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USER’S MANUAL

Gocator 2000 & 2300 Series

Version 3.5.2.143 Revision: B

2Gocator 2000 & 2300 Series

Proprietary

This document, submitted in confidence, contains proprietary information which shall not be reproduced or transferred to other documents or disclosed to others or used for manufacturing or any other purpose without prior written permission of LMI Technologies Inc.

No part of this publication may be copied, photocopied, reproduced, transmitted, transcribed, or reduced to any electronic medium or machine readable form without prior written consent of LMI Technologies, Inc.

Trademarks and Restrictions

Gocator™ is a registered trademark of LMI Technologies, Inc. Any other company or product names mentioned herein may be trademarks of their respective owners.

Information contained within this manual is subject to change.

This product is designated for use solely as a component and as such it does not comply with the standards relating to laser products specified in U.S. FDA CFR Title 21 Part 1040.

Contact Information

For more information, please contact LMI Technologies.

LMI Technologies, Inc. 1673 Cliveden Ave. Delta, BC V3M 6V5 Canada

Telephone: +1 604 636 1011 Facsimile: +1 604 516 8368

www.lmi3D.com

3Gocator 2000 & 2300 Series

Introduction

The Gocator 2000 and 2300 series of laser profiling sensors are designed for 3D measurement and control applications. Gocator sensors are configured using a web browser and can be connected to a variety of input and output devices. This guide describes the installation and use of Gocator sensors.

Notational Conventions

This guide uses the following notational conventions:

Warning Follow these safety guidelines to avoid potential injury or property damage.

Note Consider this information in order to make best use of the product.

4Gocator 2000 & 2300 Series

Introduction 3 Table of Contents 4

Safety and Maintenance 9

Laser Safety 9

Laser Classes 10 Precautions and Responsibilities 11 Class 3B Responsibilities 11

Systems Sold or Used in the USA 12 Electrical Safety 13 Environment and Lighting 14 Sensor Maintenance 14

Getting Started 16

System Overview 16

Standalone System 16

Dual Sensor System 18

Multi-Sensor System 20 Hardware 21

Gocator 2000 Sensor 21

Gocator 2300 Sensor 22

Master 100 23

Master 200 24

Master 400/800 25

Master 1200/2400 26

Gocator 2000 Cordsets 27

Gocator 2300 Cordsets 27

Calibration Targets 28 Installation 29

Grounding - Gocator 29

Grounding - Master 400/800/1200/2400 29

Mounting 30

Orientations 31 Software 33

User Interface Overview 33

Connecting to a New Sensor 34 Running for the First Time 36

Running a Standalone Sensor System 36

Running a Dual Sensor System 38 Next Steps 42

Setup and Calibration 43

Setup Page 43

Table of Contents

Operation Modes 45 Data Viewer 46

Video Mode 46 Profile and Raw Mode 47 Whole Part 48 Region Definition 50 Data Viewer Controls 50 Height Map Color Scale 51

Profile Output 52

Coordinate Systems 52

Resampled And Raw Profile Format 53 Intensity Output 54 Trigger 55

Examples 57

Settings 59 Active Area 60

Tracking Window 61 Exposure 63

Single Exposure 64

Dynamic Exposure 65

Multiple Exposures 66 Resolutions 67

X Resolution 67

Z Resolution 68 Transformations 69 Dual Sensor System Layout 70

Overlap 71

Reverse 71 Calibration 72

Calibration States 72

Alignment vs. Travel Calibration 72

Alignment Calibration 73

Travel Calibration 74

Clearing Calibration 75 Filters 76

X Resampling Interval 77

Gap Filling 78

Smoothing 79 Part Detection 80

Measurement 82

Measurement Page 82 Adding and Removing Measurements 83 Changing the Measurement Name 84 Profile Sources 86 Decisions 87 Output Filters 88 Profile Fixturing 89

5Gocator 2000 & 2300 Series

Script Measurement 91

Built-in Functions 91

Profile Measurement Tools 95

Feature Points 102 Fit Lines 104 Measurement Types 105

Width 105 Height 106 Distance 107 Position X 108 Position Z 109 Center X 110 Center Z 111 Angle X 112 Intersect X 113 Intersect Z 114 Intersect Angle 115 Intersect Area 116 Box Area 117 Difference Area 118 Difference Peak 119 Circle Radius 120 Circle X 121 Circle Z 122 Line Standard Deviation 123 Line Error Min 124 Line Error Max 125 Line Percentile 126 Gap 127 Flush 132 Gap and Flush Algorithm 136 Groove Width 138 Groove X 140 Groove Z 142 Groove Algorithm 144 Strip Width 146 Strip Height 149 Strip X 152 Strip Z 155 Strip Detection Algorithm 158 Script 162

Whole Part Measurement Tools 163

Measurement Types 167

Area 167 Volume 168 Centroid X 169 Centroid Y 170

Centroid Z 171

Height 172

Ellipse Angle 173

Ellipse Minor 174

Ellipse Major 175

Ellipse Ratio 176

Bounding Box X 177

Bounding Box Y 178

Bounding Box Width 179

Bounding Box Length 180

Script 181

Output 182

Output Page 182 Ethernet Control and Output 183 Digital Outputs 187 Analog Output 190

Toolbar 193

Saving and Loading Settings 194 Managing Multiple Settings 196 Recording and Playback 197 Downloading, Exporting and Uploading Recorded Data 198 Converting Recorded Data To Different Formats 200

Dashboard 201

Dashboard Page 201 State and Health Information 202 Metric Panel 204

Connection and Maintenance 205

Connection Page 205 Network Settings 206 Auto Starting Sensors 207 Overheat Temperature Protection 207 Buddy Assignment 208 Security 209 File Management 210 Maintenance 211 Firmware Upgrade 212

6Gocator 2000 & 2300 Series

Recovery 213

Sensor Recovery Tool 213

Gocator Configuration File 214

Setup 214 Profile 219 Part 240 Output 247

Calibration File 251

SysCal 252

Gocator Protocol 253

Concepts 254

Discovery 254 Command Channels 254 Result Channels 254 Modes 255 Buddy Communication Channels 255 States 255 Versions and Upgrades 255 Data Types 256 Profile Sources 256 Status Codes 256 Command and Reply Formats 257 Result Format 258

Discovery Commands 259

Get Address 259 Set Address 260

Upgrade Commands 261

Get Protocol Version 261 Start Upgrade 261 Get Upgrade Status 261 Get Upgrade Log 262

Control Commands 263

Get Protocol Version 263 Get System Info 263 Log In/Out 264 Change Password 265 Change Buddy 265 Get File List 265 Copy File 266 Read File 266 Write File 266 Delete File 267 Get Default File 267 Set Default File 268 Get Loaded File 268 Get Mode 268 Set Mode 269

Get Time 269

Get Encoder 269

Start 270

Scheduled Start 270

Stop 270

Trigger 271

Scheduled Digital Output 271

Scheduled Analog Output 272

Ping 272

Reset 272

Backup 273

Restore 273

Restore Factory 273

Set Connection Type 274

Get Connection Type 274

Clear Calibration 275 Data Results 276

Video 276

Profile 276

Profile Intensity 277

Part Profile 277

Part Intensity 278

Alignment Calibration 278

Travel Calibration 278

Exposure Calibration 279

Measurement 280 Health Results 282

Modbus TCP Protocol 284

Concepts 284 Messages 285 Registers 287

Control Registers 287

Output Registers 288

Measurement Registers 289

EtherNet/IP 290

Concept 290 Basic Object 291

Identity Object (Class 0x01) 291

TCP/IP Object (Class 0xF5) 291

Ethernet Link Object (Class 0xF6) 292 Assembly Object (Class 0x04) 293

Command Object 293

Sensor State Assembly Object 294

Sample State Assembly 295

7Gocator 2000 & 2300 Series

ASCII Protocol 296

Ethernet Communication 296 Asynchronous and Polling Operation 296 Serial Communication 296 Command and Reply Format 297 Special Characters 297 Standard Result Format 297 Custom Result Format 298

Control Commands 299

Start 299 Stop 299 Trigger 299 Load Configuration 300 Stamp 300 Alignment Calibration 301 Travel Calibration 301 Clear Calibration 301

Data Commands 302

Get Result 302 Get Value 302 Get Decision 303

Health Commands 304

Get Health 304

Software Development Kit 305

GenTL Driver 306

16-bit RGB Image 307 16-bit Grey Scale Image 308 Registers 310

Setting XML File 311

Troubleshooting 312

Mechanical/Environmental 312 Connection 312 Laser Profiling 312 Performance 313

Specification 314

Gocator 2000 Series 314

Gocator 2020 315 Gocator 2030 316 Gocator 2040 318 Gocator 2050 320

Gocator 2070 322

Gocator 2080 324 Gocator 2300 Series 326

Gocator 2330 327

Gocator 2340 329

Gocator 2350 331

Gocator 2370 333

Gocator 2380 335 Gocator 2000 I/O Connector 337

Grounding Shield 337

Power 337

Laser Safety Input 338

Digital Outputs 339

Digital Inputs 340

Encoder Input 341

Serial Output 341

Analog Output 342 Gocator 2300 Power/LAN Connector 343

Grounding Shield 343

Power 343

Laser Safety Input 344 Gocator 2300 I/O Connector 345

Grounding Shield 345

Digital Outputs 346

Digital Inputs 347

Encoder Input 347

Serial Output 348

Analog Output 349 Master 100 350

Master 100 Dimensions 351 Master 200 352

Master 200 Dimensions 354 Master 400/800 355

Master 400/800 Electrical Specifications 356

Master 400/800 Dimensions 357 Master 1200/2400 358

Master 1200/2400 Electrical Specifications 359

Master 1200/2400 Dimensions 359

Parts and Accessories 360

Warranty and Return Policy 363

Warranty Policy 363 Return Policy 363

8Gocator 2000 & 2300 Series

Software Licenses 364

Support 368

9Gocator 2000 & 2300 Series

Safety and Maintenance

Laser Safety

Gocator sensors contain semiconductor lasers that emit visible or invisible light and are designated as Class 2M, Class 3R, or Class 3B, depending on the chosen laser option.

Gocator sensors are referred to as components, indicating that they are sold only to qualified customers for incorporation into their own equipment. These sensors do not incorporate safety items that the customer may be required to provide in their own equipment (e.g. remote interlocks, key control. Refer to references for detail information). As such, these sensors do not fully comply with the standards relating to laser products specified in IEC 60825-1 and FDA CFR Title 21 Part 1040.

Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure.

References

1. International standard IEC 60825-1 (2001-08) consolidated edition, Safety of laser products – Part 1: Equipment classification, requirements and user’s guide.

2. Technical report 60825-10, Safety of laser products – Part 10. Application guidelines and explanatory notes to IEC 60825-1.

3. Laser Notice No. 50, FDA and CDRH http://www.fda.gov/cdrh/rad-health.html

LASER

SENSOR

WARNING: DO NOT LOOK DIRECTLY

INTO THE LASER BEAM

LASER

Safety and Maintenance • 10Gocator 2000 & 2300 Series

Laser Classes

Class 2M laser components

Class 2M laser components would not cause permanent damage to the eye under reasonably foreseeable conditions of operation, provided that any exposure can be terminated by the blink reflex (assumed to take

0.25 seconds). Because classification assumes the blink reflex, the wavelength of light must be in the visible range (400 nm to 700 nm). The Maximum Permissible Exposure (MPE) for visible radiation for 0.25 seconds is 25 watts per square meter, which is equivalent to 1 mW entering an aperture of 7 mm diameter (the assumed size of the pupil).

IEC 60825-1:2007

LASER RADIATION

DO NOT STARE INTO THE BEAM

OR VIEW DIRECTLY WITH OPTICAL

INSTRUMENTS OR MAGNIFIERS

CLASS 2M LASER PRODUCT

PEAK POWER: EMITTED WAVELENGTH:

This product is designated for use solely as a component and as such it does not fully comply with the standards relating to laser products specified in U.S. FDA CFR Title 21 part 1040 and IEC 60825-1

1 mW

660 nm

Class 3R laser components

Class 3R laser products emit radiation where direct intrabeam viewing is potentially hazardous, but the risk is lower with 3R lasers than for 3B lasers. Fewer manufacturing requirements and control measures for 3R laser users apply than for 3B lasers.

