system installation before initial use. We assume that you have
followed all safety notices and instructions found in this manual, and that
all training related to the installation was carried out.
The check list covers usage with a robot or master machine.
Overview This chapter describes how to connect the TH6D system in a production
facility and to a auxiliary axis.
NOTE!
Follow the check lists for set-up and installation
found in section 9.2.
Overview The TCP, sensor origin and advanced tracking are used to determine the
tool position in relation to the TH6D sensor head.
TCP The tool position is described by the "tool centre point (TCP)". This is a
theoretical reference point defined at a suitable position on the tool in
relation to the work piece.
Sensor origin The "sensor origin" (S0) is used to specify the desired spatial position of
the TH6D sensor head. The sensor origin describes the centre of the
measuring range.
Look ahead The distance from the TCP to the sensor origin is referred to as the " Look
distance ahead distance". This advanced tracking is necessary for determining the
position of the TCP in relation to the sensor origin during measurement
and processing.
Position of the The defined position of the sensor origin (S0) is 150 mm from the lower
sensor origin edge of the sensor head. (As shown in Figure 27.)
Please refer to the dimensioning sheet for your TH6D system and the
specifications found in 8.1 for more information.
Look ahead
distance
S0
S0
TCP
Figure 27: Sensor origin for the TH6D sensor head (CF variant)
Overview
NOTE!
The enclosure for the TH6D sensor head is made of
aluminium. Be sure that you use the specified
tightening torques!
M3 3.5 mm 0.56 Nm
M4 4.5 mm 1.30 Nm
Allgemein
ATTENTION!
The TH6D sensor head must always be properly earthed
(grounded)!
Earthing via the Note the following when earthing via the machine interface:
robotics interface Make sure that there is a metallic bond between the robot and
the TH6D sensor head. Only then will the TH6D sensor head be
connected to the robot's earth.
Do not connect the THxD power cable shield to the earth on the
power supply (A) of the TH6D sensor head.
Variant 1
24V_Power
0V_Power
24V_LSK
Shield
0V_LSK
Variant 2 The robot's earth can also be connected with a cable to the earthing screw
(B) on the TH6D sensor head's housing (refer to Figure 29).
C
B
24V_Power
0V_Power
24V_LSK
Shield
0V_LSK
24V_Power
0V_Power
24V_LSK
Shield
0V_LSK
Positioning and The installation of the TH6D sensor head in relation to the process should
installation be positioned as follows:
Information Section 3.2.1 contains more information about the influence of reflections
on the work piece.
5
2
3
4
S0
TCP
+y +x
Orientation of the The precise orientation of the TH6D sensor head to the process must be
TH6D sensor head determined using the THxDView configuration software.
Instructions for orientation can be found in section 5.14 " Set-up
and configuration of the TH6D system", following the description
of THxDView.
4.4.5 Mounting the protective glass unit on the TH6D sensor head
Overview
NOTE!
Measurements during the (joining) process should only be
made when a protective glass unit with a clean protective
glass has been attached to the TH6D sensor head!
Installing the Align the protective glass unit with the shape TH6D sensor head
protective glass (as shown in Figure 32).
unit Put the protective glass unit on the TH6D sensor head by inserting
the pins (1) into the corresponding holes.
Press the protective glass unit against the TH6D sensor head until
the retaining springs click in with an audible click.
NOTE!
The protective glass unit is properly seated when its edges
are flush with the TH6D sensor head.
Protective plate A plate is mounted on the protective glass unit to protect against process
spatter.
NOTE!
You can adapt the plate to your particular application by
manually bending the tabs along the unit's plate so that
the protected area changes.
Caution: Do not bend the plate into the sensor's
field of view! Check the positioning of the tabs in the
"Raw data" imaging area within THxDView!
Removing the Pull the protective glass unit out of the TH6D sensor head's
protective glass enclosure. Remove in the opposite direction of installation.
unit
Overview The cooling block and heat sink for the cooling module are delivered as
individual parts. They must be mounted directly on TH6D sensor head.
Installing the
ATTENTION!
cooling module
Be sure that you use properly sized screws!
2 3 4
4.4.7 Connecting the Ethernet cable to the TH6D sensor head and process
computer
Overview
CAUTION!
Danger of surge voltage!
Disconnect the power supply before connecting the
cable to the components!
Connection details Type (TH6D sensor head) M12 device connector (male plug, 4-
pole, shielded, D-coded)
Type (TH6D process computer) RJ45 connector
Cable designation: Ethernet Mxxxxxx (the number of your cable
configuration can be found in the list in section 8.3).
Connection Connect the cables according to the following assignments (as shown in
Figure 35):
X5
11
Connecting The male and female plugs should be connected in the following way:
To the TH6D sensor Align the female plug according to the coding and insert into the
head X5 plug. Tighten by turning the coupling nut clockwise.
To the TH6D Align the male plug according to the coding and insert into the
process computer socket (11) until you hear it click.
Disconnecting The male and female plugs should be disconnected in the following
manner:
From the TH6D Turn the coupling nut counter-clockwise and pull the socket from
sensor head the plug (X5).
From the TH6D Press the safety levers on the connector housing towards the plug.
process computer Pull the plug out of the socket (11).
Overview
NOTE!
The TH6D sensor head is designed with reverse
voltage protection. It is allowed to connect with
existing power supplies.
A separate mains power supply should be used for the TH6D sensor head.
A suitable mains power supply is available from Scansonic. The socket on
the TH6D sensor head is located on the top of the sensor's enclosure.
Connection details
NOTE!
The shield of the power cord should be connected to the
protective earth (PE) terminal on the mains supply.
Type (TH6D sensor head): M12 device connector (male plug, M12-
L, 4-pole, shielded, A-coded)
Type (system controller): Open-ended cable for use with main
power supply from Scansonic
Cable designation: Power Mxxxxxx (the number of your cable
configuration can be found in the list in section 8.3).
NOTE!
Power supply and laser protective circuit (0 V) are
electrically isolated from the system ground.
Connection Connect the cables according to the following assignments. (As shown in
Figure 36.)
X4 to Refer to pin-out
X4
Mains
power
supply
unit
Connect with the Align the female plug according to the coding and insert into the
TH6D sensor head X4 plug. Tighten by turning the coupling nut clockwise.
Disconnecting Turn the coupling nut counter-clockwise and pull the socket from
the plug (X4).
4.4.9 Connection for the cooling and purging air at the TH6D sensor head
Overview
WARNING!
Excessive pressure in the media lines can lead to
eye and ear damage or other injuries!
CAUTION!
Be careful to avoid damaging the equipment!
Follow the compressed air specifications for the
TH6D sensor head as described in section 8.3.
NOTE!
The enclosure for the TH6D sensor head is made of
aluminium. Never allow water to run through the cooling
channels: this could lead to corrosion!
Connection PU 6 and PU 4 hoses (with diameters of 6 and 4 mm) are used to connect
the cooling and purge air to the TH6D sensor head.
X3
X2
X1
Figure 37: Connecting the cooling and purging air to the TH6D sensor
head
Description of Insert the air supply line into the quick-lock coupling.
connections To disconnect, press the coupling's pressure ring gently towards
the coupling and pull out the hose.
