Pepperl+Fuchs SmartRunner Matcher User Manual
SmartRunner Matcher*
Light section sensor for highprecision profile comparison
FACTORY AUTOMATION
MANUAL
With regard to the supply of products, the current issue of the following document is ap-
plicable: The General Terms of Delivery for Products and Services of the Electrical Indus-
try, published by the Central Association of the Electrical Industry (Zentralverband
Elektrotechnik und Elektroindustrie (ZVEI) e.V.) in its most recent version as well as the
supplementary clause: "Expanded reservation of proprietorship"
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1 Introduction................................................................................. 5
1.1 Content of this Document ................................................................... 5
1.2 Target Group, Personnel...................................................................... 5
1.3 Symbols Used ...................................................................................... 5
2 Product Specifications............................................................... 7
2.1 Use and Application............................................................................. 7
2.2 Hazards of Laser Radiation................................................................. 9
2.3 Dimensions......................................................................................... 10
2.4 Displays and Controls ....................................................................... 10
2.5 Interfaces ............................................................................................ 12
2.6 Accessories ........................................................................................ 13
3 Installation................................................................................. 14
3.1 Storage and Disposal ........................................................................ 14
3.2 Preparation ......................................................................................... 14
3.3 Mounting the Sensor ......................................................................... 14
3.4 Electrical Connection ........................................................................ 16
3.5 Detection range.................................................................................. 19
4 Commissioning......................................................................... 20
4.1 Connecting the Sensor...................................................................... 20
5 Vision Configurator Software .................................................. 21
5.1 Connecting to Vision Configurator .................................................. 21
5.2 Application Window Structure .......................................................... 23
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5.3 Menu Bar .............................................................................................24
5.3.1 File Menu ......................................................................................... 24
5.3.2 View Menu ....................................................................................... 24
5.3.3 Sensor Menu....................................................................................25
5.3.4 Image Menu ..................................................................................... 25
5.3.5 Administration Menu ........................................................................26
5.3.6 Help Menu........................................................................................ 26
5.4 Toolbar.................................................................................................27
5.5 Sensor Data.........................................................................................28
5.6 Image Display .....................................................................................28
5.7 Configuration window........................................................................33
5.7.1 Sensor Information........................................................................... 33
5.7.2 Common Tab.................................................................................... 34
5.7.3 Matcher Tab .....................................................................................36
6 Operation................................................................................... 41
6.1 Configuration Mode............................................................................41
6.2 Code Card Mode.................................................................................47
6.2.1 Setting Device Parameters via Control Code.................................... 48
6.3 Presentation Mode .............................................................................49
6.4 Runtime Mode.....................................................................................50
6.4.1 Communication via the RS-485 Interface ......................................... 50
7 Maintenance and Repair.......................................................... 54
7.1 Maintenance........................................................................................ 54
7.2 Repair ..................................................................................................54
8 Troubleshooting........................................................................ 55
8.1 What to Do in Case of a Fault ............................................................55
9 License Note ............................................................................. 57
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Introduction
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1 Introduction
1.1 Content of this Document
This document contains information required to use the product in the relevant phases of the
product life cycle. This may include information on the following:
Product identification
Delivery, transport, and storage
Mounting and installation
Commissioning and operation
Maintenance and repair
Troubleshooting
Dismounting
Disposal
The documentation comprises the following parts:
This document
Datasheet
In addition, the documentation may comprise the following parts, if applicable:
EU-type examination certificate
EU declaration of conformity
Attestation of conformity
Certificates
Control drawings
Instruction manual
Other documents
1.2 Target Group, Personnel
Responsibility for planning, assembly, commissioning, operation, maintenance, and
dismounting lies with the plant operator.
Only appropriately trained and qualified personnel may carry out mounting, installation,
commissioning, operation, maintenance, and dismounting of the product. The personnel must
have read and understood the instruction manual and the further documentation.
Prior to using the product make yourself familiar with it. Read the document carefully.
1.3 Symbols Used
This document contains symbols for the identification of warning messages and of informative
messages.
Note!
Visit www.pepperl-fuchs.com to access further documentation for full information about the
product.
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Introduction
Warning Messages
You will find warning messages, whenever dangers may arise from your actions. It is
mandatory that you observe these warning messages for your personal safety and in order to
avoid property damage.
Depending on the risk level, the warning messages are displayed in descending order as
follows:
Informative Symbols
Action
This symbol indicates a paragraph with instructions. You are prompted to perform an action or
a sequence of actions.
Danger!
This symbol indicates an imminent danger.
Non-observance will result in personal injury or death.
Warning!
This symbol indicates a possible fault or danger.
Non-observance may cause personal injury or serious property damage.
Caution!
This symbol indicates a possible fault.
