SICK MLG-2 Pro Operating Instructions Manual
MLG-2 Pro
Measuring automation light grid
O P E R A T I N G I N S T R U C T I O N S
Described product
MLG-2 Pro
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is only
permissible within the limits of the legal determination of Copyright Law. Any modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
CONTENTS
1 About this document........................................................................ 7
1.1 Purpose of this document........................................................................ 7
1.2 Scope......................................................................................................... 7
1.3 Target group.............................................................................................. 7
1.4 Information depth..................................................................................... 7
1.5 Symbols used............................................................................................ 7
1.6 Abbreviations used................................................................................... 8
2 Safety information............................................................................ 9
2.1 Requirements for the qualification of personnel.................................... 9
2.2 Correct use................................................................................................ 9
2.3 General safety notes................................................................................. 10
3 Product description........................................................................... 11
3.1 Type labels of the MLG-2 Pro................................................................... 11
3.2 MLG-2 Pro type code................................................................................ 11
3.2.1 Monitoring height..................................................................... 12
3.2.2 Combinations of MLG-2 Pro inputs and outputs................... 13
3.2.3 Optical properties.................................................................... 13
3.2.4 MLG-2 Pro preconfigurations.................................................. 13
3.3 MLG-2 product properties........................................................................ 15
3.4 Setup and function................................................................................... 15
3.4.1 MLG-2 Pro device components............................................... 15
3.4.2 Measurement principle........................................................... 16
3.4.3 Synchronizing the MLG-2........................................................ 16
3.4.4 Beam separations and monitoring height............................. 16
3.4.5 Teach-in.................................................................................... 17
3.4.6 Beam blanking......................................................................... 18
3.4.7 Sensing ranges........................................................................ 19
3.5 Scan time.................................................................................................. 19
3.5.1 Response time, minimum presence time and reproducibil‐
ity of the MLG-2........................................................................ 20
3.5.2 Scan time with cross-beam function...................................... 20
3.5.3 Scan time with high-speed scan on the MLG-2..................... 21
3.6 Beam separation and minimum detectable object................................ 22
3.6.1 Minimum detectable object with parallel-beam function..... 22
3.6.2 Minimum detectable object length......................................... 23
3.6.3 Minimum detectable object with cross-beam function ........ 24
3.6.4 Minimum detectable object with high measurement accu‐
racy from the MLG-2................................................................ 25
3.7 Operating reserve..................................................................................... 26
3.7.1 Operating reserves on the MLG-2........................................... 26
3.8 MLG-2 operating modes........................................................................... 26
3.8.1 Standard operating mode....................................................... 27
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CONTENTS
3.8.2 Transparent operating mode.................................................. 27
3.8.3 Dust- and sunlight-resistant operating mode........................ 27
3.9 Interfaces ................................................................................................. 28
3.9.1 Output of measurement data (raw data)............................... 28
3.9.2 Preliminary evaluation............................................................. 29
3.9.3 Configurable applications of the MLG-2 Pro.......................... 29
3.10 Display and operating elements.............................................................. 31
3.10.1 Sender...................................................................................... 31
3.10.2 Receiver.................................................................................... 31
3.11 Inputs......................................................................................................... 33
3.11.1 Switching inputs on the MLG-2 Pro receiver.......................... 33
3.11.2 Test input on the sender......................................................... 33
3.12 Application examples............................................................................... 33
3.12.1 Application examples for the MLG2....................................... 33
4 Mounting............................................................................................. 35
4.1 Scope of delivery...................................................................................... 35
4.2 Recommended mounting arrangements................................................ 35
4.2.1 Mounting with light in opposite directions............................. 35
4.2.2 Mounting with light in the same direction.............................. 36
4.2.3 Placement of two light grids at right angles........................... 38
4.2.4 Minimum distance from reflective surfaces.......................... 39
4.3 Mounting procedure................................................................................. 40
4.3.1 Mounting the QuickFix bracket............................................... 40
4.3.2 Mounting the FlexFix bracket.................................................. 41
5 Electrical installation........................................................................ 43
5.1 MLG2 Pro electrical installation............................................................... 43
5.1.1 T-distributor for MLG2 Pro connection................................... 46
6 Commissioning.................................................................................. 50
6.1 Mechanical alignment of sender and receiver....................................... 50
6.2 Alignment and teach-in............................................................................ 51
6.2.1 MLG-2 Pro................................................................................. 51
7 Configuration with SOPAS ET.......................................................... 53
7.1 Preparation............................................................................................... 53
7.1.1 Installing the software............................................................. 53
7.1.2 Device selection....................................................................... 53
7.2 SOPAS ET interface................................................................................... 54
7.2.1 System boundaries, status, and interfaces........................... 55
7.2.2 Basic functions and status of the output............................... 58
7.2.3 Representation of the detection area.................................... 59
