.............................................................................................................................................32. CE сompliance
.............................................................................................................................................34. General information
.............................................................................................................................................45. Basic technical data
.............................................................................................................................................46. Example of item designation when ordering
.............................................................................................................................................57. Structure and operating principle
.............................................................................................................................................2112. Communication
.............................................................................................................................................3013. Intended use
.............................................................................................................................................3114. Technical support
Use supply voltage and interfaces indicated in the system specifications.
·
In connection/disconnection of cables, the system power must be switched off.
·
Do not use the system in locations close to powerful light sources.
2. CE сompliance
The system has been developed for use in industry and meets the requirements of
the following Directives:
·
EU directive 2014/30/EU. Electromagnetic compatibility (EMC).
·
EU directive 2011/65/EU, “RoHS“ category 9.
3. Laser safety
The system makes use of an c.w. 660 nm wavelength semiconductor laser.
Maximum output power is 1 mW. The system belongs to the 2 laser safety class according
to IEC/EN 60825-1:2014. The following warning label is placed on the housing:
The following safety measures should be taken while operating the system:
·
Do not target the laser beam to humans.
·
Do not disassemble the laser sensor.
·
Avoid staring into the laser beam.
4. General information
The system is designed for non-contact scanning and inner diameter measurement
of the pipes.
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5. Basic technical data
Parameter
Value
Measured ID range, mm
35...55
ID measurement accuracy, mm
±0.05
Angle scan resolution, points for turnover
3200
Pipe depth, mm
100
Linear translation accuracy, mm
±0.05
Laser sensor linearity, µm
±15
Laser sensor resolution, µm
3
Laser sensor sample frequency, Hz
9400
Light source
red semiconductor laser,
660 nm wavelength
Laser sensor output power, mW
1
Laser safety class
2 (IEC60825-1)
Interface
Ethernet and PROFINET
Power supply, V
220
Measurement time, s
<5
Environmental resistance
Vibration
20 g / 10…1000 Hz, 6 hours for
each of XYZ axes
Shock
30 g / 6 ms
Permissible ambient light, lx
30000
Relative humidity, %
5-95 (no condensation)
Operating ambient temperature, °С
0…+45
Storage temperature, °С
-20…+70
Weight (without cables), gram
6800
Symbol
Description
Dmin/Dmax
ID measurement range, mm.
L
Measurement depth, mm.
Pipe ID Control System. RF096-35/55-100 Series
4
Note: System parameters can be changed for a specific task.
6. Example of item designation when ordering
RF096-Dmin/Dmax-L
Example: RF096-35/55-100 - Pipe ID Control System, ID measurement range - 35...55 mm, measurement
depth - 100 mm.
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Pipe ID Control System. RF096-35/55-100 Series
7. Structure and operating principle
Operation of the system is based on scanning the pipe inner surface with a rotating
triangulation laser sensor.
The system contains a base on which the linear translation mechanism, the
controller and the interface module are installed. The linear translation mechanism carries
the rotation module on which the laser sensor is mounted. On the back of the system there
are four connectors for power and interfaces.
The system operates as follows.
The measured pipe is installed coaxially with the laser sensor. At the command of
an external controller, the laser sensor moves into the hole. The sensor begins to rotate and
scans the inner surface of the pipe, transmits the polar coordinates of the surface (distance
from the axis of rotation measured by the sensor and the corresponding angle of rotation) to
the built-in computer to calculate the required geometric parameters. The result is
transmitted to the external controller via PROFINET.
8. Connection
·
Connect the system to your controller.
·
Connect the power cable to the system.
·
Connect the system to 24V DC by using the special power cable.
The block diagram is shown below. In this diagram, I-7580 module is PROFINET IO
device of the system, and PLC is S7-1200 from Siemens. The program «Step 7 V11»
provided by Siemens does the configuration and communication.
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PC
PLC
I-7580
–
Device name: PLC_1
Device name: i-7580
IP: 192.168.1.210
IP: 192.168.6.211
IP: 192.168.1.212
Mask: 255.255.0.0
Mask: 255.255.0.0
Mask: 255.255.0.0
6
9. Network configuration
Configure the network as shown below:
9.1. PC
1. Select Start Menu > Control Panel > Network and Sharing Center. (For
Windows 8 and higher, search for Control Panel, and select Network andInternet).