IEC 60825-1:2007

LASER RADIATION

AVOID DIRECT EYE EXPOSURE

CLASS 3R LASER PRODUCT

PEAK POWER: EMITTED WAVELENGTH:

5 mW

660 nm

Class 3B laser components

Class 3B components are unsafe for eye exposure. Usually only ocular protection will be required. Diffuse reflections are safe if viewed for less than 10 seconds.

IEC 60825-1:2007

LASER RADIATION

AVOID EXPOSURE TO THE BEAM

CLASS 3B LASER PRODUCT

PEAK POWER: EMITTED WAVELENGTH:

130 mW

660 nm

IEC 60825-1:2007

LASER RADIATION

AVOID EXPOSURE TO THE BEAM

CLASS 3B LASER PRODUCT

PEAK POWER: EMITTED WAVELENGTH:

450 mW

808 nm

Labels reprinted here are examples only. For accurate specifications, refer to the label on your sensor.

Safety and Maintenance • 11Gocator 2000 & 2300 Series

Precautions and Responsibilities

Precautions specified in IEC 60825-1 and FDA CFR Title 21 Part 1040 are as follows:

Requirement Class 2M Class 3R Class 3B

Remote interlock Not required Not required Required*

Key control Not required Not required Required – cannot remove

key when in use*

Power-on delays Not required Not required Required*

Beam attenuator Not required Not required Required*

Emission indicator Not required Not required Required*

Warning signs Not required Not required Required*

Beam path Not required Terminate beam at useful

length

Terminate beam at useful length

Specular reflection Not required Prevent unintentional

reflections

Prevent unintentional reflections

Eye protection Not required Not required Required under special

conditions

Laser safety officer Not required Not required Required

Training Not required Required for operator and

maintenance personnel

Required for operator and maintenance personnel

*LMI Class 3B laser components do not incorporate these laser safety items. These items must be added and completed by the customer in their system design.

Class 3B Responsibilities

LMI Technologies has filed reports with the FDA to assist customers in achieving certification of laser products. These reports can be referenced by an accession number, provided upon request. Detailed descriptions of the safety items that must be added to the system design are listed below.

Remote Interlock

A remote interlock connection must be present in Class 3B laser systems. This permits remote switches to be attached in serial with the keylock switch on the controls. The deactivation of any remote switches must prevent power from being supplied to any lasers.

Key Control

A key operated master control to the lasers is required that prevents any power from being supplied to the lasers while in the OFF position. The key can be removed in the OFF position but the switch must not allow the key to be removed from the lock while in the ON position.

Power-On Delays

A delay circuit is required that illuminates warning indicators for a short period of time prior to supplying power to the lasers.

Beam Attenuators

A permanently attached method of preventing human access to laser radiation other than switches, power connectors or key control must be employed. On some LMI laser sensors, the beam attenuator is supplied with the sensor as an integrated mechanical shutter.

Emission Indicator

It is required that the controls that operate the sensors incorporate a visible or audible indicator when power is applied and the lasers are operating. If the distance between the sensor and controls is more than 2 meters, or mounting of sensors intervenes with observation of these indicators, then a second

Safety and Maintenance • 12Gocator 2000 & 2300 Series

power-on indicator should be mounted at some readily-observable position. When mounting the warning indicators, it is important not to mount them in a location that would require human exposure to the laser emissions. User must ensure that the emission indicator, if supplied by OEM, is visible when viewed through protective eyewear.

Warning Signs

Laser warning signs must be located in the vicinity of the sensor such that they will be readily observed. Examples of laser warning signs are as follows:

PEAK POWER WAVELENGTH

100mW 600-780nm

CLASS IIIb LASER PRODUCT

INVISIBLE AND/OR VISIBLE LASER RADIATION

AVOID DIRECT EXPOSURE TO BEAM

DANGER

FDA warning sign example

IEC 60825-1:2007

CAUTION

AVOID EXPOSURE

TO THE BEAM

CLASS 3B LASER LIGHT

IEC warning sign example

Systems Sold or Used in the USA

Systems that incorporate laser components or laser products manufactured by LMI Technologies require certification by the FDA.

Customers are responsible for achieving and maintaining this certification.

Customers are advised to obtain the information booklet Regulations for the Administration and Enforcement of the Radiation Control for Health and Safety Act of 1968: HHS Publication FDA 88-8035.

This publication, containing the full details of laser safety requirements, can be obtained directly from the FDA, or downloaded from their web site at http://www.fda.gov/cdrh.

Safety and Maintenance • 13Gocator 2000 & 2300 Series

Electrical Safety

Sensors should be connected to earth ground

All sensors should be connected to earth ground through their housing. All sensors should be mounted on an earth grounded frame using electrically conductive hardware to ensure the housing of the sensor is connected to earth ground. Use a multi-meter to check the continuity between the sensor connector and earth ground to ensure a proper connection.

Minimize voltage potential between system ground and sensor ground

Care should be taken to minimize the voltage potential between system ground (ground reference for I/O signals) and sensor ground. This voltage potential can be determined by measuring the voltage between Analog_out- and system ground. The maximum permissible voltage potential is 12 V but should be kept below 10 V to avoid damage to the serial and encoder connections. Refer to Gocator 2000 I/O Connector (page 337) and Gocator 2300 I/O Connector (page 345) for a description of connector pins.

Use a suitable power supply

The +24 to +48 VDC power supply used with Gocator sensors should be an isolated supply with inrush current protection or be able to handle a high capacitive load.

Use care when handling powered devices

Wires connecting to the sensor should not be handled while the sensor is powered. Doing so may cause electrical shock to the user or damage to the equipment.

Failure to adhere to the guidelines described in this section may result in electrical shock or equipment damage.

Safety and Maintenance • 14Gocator 2000 & 2300 Series

Environment and Lighting

Avoid strong ambient light sources

The imager used in this product is highly sensitive to ambient light hence stray light may have adverse effects on measurement. Do not operate this device near windows or lighting fixtures that could influence measurement. If the unit must be installed in an environment with high ambient light levels, a lighting shield or similar device may need to be installed to prevent light from affecting measurement.

Avoid installing sensors in hazardous environments

To ensure reliable operation and to prevent damage to Gocator sensors, avoid installing the sensor in locations;

• that are humid, dusty, or poorly ventilated

• with a high temperature, such as places exposed to direct sunlight

• where there are flammable or corrosive gases

• where the unit may be directly subjected to harsh vibration or impact

• where water, oil, or chemicals may splash onto the unit

• where static electricity is easily generated

Ensure that ambient conditions are within specifications

Gocator sensors are suitable for operation between 0 – 50 °C and 25 – 85% relative humidity (noncondensing). Measurement error due to temperature is limited to 0.015% of full scale per degree C.

The Master 200/400/800/1200/2400 is similarly rated for operation between 0 – 50 °C.

The storage temperature is -30 – 70 °C.

It is critical that the sensor is heat sunk through the frame it is mounted to. When a sensor is properly heat sunk, the difference between ambient temperature and the temperature reported in the sensor's health

channel is less than 15 °C.

Gocator sensors are high accuracy devices. It is critical that the temperature of all of its components are in equilibrium. When the sensor is powered up, a warm-up time of at least one hour is required in order to reach a consistent spread of temperature within the sensor.

Sensor Maintenance

Keep sensor windows clean

Gocator sensors are high-precision optical instruments. To ensure the highest accuracy is achieved in all measurements, the windows on the front of the sensor should be kept clean and clear of debris.

Use care when cleaning sensor windows

Use dry, clean air to remove dust or other dirt particles. If dirt remains, clean the windows carefully with a soft, lint-free cloth and non-streaking glass cleaner or isopropyl alcohol. Ensure that no residue is left on the windows after cleaning.

Turn off lasers when not in use

LMI Technologies uses semiconductor lasers in 3D measurement sensors. To maximize the lifespan of the sensor, turn off the laser when not in use.

Safety and Maintenance • 15Gocator 2000 & 2300 Series

Avoid excessive modifications to files stored on the sensor

Settings for Gocator sensors are stored in flash memory inside the sensor. Flash memory has an expected lifetime of 100,000 writes. To maximize lifetime, avoid frequent or unnecessary file save operations.

16Gocator 2000 & 2300 Series

System Overview

Gocator sensors can be installed and used in a variety of scenarios. Sensors can be connected as standalone devices, dual sensor (Main and Buddy) system, or multi-sensor system.

Standalone System

Standalone systems are typically used when only a single Gocator sensor is required. The sensor can be connected to a computer’s Ethernet port for setup and can also be connected to devices such as encoders, photocells, or PLCs.

GOCATOR I/O CORDSET

ETHERNET CORDSET

USER PC (can be disconnected after setup)

GOCATOR

CONNECT POWER AND I/O AS REQUIRED BY APPLICATION

IN - ENCODER / TRIGGER / SAFETY OUT - SERIAL / ANALOG / DIGITAL

GOCATOR 2000 SERIES

Getting Started

Getting Started • 17Gocator 2000 & 2300 Series

GOCATOR I/O CORDSET

POWER & ETHERNET CORDSET

USER PC (can be disconnected after setup)

POWER: 24-48VDC @ 13W

LASER SAFETY: +24-48VDC TO ENABLE

WIRE RICH I/O

AS REQUIRED BY APPLICATION

IN - ENCODER / TRIGGER

OUT - SERIAL / ANALOG / DIGITAL

GOCATOR

GOCATOR 2300 SERIES

Getting Started • 18Gocator 2000 & 2300 Series

Dual Sensor System

In a dual sensor system, two Gocator sensors work together to perform profiling and output the combined results. The controlling sensor is referred to as the Main sensor, and the helper is referred to as the Buddy sensor. Gocator’s software recognizes three installation orientations – None, Opposite and Wide.

For the Gocator 2000 series sensors, the Master 200 must be used to connect two sensors in a Dual Sensor (Buddy) system. Gocator 20x0 I/O cordsets are used to connect sensors to the Master 200. The Master 200 provides a single point of connection for system I/O and power. The Master 200 ensures that the scan timing is precisely synchronized across sensors. Sensors and client computers typically communicate via an Ethernet switch (minimum 100 Mbit/s).

MASTER 200

CAT5E ETHERNET CABLE

GOCATOR I/O CORDSET

ETHERNET CORDSET

ETHERNET SWITCH (NOT SUPPLIED (BY LMI)

USER PC

MAIN GOCATOR

BUDDY GOCATOR

CONNECT I/O AS REQUIRED BY APPLICATION

IN - ENCODER / TRIGGER / SAFETY OUT - SERIAL / ANALOG / DIGITAL

GOCATOR 2000 SERIES

For the Gocator 2300 series sensors, a Master 400/800/1200/2400 must be used to connect two sensors in a Dual Sensor (Buddy) system. Gocator 23x0 Master cordsets are used to connect sensors to the Master.

Getting Started • 19Gocator 2000 & 2300 Series

GOCATOR I/O CORDSET

GOCATOR POWER AND ETHERNET CORDSET

POWER, LASER SAFETY,

TRIGGER INPUTS, ENCODER

MAIN GOCATOR

BUDDY GOCATOR

GOCATOR 2300 SERIES

GIGABIT ETHERNET SWITCH

MASTER 400/800/1200/2400

Getting Started • 20Gocator 2000 & 2300 Series

Multi-Sensor System

Master 400/800/1200/2400 networking hardware can be used to connect two or more sensors into a Multi-sensor system. Gocator Master cordsets are used to connect the sensors to a Master. The Master provides a single point of connection for power, safety, encoder and digital inputs. A Master 400/800/1200/2400 can be used to ensure that the scan timing is precisely synchronized across sensors. Sensors and client computers communicate via an Ethernet switch (minimum 100 Mbit/s).

Unlike the Master 200, Master 400/800/1200/2400 does not support digital, serial or analog output.