Overview
WARNING!
Be careful to avoid damaging the equipment!
Follow the liquid coolant specifications for the
cooling module as described in section 8.3.
ATTENTION!
The enclosure for the TH6D sensor head is made of
aluminium. Never allow water to run through the
cooling channels in the TH6D sensor head: this could lead
to corrosion!
X6
X7
Overview
CAUTION!
Pay attention to your cable lengths and
installation options!
Installation
NOTE!
Do not mount the TH6D process computer on a robot axis;
this could cause damages during operations.
Overview
DANGER
Electrical shock danger – risk of injury!
A power supply unit is included in the delivery and is used to supply power
to the TH6D process computer. The connection is located at the rear of the
TH6D process computer's case.
NOTE!
Power can also be supplied to the TH6D process computer
using an industrial top-hat rail. For more information on
power supplies, please contact your local service
representative.
Connection Connect the cables according to the following assignment (as shown in
Figure 40):
TH6D process
computer
2
Connecting Align the plug according to its coding and insert in the socket (2).
Overview
CAUTION!
Danger of surge voltage!
Disconnect the power supply before connecting the
cable to the components!
The TH6D system is configured with the THxDView software, which must
be installed on a user PC.
Connection Connect the cables according to the following assignment (as shown in
Figure 41):
Ethernet
jack
6
Connecting Align the male plug according to the coding and insert into the
corresponding socket until you hear it click.
Disconnecting Press the safety levers on the connector housing towards the plug.
Pull the plug out of the socket.
Overview The base components should be connected according to Figure 42 and the
installation instructions provided in Chapter 4.
Section 4.4.9
X3
X5
Section 4.4.8
X2
X1
X4
6
Section 4.4.8
Section 4.4.12
11
2
Section 4.4.13
Overview The communication links for the TH6D process computers and the
customer's Fieldbus can use various implementations.
The analogue-digital interface is required when using analogue and digital
interfaces to communicate with the TH6D process computer.
BC DI DO AO ET
Bus terminal types The components and the bus terminals types are colour-coded.
BC Bus coupler - - 1
ET End terminal - - 1
CAUTION!
Danger of surge voltage!
Disconnect the power supply before connecting the
cable to the components!
Connecting the Connect the ADF to the TH6D process computer using the supplied
ADF Ethernet cable according to the following assignment:
TH6D process
computer
10
Connecting Align the male plug according to the coding and insert into the
socket until you hear it click.
Disconnecting Press the safety levers on the connector housing towards the plug.
Pull the plug out of the socket (10).
DANGER
Electrical shock danger – risk of injury!
Connecting two Connect the two power sources with cables as follows (as shown in Figure
external power 45):
sources
24 V 24 V Earthing
Bus coupler Bus terminals
Figure 45: Power supply on the analogue-digital interface
Parallel connection Connect one power source with cable as follows (as shown in Figure 46):
from an external
voltage source
Pass-though
connection of 24 V
to bus coupler
24 V
Bus terminals Earthing
Connecting Attach wire-end ferrules to the cable ends and insert into the
corresponding socket.
Overview The base components should be connected according to Figure 47 and the
installation instructions provided in sections 4.4, 4.5.1 and 4.5.2.
Section 4.4.9
X3
X5
Section 4.4.8
X2
X4
X1
Section 4.5.2
Section 4.5.1
6
Section 4.4.8
10
Section 4.4.12
11
2
Section 4.4.13
General
CAUTION!
information
Follow all the information in Chapter 4 during the
installation and assembly of the TH6D system!
The commissioning and operation have been divided into hardware- and
software-related procedures.
Hardware Section 5.14 describes the general operation of the TH6D system.
NOTE!
Follow the check lists for set-up and installation
found in section 9.2.
Overview
CAUTION!
The THxDView configuration software must be installed on
a separate PC. This user PC and THxDView are thus not
affected when the TH6D system is switched on or off.
The TH6D sensor head and the TH6D process computer can be switched
on/off individually or as a complete TH6D system via the main switch.
Since the interface to the supply voltage can have separated
configurations, it may be possible to use more than one main switch.
Turn on
NOTE!
Three signal beeps can be heard as the TH6D process
computer is booting up. A double beep can then be heard
after the computer has booted up successfully. Any
deviation from this beep tone sequence indicates an error.
Sequence for In general: Switch on the TH6D sensor head and the TH6D
switching on process computer simultaneously.
Information about During the initial commissioning, the TH6D process computer may be in
switching on standby mode after the power supply is switched on. Thus it may need to
be switched on manually.
If the status LED on the ON/OFF switch (7) of the TH6D process computer
is red, press the switch briefly to start up.
NOTE!
If the power supply is interrupted to the TH6D process
computer while it is switched on, then you should switch
the TH6D sensor head and the TH6D process computer
back on.
Information The user PC running THxDView can be switched on and off separately
about from the TH6D system. If the TH6D system is switched off before
disconnections THxDView, then you will notice the disconnection in the THxDView
software. The system status displays the message "No System". When
switched back on, THxDView automatically connects to the previously
connected TH6D system. This can be checked with the connection status
in THxDView. (Refer to section 5.8.)
Switching off Follow the information and instructions about archiving data as
described in section 5.14.8 before you switch off the TH6D
system.
Then the TH6D system can be turned off using the main switch.
Overview The THxDView GUI software is used to set and monitor parameters while
working with the TH6D system.
NOTE!
PC hardware Standard PC/IPC hardware, Pentium 4 processor or faster, min. 2.0 GHz,
min. 1 GB RAM, screen resolution of 1024 x 768
NOTE!
A local Java application is installed with the software. This
Java application will also be removed if you uninstall
THxDView.
Prerequisites
CAUTION!
The following are required in order to install and use the THxDView
software:
Overview
NOTE!
The illustrations used here to show the software and
installation may vary visually depending on your operating
system. However the content and functionality will be
similar.
Starting the Insert the installation CD (included in the delivery) in your PC.
installation The installation should start automatically. If automatic start is deactivated
on the PC, you will need to follow the instructions below:
Initialization The installation begins with the window shown in Figure 48.
Installation The following window details which software components will be installed.
information (As shown in Figure 49.)
License The license agreement comes next. (As shown in Figure 50.)
agreement
Read the license agreement in its entirety.
Click on the "I Agree" button in order to accept the terms of the
license agreement and start the installation, or
Click on "Cancel" if you do not accept the license terms. The
installation will then be aborted.
Changing the You can change the pre-set installation directory as follows: (As shown in
installation path Figure 51.)
Selecting the Select a directory on your PC or network from the window (as
installation shown in Figure 52) and then click on "OK".
directory Click on "Install" to continue with the installation (as shown by 2 in
Figure 51).
Progress of The required files are now copied to the hard drive. The status bar shows
installation the progress. (As shown in Figure 53.)
Finishing the The installation ends with the windows shown in the illustration. (As shown
installation in Figure 54.)
Click on the "Finish" button.
NOTE!
The user PC's subnet must be set to match the IP address
of the TH6D process computer before any connection
between the two computers can be established.
Starting Start THxDView using the shortcut created on the desktop (as
THxDView shown in Figure 55).