Non-observance could interrupt the device and any connected systems and plants, or result in
their complete failure.
Note!
This symbol brings important information to your attention.
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Product Specifications
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2 Product Specifications
2.1 Use and Application
This manual applies to the light section sensors VLM350-F280-2E2-1000, VLM350-F280-R41001 and VLM350-F280-R4-1101 (hereafter referred to as
sensor). The sensor compares
cu
rrent height profiles with a previously taught-in height profile. The sensor is based on
SmartRunner technology and combines the light section method for detecting height profiles
with a 2-D vision sensor.
An emitter optic is used to project a laser line onto an object as part of the light section method.
This is detected by a camera at a specific angle. A height and width profile is created using the
triangulation principle. This laser technology provides reliable measurements on different
surfaces.
The sensor is commissioned and operated using the Vision Configurator software. In addition,
preset parameters can be transferred to the sensor via Data Matrix control codes. In this way
you have the opportunity to quickly adapt the settings to the conditions of the measuring
environment and the measuring object without using a laptop in case of replacement.
Structure of the sensor
Figure 2.1 Overview of components and measurement result
The SmartRunner has an optimized hardware and software platform. It is available in different
versions for specific applications. The device is certified according to laser protection class 1.
Features of the sensor
The sensor, optimized and pre-configured for comparing height profiles, offers protection from
damage and from the production of rejects. An object is identified by comparing with stored
reference profiles, which detects whether the object is in the correct position. This means
gripping processes, such as in robotics, are always accurate.
1 Flat profile
2 Raised profile
3 Emitter optic (vision sensor including LED lighting)
4 Camera
5 Height profile on the image sensor (measuring result)
1
1
2
2
3
4
5
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Product Specifications
The integrated control interface of the sensor has been optimized by the factory to report
deviations from a previously programed contour. Via the profile comparison, the sensor
detects the recorded contour of an object, its correct location, and spacing. In case of a fault,
collisions and damage are safely eliminated and lengthy machine downtimes are therefore
avoided.
For this, the sensor is taught in to a specific height profile and a trigger executes a
reconciliation between the currently-recorded contour and the reference contour. A "good"
signal is produced if these are identical. If the two profiles differ, a "Bad" signal is produced.
Figure 2.2 Capturing object contour, position, and distance
Figure 2.3 Sensor
Position Designation Function
1 Good-signal-scenario 1 Taught-in reference contour with adjustable
tolerance range
2 Good-signal-scenario 2 Slight torsion within the tolerance range
3 Bad-signal-scenario 3 Excessive torsion outside the tolerance range
4 Bad-signal-scenario 4 Too great a distance between sensor and object
5 Bad-signal-scenario 5 Incorrect or faulty object detected
2
1
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Product Specifications
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Parameterization and Operating Modes
The laser-line triangulation sensor can be configured or parameterized via 3 different methods.
Reading in code cards via the sensor camera
Processing configuration telegrams via the bus interface
Using the Vision Configurator software
The sensor has different operating modes, which can be activated for configuration,
presentation, or normal operation.
Runtime mode: measurement mode, sensor works as configured
Configuration mode: mode for configuring the sensor via data telegrams and via the
Vision Configurator configuration program
Code card mode: mode for configuring the sensor via Data Matrix control codes without
the assistance of a PC
Presentation mode: mode for presentation or testing without the assistance of a PC
2.2 Hazards of Laser Radiation
This section describes the contents and location of the warning label.
The sensor used corresponds to the safety standard IEC 60825-1:2007 for a laser class 1
product. In addition, the US regulation 21 CFR 1040.10 and 1040.11 is fulfilled except for
Laser Notice No. 50 dated June 24, 2007.
The warning label is fixed to the back of the housing as shown in the following figure.
Figure 2.4 Laser radiation warning message
Warning!
Class 1 laser light
The laser light can be an irritant, especially in a dark environment. Do not point lasers at
people!
Never look into the laser beam port if the sensor is operating.
Maintenance and repairs must be carried out by authorized service personnel only!
Install the device so that the warning is clearly visible and legible.
Do not remove the sensor's protective cover.
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Product Specifications
2.3 Dimensions
The devices in the SmartRunner series have the following identical housing dimensions.
Figure 2.5 Dimensions of the SmartRunner series
2.4 Displays and Controls
Figure 2.6 Overview of displays and controls
38 12 M4
55
85
99.1
32 48
5
8 15.35
M4
20
A
A
14
1
3
4
2
12
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Description of the LEDs
Figure 2.7 LEDs overview
Position Designation Function
1 Emitter optic
protective cover
Is used to protect against damage and contamination
2 Reception optic
protective cover
Is used to protect against damage and contamination
3 LEDs The functional description for the LEDs can be found in
the table below.