MASTER 400/800/1200/2400

USER PC

GIGABIT ETHERNET SWITCH

CAT5E ETHERNET CABLE

ETHERNET CORDSET

GOCATOR 2000 SERIES

POWER, LASER SAFETY, TRIGGER INPUTS, ENCODER

GOCATOR

MASTER 400/800/1200/2400

USER PC

GIGABIT ETHERNET SWITCH

CAT5E ETHERNET CABLE

GOCATOR POWER AND ETHERNET TO MASTER CORDSET

GOCATOR 2300 SERIES

POWER, LASER SAFETY,

TRIGGER INPUTS, ENCODER

GOCATOR

Getting Started • 21Gocator 2000 & 2300 Series

Hardware

Gocator 2000 Sensor

CAMERA

LASER EMITTER

LAN CONNECTOR

I/O CONNECTOR

SERIAL NUMBER

POWER, RANGE, LASER

INDICATORS

Item Description

Camera Observes laser light reflected from target surfaces.

Laser Emitter Emits structured light for laser profiling.

I/O Connector Accepts power and input/output signals.

LAN Connector Connects to 100 Mbit/s Ethernet network.

Power Indicator Illuminates when power is applied (blue).

Range Indicator Illuminates when camera detects laser light and is within the target range (green).

Laser Indicator Illuminates when laser safety input is active (amber).

Serial Number Unique sensor serial number.

Getting Started • 22Gocator 2000 & 2300 Series

Gocator 2300 Sensor

CAMERA

LASER EMITTER

LAN CONNECTOR

I/O CONNECTOR

POWER/LAN CONNECTOR

SERIAL NUMBER

POWER, RANGE, LASER

INDICATORS

Item Description

Camera Observes laser light reflected from target surfaces.

Laser Emitter Emits structured light for laser profiling.

I/O Connector Accepts input and output signals.

Power / LAN Connector Accepts power and laser safety signals and connects to 1000 Mbit/s Ethernet network.

Power Indicator Illuminates when power is applied (blue).

Range Indicator Illuminates when camera detects laser light and is within the target range (green).

Laser Indicator Illuminates when laser safety input is active (amber).

Serial Number Unique sensor serial number.

Getting Started • 23Gocator 2000 & 2300 Series

Master 100

The Master 100 is used by the Gocator 2300 series for standalone system setup. The Master 100 is designed for development use only.

Sensor IO Port

Master Host Port

Master Power Port

Encoder/Output Port

Master Ethernet Port

48V Power Supply*

(Pin 1)

Item Description

Gocator Power Port Connects to the Gocator Power/LAN connector. Provides power and laser safety to the

Gocator.

Gocator Sensor I/O Port Connects to the Gocator I/O connector.

Laser Safety Switch Toggles laser safety signal provided to the sensors [O= laser off, I= laser on].

Power Switch Toggles sensor power.

Trigger Signals a digital input trigger to the Gocator.

Encoder Accepts encoder A, B and Z signals.

Digital Output Provides digital output.

Power Accepts power (+48 V).

Refer to Master 100 (page 350) for pinout details.

Getting Started • 24Gocator 2000 & 2300 Series

Master 200

The Master 200 supports standalone or dual sensor setup. It is only used by the Gocator 2000 series.

POWER SWITCH

CONNECTION TO SENSOR 1

CONNECTION TO SENSOR 2

LASER SAFETY SWITCH

INPUT/OUTPUT

ENCODER (PORT 1 ONLY)

ENCODER (PORT 1&2)

POWER AND LASER SAFETY

POWER (FOR DEMO USE ONLY*)

Item Description

Connection to Sensor 2 Gocator I/O connection for Sensor 2 (Buddy sensor).

Connection to Sensor 1 Gocator I/O connection for Sensor 1 (Main sensor).

Laser Safety Switch Toggles laser safety signal provided to the sensors [O= laser off, I= laser on].

Power Switch Toggles sensor power.

Input/Output Accepts digital input and provides digital output, serial output, and analog output.

Encoder (Port 1 only) Accepts encoder for Standalone sensor operation (Main sensor only).

Encoder (Port 1 & 2) Accepts encoder for Dual Sensor operation (Main and Buddy sensors).

Power and Laser Safety Accepts power (+24 to +48 V at 10 Watts) and laser safety inputs.

Refer to Master 200 (page 352) for pinout details.

Getting Started • 25Gocator 2000 & 2300 Series

Master 400/800

SENSOR PORTS 5-8

SENSOR PORTS 1-4

LED INDICATORS

MASTER 400 FRONT

MASTER 400/800 REAR

POWER AND SAFETY

ENCODER

INPUT

SENSOR PORTS 1-4

LED INDICATORS

Item Description

Sensor Ports Master connection for Gocator sensors (no specific order required).

Ground Connection Earth ground connection point.

Laser Safety Laser safety connection.

Encoder Accepts encoder signal.

Input Accepts digital input.

Refer to Master 400/800 (page 355) for pinout details.

Getting Started • 26Gocator 2000 & 2300 Series

Master 1200/2400

SENSOR PORTS 13-24 (2400 ONLY)

SENSOR PORTS 1-12

LED INDICATORS

GROUND CONNECTION

POWER AND SAFETY

ENCODER

INPUT

SENSOR PORTS 1-12

LED INDICATORS

MASTER 1200 FRONT

MASTER 2400 FRONT

MASTER 1200/2400 REAR

Item Description

Sensor Ports Master connection for Gocator sensors (no specific order required).

Ground Connection Earth ground connection point.

Laser Safety Laser safety connection.

Encoder Accepts encoder signal.

Input Accepts digital input.

Refer to Master 1200/2400 (page 358) for pinout details.

Getting Started • 27Gocator 2000 & 2300 Series

Gocator 2000 Cordsets

Gocator 2000 sensors use three cordsets. The Ethernet cordset is used for sensor communication via 100 Mbit/s Ethernet with a standard RJ45 connector. The Gocator I/O cordset provides power and laser safety interlock to sensors. It also provides digital I/O connections, an encoder interface, RS-485 serial connection, and an analog output. The Gocator Master cordset provides electrical connection between the sensor and a Master 400/800/1200/2400.

M12 ETHERNET CONNECTOR 4 PIN, D-CODE, MALE

RJ45 8 PIN JACK

CORDSET, GOCATOR, ETHERNET, Xm

M16 I/O CONNECTOR 19 PIN, MALE

PIGTAILED LEADS

CORDSET, GOCATOR I/O, Xm

RJ45 8 PIN JACK

M16 I/O CONNECTOR 19 PIN, MALE

CORDSET, GOCATOR, MASTER, Xm

The maximum cordset length is 60m. Refer to Gocator 2000 I/O Connector (page 337) for pinout details. Refer to Parts and Accessories (page 360) for cordset lengths and part numbers. Contact LMI for information on creating cordsets with customized length and connector orientation.

Gocator 2300 Cordsets

Gocator 2300 sensors use two types of cordsets. The Power & Ethernet cordset provides power, laser safety locklock to the sensor. It is also used for sensor communication via 1000 Mbit/s Ethernet with a standard RJ45 connector. The Gocator I/O cordset provides digital I/O connections, an encoder interface, RS-485 serial connection, and an analog output. The Master version of the Power & Ethernet cordset provides direct connection between the sensor and a Master 400/800/1200/2400.

M16 I/O CONNECTOR 19 PIN, MALE

PIGTAILED LEADS

M16 CONNECTOR 14 PIN, FEMALE

PIGTAILED LEADS

CORDSET, GOCATOR I/O, Xm CORDSET, POWER & ETHERNET, Xm CORDSET, GOCATOR POWER & ETHERNET TO MASTER, Xm

RJ45 8 PIN JACK

The maximum cordset length is 60m. Refer to Gocator 2300 I/O Connector (page 345) and Gocator 2300 Power/LAN Connector (page 343) for pinout details. Refer to Parts and Accessories (page 360) for cordset lengths and part numbers. Contact LMI for information on creating cordsets with custom length or connector orientation.

Getting Started • 28Gocator 2000 & 2300 Series

Calibration Targets

Calibration targets are used for alignment calibration or travel calibration.

Calibration disks are typically used with systems containing a single sensor and can be ordered from LMI Technologies. When choosing a disk for your application, select the largest disk that fits entirely within the required field of view. Refer to Parts and Accessories (page 360) for calibration disk part numbers.

100mm DIAMETER DISK

40mm DIAMETER DISK

For wide, multi-sensor systems, calibration bars are required to match the length of the system by following the guidelines illustrated below. (LMI Technologies does not manufacture or sell calibration bars.)

ONE HOLE PER SENSOR, CENTERED IN EACH SENSOR’S FIELD OF VIEW.

DIAMETER MUST BE LARGE ENOUGH FOR HOLE TO BE DETECTED BY SENSOR (DEPENDS ON SENSOR RESOLUTION).

LENGTH OF BAR SHOULD BE GREATER THAN THE COMBINED FIELD OF VIEW OF ALL SENSORS.

HOLE DISTANCE (BETWEEN HOLES’ CENTERS).

Refer to Calibration (page 72) for more information on calibration procedures.

Getting Started • 29Gocator 2000 & 2300 Series

Installation

Grounding - Gocator

Gocators should be grounded to the earth/chassis through their housings and through the grounding shield of the Power I/O cordset. Gocator sensors have been designed to provide adequate grounding through the use of M5 x 0.8 pitch mounting screws. Always check grounding with a multi-meter to ensure electrical continuity between the mounting frame and the Gocator's connectors.

It is imperative that the frame or electrical cabinet that the Gocator is mounted to is connected to earth ground.

Grounding - Master 400/800/1200/2400

The mounting brackets of all Masters have been designed to provide adequate grounding through the use of star washers. Always check grounding with a multi-meter by ensuring electrical continuity between the mounting frame and RJ45 connectors on the front.

It is imperative that the frame or electrical cabinet that the Master is mounted to is connected to earth ground.

Getting Started • 30Gocator 2000 & 2300 Series

Mounting

Sensors should be mounted using four M5 x 0.8 pitch screws of suitable length. The recommended thread engagement into the housing is 8 - 10 mm. Proper care should be taken in order to ensure that the internal threads are not damaged from cross-threading or improper insertion of screws.

Sensors should not be installed near objects that might occlude a camera’s view of the laser.

Sensors should not be installed near surfaces that might create unanticipated laser reflections.

channel is less than 15 °C.

Getting Started • 31Gocator 2000 & 2300 Series

Orientations

The examples below illustrate the possible mounting orientations for standalone and dual sensor system.

For more information on orientations, refer to Dual Sensor System Layout (page 70).

Single Sensor Orientations:

Single sensor above conveyor

Single sensor on robot arm

Getting Started • 32Gocator 2000 & 2300 Series

Dual Sensor System Orientations:

Side-by-side for wide-area measurement (Wide)

Main

Buddy

Main must be on the left side (when looking into the

connector) of the Buddy (Wide)

Above/below for two-sided measurement (Opposite)

Main

Buddy

Main must be on the top with Buddy on the bottom

(Opposite)

Getting Started • 33Gocator 2000 & 2300 Series

Software

User Interface Overview

Gocator sensors are configured by connecting to a Main sensor with a web browser. The Gocator web interface is illustrated below.

1 2 3 4 5 6

Element Description

1 Connection Page For network configuration and maintenance.

2 Setup Page For configuring settings such as trigger source and exposure, and to perform

calibration steps.

3 Measurement Page For configuring measurements.

4 Output Page For configuring measurement result outputs to external devices.

5 Dashboard Page For viewing performance statistics and results.

6 Metric Panel Summarizes important performance statistics.

7 Help Online help resources, including User Manual, Firmware updates, and SDK.

8 Toolbar Controls sensor operation, manages configurations and replays recorded

measurement data.

9 Configuration Area Provides controls to configure profiling and measuring parameters.

10 Data Viewer Displays sensor data, tool setup controls, and measurements.

Getting Started • 34Gocator 2000 & 2300 Series

Connecting to a New Sensor

Sensors are shipped with the following default network configuration:

Setting Default

DHCP Disabled

IP Address 192.168.1.10

Subnet Mask 255.255.255.0

Gateway 0.0.0.0

All Gocator sensors are configured to 192.168.1.10 as the default IP address. For a dual sensor system, the Main and Buddy sensors must be assigned unique addresses before they can be used on the same network. Prior to proceeding, connect the Main and Buddy sensors one at a time (to avoid an address conflict) and use the steps on page 38 to assign each sensor a unique address.