Otherwise From the Windows Start menu, find THxDView under the following
sub-menu:
scansonic \ THxDView \ THxDView.exe
Start-up window THxDView starts with the following window. (As shown in Figure 56 )
User login You must first login before you can work with THxDView or change
settings.
Information Section 5.14.1 contains more information about the user login.
Exiting
CAUTION!
THxDView
Data loss is possible!
Click on the "Exit" button (in upper right, as shown in Figure 57)
in the opened window in order to exit.
The contents in this section are not visible until a TH6D system has been
connected to the user interface (refer to section 5.14.2).
2 5
3 4
Brief summary The following list gives a brief summary of the user interface areas in the
THxDView software.
Menu bar The menu bar (1) contains options for settings (refer to section 5.5):
Logging in Help
Extras Selecting a system
Image area The image area (2) allows you to choose between two different methods
for representing the laser beams on the work piece:
System status The system status area (4) shows the status of the TH6D system. The
area following information is displayed:
Information The information area (5) informs about system parameters and provides
area help for the configuration. The following information is displayed:
Parameter Parameters can be set in the parameter configuration area (6). This area
configuration is divided into the main tabs:
area
Menu bar The following additional THxDView functions can be selected from the
menu bar.
Login The "Login" option allows you to select an access level for users of the
TH6D system. More information can be found in section 5.14.1.
Extras The "Extras" option allows you to change the language settings.
Help The "Help" option allows you to view the system information. (As shown
in Figure 60.)
Selecting a The "Select System" option allows you to manage the sensor systems,
system connect or disconnect to a TH6D system. If multiple TH6D systems are
visible on the network, they will be displayed here. It is not possible to
connect THxDView simultaneously with multiple TH6D systems.
"Raw Data" main The "Raw Data" tab shows the laser lines resulting from the preliminary
tab evaluation in the TH6D sensor head. (As shown in Figure 61.)
The white lines indicate the edges of the work piece. The yellow dots
indicate where a seam has been detected (seam points = SP).
The laser lines are projected from the TH6D sensor head out towards the
camera's field of view. Since the camera in the TH6D sensor head is
protected against extraneous light by a narrow-band optical filter, only
those areas of the work piece surface which are illuminated by the laser
lines are visible.
The coordinates for the "Raw Data" sensor image are defined as follows:
SP
+z
-z
+y -y
"Evaluation" The "Evaluation" tab shows the results of the analysed raw data. This
main tab provides the user with information on the lateral and vertical positioning
to the joint. (Refer to Figure 62 and Figure 63.)
Measuring activated
The green lines indicate
those sections of the laser
lines recorded by the
camera that can be
analysed.
The measurement points
on the detected seam are
marked in yellow.
Note
NOTE!
Flickering green lines and yellow dots indicate locations
with insufficient seam detection. Fine tuning of the
settings in THxDView can help fix this.
Overview The "Errors and Warnings" section of the Reports area can be found in the
lower left part of the THxDView window. This section displays errors,
warnings and additional information. (As shown in Figure 64)
5.7.2 Events
Overview Logged system events are displayed in the "Events" section of the
Reports area. This section lists successful and unsuccessful save/delete
actions, for example.
Overview The "System Status" area is located in the lower right of the TXxDView
window. It displays the status of the TH6D system. This area displays the
network connection between THxDView and the TH6D process computer,
the operating mode, the active measurement process and the
composition of the active job.
Overview The current status of the network connection between THxDView and the
TH6D process computer is displayed in the left section of the "System
Status" area. (Refer to the marked area in Figure 67.)
Overview The current status of the operating mode is shown in the second (from
left) section in the "System Status" area.
Changing the
CAUTION!
operating mode
It is not possible to change modes during active
processing in automatic mode! Wait until the
program has finished.
The status display is also a button that is used to switch the operating
mode.
Overview The current status of the measuring process is shown in the third (from
left) section in the "System Status" area. (Refer to the marked area in
Figure 69.)
Displays the The displays for the quality of the measuring process and the
quality of the corresponding largest contiguous measurement error depend on the
measuring particular application. Two important factors influencing this are the
process shape of the work piece and the measurement path across the work
piece. A definitive conclusion about measuring quality differences can
only be made by comparing the measurements from identical test pieces
and analysing the measurement data.
Overview The status of the active job is shown in the fourth (from left) section in
the "System Status" area. (As shown by the marked area in Figure 70.)
This status is visible in automatic mode and set-up mode.
In this example, the active job includes the seam pattern profile
"a1_seam", the camera profile "a1_camera", the calibration profile
"a1_calibration" and the process control profile "a1_process_control".
NOTE!
The TH6D sensor head is not activated when the TH6D
system is in automatic mode and receives no job number
from the robot controller.
Overview The information area contains the main tabs "Measurements" and
"Sketch". These tabs inform about measured results and the system
states of TH6D-sensor system and serve as a guide for setting
parameters. Both tabs are explained in the following chapter.
Overview The main "Measurements" tab summarizes the values measured by the
TH6D system. According to the geometry of the work pieces, the values
change dynamically during the measurement. (As shown in Figure 71.)
NOTE!
The measured values are only displayed while in set-up
mode. No measurements are displayed while in automatic
mode.
Displayed The measured values displayed by the sensor system are related to the
measurements sensor coordinate system which influences the process or the
position/track corrections.
Information
CAUTION!
Output data does not need to match the data sent to the
robot! It is transformed based on the defined machine
protocol.
The main The "Sketch" tab in the information area provides graphic support to help
"Sketch" tab in you with parameter changes in the "Parameter configuration area". The
the graphical display can be used as a guide for interpreting the
information area corresponding parameter.
NOTE!
Explanatory diagrams are not yet available for all
parameters.
Figure 72: Information area – diagram (example for adjusting the angle)
Structure The main sketch tab is divided into two sections. In the upper section
examples of the currently selected seam pattern profile are shown. At the
bottom of the section the selected parameter is explained graphically.
About the
NOTE!
parameter values
The default values and allowed value ranges are shown
when a parameter is selected.
Information Sections 5.11 and 5.12 describe the parameters and their functions.
Overview The "Parameter configuration area" (as shown in Figure 75) consists of
three tabs:
Profile System
These main tabs allow you to specify and change parameters in order to
optimize the seam tracking. The functions of each main tab and their
associated sub-tabs are described below.
"Profile" tab The seam detection is configured in THxDView using four profiles. They
can be selected using the "Profile" tab within the parameter configuration
area. Specific parameters can be activated, deactivated, or assigned
values for each of these profiles. (As shown in Figure 76)
1 2 3 4
Overview The "Seam Pattern" tab allows you to select pre-defined seam pattern
profiles (templates). These templates contain specific parameters for
recording the seam shape.
Information Section 5.11.3 describes the parameters contained in the seam pattern
profiles.
More information about creating and saving custom stitch patterns can be
found in section 5.14.8.
Overview
NOTE!
Pre-defined seam pattern profiles are marked with the
word "(template)" in their profile names. Saved
customized profiles contain the name of the template on
which they were based.
THxDView has various templates for different seam patterns. The user
can select a template that matches his particular application. The
parameter settings for the selected template can then be used to create
the customer-specific seam pattern profile. This profile must be saved
under a unique suitable name.