2. Click Change adapter settings.
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Pipe ID Control System. RF096-35/55-100 Series
3. Right-click on Local Area Connection and select Properties.
4. Select Internet Protocol Version 4 (TCP/IPv4) and click on Properties.
5. Select Use the following IP address and enter the IP address, Subnet Mask,
Default Gateway and DNS server.
Click OK and close the Local Area Connection Properties window.
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8
9.2. PLC
1. Double-click the TIA icon to start Step 7 V11.
2. Click Project view.
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Pipe ID Control System. RF096-35/55-100 Series
3. Search for accessible devices.
4. Select PLC and click the Online & diagnostics button.
5. Set the IP address and the subnet mask.
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6. Set the device name.
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Pipe ID Control System. RF096-35/55-100 Series
9.3. I-7580 module
1. Search for accessible devices.
2. Select I-7580 module and click the Online & diagnostics button.
3. Select Menu > Options > Install general station description file (GSD).
4. Select and install the GSD file.
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14
11. Project setup
Please follow the steps to setup the project:
1. Double-click the TIA icon to start Step 7 V11.
2. Create the project.
Step 1: Create the project
1. Add the PLC device.
Step 2: Project configuration
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Pipe ID Control System. RF096-35/55-100 Series
2. Select Add new device.
3. Set the PLC name to «PLC_1».
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16
4. Set the IP address and the subnet mask for PLC and add the new subnet.
5. Add the I-7580 module.
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Pipe ID Control System. RF096-35/55-100 Series
6. Select the PROFINET interface.
7. Set the device name to «i-7580».
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18
8. Set the IP address for the I-7580 module.
9. Set the module type for the I-7580 module.
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Pipe ID Control System. RF096-35/55-100 Series
10. Set parameters for the I-7580 module.
11. Compile and download to the device.
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Pipe ID Control System. RF096-35/55-100 Series
12. Communication
12.1. Communication sequence
The I-7580 module basically contains 4 buffers:
·
PROFINET IO device input buffer.
·
PROFINET IO device output buffer.
·
COM port input buffer.
·
COM port output buffer.
The PROFINET IO controller basically contains 2 buffers:
·
PROFINET IO controller input buffer.
·
PROFINET IO controller output buffer.
In the I-7580 module, data is transferred from the COM port input buffer to the
PROFINET IO device output buffer, and from the PROFINET IO device input buffer to the
COM port output buffer. The data flow is illustrated below.
During each message cycle, the PROFINET IO controller writes the content of its
output buffer to the PROFINET IO device input buffer and reads the content of the
PROFINET IO device output buffer to its input buffer. The exchange cycle is taking place
even though the content of the PROFINET IO controller and PROFINET IO device output
buffer has not changed. The data flow between the PROFINET IO controller and the I-7580
module is shown below.
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Byte
Data
Description
0
0x00
I-7580 does not transmit I/O data.
0x01
I-7580 transmits data to the COM port.
0x02
I-7580 receives data from the COM port.
1
Error State
Bit 0: Output FIFO overflow
Bit 1 : Input FIFO overflow
Bit 2 : Output Data loss
Bit 3 : Input Data loss
Bit 4 : Input Data overflow
2
Length
Received data length (High byte)
3
Received data length (Low byte)
4
Input
Received data count (High byte)
5
Count
Received data count (Low byte)
6
Output
Transmitted data count (High byte)
7
Count
Transmitted data count (Low byte)
8 511
Data
Receive data from the COM port
12.2. PROFINET Input Data Area
The maximum input data length of I-7580 is 512 bytes. The first 8 bytes of the
received input data are reserved for the communication status. The remaining data in the
input data area represents the data packet received from the serial network. The 9th byte
therefore shows the first byte of the received serial data.
22
The I-7580 module has three modes to identify data from two batches of data
packet. These modes are: (1) Interval time, (2) Fixed data length, and (3) End character of
data.
12.2.1. "Interval time" mode
If the time between two consecutive bytes exceeds the timeout value, the module
transfers the data from the COM port input buffer to the PROFINET IO device output buffer.
The default timeout value is set to the duration needed to send one data byte. That means if
after a time period of one byte no additional data arrives, then the data that is already in the
COM port input buffer will be regarded as a data packet.
The interval time between messages arriving at the COM port must be greater than
2 milliseconds.
12.2.2. "Fixed data length" mode
The converter counts the number of bytes arriving at the COM port. If the specified
amount of data has entered the serial input buffer, the content is removed from the input
buffer and transferred to the PROFINET IO device output buffer. The last string will only be
send after a transmit time of three bytes has elapsed. To use this feature, you need to set
the “Input fixed length data” parameter to “Enable”. The data length has to be defined in
bytes 5-6 of the PROFINET output data area (please refer to section "PROFINET Output
Data Area").