To connect to a sensor for the first time:

1 Connect cables and apply power.

Sensor cabling is illustrated in System Overview (page 16)

GOCATOR I/O CORDSET

ETHERNET CORDSET

USER PC (can be disconnected after setup)

GOCATOR

CONNECT POWER AND I/O AS REQUIRED BY APPLICATION

IN - ENCODER / TRIGGER / SAFETY OUT - SERIAL / ANALOG / DIGITAL

GOCATOR 2000 SERIES

GOCATOR I/O CORDSET

POWER & ETHERNET CORDSET

USER PC (can be disconnected after setup)

POWER: 24-48VDC @ 13W

LASER SAFETY: +24-48VDC TO ENABLE

WIRE RICH I/O

AS REQUIRED BY APPLICATION

IN - ENCODER / TRIGGER

OUT - SERIAL / ANALOG / DIGITAL

GOCATOR

GOCATOR 2300 SERIES

Getting Started • 35Gocator 2000 & 2300 Series

2 Change client network settings.

Windows 7:

» Open the Control Panel and select Network and

Sharing Center, then click Change Adapter Settings.

» Right-click the desired network connection, and

then click Properties.

» On the Networking tab, click Internet Protocol

Version 4 (TCP/IPv4), and then click Properties.

» Select “Use the following IP address” option.

» Enter IP Address “192.168.1.5” and Subnet Mask

“255.255.255.0”, then click OK.

Mac OS X v.10.6:

» Open the Network Pane in System Preferences and

select Ethernet.

» Set Configure to “Manually”.

» Enter IP Address “192.168.1.5” and Subnet Mask

“255.255.255.0”, then click Apply.

3 Enter the sensor's IP address 192.168.1.10 in a

web browser.

Firefox 3.5+, Chrome 4.0+, and Internet Explorer

8.0+ are supported. IMPORTANT! The Adobe Flash browser plug-in, version 10.0+, must be installed.

http://192.168.1.10

4 Select the language

After selecting the language, the browser will refresh and the web interface will display in the selected language.

5 Press the Login button.

The Administrator password is initially blank.

Refer to Troubleshooting (page 312) if you experience any problems while attempting to establish a connection to the sensor.

Getting Started • 36Gocator 2000 & 2300 Series

Running for the First Time

The Gocator is shipped with a default configuration that will produce laser ranges on most targets. The following sections walk through the steps required to setup the sensor(s) to produce laser ranges.

Running a Standalone Sensor System

After the sensor is installed, laser profiling can be exercised to verify basic sensor operation.

To run a sensor for the first time:

1 Power up the sensor.

The power LED (blue) should turn on immediately.

POWER LED

2 Enter the sensor's IP address 192.168.1.10 in a

web browser.

http://192.168.1.10

3 Login as Administrator with no password.

The interface display language can be changed using the language option. After selecting the language, the browser will refresh and the web interface will display in the selected language.

4 Select the Connection Page.

5 Specify the Connect To setting.

The Connect To setting specifies whether the sensor system is standalone, connected to a Master 200 or a Master 400/800/1200/2400. For single sensor operations select Standalone or Master 200.

Getting Started • 37Gocator 2000 & 2300 Series

6 Ensure that the Data Source selector is

showing LIVE.

RECORD

SNAPSHOT

START

DATA SOURCE

7 Ensure that the Laser Safety Switch is enabled

or the Laser Safety input is high.

8 Select the Setup Page.

9 Press the Start button to start the sensor.

The Start button is used to run sensors continuously, while the Snapshot button is used to trigger a single profile.

Master 200

Master 400/800/1200/2400

Safety_in+

5V - 48VDC

Safety_in-

Standalone

10 Move a target into the laser plane.

If a target object is within the sensor’s measurement range, the Data Viewer will display the shape of the target and the sensor’s range indicator LED will illuminate.

If you cannot see the laser, or if a profile is not displayed in the Data Viewer, refer to Troubleshooting (page 312).

11 Press the Stop button.

You should now see the laser turns off.

RECORD

SNAPSHOT

STOP

DATA SOURCE

Getting Started • 38Gocator 2000 & 2300 Series

Running a Dual Sensor System

After the sensors are installed, laser profiling can be exercised to verify basic sensor operation.

If Master 200 is used and an encoder input is required, the encoder signals must be connected to the Encoder (Port 1 & 2). Refer to Master 200 (page 24) for more details.

To run a dual sensor setup for the first time:

1 Turn off the sensors and unplug the Ethernet

network connection of the Main sensor.

All sensors are shipped with a default IP address of

192.168.1.10. Ethernet networks require a unique IP address for each device. Skip step 1 to 3 if the Buddy sensor's IP address is already setup with an unique address.

MAIN

ETHERNET CORDSET

GOCATOR POWER I/O CORDSET

2 Power up the Buddy sensor.

The power LED (blue) of the buddy sensor should turn on immediately.

POWER LED

3 Enter the sensor's IP address 192.168.1.10 in a

web browser.

This will log into the Buddy sensor.

http://192.168.1.10

4 Login as Administrator with no password.

5 Select the Connection Page.

Getting Started • 39Gocator 2000 & 2300 Series

6 Modify the IP address to 192.168.1.11 in the

Network settings and click the Save button.

When you click the Save button, you will be prompted to confirm your selection.

7 Turn off the sensors, re-connect the Main

sensor's Ethernet connection and power-cycle the sensors.

After changing network configuration, the sensors must be reset or power-cycled before the change will take effect.

MAIN

ETHERNET CORDSET

GOCATOR POWER I/O CORDSET

8 Enter the sensor's IP address 192.168.1.10 in a

web browser.

This will log into the Main sensor.

http://192.168.1.10

9 Login as Administrator with no password.

The interface display language can be changed using the language option. After selecting the language, the browser will refresh and the web interface will display in the selected language.

10 Select the Connection Page.

Getting Started • 40Gocator 2000 & 2300 Series

11 Specify the Connect To setting.

The Connect To setting specifies whether the sensor system is standalone, connected to a Master 200 or a Master 400/800/1200/2400. For dual sensor operation select Master 200 or Master 400/800/1200/2400.

12 Go to Connection Page > Available Sensors

panel.

The serial number of the Buddy sensor is listed in the Available Sensors panel.

13 Select the Buddy sensor. Click the Assign

button.

The Buddy sensor will be assigned to the Main sensor and its status will be updated in the System panel

The firmware on Main and Buddy sensors must be the same for Buddy assignment to be successful. If the firmware is different, connect the Main and Buddy sensor one at a time and follow the steps in Firmware Upgrade (page 212) to upgrade the sensors.

14 Ensure that the Data Source selector is

showing LIVE.

RECORD

SNAPSHOT

START

DATA SOURCE

Getting Started • 41Gocator 2000 & 2300 Series

15 Ensure that the Laser Safety Switch is enabled

or the Laser Safety input is high.

16 Select the Setup Page.

17 Press the Start button to start the sensors.

The Start button is used to run sensors continuously, while the Snapshot button is used to trigger a single profile.

Master 200 (for Gocator 2000)

Master 400/800/1200/2400 (for Gocator 2300)

18 Move a target into the laser plane.

If a target object is within the sensor’s measurement range, the Data Viewer will display the shape of the target and the sensor’s Range Indicator LED will illuminate.

Click the Main and Buddy button under the Setup Page to view the profile data from the main and buddy sensor

If you cannot see the laser, or if a profile is not displayed in the Data Viewer, refer to Troubleshooting (page 312).

19 Press the Stop button.

You should now see the lasers turn off.

RECORD

SNAPSHOT

STOP

DATA SOURCE

Getting Started • 42Gocator 2000 & 2300 Series

Next Steps

After completing the steps in this chapter, the Gocator measurement system is ready to be configured for an application using the software interface. The interface is explained in the following chapters:

Setup and Calibration (page 43)

Fine tunes laser profiling for an application.

Measurement (page 82)

Programs measurements on sensors that are equipped with profile tools.

Output (page 182)

Profile data, measurements, and Pass/Fail results can be transmitted to external devices for process control or data analysis.

Toolbar (page 193)

Controls system operation, record and playback data, and manages sensor configurations.

Dashboard (page 201)

Provides real-time monitoring of its health and measurement results.

Connection and Maintenance (page 205)

Setups the sensor connections, networking and performs maintenance tasks.

43Gocator 2000 & 2300 Series

Setup and Calibration

Setup Page

This chapter describes the steps to configure Gocator sensors for laser profiling using the Setup Page. Setup and calibration steps should be performed before programming measurements or outputs.

2 3 4 5 6

Element Description

1 Operation Mode Panel Use the Operation Mode panel to set the current operation mode (Video, Profile, Part

or Raw) and other options.

2 Trigger Panel Use the Trigger panel to specify the trigger source and trigger related settings.

3 Sensor Panel Use the Sensor panel to specify settings for an individual sensor, such as active area

or exposure.

4 Layout Panel Use the Layout panel to configure the dual sensor system and to perform alignment or

travel calibration.

5 Filters Panel Use the Filters panel to specify settings for post processing of the profiles.

6 Part Detection Panel Use the Part Detection panel to set the part detection logic for sorting profiles into

discrete objects.

Setup • 44Gocator 2000 & 2300 Series

Element Description

7 Data Viewer Use the Data Viewer to display sensor data and adjust regions of interest. Depending

on the current operation mode, the data viewer can display video images, profile plots or part views.

The following table provides quick references for specific goals that users could achieve from the panels in the setup page.

Goal References

1 Select a trigger source that is appropriate for the application. Trigger (page 55)

2 Ensure that camera exposure is appropriate for laser profiling. Exposure (page 63)

3 Find the right balance between profile quality, speed, and CPU

utilization.

Active Area (page 60) Exposure (page 63) Resolutions (page 67)

4 Specify mounting orientations for dual sensor systems. Dual Sensor System Layout (page

70)

5 Calibrate the system so that laser profile data can be aligned to a

common reference and values can be correctly scaled in the axis of motion.

Alignment Calibration (page 73)

Travel Calibration (page 74)

6 Specify smoothing, gap-filling and resampling parameters to remove

effects of occlusions.

Filters (page 76)

7 Setup the part detection logic to sort profiles into discrete objects. Part Detection (page 80)

Setup • 45Gocator 2000 & 2300 Series

Operation Modes

The Gocator web interface supports four operation modes: Video, Profile, Raw and Whole Part. The operation mode can be selected in the Operation Mode panel.

Mode and Option Description

Video Output video images from the Gocator. This mode is useful for configuring exposure

time and troubleshooting stray light or ambient light problems.

Profile Output profiles and perform profile measurements. Video images are processed

internally to produce laser profiles and cross-sectional measurements.

Whole Part Output 3D point clouds and perform part measurements. Laser profiles are sorted

into discrete parts. The parts are then processed internally to produce measurements . "Whole Part" is often referred to as "Part" in the Gocator web interface and in this document.

Raw Output profiles. In Raw Mode, video images are processed internally by the sensor

to produce laser profiles. Use this mode to extract unprocessed ranges from the Gocator at the highest possible rate. Post-profiling processing and measurements are disabled.

Acquire Intensity When enabled, an intensity value will be produced for each laser profile point.

Setup • 46Gocator 2000 & 2300 Series

Data Viewer

The Data Viewer can display video images, profile plots, intensity images and height maps. It is also used to configure active area and measurement tools. Its use is dependent on the current operation mode and the panel selection.

Video Mode

The Data Viewer displays camera images. In a dual sensor system, camera images from the Main or the Buddy sensor can be displayed.

To select the view of the display:

1 Navigate to the Setup Page.

2 Select the View.

Select the Main or the Buddy sensor from the drop-down list at the top of the Data Viewer.

Setup • 47Gocator 2000 & 2300 Series

Profile and Raw Mode

In Profile and Raw mode, the Data Viewer displays profile plots.

In a dual sensor system, profiles from individual sensors or from a combined view can be displayed. While in the Setup Page, selecting a panel (e.g. Sensor Panel or Layout Panel) will automatically set the display to the most appropriate display view.

To manually select the display view in the Setup Page:

1 Navigate to the Setup Page.

2 Select the View.

An individual sensor or the combined view can be selected from the drop-down list at the top of the Data Viewer.

In the Measurement Page, the view of the display is set to the Profile Source of the selected measurement tool (page 86).

Setup • 48Gocator 2000 & 2300 Series

Whole Part

In addition to displaying profiles, the Data Viewer can display height maps and intensity images of the detected objects. Users select the data to display from the View option.