NOTE!
Changed seam pattern templates must be saved under a
different name! When restarting the TH6D system, the
default values are re-loaded into the pre-defined
templates.
Templates for the A drop-down list in the "Seam Pattern" tab allows you to select from the
seam pattern following templates for seam pattern profiles. (As shown in Figure 78)
profiles
Open edge V-Area TB-Area
Overlap seam HY-seam M-Depth
Tailored blank U-Seam
V-seam HU-seam
Information
NOTE!
The "Sketch" information area contains helpful information
describing the parameters.
Open edge The "open edge" seam pattern profile specifies a special form which can
be used for all processes that run parallel to a work piece edge.
Example After cutting glass, the edge can be ground or an adhesive can be applied
application to the work piece edge in parallel.
Overlap seam The "overlap seam" seam pattern profile can be used in a process where
the work piece edges overlap. Figure 80 shows an example of the overlap
joint.
Tailored blank The "tailored blank" seam profile is an all-purpose template for other
seams that are not defined here. All parameters in this seam pattern
profile can be changed.
a
Gap a Offset d
TB-Area The seam sample profile "TB-Area" is suitable for geometries which are
not defined as a standard seam pattern.
V-seam The seam sample profile "V-seam" can be used in applications where the
seam has been prepared or where V-shaped work pieces are positioned
next to each other.
V-Area The seam pattern template "V area" is suitable for applications of thick
sheet metal, and for the multi-pass welding where the seam area is
needed to calculate the number of layers.
HY-seam
U-seam
HU-seam
M-Depth The seam pattern template "M-depth" is suitable for applications where
only the distance measurement is needed to create an even surface. This
stitch pattern template is not part of the standard software.
Parameter
NOTE!
The "Sketch" area contains helpful information describing
the parameters for the seam pattern profiles.
Parameter
NOTE!
The particular parameters contained within a seam pattern
profile vary according to each profile.
Line quality Depending on the roughness of the work piece surface, there may be
interruptions in the laser lines shown under the "Raw Data" tab. The "line
quality" parameter is adapted to the surface roughness and influences the
analysis and representation of the reflected laser lines.
You can use the illustration in the "Evaluation" area to evaluate the
importance of changing this parameter. The parameters are selected
using a drop-down list. The following values can be selected:
Example of the line In Figure 88, the "Evaluation" image area shows (A) the raw image of a
quality of a overlap rough surface of the work piece. No changes to the parameters are made
seam here.
In Figure 88, a line quality of "fine" has been selected (B) for this work
piece surface. There are many scattered line elements visible here. This
makes the seam detection more difficult.
In Figure 88, a line quality of "very coarse" has been selected (C) for this
work piece surface. Multiple line elements have been merged together so
the seam detection is functioning well.
A
Raw data
B C
Evaluation – "Fine" line quality Evaluation – "Coarse" line quality
Pattern location "Pattern location" describes the arrangement of work pieces (sheets) at
the joint. It determines which side the upper sheet is on. The value "any"
is suitable for a first test run. It should, however, be limited by the
specification "upper sheet is right" or "upper sheet is left".
Reference area A "reference area" is specified to determine an area to the left and right
of the joint line where the measured values can be calculated. The
reference area is also required for measuring the angle information.
By default, the "sensor" setting does not have a reference area specified.
The measured mismatch and gap width values are evaluated in the
sensor coordinate system. So when the TH6D sensor head is aligned
diagonally to the work piece surface, these measurements do not match
up with reality.
Information on the For the "overlap seam" pattern, if the TH6D sensor head is aligned
overlap seam diagonally to the joint (as shown in Figure 89 A and B), then the
measured mismatch is specified as the gap. If this gap is greater than 0.5
mm, then a reference area must be selected. Otherwise there will be no
seam detection.
A B
Gap
+z +z
+y +y
+x +x
TCP alignment "TCP alignment" is used to specify the precise position of the seam point.
The point may lie on the left or right end, or between the end points and
the laser lines.
Depth "Depth" is used to specify the distance from the top edge to the bottom
edge of the work piece. The depth parameter must be specified so that
the TH6D system can properly calculate the area.
Information on the When using the "HV-seam" pattern and when the TH6D sensor head is
HV-seam aligned diagonally to the joint, the seam is not detected over the entire
depth of the work piece joint. Instead, the detection is carried out until
the start of mutually parallel work piece edges of the joint.
+z
+y
+x
Angle The "angle" setting (left/right) is used to help avoid detecting false joints
left/right on the work piece. You can eliminate multiple reflections in the evaluation
by specifying the correct inclinations of the laser lines. This results in a
more stable seam detection process.
It must be possible to distinguish between the left and right angle since
the angle is being measured from the joint line to the adjacent level. In
the lines "angle left/right", the left value represents the smallest border
while the right value represents the largest border of the angular range.
Opening angle In addition to the "angle left/right" parameters, the "opening angle"
between the edges of the seam can be specified. This is useful when you
cannot define a boundary with "angle left/right" because the orientation
of the sensor to the work piece has changed. If the TH6D sensor head is
pivoted laterally from the joint line, this changes the inclination of the
laser lines in the camera image. The angle constraint then becomes a
hindrance. The opening angle, however, remains unchanged.
Interference at When working with reflective surfaces (aluminium or CrNi steel), the joint
the seam line is brightened by multiple reflections of the laser beams. This
interferes with the measurement and evaluation for the seam tracking.
The "interference at seam" (left/right) parameter indicates an area of the
seam that cannot be evaluated.
Mismatch "Mismatch" is determined by the thickness of the work piece and any
possible air gap. The "Mismatch" is the vertical distance from the
reference area to the nearest edge of the second work piece. You can
limit this value when you know the thickness of your work pieces in order
to avoid faulty detection (refer to Figure 93). A large air gap between the
overlapping work pieces can also be detected.
Gap "Gap" defines a gap at the joint between the work pieces. When using the
seam shape "tailored blank", it is possible (and sometimes desired) that
there will be a gap at the joint line. (As shown in Figure 94.)
Note The parameters "Mismatch" and "gap" are very helpful for eliminating
visual ambiguities in the camera image.
Interpolation An isolated seam point is designated as the base point. The "Interpolation
point tolerance point tolerance" parameter is used to expand the tolerance range of the
(l,v) seam point in the side (I) and height (V) directions. It is used to calculate
and evaluate the seam tracking. This is useful when there is minor
damage to work piece edges which could cause an excessive gap at the
joint line (for example, on an overlap seam).
Example In the example shown in Figure 95, the end point of the left middle line of
the joint line (vertical with red dashes) is too far away which corresponds
to a gap.
Example – For example, by specifying a value of 1 for the "side" parameter (S), the
continued algorithm accepts this deviation and recognizes the overlap seam
flawlessly. Figure 96
Search area The parameter "search area" is used if there is major interference (i.e.
left/right caused by reflections) in the proximity of the selected joint line. Such
interference occurs less often in the edge region of the V-seam.
Therefore, it is often useful to define a search area for these points.
The search area for the "overlap seam" shape is defined by starting at the
joint on the left and right.