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Byte
Data
Description
1
0 255
Data output command.
2
0x01
Control bit – clear all diagnostic messages.
0x02
Control bit – clear Received data count.
0x04
Control bit – clear Transmitted data count.
3
Length
Output data length (High byte).
4
Output data length (Low byte).
Pipe ID Control System. RF096-35/55-100 Series
12.2.3. "End character" mode
As soon as the converter detects the end characters of the incoming serial data
stream, it removes the data from the serial receive buffer and transfers it to the PROFINET
IO device output buffer of the converter.
If the time interval between two consecutive bytes is longer than the time needed to
transmit three bytes, then the module treats this situation as an end of a string.
To use this feature, the "End char of input data" parameter must not be set to
"None".
12.3. PROFINET Output Data Area
The maximum output data length of I-7580 is 384 bytes. The first 8 bytes are
needed to set the communication behavior of the converter.
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5
Length
Fixed data length (High byte).
6
Fixed data length (Low byte).
7
0~255
Interval time between the two batches of the data.
8
0~255
Timeout value.
9~384
Data
Output data to COM port.
ATTENTION!
The converter will send no data to the connected serial devices if the content of the first byte of
two consecutive PROFINET messages is identical. Even if the remaining bytes differ, no
message will be forwarded to the COM port. The converter detects a new data packet only by
checking the first byte.
12.3.1. Data output command (byte 1)
The PROFINET IO Controller is cyclically polling the I-7580 module. The PROFINET
IO Controller sends data from its output buffer to the input buffer of the converter. If no new
data is put on the PROFINET IO Controller output buffer, the PROFINET IO Controller sends
the same data in each polling cycle. Therefore, it is necessary for the converter to detect
whether the data arriving at its PROFINET IO device input buffer has already been sent
before or is new. The converter recognizes a new data packet when the value of the first
byte differs from the previous data packet. A change of the first byte results in an immediate
output of the newly arrived data (at the PROFINET IO device input buffer) to the serial COM
port.
When the user wants to send a new data packet to the converter, the user should
increase progressively the first byte (ex: 0->1, 1->2, 2->3, …, 255->0), and the converter will
send the new data packet to the serial COM port. If the user changes the first byte but
doesn’t increase progressively it (ex: 0->2, 1->3, 2->5), the converter will send a diagnostic
message "Output data - data loss". This message informs the user that the PROFINET data
may be loss.
24
12.3.2. Control bit (byte 2)
Bit 0: When this bit is set, all diagnostic messages sent by the I-7580 module will be
cleared.
Bit 1: When this bit is set, the I-7580 module sets the Received data count to zero
(please refer to section "PROFINET Input Data Area").
Bit 2: When this bit is set, the I-7580 module sets the Transmitted data count to
zero (please refer to section "PROFINET Input Data Area").
Bit 3~7: The remaining bits have to be set to zero.
12.3.3. Output data length (byte 3, byte 4)
The default value for the output data length is 0. It has to be set for every single
output command, otherwise no data will be sent to the COM port.
These two bytes determine the number of bytes copied from the I-7580 PROFINET
IO device input buffer to the COM port output buffer. This means that regardless of the data
length sent by the master, only the number of bytes specified in the third byte will be
forwarded to the COM port.
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Pipe ID Control System. RF096-35/55-100 Series
12.3.4. Fixed data length (byte 5, byte 6)
These two bytes determine the length of the response data string. The converter
waits until the data arriving at the COM port buffer has reached the specified length.
To use this feature, the "Input fixed length data" parameter has to be set to
"Enable".
12.3.5. Interval time (byte 7)
This byte can increase the interval time between two batches of the data packet. It
means the converter can delay the data output from PROFINET to the COM port.
Example: Interval time – 15 ms.
12.3.6. Timeout value (byte 8)
The timeout is only relevant for the communication between the I-7580 converter
and the serial network. The converter receives the response of the device at the COM port
as a continuous data stream. A silent interval in the data stream exceeding the timeout
value signals the converter the end of the message and forwards this message to its
PROFINET IO device output buffer.
Valid values for the timeout: 0 to 255.
The value "0" represents the minimum value which equals the transmission time of
one byte [(start bit+data bit+parity bit+stop bit)/Baudrate].