Users can use the 3D button to view Whole Part data in 3D viewer. The 3D model is overlaid with the information selected in the View option.

View Option

View Option Information

Profile Only available in 2D view. Plots the last collected profile.

Heightmap In 2D view, displays the pseudo color height map.

In 3D view, overlays the 2D pseudo-color map ion the 3D model.

Uniform Only available in 3D view. Overlays a uniform shaded surface on the 3D model.

Intensity In 2D view, display the intensity.

In 3D view, overlays the intensity map on the 3D model.

Choosing the Profile view option will switch the data viewer out of the 3D viewer and display the profile plot.

2D viewer for height map 2D viewer for intensity

Setup • 49Gocator 2000 & 2300 Series

3D viewer with height map overlay 3D viewer dwith intensity overlay

3D data viewer with uniform overlay

Users can toggle between 2D and 3D viewer by clicking on the 3D button. Refer to Data Viewer Controls (page 50) for explanations on the available controls.

In a dual sensor system, data from individual sensors or from a combined view can be selected. While in the Setup Page, selecting a panel (e.g. Sensor Panel, Layout Panel or Part Detection panel) will automatically set the display to the most appropriate display type and display view.

To manually select the display type and the display view in the Setup Page:

1 Navigate to the Sensor Page.

2 Select the View.

Profile, Height map, uniform and Intensity can be selected from the left drop-down list. An individual sensor or the combined view can be selected from the right drop-down list.

Setup • 50Gocator 2000 & 2300 Series

Region Definition

The Data Viewer can also be used to define a region of interest.

To setup a region of interest:

1 Move the mouse cursor to the rectangle.

The rectangle is automatically displayed when a setup or measurement requires an area to be specified.

2 Drag the rectangle to move it, and use the handles on the rectangle’s border to resize it.

Data Viewer Controls

The data viewer is controlled by mouse clicks and by the buttons on the display tool bar. The mouse wheel can be also be used for zooming in and out.

Press 'F' when the cursor is in the data viewer to change into full screen.

1:1 Aspect Ratio Reset Zoom

Scaling Setting

Toggle 3D Mesh

Pan

Zoom in / out

Setup • 51Gocator 2000 & 2300 Series

Height Map Color Scale

Height maps are displayed in pseudo-color; the height (Z) axis is color coded. The scaling of the colors to the height values can be adjusted.

To change the scaling of the height map:

1 Select Height Map from the View setting.

2 Click the Scaling button.

This will bring up the range scaling dialog box. To manually set the scale, uncheck the Auto Range option. Enter the minimum and maximum height to which the colors will be mapped.

Setup • 52Gocator 2000 & 2300 Series

Profile Output

Goactor measures the height of the object calculated from laser triangulation. The Gocator reports a series of ranges along the laser line, with each range representing the distance from the sensor's origin plane. Each range contains a height and a position in the sensor's field of view.

Coordinate Systems

Range data is reported in sensor or system coordinates depending on the calibration state. The coordinate systems are described below.

Sensor Coordinates

Prior to calibration, individual sensors use the coordinate system shown here.

The z-axis represents the sensor’s measurement range (MR), with the values increasing towards the sensor.

The x-axis represents the sensor’s field of view (FOV).

The origin is at the center of the MR and FOV.

In Part data, the Y-axis represents the relative position of the part in the direction of travel. y-position increases as the object moves forward (increasing encoder position).

System Coordinates

Alignment calibration or travel calibration can be used to establish a common coordinate system for the Main and Buddy sensors. Calibration determines the adjustments to X, Z, and Tilt (rotation in the X–Z plane) required to align the data from each sensor.

System coordinates are aligned such that the system x-axis is parallel to the calibration target surface. The system Z-origin is set to the base of the calibration target object. The Tilt angle is positive when rotating from the X to the Z axis.

Similar to the sensor coordinates, y-positions increases when the encoder increases.

For Wide and Opposite layouts, profiles and measurements from the Main and Buddy sensors are expressed in a unified coordinate system. Isolated layouts express results using a separate coordinate system for each sensor.

MAIN BUDDY

MAIN

Setup • 53Gocator 2000 & 2300 Series

Resampled And Raw Profile Format

Profile data produced by Profile or Part mode are processed differently than by Raw Mode. In Profile or Part mode, the ranges are resampled to an even interval along the laser line (x-axis). The resampling divides the x-axis into fixed size "bins" at even intervals. Profile points that fall into the same bin will be combined into a single range value (z). The size of the resampling interval can be configured in the Filters panel (page 76).

In the Ethernet data channel, only the range values (z) are reported and the x-positions can be reconstructed through the array index at the receiving end (the client).

Resampling reduces the complexity for downstream algorithms to process the profile data from the Gocator, but at the cost of higher processing load on the sensor’s CPU.

In contrast, Raw Mode outputs unprocessed range data. Ranges are reported in (x,z) coordinate pairs, freeing up processing resources in the Gocator, but typically requiring more complicated processing on the client side.

All built-in measurement tools in the Gocator operate on resampled data in Profile or Part Mode.

Setup • 54Gocator 2000 & 2300 Series

Intensity Output

Gocator sensors can produce intensity images that measure the amount of light reflected by an object. An 8-bit intensity value is output for each range value along the laser line. Gocator applies the same coordinate system and resampling logic as the ranges (page 52) to the intensity values.

Setup • 55Gocator 2000 & 2300 Series

Trigger

A trigger is an event that causes a sensor to take a single picture. When a trigger is processed, the laser is strobed and the camera exposes to produce an image. The resulting image is processed inside the sensor to yield a laser profile (range/distance information), which can then be used for measurement.

The laser and camera inside a sensor can be triggered by one of four sources:

Trigger Source Description

Time Sensors have an internal clock that can be used to generate fixed-frequency triggers.

The external input can be used to enable or disable the time triggers.

Encoder An encoder can be connected to provide triggers in response to motion. Three

encoder triggering behaviors are supported:

1. Ignore Backward

A scan is triggered only when the target object moves forward. If the target object moves backward, it must move forward by at least the distance of one encoder spacing to trigger a scan.

2. Track Backward

A scan is triggered when the target object moves forward. If the target object moves backward, it must move forward by at least the distance that the target travelled backward, plus one encoder spacing, to trigger a scan.

Setup • 56Gocator 2000 & 2300 Series

Trigger Source Description

Encoder 3. Bi-directional

A scan is triggered when the target object moves forward or backward.

When triggers are received at a frequency higher than the maximum frame rate, some triggers may not be accepted. The Trigger Drops Indicator in the Dashboard can be used to check for this condition.

The external input can be used to enable or disable the encoder triggers.

Refer to Encoder Input (page 341) for more information on connecting the encoder to Gocator sensors.

External Input A digital input can provide triggers in response to external events (e.g. photocell).

When triggers are received at a frequency higher than the maximum frame rate, some triggers may not be accepted. The Trigger Drops Indicator in the Dashboard can be used to check for this condition.

Refer to Digital Inputs (page 340) for more information on connecting external input to Gocator.

Software A network command can be used to send a software trigger. Refer to Gocator Protocol

(page 253) for more information.

Setup • 57Gocator 2000 & 2300 Series

Examples

Example: Encoder + Conveyor

Encoder triggering is used to perform profile measurements at a uniform spacing.

The speed of the conveyor can vary while the object is being measured; an encoder ensures that the measurement spacing is consistent, independent of conveyor speed.

Conveyor Speed

Time

Example: Time + Conveyor

Time triggering can be used instead of encoder triggering to perform profile measurements at a fixed frequency.

Measurement spacing will be non-uniform if the speed of the conveyor varies while the object is being measured.

It is strongly recommended to use an encoder with transport-based systems due to the difficulty in maintaining constant transport velocity.

Conveyor Speed

Time

Example: External Input + Conveyor

External Input triggering can be used to produce a snapshot for profile measurement.

For example, a photocell can be connected as an External Input to generate a trigger pulse when a target object has moved into position.

An External Input can also be used to gate the trigger signals when Time or Encoder triggering is used. For example, a photocell could generate a train of trigger pulses as long as there is a target in position.

Setup • 58Gocator 2000 & 2300 Series

Example: Software Trigger + Robot Arm

Software triggering can be used to produce a snapshot for profile measurement.

A software trigger can be used in systems that employ external software to orchestrate the activities of system components.

Setup • 59Gocator 2000 & 2300 Series

Settings

The trigger source is selected using the Trigger panel in the Setup page.

After specifying a trigger source, the Trigger Panel will show the parameters that can be configured.

Parameters Trigger Source Description

Trigger All Selects the trigger source. (Time, Encoder, External Input, or Software)

Max Frame Rate All Reports the maximum frame rate, which is a function of the current Active

Area, Exposure, and Resolution settings.

Frame Rate Time The Frame Rate setting can be used to control the frame rate. Select the

Max check box to lock to the maximum frame rate. Fractional values are supported. For example, 0.1 can be entered to run at 1 frame every 10 seconds.

Gate using External Input

Time, Encoder External input can be used to enable or disable profiling in a sensor. When

enabled, the sensor will respond to time or encoder triggers only when the external input is asserted.

Refer to Digital Inputs (page 340) for more information on connecting external input to a Gocator senor.

Travel Speed Time Travel Speed provides proper scaling in the y-axis (axis of motion). Travel

Speed can be calculated automatically by performing Travel Calibration or set manually after clicking on the unlock button.

Encoder Behavior Encoder Encoder Behavior setting is used to specify how the Gocator sensor is

triggered when the target moves.

Encoder Resolution Encoder Encoder Resolution (millimeters per tick) provides proper scaling in the y-axis

(axis of motion). The encoder resolution can be calculated automatically by performing Travel Calibration or set manually after clicking on the unlock button.

Spacing Encoder Encoder Spacing setting is used to specify the distance between triggers

(mm). Internally the Gocator sensor rounds the spacing to a multiple of the encoder resolution.

Units External Input,

Software

Units specifies whether the trigger delay, output delay and output scheduled command operates in the time or the encoder domain. The unit is implicitly set to microseconds with Time trigger source, and millimeters with Encoder trigger source.

Trigger Delay External Input Trigger delay can be used to control the time or spacing the sensor

waits before a frame after the external input is activated. This is used to compensate for the positional difference between the source of the external input trigger (e.g. photocells) and the sensor.

Trigger delay is only supported in the single exposure mode (page 63).

Setup • 60Gocator 2000 & 2300 Series

Active Area

Active area refers to the region within the sensor’s maximum field of view that is used for laser profiling.

By default, the active area covers the sensor’s entire field of view. By reducing the active area, the sensor can operate at higher speeds.

Active area is specified in sensor coordinates, rather than in system coordinates. As a result, active area must be configured before Alignment or Travel calibration is performed. Refer to Coordinate Systems (page 52) for more information on sensor and system coordinates.

Active Area can only be set when the sensor is not calibrated.

FIELD OF VIEW

ACTIVE AREA

To set the active area:

1 Navigate to the Sensor panel.

Active area is specified separately for each sensor. Click the arrow next to Active Area to expand the panel.

2 Click the Select button.

If the Select Active Area button is disabled, then calibration may need to be cleared. Refer to Clearing Calibration (page 75) in this chapter for information on clearing calibration.

3 Position and resize the Active Area rectangle shown in the Data Viewer.

4 Click the Save button.

Laser profiling devices are usually more accurate at the near end of the measurement range. If your application requires a measurement range that is small relative to the maximum measurement range of the sensor, mount the sensor such that the active area can be specified at the near end of the measurement range.

Setup • 61Gocator 2000 & 2300 Series

Tracking Window

The Gocator can track a relatively flat object in real-time to achieve very high scan rates. This feature is based on tracking the object height using a small window, called the Tracking Window, that moves dynamically to cover a larger measurement range. Users can balance the gain in speed and the tracking ability by configuring the size of the tracking area. This feature is typically used in road or web scanning applications where the target is a continuous flat surface.

A laser line remains tracked as long as the percentage of detected laser point exceeds the user defined search threshold. When the sensor loses track of the laser line, the sensor will search for the laser line using the full active area.

Tracking Window is only supported on the Gocator 2300 series.

Setup • 62Gocator 2000 & 2300 Series

To enable tracking window:

1 Check the Tracking Window box.

Checking the Tracking Window box expands the panel to reveal the settings for the window used to track the object height.