For "tailored blank" and "v-seam", you can define minimum and
maximum limits for the search area independently of the joint. The
search area to the right and left of the seam position can be defined by
entering the minimum and maximum limits.
For the seam pattern "open edge", the position of the search area can
only be defined to one selected edge.
(The search area can be defined as an area or only as a line for all seam
shapes.) It must be possible to reliably detect all three laser lines in this
case.
Line length By specifying the length of line, only line elements for the joint detection
(left/right) are selected which are contained in the specified range.
Line diff. The "Line diff. (A, L)" parameter is used for smoothing those line ele-
(A, L) ments that do not lie precisely on the theoretical line direction (angle =
A). It is also used to merge small gaps (gap = L).
L W
Preferred joint The "preferred joint position" parameter allows you to manually define
position the seam position so you can eliminate ambiguities during the seam
detection. This eliminates the risk of faulty detection. It can be used, for
example, when an additional edge is located under the selected work
piece edge or when a clamp causes two steps of equal height to be
visible.
Examples of Figure 98 shows two overlapping overlap seams; the position of the upper
preferred joint sheet is not clear in such a case. Unambiguous detection is only possible
position after the "preferred seam position" parameter has been specified.
Left/Right By choosing the parameter "joint is on the left" or " joint is on the right",
the detection of the seam position occurs in the middle position between
the two higher or two lower lying surfaces. (As shown in Figure 99)
Position of the seam – on the left Position of the seam – on the right
Information Sections 5.11 and 5.14.8 contain more information on the various
templates for the seam pattern profiles and on creating additional
profiles.
Overview The "Camera" tab allows you to select a pre-defined profile (template)
which contains specific parameters for configuring the camera imaging in
the TH6D sensor head. It is also possible to create custom profiles by
changing the parameters in the existing templates.
Camera profiles Templates and custom camera profiles can be selected from the drop-
down list.
Dynamic range The "dynamic range extension" parameter can be used with extreme
extension brightness to reduce the over-exposure of the camera. The "slight"
setting is the default.
Exposure time
NOTE!
Laser power The "Laser power" parameter affects the power of the laser diode. At
higher power, the intensity of the laser light is increased. The actual
setting of this value must be tested on the work piece. There is no
recommended value for this parameter, since there are many variable
factors for each situation (the sensor orientation, shape of the work piece
surface, reflective properties or the surface, etc.). The brightness should
only be set as bright as required. Unnecessary brightness would shorten
the lifespan of the laser diode.
Overview
CAUTION!
The calibration depends on the machine in use. It is only
required when the TH6D system is used with linear axes
and Kuka robots.
Overview
CAUTION!
Example Figure 101 shows an example of the process control of the overall A/D
corrective interface. The analogue voltages can be scaled here and also
assigned an offset. The user can check off which parameter should be
sent as a voltage value to the controller.
Information The interface can be chosen from the main "System" tab and then the
sub-tab "Machine Interface" (section 5.12.2).
Main tab The "System" tab allows you to configure a job list and select the
"System" machine interface. This is also where the operating range of the analysis
software can be configured.
1 2 3
Overview The "Job List" tab can be used to create jobs from the parameter profiles
that have already been defined in the "Profile" main tab.
The user can create jobs for specific applications. These are then saved
on the TH6D process computer. For the actual processing, the facility
controller invokes the job needed for that particular application. This is
achieved using the job number assigned by the sequence program.
Jobs
NOTE!
For more information on setting up profiles and creating
jobs, refer to section 5.14.8.
Information The System Status area shows the job compilation that is currently being
used. (Refer to 2 in Figure 104.)
Sections 5.8.4 and 5.14.8 contains more information about Jobs, their
status and creation.
Overview The "Machine Interface" tab is used to select which machine interface is
connected to the TH6D system.
This selection must be specified because each interface provides different
machine-dependent parameters for configuring the user interface.
A/D correction General interface for control of two auxiliary axes via
the control voltage
Changing the
NOTE!
interface
The system is rebooted after the machine interface is
changed.
Select the interface to use from the drop-down list (as shown by 1
in Figure 105).
Click on "Save" (2).
After changing the machine interface, the system automatically
restarts.
The system then starts with the newly selected configuration.
NOTE!
When an interface is changed, the assigned process
control is loaded which provides the relevant parameters.
Information For more information about the available interfaces and their parameters,
refer to section 5.9.
Overview The "Configuration" tab allows you to configure the settings for playing
back the recorded image from the camera in the TH6D sensor head. (As
shown in Figure 106.)
In the "Evaluation" area, you can restrict the camera image to width X
and height Y so that areas of interference can be ignored.
Configuration
CAUTION!
This configuration does not change the size of the TH6D
sensor head's field of view. Adjustments only affect the
"Evaluation" image area.
The only visual change in the "Evaluation" image is that the laser lines
are shorter. The size of the visual frame remains unchanged. (As shown
in Figure 106.)
Example The change to the parameter "search window x and y" (as shown in
Figure 107) has the following influence on the "Evaluation" image area:
x
20
751
100
400
y
Figure 107: THxDView – configuring the "Evaluation" image area
(example)
Example – The changes have no effect on the sensor's field of measurement, as can
continued be seen in the "Raw data" image area. (As shown in Figure 108)
Machine- The machine interface "analogue-digital correction" only works with the
dependent auxiliary module "analogue-digital interface (ADF)." More information and
auxiliary modules the installation instructions can be found in sections 3.4.1 and 4.5.1.
NOTE!
Digital The status of digital inputs and outputs is shown by fields (1). (As shown
inputs/outputs in Figure 109.)
Analogue The "Analogue On/Off" field is divided into four analogue inputs (2) and 4
inputs/outputs analogue outputs (3). In the "Analogue Out" field (3), four analogue
outputs are displayed for each default voltage value. The four analogue
inputs (2) are by default not operated.
2 3
∆x (scale, offset) Scaling factor for the output of the measured value
on the gap between the laser lines; added to the
measured value
∆y (scale, offset) Scaling factor for the output of the measured value
on the position in lateral direction; added to the
measured value
∆z (scale, offset) Scaling factor for the output of the measured value
on the position in height; added to the measured
value
Gap (scale, offset) Scaling factor for the output of the measured value
on the gap width; added to the measured value
Mismatch (scale, offset) Scaling factor for the output of the measured value
on the step height; added to the measured value
IF UDP data
NOTE!
The UDP-machine interface is used for non-standard
applications.
IP address:
Dead time
Delay Delay is the system delay time or response time required by the TH6D
system when it outputs a data record. This value is automatically sent to
the robot controller when the communication link is established.
ATTENTION!
You should only change this delay value when the
communication link between the TH6D system and robot
controller times out!
Initial During the initial commissioning the TH6D process computer may still be
commissioning in standby mode. It must then be manually switched on using the ON/OFF
information switch on the TH6D process computer. Refer to the information about the
status display and the position of this switch as described in section 3.5.2.
NOTE!
Parameter changes and other adjustments can only be
carried out while in the set-up mode. In this operating
mode, the laser lines are switched on, unless this is
prevented by the applicable laser safety regulations.
Overview After the THxDView software is successfully installed and started up, the
user must log on to the TH6D system.
THxDView provides different levels of access, each of which is secured by
a password.