The value "1" assigns a timeout value of either 1 or 10 milliseconds depending on
the chosen unit (1 or 10 ms).
The value "255" represents either 255 milliseconds (time unit: 1 ms) or 2550
milliseconds (time unit:10 ms).
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Area
byte
Data from PLC to System
Data from System to PLC
Description
Var Type
Description
Var Type
0
Calibration diameter
Real
Last diameter read average
Real4Real
Last diameter read minimum
Real
8 Real
Last diameter read maximum
Real
12
Measurement position (from a zero
point of a pipe)
Real
Real
16
Int
Int
18 Int Int
20 Int Int
22 Int Int
24.0
Start calibration command
Bool
Calibration running
Bool
24.1 Bool
Calibration Done
Bool
24.2
Bool
Calibration error
Bool
24.3
Start measure command
Bool
Measure running
Bool
24.4
Bool
Measure Done
Bool
24.5 Bool
Measure error
Bool
24.6
New data transfer
Bool
New data transfer request read
Bool
24.7 Bool
New transfer data read
Bool
25.0
Abort measure
Bool
System error
Bool
25.1
Move to zero
Bool
Move to zero running
Bool
25.2 Bool
Move to zero Done
Bool
25.3 Bool
Move to zero error
Bool
25.4 Bool
Bool
25.5 Bool
Bool
25.6 Bool
Bool
25.7 Bool
Bool
This byte specifies the timeout for the data stream of the serial response. If the
multiply responses are expected for every request sent by the converter, then the timeout
applies to all these messages.
12.4. Communication between PLC and system
Communication between PLC and system:
26
12.4.1. General information
Every system error of the pipe control system must set the System error variable.
If this bit is raised up during any measurement, every cycle will be interrupted and
measurement results will not be read.
If for any reason PLC sets the Abort measure variable during the measurement
cycle, the pipe control system must finish the running procedure and move a laser sensor
into a safe position. This can be done if the operator checks for any anomaly during the
measurement cycle.
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Pipe ID Control System. RF096-35/55-100 Series
12.4.2. Data transfer
·
PLC prepares variables with the new data according to production requirements:
Calibration diameter, Measurement position.
·
PLC requires to save the new data in the pipe control system by setting the New
data transfer flag = TRUE and waits until the process is complete.
·
The pipe control system sets New data transfer request read = TRUE and
holds it until all data is read.
·
When the pipe control system has finished reading the new data from PLC, it sets
New transfer data read = TRUE and holds this flag waiting a reply from PLC.
·
PLC reads that the pipe control system has completed the procedure and resets
New data transfer = FALSE.
·
The pipe control system resets variables New data transfer request read =
FALSE and New transfer data read = FALSE.
12.4.3. Calibration
·
PLC requires to perform the calibration procedure for the pipe control system by
Start calibration command = TRUE and holds this flag until the process is
complete.
·
When the pipe control system starts the calibration cycle, it sets Calibration
running = TRUE and holds it until the process is complete.
·
When the pipe control system has completed the calibration process, it sets
Calibration Done = TRUE and holds it waiting a reply from PLC.
·
PLC reads that the pipe control system has completed the procedure and resets
Start calibration command = FALSE.
·
The pipe control system resets variables Calibration running = FALSE ,
Calibration Done = FALSE.
12.4.4. Measurement
·
PLC requires to make a new measurement by Start Measure command =
TRUE and holds the flag until the process is complete.
·
The pipe control system starts the measurement cycle, sets Measure running =
TRUE and holds it until the process is complete.
·
When the pipe control system has completed the measurement process, it writes
variables Last diameter average, Last diameter read minimum, Lastdiameter read maximum, sets Measure Done = TRUE and holds this flag until
all the measurement data is read by PLC.
·
PLC reads that the pipe control system has completed the measurement
procedure and resets Start Measure command = FALSE.
·
The pipe control system resets variables Measure running = FALSE, Measure
Done = FALSE.
12.4.5. Go to zero
·
PLC requires the pipe control system to go to a zero position, sets Move to zero
= TRUE and holds this flag until the process is complete.
·
The pipe control system starts to move a laser sensor to a zero position, sets
Move to zero running = TRUE and holds the flag until the process is complete.
·
When the pipe control system has completed the process, it sets Move to zero
Done = TRUE and holds it waiting a reply from PLC.
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·
PLC reads that the pipe control system has completed the procedure and resets
Move to zero = FALSE.
·
The pipe control system resets variables Move to zero running = FALSE,
Move to zero Done = FALSE.