2 Resize the Tracking Window shown in the Data Viewer.

Only the height of the window is required. User can move the position of the tracking window to cover a live profile to help adjust the window height.

3 Edit the Search Threshold setting.

The search threshold defines the minimum percentage of the points detected across the profile for the laser to be considered tracked. If the tracking is lost, the sensor will search for the laser using the full active area.

The sensor adjusts the position of the tracking window such that the area is centered around the average height of the entire visible laser profile. Users should adjust the lighting and the active area to remove all background objects (i.e. conveyer belt surface, ambient lights).

Setup • 63Gocator 2000 & 2300 Series

Exposure

Exposure determines the duration of camera and laser on-time. Longer exposures can be helpful to detect laser signals on dark or distant surfaces, but increasing exposure time decreases the maximum speed. Different target surfaces could require different exposures for optimal results. Gocator sensors provide three exposure modes for the flexibility needed to scan different types of target surfaces.

Exposure Mode Description

Single Exposure Uses single exposure for all objects. Used when the surface is

uniform and is the same for all targets.

Dynamic Exposure Automatically adjust the exposure after each frame. Used when the

target surface varies between scans.

Multiple Exposures Uses multiple exposures to create a single profile. Used when the

target surface has a varying reflectance within a single profile (e.g. white and black color)

Video mode enables you to see how the laser appears on the camera and to identify any stray light or ambient light problems. When exposure is tuned correctly, the laser line should be clearly visible along the entire length of the viewer. If it is too dim, increase the exposure value; if it is too bright decrease exposure value.

Under exposure

Laser line is not detected.

Increase the exposure value.

Over exposure

Laser line is too bright.

Decrease the exposure value.

In a dual sensor system, the Main and the Buddy sensor must use the same exposure mode or the system will fail to start.

Setup • 64Gocator 2000 & 2300 Series

Single Exposure

The sensor uses a fixed exposure in every scan. The is used when the target surface is uniform and is the same for all parts.

To enable single exposure:

1 Place a representative target in view of the sensor.

The target surface should be similar to the material that will normally be measured.

2 Select Profile, Part or Raw Mode.

3 Navigate to the Sensor panel.

Click the arrow next to Exposure to expand the panel. Click the Main or Buddy sensor button to select the sensor.

4 Select Single.

5 Edit the Exposure setting.

The auto-set function can be used to automatically tune the exposure. Press the Auto Set button and the sensor will turn on and automatically tune the exposure time.

6 Run the sensor and check that laser profiling is satisfactory.

If not satisfactory, adjust the exposure values manually. Switch to Video mode to use video to help tune the exposure (page 62).

Setup • 65Gocator 2000 & 2300 Series

Dynamic Exposure

The sensor automatically uses past profile information to adjust the exposure to yield the best profile. This is used when the target surface changes from scan to scan.

To enable dynamic exposure:

1 Select Profile, Part or Raw Mode.

2 Navigate to the Sensor panel for the Main or Buddy sensor.

Click the arrow next to Exposure to expand the panel. Click the Main or Buddy button to select the sensor.

3 Select Dynamic.

4 Set the minimum and maximum exposure.

The auto-set function can be used to automatically set the exposure. First, place the brightest target in the field of view and press the Auto Set Min button to set the minimum exposure. Then, place the darkest target in the field of view and press the Auto Set Max button to set the maximum exposure.

5 Run the sensor and check that laser profiling is satisfactory.

If not satisfactory, adjust the exposure values. Switch to Video mode to use video to help tune the exposure (page 62).

Setup • 66Gocator 2000 & 2300 Series

Multiple Exposures

The sensor combines data from multiple exposures to create a single laser profile. Multiple exposures can be used to increase the ability to detect light and dark materials that are in the field of view simultaneously.

Up to five exposures can be defined with each set to a different exposure level. For each exposure the sensor will perform a complete scan at the current frame rate making the effective frame rate slower. For example, if two exposures are selected then the speed will be halved of the single exposure frame rate. The sensor will perform a complete scan for each external input or encoder trigger.

The resulting profile is a composite created by combing data collected with different exposures. The sensor will choose profile data that is available from the lowest numbered exposure step. It is recommended to use larger exposure for higher numbered step.

Users must ensure the exposure steps set for composite exposure are the same between the Main and Buddy sensors in Dual Sensor Mode.

To enable multiple exposures:

1 Select Profile, Part or Raw Mode.

2 Navigate to the Sensor panel.

Click the arrow next to Exposure to expand the panel. Click the Main or Buddy button to select the sensor.

3 Select Multiple.

4 Press the + button to add an exposure step.

Up to a maximum of five exposure settings can be added.

5 Set the exposure level to make the Gocator less or more sensitive (as required).

The auto-set function can be used to automatically set the exposure. To use the auto-set function, place target material in the field of view then select an exposure step and press the Auto Set button. Repeat this procedure for each exposure step.

6 Select the exposure step used for intensity output

If intensity acquisiton is enabled, select the exposure step that is used to capture the intensity output.

7 Run the sensor and check that laser profiling is satisfactory.

If not satisfactory, adjust the exposure values. Switch to Video mode to help tune the exposure (page

62).

Setup • 67Gocator 2000 & 2300 Series

Resolutions

Resolutions can be set independently for the x-axis and z-axis. Reducing the resolution increases speed or reduces CPU utilization while maintaining the sensor's field of view.

X Resolution

The X Resolution setting can be used to decrease the profile's x-resolution in order to decrease sensor CPU utilization. The X Resolution setting works by reducing the number of image columns used for laser profiling.

The CPU Load bar at the top of the interface displays how much of the CPU is being utilized.

To configure X resolution:

1 Navigate to the Sensor panel.

Click the arrow next to Resolution to expand the panel. Click the Main or Buddy button to select the sensor. X resolution is specified separately for each sensor.

2 Select a resolution value.

X resolution values are expressed as fractions. For example, a resolution value of 1/2 indicates that every second camera column will be used for laser profiling.

3 Check that laser profiling is satisfactory.

After adjusting the resolution, confirm that laser profiling characteristics are satisfactory.

Setup • 68Gocator 2000 & 2300 Series

Z Resolution

The Z Resolution setting can be used to decrease the profile's Z resolution in order to increase speed. The Z Resolution setting works by reducing the number of image rows that is used for laser profiling.

On the Gocator 2000, decrease Z resolutions will increase speed. On the Gocator 2300, both X and Z resolutions need to be decreased to increase speed.

To configure Z resolution:

1 Navigate to the Sensor panel.

Click the arrow next to Resolution to expand the panel. Click the Main or Buddy button to select the sensor. Z resolution is specified separately for each sensor.

2 Select a resolution value.

Z resolution values are expressed as fractions. For example, a resolution value of 1/2 indicates that every second camera row will be used for laser profiling.

3 Check that laser profiling is satisfactory.

Decreasing z resolution can reduce laser profiling accuracy. After adjusting the resolution, confirm that laser profiling characteristics are satisfactory.

Setup • 69Gocator 2000 & 2300 Series

Transformations

The transformation settings are used to control how ranges are converted from sensor coordinates to system coordinates.

Element Description

X Offset Specifies the shift along the x-axis. With Normal orientation, a positive value shifts the profiles

to the right. With Reverse orientation, a positive value shifts the profile to the left.

Z Offset Specifies the shift along the z-axis. A positive value shifts the profiles towards the sensor.

Angle Specifies the tilt (rotation in the X-Z plane). A positive value rotates the profile counter-

clockwise.

Orientation Specifies the direction of the x-axis. Setting to Reverse will flip the profile about the z-axis.

When applying the transformations, Angle is applied before X and Z offsets.

To configure transformation settings:

1 Select the Profile, Part or Raw Mode.

2 Navigate to the Sensor panel.

Click the arrow next to Transformation to expand the panel. Click the Main or Buddy button to select the sensor. Transformations can be configured separately for each sensor (click the arrow next to Transformations to expand the settings).

3 Click the unlock button to make the fields editable.

4 Set the parameter values.

5 Check that the transformation settings are applied correctly after profiling is restarted.

Setup • 70Gocator 2000 & 2300 Series

Dual Sensor System Layout

Mounting orientations need to be specified for a dual sensor (Buddy) system. This information allows the Alignment or Travel Calibration procedures to determine the correct system-wide coordinates for laser profiling and measurements. Refer to Coordinate Systems (page 52) in this chapter for more information on sensor and system coordinates.

To specify the layout, navigate to the Layout panel on the Setup Page:

Supported Orientations

Orientation Example

None (Isolated)

Each sensor operates as an isolated device. Measurements are reported in a separate coordinate system for each sensor.

Wide

Sensors are mounted in Left (Main) and Right (Buddy) positions for a larger combined field of view. Sensors may be angled to avoid occlusions.

Main

Buddy

Main

Buddy

Setup • 71Gocator 2000 & 2300 Series

Orientation Example

Opposite

Sensors are mounted in Top (Main) or Bottom (Buddy) positions for a larger combined measurement range and the ability to perform Top/Bottom differential measurements.

Main

Buddy

Overlap

If the Main and Buddy sensors are mounted such that the camera from one sensor can detect the laser from the other sensor, the Overlap feature can be used to eliminate laser interference. Overlap creates a time offset for laser exposures and ensures that interfering lasers are not strobed at the same time. Use of the overlap feature may reduce the maximum frame rate.

Reverse

In the Wide layout, the Buddy sensors can be mounted such that it is rotated 180 degrees around the z-axis to prevent occlusion along the y-axis. Enable the Reverse feature when the buddy is mounted in this reverse orientation.

Setup • 72Gocator 2000 & 2300 Series

Calibration

Although Gocator sensors are pre-calibrated and ready to deliver profiles out of the box, calibration procedures are required to compensate for sensor mounting inaccuracies, to align multiple sensors into a common coordinate system, and to determine the resolution (with encoder) and speed of the transport system.

Gocator sensors support two types of calibration procedures: Alignment Calibration and Travel Calibration. Travel calibration performs essentially the same role as alignment calibration, but calibrates encoder resolution and y-axis offsets in addition to the corrections provided by alignment calibration.

Once calibration has been completed, the values derived will be saved automatically and reloaded each time the sensor is reset or powered up.

Calibration States

A Gocator can be in one of three calibration states: None, Manual, or Auto.

Calibration States

State Explanation

None Sensor has no calibration. Ranges are reported in default sensor

coordinates.

Manual User has manually edited transformations or encoder resolution.

Auto Sensor is calibrated using either alignment or travel calibration.

An indicator on the Calibration panel will display CALIBRATED, MANUALLY CALIBRATED or NOT CALIBRATED.

Alignment vs. Travel Calibration

The table below summarizes the differences between alignment calibration and travel calibration.

Alignment Calibration vs. Travel Calibration

Alignment Calibration Travel Calibration

Target Type Flat Surface or Cal Bar Cal Disk or Cal Bar

Target/Sensor Motion Stationary Linear Motion

Calibrates Tilt Yes Ye s

Calibrates z-axis Offset Yes Yes

Calibrates x-axis Offset Yes (Cal Bar Required) Yes

Calibrates Encoder No Ye s

Calibrates Travel Speed No Yes

Refer to Coordinate Systems (page 52) for definitions of coordinate axes. Calibration disks and bars are described in Calibration Targets (page 28).

The procedures to perform alignment calibration or travel calibration are described in the next sections. After calibration, the coordinate system for laser profiles will change from Sensor Coordinates to System Coordinates.

Setup • 73Gocator 2000 & 2300 Series

Alignment Calibration

Alignment calibration can be used to compensate for mounting inaccuracies by aligning sensor data to a common reference surface (often a conveyor belt).

To perform alignment calibration:

1 Ensure that all sensors have a clear view of the target surface.

Remove any irregular objects from the sensor's field of view that might interfere with alignment calibration. If using a calibration bar for dual sensor system, ensure that the lasers illuminate a reference hole on the calibration bar.

2 Navigate to the Layout panel and select Alignment Calibration.

Click the arrow button next to Calibration to expand the panel.

3 Clear the previous calibration if present.

Press the Clear Calibration button to remove the existing calibration.

4 Select a calibration Target.

Select Flat Surface to use the conveyor surface (or other flat surface) as the calibration reference, or Bar to use a custom calibration bar. If using a calibration bar, specify the bar dimensions and reference hole layout. Refer to Calibration Targets (page 28) for more information.