4 Function keys in
Presentation mode
Function key 1: triggers an evaluation
Function key 2: when pressed and held for 2 seconds,
activates the teach-in process. When pressed and
held for longer than 2 seconds, activates Code Card
mode
Function keys in
Runtime mode
Function key 1: no function
Function key 2: when pressed and held for longer than
2 seconds, activates Code Card mode
5 Electrical Connection The sensor is connected electrically via a MAIN 8-pin M12
connector plug on the bottom of the housing. See chapter
3.4.
Note!
The function keys are only activated during a parameterizable time span after the sensor is
switched on, after which they are locked. The default value for this time span is 5 minutes.
The function keys have different functions depending on the selected operating state.
Position Designation Function
1 Ready (green/red) Lights up red if there is a sensor fault
Lights up green when the sensor is ready for operation
Flashes green if the sensor is in Configuration mode
2 Match 3/4
(green/yellow)
Lights up green if the scanned profile matches the
taught-in profile 3 (MATCH 3)
Lights up yellow if the scanned profile matches the
taught-in profile 4 (MATCH 4)
2
1
5
6
7
8
4
3
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Product Specifications
2.5 Interfaces
The RS-485 Interface
The reader is equipped with an RS-485 interface for communication purposes, i.e.,
parameterizing the reader functions or reading out current process data during operation. This
interface is operated in 8-E-1 operating mode and fitted with a terminator that can be activated
or deactivated by parameterizing the sensor head.
The RS-485 interface supports the following transfer rates:
38400 bit/s
57600 bit/s
76800 bit/s
115200 bit/s (default value)
230400 bit/s
Data structure of the RS-485 interface
3 Result (green/red) Lights up green if a scanned profile matches a taught-
in profile
Lights up red if a scanned profile does not match a
taught-in profile
Applies in Code Card
mode
Lights up green when a correct code has been read
Lights up red when an incorrect code has been read
Off if no code has been read
4 Match 1/2
(green/yellow)
Lights up green if the scanned profile matches the
taught-in profile 1 (MATCH 1)
Lights up yellow if the scanned profile matches the
taught-in profile 2 (MATCH 2), optional
5 Diagnosis (red) Lights up red if a bus error has occurred
Lights up red if a system error has occurred on the
interface controller
Flashes red if the sensor is in Update mode
6 POWER (green) Lights up as soon as voltage is present
Flashes in Configuration mode
7 Teach in (yellow) Lights up yellow during the teach in process
8 TRIGGER (yellow) Lights up yellow if the hardware trigger signal is
activated
Position Designation Function
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Product Specifications
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2.6 Accessories
Other accessories can be found online at www.pepperl-fuchs.com.
Order designation Description
V19-G-5M-PUR-ABG Single-ended female cordset, M12, 8-pin, shielded, PUR
cable
VLX-MB1 Mounting aid, adaptable 360° adjustment of mounting head
and mounting foot
VLX-MB2 Mounting aid, fixing bracket
PCV-USB-RS485 Converter
Set
USB to RS 485 interface converter
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Installation
3Installation
3.1 Storage and Disposal
Keep the original packaging. Always store and transport the device in the original packaging.
Store the device in a clean and dry environment. The permitted ambient conditions must be
considered, see datasheet.
Disposing of device, packaging, and possibly contained batteries must be in compliance with
the applicable laws and guidelines of the respective country.
3.2 Preparation
Unpacking the unit
1. Check that all package contents are present and undamaged.
If anything is damaged, inform the shipper and contact the supplier.
2. Check that all items are present and correct based on your order and the shipping
documents.
If you have any questions, please contact Pepperl+Fuchs.
3. Keep the original packing material in case you need to store or ship the unit at a later time.
3.3 Mounting the Sensor
The operating distance differs depending on the sensor. The correct operating distance can be
found in the datasheet for the sensor to be installed.
The following illustration shows all the relevant housing dimensions in mm:
Note!
Mounting an optical device
Do not aim the sensor at the sun.
Protect the sensor from direct long-term exposure to sun.
Prevent condensation from forming by not exposing the sensor to any major fluctuations
in temperature.
Do not expose the sensor to the effects of any aggressive chemicals.
Keep the lenses and reflector of the device clean. Clean with a soft cloth, using standard
commercial glass cleaner if necessary.
We recommend to clean the optical surface and to check screw fittings and electrical
connections at regular intervals.
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Installation
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Figure 3.1 Space requirements
The surface must be level to prevent the housing from becoming misaligned when the fittings
are tightened. We advise securing the screws with spring disks to prevent the sensor
becoming misaligned. Following installation of the sensor, ensure that there is still sufficient
space to connect the connection cable to the sensor
Mounting the Housing
The device has 2 M4 threads on the base and on both sides of the housing to allow easy
installation of the sensor in your plant. This means there are 3 different ways to mount the
sensor in your plant.