12.5. Communication tests
The user can perform communication tests by connecting the system to the PC
using the Ethernet connector.
1. On the PC, we use "PuTTY" to test.
Pipe ID Control System. RF096-35/55-100 Series
Step 1: Run SSH client
28
2. Enter a host name 192.168.1.100 as shown below, and click Connect (Open).
Step 2: Work with terminal
1. Write Login and Password:
Login: pi
Password: raspberry
2. After 5-10 seconds, when you see a picture as shown below (the process is
restarted for a new session), press Ctrl+C to end it.
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Pipe ID Control System. RF096-35/55-100 Series
3. Enter the command «ps -a» to check if the «run» process is exited. If the process
still works, kill it by the command «kill -9 XXX», where XXX – the number of the «run»
process.
4. Run the test process: «LD_LIBRARY_PATH=. ./run_contest».
5. Make a selection by typing a number [1-4]:
1 - Test the data transfer command by setting the measurement position to 10.5
mm.
2 - Test the calibration process.
3 - Test the measurement process.
4 - Test the "move to zero" process.
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12.6. Diagnostic messages
Type
Description
Output Data Error
FIFO overflow.
Data loss.
Input Data Error
FIFO overflow.
The I-7580 module has two types of diagnostic messages: "Output Data Error" and
"Input Data Error".
12.6.1. Output Data Error
Pipe ID Control System. RF096-35/55-100 Series
1. When the PROFINET network speed is higher than the serial network speed and
the PROFINET IO controller continuously transmits data to the I-7580 module, the
output buffer of the I-7580 module will overflow, and the I-7580 module will send a
diagnostic message "Output Data Error – FIFO overflow".
2. When the I-7580 module receives the data output command (first byte of the
output data area, please refer to section "PROFINET Output Data Area") from
the PROFINET IO controller and the command is not increased continuously (for
example: 0->1, 1->2 ... 254->255, 255->0), the I-7580 module will send a
diagnostic message "Output Data Error – Data loss" to the PROFINET IO
controller.
12.6.2. Input Data Error
1. When the serial network speed is higher than the PROFINET network speed and
the serial device continuously transmits data to the I-7580 module, the input
buffer of the I-7580 module will overflow, and the I-7580 module will send a
diagnostic message "Input Data Error – FIFO overflow".
2. When the I-7580 module cannot receive data in time from the COM port, it will
send a diagnostic message "Input Data Error – Data loss". Please refer to
section "PROFINET Input Data Area".
3. The maximum input data length for the COM port of the I-7580 module is 506
bytes. When the COM port of the I-7580 module receives data larger than 506
bytes, it will send a diagnostic message "Input Data Error – Data overflow".
30
13. Intended use
13.1. Preparation for use
·
Check the condition of the output window of a laser sensor and, if necessary, wipe
it with a soft cloth.
·
Rotate a laser sensor by hand and check the smooth progress.
·
Check the cables and power supply.
·
Make sure that the network settings are correct.
·
Switch on the system.
·
Run the test procedures. Please refer to section 12.5. "Communication tests".
13.2. Measurements
Run the sequence of commands described in section 12.4. "Communication
1F, Building 9, 100 Xianlie Rd.,
Guangzhou, China
Tel: +86 755 85267190/
+86 15989362481
Fax: + 86 755 85267190
shengz_k@163.com
www.jrktech.com
CHINA
Shanghai micron-metrology
com., Ltd.
Room 602 unit 4, lane 399,
Mudan road, Pudong New district
Shanghai, China
Tel: +86-21-68416510
sales@micron-metrology.cn
www.micron-metrology.cn
Pipe ID Control System. RF096-35/55-100 Series
14. Technical support
Technical assistance related to incorrect operation of the system and to problems
with a service program is free. Requests for technical assistance should be addressed at
support@riftek.com.
15. Warranty policy
Warranty assurance for the Pipe ID Control System RF096-35/55-100 Series - 24
months from the date of putting in operation; warranty shelf-life - 12 months.
16. Revisions
17. Distributors
RF096-35/55-100 [Revision 1.0.0] 12.12.2018
Pipe ID Control System. RF096-35/55-100 Series
CHINA
Zhenshangyou Technologies
Co., Ltd.
Rm 2205-2210, Zhongyou Hotel
1110 Nanshan Road, Nanshan
District 518054 Shenzhen, China
Tel: +86 755-26528100/8011/8012
Fax: +86 755-26528210/26435640