5 Press the Calibrate button.

The sensors will start and the alignment calibration process will take place. Calibration is performed simultaneously for all sensors. If the sensors do not calibrate, check and adjust the exposure settings.

Alignment calibration uses the exposure defined for the single exposure mode, regardless of the current exposure mode.

6 Use Profile Mode to inspect calibration results.

Laser profiles from all sensors should now be aligned to the calibration target surface. The base of the

calibration target (or target surface) provides the origin for the system z-axis.

Alignment calibration does not automatically calibrate the resolution of the encoder (if present) or the travel speed. However, the these values can be manually entered if desired. Refer to Trigger (page 55) for more information.

When using a calibration bar, there can be at most one hole in each sensor's field of view.

Setup • 74Gocator 2000 & 2300 Series

Travel Calibration

Travel calibration can be used to achieve alignment calibration and motion calibration in a single procedure.

To perform travel calibration:

1 Place the calibration target prior to the laser plane.

Remove extraneous objects from the transport system such that the calibration target will be the only object that is scanned.

2 Navigate to the Layout panel and select Travel Calibration.

Click the arrow button next to Calibration to expand the panel.

3 Clear the previous calibration, if present.

Press the Clear Calibration button to remove the existing calibration.

4 Select a calibration Target.

Select one of the Disk options to use a standard disk target or Bar to use a custom-made calibration bar. If using a calibration bar, specify the bar dimensions and reference hole layout. Refer to Calibration Targets (page 28) for more information.

5 Press the Calibrate button.

The sensors will start and then wait for the calibration target to pass through the laser plane.

Travel calibration uses the exposure defined for the single exposure mode, regardless of the current exposure mode.

6 Engage the transport system.

When the calibration target has passed completely through the laser plane, the calibration process will complete automatically. To properly calibrate the travel speed, the transport system must be running at the production operating speed before the target passes through the laser plane.

7 Use Profile Mode to inspect calibration results.

Laser profiles from all sensors should now be aligned to the calibration target surface. The base of the

calibration target (or target surface) provides the origin for the system z-axis.

When using a calibration bar, there can be at most one hole in each sensor's field of view. If a disk is used for calibrating a dual-sensor setup in a wide layout, half of the disk must be in each sensor's field of view.

Setup • 75Gocator 2000 & 2300 Series

Clearing Calibration

To clear calibration:

1 Navigate to the Calibration panel on the Setup page.

2 Click the Calibration or Clear Calibration button.

If the Clear Calibration button is pressed, the calibration will be erased and sensors will revert to using Sensor Coordinates.

Setup • 76Gocator 2000 & 2300 Series

Filters

The Filters Panel can be used to post process the profile before it is output or is used by measurement tools. Three types of filters are supported:

Filters Description

X Resampling Interval Configure resampling interval size to balance between CPU loading, output data rate

and x-resolution.

Smoothing Apply moving window averaging to reduce random noise in a profile.

Gap Filling Fill in missing data caused by occlusions using information from the nearest neighbors.

Setup • 77Gocator 2000 & 2300 Series

X Resampling Interval

Resampling interval is the spacing between data points in a resampled profile (page 52). A larger interval creates profiles with lower x-resolution but reduces CPU usage and potentially increases the maximum frame rate. A larger interval also reduces the data output rate.

By default, the Gocator output data at the medium resolution.

To configure the X resampling interval:

1 Select the Profile or Part Mode.

2 Navigate to the Filters panel.

Click the arrow next to X Resampling to expand the panel.

3 Select a resampling interval level.

Maximum Speed: Use the lowest x-resolution within the active area as the resampling interval. This setting minimizes CPU usage and data output rate but the profile has the lowest x-resolution (i.e. least detail)

Balanced: Use the x-resolution at the middle of the active area as the resampling interval. This setting balances CPU load, data output rate and the x-resolution.

Maximum Resolution: Use the highest x-resolution within the active area as the resampling interval. This setting maximizes resolution but has higher CPU load and has the highest data output rate. (i.e. greatest detail).

Setup • 78Gocator 2000 & 2300 Series

Gap Filling

Gap filling works by filling in missing data points using the lowest values from the nearest neighbors. The sensor can fill gaps along both the x-axis and the y-axis. X gap filling works by filling in the gaps within the same profile. Y gap filling works by filling in gaps in the direction of travel at each x location.

If both X and Y gap filling are enabled, missing data is filled along the x-axis first, then along the y-axis.

To configure X gap filling:

1 Select the Profile or Part Mode.

2 Navigate to the Filters panel.

Click the arrow next to Gap Filling to expand the panel.

3 Enable X gap filling and select the maximum width value.

The maximum gap value represents the maximum gap width that the Gocator will fill. Gaps wider than the maximum width will not be filled.

4 Check that the laser profiling is satisfactory.

To configure Y gap filling:

1 Select the Profile or Part Mode.

2 Navigate to the Filters panel

Click the arrow next to Gap Filling to expand the panel.

3 Enable Y gap filling and select the maximum width value.

The maximum gap value represents the maximum gap width that the Gocator will fill. Gaps wider than the maximum width will not be filled.

4 Check that the laser profiling is satisfactory.

Setup • 79Gocator 2000 & 2300 Series

Smoothing

Smoothing works by substituting a profile result with the average value of itself and its nearest neighbors. Smoothing can be applied along the x-axis or the y-axis. X smoothing works by calculating a moving average across samples within the same profile. Y smoothing works by calculating a moving average in the direction of travel at each x location.

If both X and Y smoothing are enabled, the data is smoothed along x-axis first, then along the y-axis.

To configure X smoothing:

1 Select the Profile or Part Mode.

2 Navigate to the Filters panel.

Click the arrow next to Smoothing to expand the panel.

3 Enable X Smoothing and select the window value.

The window value represents the averaging window size in the x-axis.

4 Check that the laser profiling is satisfactory.

To configure Y smoothing:

1 Select the Profile or Part Mode.

2 Navigate to the Filters panel.

Click the arrow next to Smoothing to expand the panel.

3 Enable Y Smoothing and select the window value.

The window value represents the average window size in the y-axis.

4 Check that the laser profiling is satisfactory.

Setup • 80Gocator 2000 & 2300 Series

Part Detection

In Part Mode, the Gocator sensor analyzes each profile to identify discrete objects. Part measurements can then be performed on each discrete object.

Part detection can be performed when the trigger source is set to Time or Encoder. To use the Time trigger source, the travel speed needs to be calibrated. To use the Encoder trigger source, the encoder resolution needs to be calibrated. Refer to Travel Calibration (page 74) for more information.

Multiple parts can pass through the laser at the same time and will be individually tracked. Parts can be separated along the laser line (x-axis), in the direction of travel (y-axis) or by gated external input.

The following settings can be tuned to improve the accuracy and reliability of the part detection.

Setting Description

Gap Threshold Determines the minimum separation between objects in the XY plane. If parts are

closer than the gap interval, they will be merged into a single part.

Height Threshold Determines the minimum profile height for part detection. This setting is useful when

measuring objects on a conveyor, to prevent the conveyor from being detected as a part. Any data points below the height threshold will not be taken into account when calculating the part measurements

In an opposite layout, the threshold is applied to the difference between the top and the bottom profile. Target thinner than the threshold value is ignored, including places where only one of either top or bottom is detected.

To separate part by gated external input, set the Height Threshold to the Active area Z-offset (i.e. minimum Z position of the current Active Area), set the trigger source to Time or Encoder and check the Gate Using External Input check box.

Area Threshold Determines the minimum area for a detected part. Set this value to a reasonable

minimum in order to filter out small objects or noise.

Length Max Determines the maximum length of the part object. When the object exceeds the

maximum length, it is automatically separated into two parts. This is useful to break a long object into multiple sections and perform measurements on each section.

To setup part detection:

1 Navigate to the Operation Mode Panel, select Part Mode.

Setup • 81Gocator 2000 & 2300 Series

2 Navigate to the Part Detection panel.

3 Adjust the settings.

82Gocator 2000 & 2300 Series

Measurement

Measurement Page

Measurement tools are configured using the Measurement Page.

The content of the Measurement Page is controlled by the current operation mode. In Profile Mode, the Measurement Page displays tools for profile measurement. In Part Mode, the Measurement page displays tools for part measurement. The Measurement page is disabled in Video and Raw mode.

Element Description

1 Tools Panel Use the Tools panel to add new measurements or to configure fixturing.

2 Measurement Panel For each measurement that is added, a configuration area will appear below the

Measurements panel. Use this area to adjust settings for the measurement.

3 Data Viewer Displays laser profile or part data, setup tools and display result calipers related to the

selected measurement. Parts are displayed using a height map; A top-down view of the XY plane, where color represents height.

4 Feature Area Configurable region of interest from which feature points are detected. These feature points

are used to calculate the measurements. The number of feature area displayed depends on which measurement tool is currently selected.

Measurement • 83Gocator 2000 & 2300 Series

Adding and Removing Measurements

To add a new profile measurement:

1 Select the desired measurement type.

Click on the item in the drop-down list next to Add Measurement to select the measurement type.

2 Press the Add button.

A configuration panel for the new measurement will be added to the bottom of the stack.

To remove a new profile measurement:

1 Select the desired measurement.

Click on the title bar of the measurement to select it.

2 Click the Remove button.

The measurement will be removed from the list of measurements.

If the Add Measurement list contains only the Distance measurement, then the sensor is not equipped with profile tools. The Distance measurement is provided in all sensors to demonstrate the measurement capability.

Measurement • 84Gocator 2000 & 2300 Series

Changing the Measurement Name

Each measurement can be assigned a unique name. This allows multiple measurements of the same type to be distinguished in the web interface. The name is also referenced by the Script tool.

To edit a measurement name:

1 Click on the measurement name.

2 Enter a new name.

3 Press the Tab key.

The name change will be completed when you press the Tab Key or click outside of the name edit field.

Measurement • 85Gocator 2000 & 2300 Series

Measurement ID

Measurement ID is used to uniquely identify a measurement in the Gocator protocol or in the SDK. The value must be unique amongst all profile and part measurements.

To edit a measurement ID:

1 Select a measurement.

Click on the + in a measurement panel to expand the panel.

2 Click on the measurement ID.

3 Enter a new number.

The value must be unique amongst all measurements in Profile and Part Mode.

4 Press the Tab key.

The name change will be completed when you press the Tab Key or click outside of the measurement ID edit field.

Measurement • 86Gocator 2000 & 2300 Series

Profile Sources

For dual sensor systems, measurements must specify a profile source. The profile source determines the data that will be used for the measurement.

The following options are available:

Profile Source Description

Main Profile data is provided by the Main sensor. This is the only option for standalone

systems.

Buddy Profile data is provided by the Buddy sensor.

Both Profile data is provided by the Main and the Buddy sensor.

To select the profile source:

1 Select a measurement.

Click on the + in a measurement panel to expand it.

2 Select the profile Source.

Select the source in the drop down list. The drop down list will not appear if Main is the only option.

Measurement • 87Gocator 2000 & 2300 Series

Decisions

Results from a measurement tool can be compared against minimum and maximum thresholds to generate pass / fail decisions. The decision state is pass (value displayed in green) if a measurement value is between the minimum and maximum threshold, otherwise the decision state is fail (value displayed in red).

Value (50.380) is within the decision thresholds (Min: 80, Max:100). Decision: Pass

Value (51.216) is outside decision thresholds (Min:80, Max:100)

Decision: Fail

Value (51.216) is outside the decision thresholds (Min: 80, Max: 100). Decision: Fail

Along with measurement values, decisions can be sent to external programs and devices. In particular, decisions are often used in conjunction with digital outputs to trigger an external event in response to a measurement. Refer to Output (page 182) for more information on transmitting values and decisions.

Measurement • 88Gocator 2000 & 2300 Series

Output Filters

Filters can be applied to measurement values before they are output from the Gocator sensors. Two filters are supported.

Operation Description

Hold Last Valid Hold the last valid value when the measurement is invalid. Measurement is invalid if

there is no valid value.

Smoothing Apply moving window averaging to reduce random noise in a measurement output.

The averaging window is configured in number of frames.