The passwords are also listed on a separate data sheet that is included
with the User's Manual. Passwords may be changed from the
Administrator access level.
Access level and Extended View: Parameters can be viewed but not
Access rights changed.
User login Click on the "Login" button (as shown Figure 112).
Select the desired access level.
Enter the password in the window that appears and then click
"Login" (as shown in Figure 113).
The "Login" menu option then changes to show the current access
level.
Login failure An error message will be displayed if you enter a wrong password.
The password can be re-entered (as shown in Figure 114).
After logging in, you can click on the menu bar to change access levels.
You will have to enter a new password if you are switching to a higher
access level.
Click again on the option with the name of the current access level
(for example User access, as shown in Figure 115).
Overview
NOTE!
The TH6D system is delivered with the factory default IP
address and port permissions. Only service personnel can
change these settings.
The TH6D process computer comes standard with the following default
connection settings for the user PC with THxDView:
IP address: 192.168.0.201
Subnet mask: 255.255.255.0
The user PC and the TH6D process computer must be in the same
address range. The fourth number block in the IP address range may
not be 201. The address for the subnet mask must stay as shown above.
Note All connected TH6D systems will be shown in THxDView, even if they are
in another address range.
Checking the IP You can select the menu option "Select System" in order to display the
addresses TH6D systems connected to the user PC along with their IP addresses.
You can select a system here. A sensor system management option is
available for checking IP addresses and to operate a TH6D system with a
specific serial number.
Open the sensor Click on the "Select system" button in the menu bar (as shown in
system Figure 116).
management Select the "Manage Sensor Systems" option.
1
2
Establishing a After the network connections have been configured on the user PC, a
connection link can be established to the TH6D system.
Status display A successful connection is indicated with green in the "system status"
for the area and the name of the connected TH6D system. (Refer to the marked
connection area in Figure 119.)
Information Section 5.8 contains more information about the status display in the
"system status" area.
Information The user PC running THxDView can be switched on and off separately
about from the TH6D system. If the TH6D system is switched off before
disconnections THxDView, then you will notice the disconnection in the THxDView
software. The system status displays the message "No System".
Setting the
NOTE!
automatic
connection You can configure the settings so that a connection is
automatically established between THxDView and the
TH6D system when the software starts up.
The next time you start THxDView, the program automatically tries to
connect to the previously connected TH6D system. This process can be
interrupted within four seconds.
Overview
NOTE!
Additional languages are being prepared. Please contact
your local sales and service partner.
Changing the Click on the "Extras" button (as shown in Figure 122).
language Select the language in "Language" option.
A reboot is not required when changing the language.
Operating modes
NOTE!
When selecting the operating mode, there must be an
existing connection to a TH6D system and you must be
logged in at the "Parameterization" access level.
Selecting the
CAUTION!
set-up operating
mode It is not possible to change modes during active
processing in automatic mode! Wait until the
program has finished.
The default operating mode when starting the TH6D system is the
automatic mode.
"Setup Mode" is
activated
NOTE!
When "Setup Mode" is activated, the laser lines are
switched on, unless this is prevented by the applicable
laser safety regulations.
Requirements First, the installation and connection of the TH6D sensor head, TH6D
process computer, facility controller, user PC and THxDView must be
carried out (as described in Chapter 4). The TH6D sensor head can then
be positioned
NOTE!
The emitted laser lines are much longer than the
measuring field of the TH6D sensor head. Thus the sensor
head must be carefully positioned over the joint.
Positioning the Move the tool (e.g. torch) to the desired working position. Align the
TH6D sensor sensor head TH6D sensor head as described below:
head The TH6D sensor head should be positioned at a height of 150
mm above the butt edge of the work piece.
The optimal
NOTE!
setting
Set-up mode must be activated in order to carry out
configurations manually.
To optimally adjust the lateral and vertical position of the TH6D sensor
head above the butt edge of the work piece:
The example illustrations below show different gaps that the TH6D sensor
head can have to the seam area, using an example of a V-seam:
Overview
NOTE!
Set-up mode must be activated in order to change
parameters.
Parameters values must be saved in the profile in order to
save the values permanently. (Refer to section 5.14.8.)
Camera settings In the "Camera" option of the main "Profiles" tab, the value for the laser
brightness (2) should be specified in the input box so that the laser lines
in the "raw data" image area are still faintly visible. This value is very
dependent on the roughness of the work piece surface and its colouration.
For reflective surfaces (such as stainless steel and aluminium), a value of
at least 200 must be specified here.
1
2
0
0
0
Figure 125: THxDView – changing the camera settings
Overview
NOTE!
Set-up mode must be activated in order to change
parameters.
Parameters values must be saved in the profile in order to
save the values permanently. (Refer to section 5.14.8.)
Changing the At the User acces, Service or Administrator access level, you can change
parameters the corresponding parameters within their specified value ranges.
Input incorrect If an invalid value is entered, the initial value is displayed in red
(as shown by 4 in Figure 127).
The help bar will show the wrong entry by marking it with a red
circle and white X (as shown by 3 in Figure 127).
Overview
NOTE!
Jobs cannot be created using profile templates. They can
only be created from customer-specific profiles.
Creating a user- From the main "System" tab, select one of the tabs "Seam
specific profile Pattern", "Camera", "Calibration " or "Process control " (as shown
by 1 in the example in Figure 128).
Choose a template that is suited to your processing task, or
choose an existing profile from the drop-down list (2) of the
selected tab.
Setting up a new Change the parameters necessary for your optimizations (3).
profile Save the newly created profile using the following specifications.
If needed, repeat these steps for the other tabs (1).
Setting up a new
profile – continued
1
2
4 5
Saving a new
NOTE!
profile
Tabs containing changed but unsaved parameters are
marked with an "*" before the tab name. (Refer to 1 in
Figure 128.)
Click on the "Save As" button (5 in Figure 128) after you have
finished optimizing the parameters. You can then save your
customization to a new profile.
Give the profile a clear name and click on "Save" (6 and 7 in
Figure 129).
Information The "Reports” area shows when the profile has been saved
about saving successfully.
The profile that you created is now in the drop-down list (as
shown by 8 in Figure 130) and can be selected when compiling a
job.
Figure 130: THxDView – selecting the profile from the drop-down list
Creating a job The profile can be compiled into application-specific jobs after the set-up
is complete. These are created in the "Job List" tab under the main
"System" tab. (As shown in Figure 131.)
Creating jobs – Jobs can be assigned a unique job name. Each job is assigned a unique
continued number by which it is saved in the TH6D process computer. For the
automated processing, the machine controller invokes the desired job
using the job number. This job is uploaded to the TH6D process computer
and executed. The machine controller cannot change this job during an
active measurement.
Creating a new job Click on the "Create Job" button (9) in the "Job List" tab.
A new row (10) will appear in the job list with fields that you need
to fill in.
10
00
9
0
Figure 132: THxDView – creating a new job 0
Assign a job name Click in the column (11) and enter a unique job name (as shown
and profiles in Figure 133).
11
Then assign the desired profile to each profile type from the drop-
down lists (as shown by 12 in Figure 134).
All four profile types must be assigned profiles in order to save the
job.