One-sided lateral mounting with M4 screws: You can mount the housing on its right-hand
or left-hand side using the 2 M4 threaded sleeves. The maximum screw-in depth of the
M4 screws is 8 mm.
Continuous lateral mounting with M3 screws: M4 threaded sleeves are designed in such
a manner that M3 screws pass all the way through the housing. Use 2 sufficiently long M3
screws with 2 lock nuts to mount the device in the plant
38 12 M4
55
85
99.1
32 48
5
8 15.35
M4
20
A
A
14
Caution!
Damage to the equipment caused by improper installation!
Device components can be damaged if the permissible screw-in depths and the maximum
permissible tightening torque is exceeded.
Note that the threads on the bottom of the housing are not thru–holes.
Observe the maximum permissible screw-in depth to avoid damaging the device or mounting
incorrectly.
Never exceed the maximum permissible tightening speed of the fixing screws. The maximum
tightening torque of the mounting screws must not exceed 2 Nm.
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Installation
Mounting on the underside of the device with M4 screws: You can use the 2 threaded
sleeves to mount the housing on the underside of the device. The maximum screw-in
depth of the M4 screws is 5 mm.
Positioning the Sensor
When positioning the sensor, ensure that the camera's field of vision is not obscured by the
objects being scanned.
3.4 Electrical Connection
Connecting the Supply Voltage
The sensor is connected electrically via a MAIN 8-pin M12 connector plug on the bottom of the
housing. The power supply and data transfer take place via this connection. To connect the
sensor, proceed as follows:
1. Plug the 8-pin M12 socket into the plug on the bottom of the housing.
2. Screw the lock nut onto the connector as far as it will go. This ensures that the power cable
cannot be pulled out inadvertently.
Tip
The corner of the housing where the MAIN 8-pin M12 connector plug is located can be rotated.
Depending on the mounting position, you can rotate the connector plug in a different direction
to ensure simple cabling.
Figure 3.2 M12 connector plug
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Figure 3.3 Connection layout
Pepperl+Fuchs single-ended female cordsets are manufactured in accordance with EN609475-2. When using a V19-G-5M-PUR-ABG single-ended female cordset with an open cable end,
connector pins are assigned as follows:
Pin Wire color Signal Description
1 white IN trigger Trigger input. Triggers an evaluation, if the
sensor is in continuous evaluation mode
(independent)
2 brown +UB + 24 V power supply
3 green Data+ RS-485 RS-485 interface: Data +
4 yellow Data- RS-485 RS-485 interface: Data -
5 gray Teach Control signal for teaching in the background
line
6 pink Good Output 1 is set if the height profile detected
matches the taught-in profile in terms of form
and position.
Once the teach-in process has been
performed, this output signals that teach-in
was successful
7 blue GND Ground for the + 24 V power supply
8 red Bad Output 2 is set if:
No object has been detected
or
The form detected does not match the
taught-in form
or
The position detected is outside the
tolerance.
Once the teach-in process has been
performed, this output signals that teach-in
has not been successful
1
4
6
7
8
5
3
2
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Installation
Connection using the RS-485 Interface
Figure 3.4 PCV-USB-RS-485 Converter Set
1. Plug a plug-in power supply into a socket and connect it to the interface converter.
The indicator LEDs on the sensor light up.
2. Establish a USB connection between the PC system and interface converter.
The PWR LED on the interface converter lights up red.
Shielding Cables
The shielding of connection lines is required to suppress electromagnetic interference.
Establishing a low resistance or low impedance connection with the protective conductor or
equipotential bonding circuit is a particularly important factor in ensuring that these
interference currents do not become a source of interference themselves. Only use connection
lines with braid. Avoid connection lines with foil shield because this would increase the line
capacities. The shielding is integrated at both ends, i.e., in the switch cabinet, on the control
panel, and on the reader. The grounding terminal available as an accessory allows easy
integration in the equipotential bonding circuit.
In exceptional cases, the shielding of a connection at one end may be more favorable if:
An equipotential bonding cable is not laid or cannot be laid.
A film shield is used.
The following points relating to shielding must also be noted:
Use metal cable clips that cover large areas of the shield.
After installing the cable shield in the control cabinet, place it directly on the equipotential
bonding rail.
USB
110 V / 230 V
24 V DC
RS 485
Caution!
Damage to the device
Connecting an alternating current or excessive supply voltage can damage the device or
cause the device to malfunction.
Electrical connections with reversed polarity can damage the device or cause the device to
malfunction.
Connect the device to direct current (DC). Ensure that the supply voltage rating is within the
specified device range. Ensure that the connecting wires on the female cordset are connected
correctly.
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