If Hold Last Valid is enabled, smoothing uses the output of the Hold Last Valid filter.

To configure the output filters:

1 Select a measurement.

Click on the + in a measurement panel to expand it. Click the arrow next to Output to expand the panel.

2 Enable filters and configure the settings.

Measurement • 89Gocator 2000 & 2300 Series

Profile Fixturing

Profile fixturing is used to track the movement of parts along the laser line (x-axis and z-axis). The movement is calculated as an offset and is used to correct the positions of the feature areas. This ensures that the regions-of-interest used to detect features are correctly positioned for every part.

Profile fixturing is not required in order to use measurement functions. This is an optional feature intended to make measurements more robust when the x-position and the height of the target varies from target to target.

A profile template is needed for fixturing to function. The profile template is the reference used to calculate the profile movement in the x-axis and z-axis. User defines a detection area (white rectangles in the picture above) and the type of feature point to detect within the area. When the profile template and the live profile falls into the area, the movement is calculated by computing the difference between the positions of the feature point of the profile template and the live profile.

To register a profile template:

1 Position a representative target object within the field of view.

The target should be similar to the objects that will later be measured. The Start or Snapshot buttons can be used to view live profile data while positioning the target.

2 Click the Register button.

A snapshot of the target object will be captured and set as the current profile template. The profile template is shown in white within the Data Viewer.

After a profile is registered, fixturing in the x-axis and z-axis can be configured independently.

Measurement • 90Gocator 2000 & 2300 Series

To set up profile fixturing in the x-axis:

1 Press the Fixturing button in the Measurement panel.

2 Enable X Fixturing

Check the X-Fixturing box to enable fixturing in the x-axis.

3 Adjust the detection area.

Profile data within the detection area will be used to calculate the feature point for fixturing.

4 Select an feature point type.

Select the feature point type from the Detect drop-down box. The point type determines how the feature point is calculated from the profile data within the detection area.

To set up profile fixturing in the z-axis with a new template:

1 Press the Fixturing button in the Measurement panel.

2 Enable Z Fixturing.

Check the Z Fixturing box to enable fixturing in the z-axis.

3 Adjust the detection area.

Profile data within the detection area will be used to calculate the feature point for fixturing.

4 Select an feature point type.

Select the feature point type from the Detect drop-down box. The point type determines how the feature point is calculated from the profile data within the detection area.

When profile fixturing is used, the measurement's areas should be setup to match with the profile template. The profile template is hidden when the sensor is running. When the sensor is stopped and the user is viewing the measurement page, the profile template will be automatically reloaded in the Data Viewer.

To clear a registered profile template:

1 Press the Fixturing button in the Measurements panel.

2 Click the Clear button.

Changes to profile fixturing and the template are temporary until they are saved. Refer to Saving and Loading Settings (page 194) for more details on how to save changes.

Measurement • 91Gocator 2000 & 2300 Series

Script Measurement

A Script measurement can be used to program a custom measurement using a simplified C-based syntax. Similar to other measurement tools, a script measurement can produce a measurement value and a measurement decision.

The following elements of the C language are supported:

Supported Elements

Elements Supported

Control Operators

if, while, do, for, switch and return.

Data Types char, int, unsigned int, float, double, long long (64-bit integer).

Arithmetic and Logical Operator

Standard C arithmetic operators, except ternary operator (i.e. “condition? trueValue: falseValue”). Explicit casting (e.g. int a = (int) a_float) is not supported.

Function Declarations Standard C function declarations with argument passed by values. Pointers are not

supported.

Built-in Functions

Measurement Functions

Measurement Functions Descriptions

int Measurement_Exists(int id) Tests for the existence of a measurement by ID.

Parameters: id – Measurement ID Returns: 0 – measurement does not exist 1 – measurement exists

int Measurement_Valid(int id) Retrieves the valid/invalid state of a measurement by its ID.

Parameters: id - Measurement ID Returns 0 - Measurement is invalid 1 - Measurement is valid

long long Measurement_Value (int id) Retrieves the value of a measurement by its ID.

Parameters: id - Measurement ID Returns: Value of the measurement 0 – if measurement does not exist

A measurement value is received as a fixed point integer with a scaling of 1/1000. For example, a 3.654mm value is received as 3654.

int Measurement_Decision (int id) Retrieves the decision of a measurement by its ID.

Parameters: ID - Measurement ID Returns: Decision of the measurement 0 – if measurement decision is false 1 – If measurement decision is true

Measurement • 92Gocator 2000 & 2300 Series

int Measurement_NameExists(char *name) Determines if a measurement exist by name.

Parameter: name – name of a measurement Return: 0 – measurement does not exist 1 – measurement exists

int Measurement_Id (char *name) Retrieves the measurement ID by the measurement name.

Parameters: name – name of a measurement Returns:

-1 – measurement does not exist Other – Measurement ID

void Output_Set (long long value, int decision)

Output a value and decision. Only the last output value / decision in a script run is kept and passed to the Gocator output.

Parameters: value - value output by the script decision - decision value output by the script. Can only be 0 or 1

Memory Functions

Memory Functions Descriptions

void Memory_Set64s (int id, long long value) Stores a 64-bit signed integer in persistent memory.

Parameters: id - ID of the value value - Value to store

long long Memory_Get64s (int id) Retrieves a 64-bit signed integer from persistent memory.

Parameters: id - ID of the value Returns: value - Value stored in persistent memory

void Memory_Set64u (int id, unsigned long long value)

Stores a 64-bit unsigned integer in the persistent memory Parameters: id - ID of the value value - Value to store

unsigned long long Memory_Get64u (int id) Retrieves a 64-bit unsigned integer from persistent memory.

Parameters: id - ID of the value Returns: value - Value stored in persistent memory

void Memory_Set64f (int id, double value) Stores a 64-bit double into persistent memory.

Parameters: id - ID of the value value - Value to store

double Memory_Get64f (int id) Retrieves a 64-bit double from persistent memory. All persistent memory

values are set to 0 when the sensor starts. Parameters: id - ID of the value Returns: value - Value stored in persistent memory

Measurement • 93Gocator 2000 & 2300 Series

int Memory_Exists (int id) Tests for the existence of a value by ID.

Parameters: id – Value ID Returns: 0 – value does not exist 1 – value exists

void Memory_Clear (int id) Erases a value associated with a ID.

Parameters: id – Value ID

void Memory_ClearAll() Erases all value from persistent memory

Stamp Functions

Stamp Functions Descriptions

long long Stamp_Frame() Retrieves the frame index of the current frame.

long long Stamp_Time() Retrieves the time stamp of the current frame.

long long Stamp_Encoder() Retrieves the encoder position of the current frame.

long long Stamp_EncoderZ() Retrieves the encoder index position of the current frame.

unsigned int Stamp_Inputs() Retrieves the digital input state of the current frame.

Math Functions

Math Functions Descriptions

float sqrt(float x) Calculates square root of x

float sin(float x) Calculates sin(x) (x in radians)

float cos(float x) Calculates cos(x) (x in radians)

float tan(float x) Calculates tan(x) (x in radians)

float asin(float x) Calculates asin(x) (x in radians)

float acos(float x) Calculates acos(x) (x in radians)

float atan(float x) Calculates atan(x) (x in radians)

float pow (float x, float y) Calculates the exponential value. x is the base, y is the exponent

float fabs(float x) Calculates the absolute value of x

Measurement • 94Gocator 2000 & 2300 Series

Example: Accumulated Volume

The following example demonstrates how to create a custom measurement that is based on the values from other measurements and persistent values. The example calculates the volume of the target using a series of box area measurement values.

/* Calculate the volume of an object by accumulating the boxArea measurements*/ /* Encoder Resolution is 0.5mm. */ /* BoxArea Measurement ID is set to 1*/

long long encoder_res = 500; long long boxArea = Measurement_Value(1); long long Volume = Memory_Get64s(0);

if (boxArea > 0) { Volume = Volume + (boxArea/1000) * encoder_res; }

Memory_Set64s(0, Volume);

if (Volume > 1000000) { Output_Set(Volume, 1); } else { Output_Set(Volume, 0); }

95Gocator 2000 & 2300 Series

This chapter describes the profile measurement tools available in sensors that are equipped with Measurement Tools.

Most measurement functions detect and compare feature points or lines found within laser profile data. Measurement values are compared against minimum and maximum thresholds to yield decisions.

Measurement Examples

Width

Measures the difference in the x-axis position of two feature points.

Refer to Width (page 105).

Width

Height

Measures the difference in the z-axis position of two features.

Refer to Height (page 106).

Height

Distance

Measures the Euclidean distance between two features.

Refer to Distance (page 107).

Distance

Position X

Finds the x-axis position of a feature.

Refer to Position X (page 108).

Position X

Position Z

Finds the z-axis position of a feature.

Refer to Position Z (page 109).

Position Z

Profile Measurement Tools

Measurement • 96Gocator 2000 & 2300 Series

Measurement Examples

Center X

Finds the average location of two features and measures the x-axis position of the average location.

Refer to Center X (page 110).

Center X

Center Z

Finds the average location of two features and measures the z-axis position of the average location.

Refer to Center Z (page 111).

Center Z

Angle X

Fits a line to profile points within one or two areas and measures the angle between the fitted line and the x-axis.

Refer to Angle X (page 112).

Angle X

Intersect X

Finds the intersection between two fitted lines and measures the x-axis position of the intersection point.

Refer to Intersect X (page 113).

Intersect X

Intersect Z

Finds the intersection between two fitted lines and measures the z-axis position of the intersection point.

Refer to Intersect Z (page 114).

Intersect Z

Intersect Angle

Finds the angle subtended by two fitted lines.

Refer to Intersect Angle (page 115).

Intersect Angle

Measurement • 97Gocator 2000 & 2300 Series

Measurement Examples

Intersect Area

Measures the cross-sectional area within a region that is above or below a fitted baseline.

Refer to Intersect Area (page 116).

Intersect Area [Object]

Intersect Area [Clearance]

Box Area

Measures the cross-sectional area within a region.

Refer to Box Area (page 117).

Box Area

Difference Area

Measures the difference in cross-sectional area between live profile and the template.

Refer to Difference Area (page 118).

Difference Area

Live Profile

Template

Difference Peak

Measures the maximum difference in height between the live profile and the template.

Refer to Difference Peak (page 119).

Difference Peak

Circle Radius

Finds the best-fitted circle and measures the circle radius.

Refer to Circle Radius (page 120).

Radius

Measurement • 98Gocator 2000 & 2300 Series

Measurement Examples

Circle X

Finds the best-fitted circle and measures the circle center position in the x-axis.

Refer to Circle X (page 121).

Center

(X, Z)

Circle Z

Finds the best-fitted circle and measures the circle center position in the z-axis.

Refer to Circle Z (page 122).

Center

(X, Z)

Line Standard Deviation

Finds the best-fitted line and measures the standard deviation of the laser points from the best-fitted line.

Refer to Line Standard Deviation (page 123).

Standard Deviation

Line Error Min

Finds the best-fitted line and measures the minimum error from the best-fitted line.

Refer to Line Error Min (page 124).

Line Error Min.

Line Error Max

Find the best-fitted line and measures the maximum error from the best-fitted line.

Refer to Line Error Max (page 125).

Line Error Max.

Line Percentile

Finds the best-fitted line and measures the range (in z) that covers a percentage of points around the best-fitted line.

Refer to Line Percentile (page 126)

Covers % of Spots

Measurement • 99Gocator 2000 & 2300 Series

Measurement Examples

Gap

Measures the distance between two surfaces. The surface edges can be curved or sharp.

Refer to Gap (page 127)

Gap

Flush

Measures the flatness between two surfaces. The surface edges can be curved or sharp.

Refer to Flush (page 132)

Flush

Groove Width

Measures the width of a groove.

Refer to Groove Width (page 138)

Width

Measurement • 100Gocator 2000 & 2300 Series

Measurement Examples

Groove X

Measures the x-position of the bottom of a groove.

Refer to Groove X (page 140)

(X, Z)

Groove Z

Measures the z-position of the bottom of a groove.

Refer to Groove Z (page 142)

(X, Z)

Strip Width

Measures the width of a strip.

Refer to Strip Width (page 146)

Width

Strip Height

Measures the height of a strip.

Refer to Strip Height (page 149)

Height

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