Templates cannot be selected.
12
The reference text "new" will appear under the assigned job number after
you have named it and assigned a profile. (Refer to Figure 135.) This
indicates that the job has been created but not yet saved.
13
00
Changing of The composition and name of created jobs can be changed after the jobs
deleting a job have been created. The assigned job number remains the same.
Click on the row of the job you wish to change – the job entries
can now be edited.
Change the job name or assign different profiles to the profile
types.
The reference text "changed" will be displayed under the job
number.
Click on the "Save" button to apply the changes.
Information The name of the template is based on the corresponding profile and
shown in parentheses after the profile name. (Refer to 14 in Figure 137.)
14
15
The current job and its contents can be seen in the "System State" (15)
area.
DANGER!
There is a risk of injury from the master machines!
Do not stay in the swivel range of master machines when they are turned on!
Disconnect the power from the master machines before starting to work on
the TH6D system!
WARNING
Danger of getting stuck!
When the power supply is turned on, keep hands, hair, pieces of clothing and
tools away from the moving parts of the processing equipment.
Disconnect the power supply before beginning work on the TH6D system.
WARNING
Danger to health through harmful gases and fumes!
WARNING
Loud noises can be dangerous!
The loud noises caused by emitted media can damage your hearing.
Always wear protective gear for your ears when changing pressurized hoses!!
Or make sure that you de-pressurize all facility components!
WARNING
Danger from excessive pressure!
Always wear protective gear for your eyes and ears when changing
pressurized hoses!
Or make sure that you de-pressurize all facility components!
WARNING!
Risk of injury from hot components!
There is a risk of burn injury from hot components when carrying out maintenance
work immediately following the work process.
Allow the work pieces to cool down or wear suitable protective gloves!
Normally, a maintenance interval after every eight hours of processing time is adequate.
Scansonic recommends a diagnosis of the maintenance intervals in order to determine more
precise intervals.
NOTE!
If the quality of the seam detection deteriorates (as
indicated by the value in THxDView), this indicates that
you need to replace or clean the protective glass. (As
shown in Figure 138.)
After the protective glass is changed, the percentage value for the seam
detection should return to the proper range. (As shown in Figure 139.)
CAUTION!
The maintenance information in the table below is a recommendation but does not
guarantee error-free functionality.
Hose connections Check that the input and When 6.3.3 6-9
output sides are connected
necessary
firmly and that there are no
leaks or damage.
Cable connections Check that the input and When 6.3.3 6-9
output sides are connected
necessary
firmly and that there is no
damage.
Overview
NOTE!
The TH6D system may only be used for welding processes
together with a TH6D sensor head and an attached
protective glass unit with a clean protective glass!
The protective glass unit with the built-in protective glass protects the
optical elements in the TH6D system from mechanical contamination,
process spatter and deposits.
Maintenance Check regularly that the protective glass is clean (check for
procedure deposits or spatter) and undamaged.
Clean the protective glass.
Replace the protective glass if it is scratched.
Removing the
NOTE!
protective glass
unit The TH6D sensor head and the protective glass unit may
be heated up during the thermal processing. Allow the
modules to cool down before removal, or wear suitable
protective gloves!
Remove the In order to replace the protective glass, take hold of it with your
protective glass thumb and forefinger at the red marks (as shown in Figure 140).
Gently lift the protective glass up and pull out diagonally.
Figure 140: Replacing the protective glass – removing the protective glass
Cleaning the Any contamination of the protective glass from the process should be
protective glass cleaned as follows:
Replacing parts Within this module, the following components can or must be replaced:
To insert new
CAUTION!
protective glass
Do not touch the unprotected surfaces of the
protective glasses!
NOTE!
Protective glasses are coated on both sides with a
protective foil. These foils must be removed during the
insertion, according to the instructions below.
Take hold of the sides of the new protective glass using your
thumb and middle finger (hold the marked points shown in Figure
141).
Carefully remove the protective foil on the bottom side (towards
the protective glass unit).
Use your forefinger to push down on the protective glass so that it
is positioned between the spring strips.
After it snaps into place, peel off the foil from the top side of the
protective glass.
Figure 141: Replacing the protective glass – inserting the new protective
glass
Installing the Install the protective glass unit (with the new protective glass) so
protective glass that it is aligned flush with the TH6D sensor head and until you
hear a clicking sound.
unit
Section 4.4.5 contains more information about the installation.
Functional testing Check that everything has been installed properly before re-
commissioning. Use a functional test with sample measurements.
Move the TH6D sensor head manually over the work piece.
Open up the THxDView program and switch the TH6D system into
set-up mode.
Activate the measurement function in THxDView. Stop it after
about ten seconds.
Function test – You can check the image by clicking on the "Raw Data" tab and
continued then on "Evaluation" in the image area (refer to section 5.6).
When compared to measurements taken before the protective
glass was replaced, the new test measurements should exhibit less
or no errors and the percentage values for the seam detection
should be improved.
(Refer to the example in Figure 142.)
If the seam detection is functioning smoothly, you can switch the
TH6D system to automatic mode and log out of THxDView.
If the seam detection is still problematic, check that the protective
glass and the protective glass unit properly seated and consider
changing the parameter settings (refer to section 5.14.7).
Overview
CAUTION!
A re-calibration is required after the position of the TH6D
sensor head is changed in relation to the tool or when it is
dismantled. Also check the calibration after cleaning!
The TH6D sensor head may get dirty depending on the nature of your
process. Any such contamination should be removed regularly.
Cleaning
CAUTION!
Disconnect the power supply before cleaning!
Use only clean, lint-free cloths for cleaning the protective glasses
on the TH6D sensor head.
You may use a gentle, non-abrasive detergent (never use water or
aggressive chemical agents!).
You may also use ethanol for cleaning.
Overview The connections for the media-supply hoses and cables on the input side
of the TH6D sensor head are under heavy stress due to the motions of the
master machine/robot. These connections need to be inspected regularly.
7.1 Notes
It is not possible to totally exclude the possibility of malfunctions even after proper inspections
have taken place. We do not yet have a comprehensive list of faults and solutions.
Thus we recommend that you contact customer service if you are experiencing malfunctions or
difficulties.
Rudolf-Baschant-Straße 2
Sales and
service partner
Information
Warnings
1. W180 Excessive There is a problem with the TH6D sensor head's cooling
temperature at (air or water).
sensor Check the coolant connections and coolant lines.
Check the temperature of the coolant (refer to the
information in section 8.3 Medium)
2. W400 Laser off Status alert indicating that the laser is switched off
(system standby).
3. W401 Laser safety circuit The laser safety circuit (LSC) is open.
off Check that the LSC is closed.
Check the LSC switch to make sure it is functioning
properly.
Check the LSC cable. Replace it if it is defective.
5. W720 Sensor change The calibration profile for the actual job is no longer
without tool valid because a sensor has been changed.
calibration Add the current calibration profile for the actual job.
Attention: This warning message can occur after E720
has been fixed when an internal tool calibration has
been carried out but not specified in the job.
Errors
3. E110 There is an error with The calibration version of the TH6D sensor head does
the sensor not match with the software in the TH6D process
calibration. computer.
5. E150 Internal sensor error Electronic defect in the TH6D sensor head.
6. E300 Process interface is The process interface to the master machine (section
not ready 5.9) is not able to communicate because of an
initialization error.
8. E600 Job is not selected The job was not selected by the master machine /
robot or no job number was sent by the master
machine / robot to the TH6D system.
Check the programming on the master machine /
robot to ensure that the jobs numbers are assigned
properly.
9. E605 Job number not An improper job number has been selected or sent. The
allowed job number is not assigned in the TH6D process
computer.
Check the programming on the master machine /
robot to ensure that the jobs numbers are assigned
properly.
10. E610 Error in job profile The TH6D system has a software error.
11. E620 Job profile is missing The TH6D system has a software error.
12. E650 Job internal error The TH6D system has a software error.
13. E720 Sensor change has Code indicates that a TH6D sensor head was changed.
been detected When a TH6D sensor head is changed, the TH6D
system automatically switches to manual mode.
Configurations TH6D-150-CFAA-AB
TH6D-150-KFAA-AB
Dimensions 70 x 121 x 40 mm (L x H x W)
Dimensions
(z = 0 mm)
(x = 0 mm)
Operating range
S0 S0
(z = 0 mm)
(x = 0 mm)
Operating range
S0 S0
NOTE!
Seam search and measurement will only function when the currently selected job has
been created and activated.
8.3 Medium
ATTENTION!
This information is relevant only when using the optional cooling module!
Do not allow any liquid coolants into the TH6D sensor head!
pH value 5.5 – 8
Operating temperature TH6D sensor head: +10 to +50 °C (min. 5 °C above the
condensation point!)
NOTE
Please specify the article number and name when ordering.
and M001705
6 M001704 THxD power cable [10 m] Cable for power supply to the
TH6D sensor head
and M001707
3 M001706 THxD power cable [15 m] Cable for power supply to the
TH6D sensor head
and M001709
6 M001708 THxD power cable [25 m] Cable for power supply to the
TH6D sensor head
3 M001835 Tip insert for the calibration Insert for calibration plate, to
plate help calibrate laser
applications
9.1 Annex
1 Mechanical mounting
Overview: Please follow the instructions for installing the TH6D system in
Chapter 4.
Orientation: The TH6D sensor head should be aligned with the work piece
surface so that the edges of the work piece can be detected in the sensor
measuring range. (Raw data in THxDView)
Protective glass unit with protective glass should be mounted on the TH6D
sensor head.
(Refer to section 4.4.5.)
The Ethernet cable should connect the TH6D sensor head (plug-in slot X5)
to the TH6D process computer (plug-in slot 5). (Refer to section 0.)
The power cable should connect the TH6D sensor head (plug-in slot X4) to
the mains power supply unit. (Refer to section 4.4.8.)
The power supply cable should be connected to the TH6D process computer
(plug-in slot 2). (Refer to section 4.4.12.)
Strain relief mechanisms should be in place for the individual cables and
hoses.
2 Media supply
The compressed air supply for the cooling air (for the optional cooling air)
should be connected with the TH6D sensor head (plug-in slots X2, X3, X3).
(Refer to section 4.4.9.)
The compressed air supply (cooling and purging air) should be connected
to the proper maintenance unit via a cut-off valve (with filter and de-
humidifier).
The processing parameters should have been verified and specified when
necessary using THxDView.
Notes When returning the TH6D system, please fill out this declaration
completely.
Adding a device
Configuration number:
Serial number:
Type of contamination:
Other details:
Company
Address
Telephone
Contact person:
Date: Signature:
12°C 0.4 1.8 3.2 4.5 5.6 6.7 7.8 8.7 9.6 10.5 11.3
14°C 2.2 3.8 5.1 6.4 7.6 8.7 9.7 10.7 11.6 12.6 13.4
15°C 3.1 4.7 6.1 7.4 8.5 9.6 10.7 11.7 12.6 13.5 14.4
16°C 4.1 5.6 7.0 8.3 9.5 10.6 11.7 12.7 13.6 14.6 15.5
17°C 5.0 6.5 7.9 9.2 10.4 11.5 12.5 13.6 14.5 15.4 16.2
18°C 5.9 7.4 8.8 10.1 11.3 12.4 13.5 14.6 15.4 16.3 17.3
19°C 6.8 8.3 9.8 11.1 12.3 13.4 14.5 15.5 16.4 17.4 18.2
20°C 7.7 9.3 10.7 12.0 13.2 14.4 15.5 16.5 17.4 18.4 19.2
21°C 8.6 10.2 11.6 12.9 14.2 15.4 16.4 17.4 18.4 19.3 20.2
22°C 9.5 11.2 12.5 13.9 15.2 16.3 17.4 18.4 19.4 20.3 21.2
23°C 10.4 12.0 13.5 14.9 16.0 17.3 18.4 19.4 20.4 21.3 22.2
24°C 11.3 12.9 14.4 15.7 17.1 18.2 19.2 20.3 21.4 22.3 23.2
25°C 12.2 13.8 15.4 16.7 18.0 19.1 20.2 21.4 22.3 23.3 24.2
26°C 13.2 14.8 16.3 17.7 18.9 20.1 21.3 22.3 23.3 24.3 25.2
27°C 14.1 15.7 17.2 18.6 19.8 21.1 22.2 23.3 24.3 25.2 26.1
28°C 15.0 16.6 18.1 19.4 20.9 22.1 23.2 24.3 25.3 26.2 27.2
29°C 15.9 17.6 19.0 20.5 21.8 23.0 24.2 25.2 26.2 27.3 28.2
30°C 16.8 18.4 20.0 21.4 23.7 23.9 25.1 26.1 27.2 28.2 29.1
32°C 18.6 20.3 21.9 23.3 24.7 25.8 27.1 28.2 29.2 30.2 31.2
34°C 20.4 22.2 23.8 25.2 26.5 27.9 28.9 30.1 31.2 32.1 33.1
36°C 22.2 24.1 25.5 27.0 28.4 29.7 30.9 32.0 33.1 34.2 35.1
38°C 24.0 25.7 27.4 28.9 30.3 31.6 32.8 34.0 35.0 36.1 37.0
40°C 25.8 27.7 29.2 30.8 32.2 33.5 34.7 35.9 37.0 38.1 39.1
45°C 30.3 32.2 33.9 35.4 36.9 38.2 39.5 40.7 41.9 43.0 44.0
50°C 34.8 36.6 38.5 40.1 41.6 43.0 44.3 45.6 46.8 47.9 49.0
(1) Values are rounded off.
The condensation point tables indicates when condensation will occur at different surface temperatures, and
depending on the air temperature and relative humidity.
Example: At an air temperature of 20°C and a relative humidity of 70%, the condensation point will be
reached when the object temperature is 14.40°C.
Our recommendation: Make sure that you choose an operating temperature (cool water temperature) that is
high enough so that there is no chance of condensation even when there are changes in the surrounding
temperature or air humidity. You may need to temper the effect of the coolant water if you are in doubt.
The information is provided here to the best of our knowledge but is not legally binding for any third parties.
The purchase still has an obligation to check the information himself. The user is responsible whenever the
equipment is used at temperatures above the condensation point.