7.2.4 Expandable menus.................................................................. 62
7.3 System settings......................................................................................... 64
7.3.1 System settings for the user levels EASY and EXPERT......... 64
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7.3.2 System settings for the EXPERT user level............................ 65
7.4 Measuring and diagnostic functions for switching outputs................... 66
7.4.1 Height classification................................................................ 67
7.4.2 Object recognition.................................................................... 69
7.4.3 Object detection/object width................................................ 71
7.4.4 Hole detection/hole size......................................................... 73
7.4.5 Outside/inside dimension....................................................... 75
7.4.6 Classification of an object position........................................ 77
7.4.7 Classification of a hole position.............................................. 78
7.4.8 Diagnostics............................................................................... 80
7.5 Measuring and diagnostic functions for analog outputs....................... 80
7.5.1 Object height measurement .................................................. 81
7.5.2 Hole detection ......................................................................... 81
7.5.3 Object detection....................................................................... 82
7.5.4 Measuring the outer or inner dimension .............................. 82
7.5.5 Measurement of the object position ..................................... 83
7.5.6 Measurement of the hole position ........................................ 83
7.5.7 Diagnostic functions ............................................................... 83
7.6 Advanced settings for the outputs........................................................... 84
7.7 Zones......................................................................................................... 85
7.7.1 “Zone measuring” function..................................................... 85
7.8 Data output via the interfaces................................................................. 87
7.8.1 RS485 – Data transmission format....................................... 87
7.8.2 RS485 – Transmission mode................................................. 88
7.8.3 RS485 and IO-Link – Data transmission content................. 88
7.9 Teach-in..................................................................................................... 90
7.10 Performance options................................................................................ 93
7.10.1 “Cross beam” function............................................................ 96
7.10.2 Energy options (only in the EXPERT user level)..................... 99
7.11 Beam evaluation....................................................................................... 99
7.11.1 “Blocked Beams Hold (BBH)” evaluation mode.................... 99
7.11.2 “Lost Beams Hold (LBH)” evaluation mode........................... 101
7.12 Simulation................................................................................................. 102
7.13 Beam monitor (only in the EXPERT user level)....................................... 103
7.14 Function programming (in the EXPERT user level)................................. 104
7.14.1 Beam functions........................................................................ 107
7.15 MLG-2 configuration with the internal web server................................. 108
8 IO-Link................................................................................................. 110
8.1 Configuration via acyclic service data..................................................... 110
8.2 Data storage (IO-Link)............................................................................... 110
8.3 Output of process data from the MLG-2 Pro........................................... 110
9 RS-485................................................................................................ 112
9.1 Payload...................................................................................................... 112
9.2 Data volume for the beam functions....................................................... 113
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CONTENTS
9.3 Data volume for the separators............................................................... 113
9.4 Transmitting the beam status.................................................................. 114
9.5 Calculation examples for the total data volume..................................... 114
10 Servicing............................................................................................. 115
11 Troubleshooting................................................................................. 116
11.1 Response to faults.................................................................................... 116
11.2 SICK support............................................................................................. 116
11.3 LED indicators and error indicators......................................................... 116
11.3.1 .................................................................................................. 117
11.4 Advanced diagnostics on the MLG-2....................................................... 117
12 Decommissioning............................................................................. 118
12.1 Disposal..................................................................................................... 118
12.2 Returns...................................................................................................... 118
13 Technical data....................................................................................119
13.1 Data sheet................................................................................................. 119
13.2 Diagrams................................................................................................... 122
13.2.1 Response time and minimum presence time without high-
speed scan............................................................................... 122
13.2.2 Response time and minimum presence time during high-
speed scan with 2,5 mm resolution....................................... 123
13.2.3 Response time and minimum presence time during high-
speed scan with up to 3.5 m sensing range.......................... 123
13.2.4 Response time and minimum presence time during high-
speed scan with up to 8.5 m sensing range.......................... 124
13.2.5 Minimum detectable absorption............................................ 124
13.3 Dimensional drawings.............................................................................. 126
13.3.1 MLG-2 Pro dimensional drawing............................................. 126
13.3.2 Measurement tables............................................................... 127
14 Ordering information........................................................................ 128
15 Accessories........................................................................................ 129
15.1 Accessories............................................................................................... 129
16 Annex.................................................................................................. 132
16.1 Compliance with EU directive................................................................... 132
17 List of figures..................................................................................... 133
18 List of tables....................................................................................... 136
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1 About this document
1.1 Purpose of this document
These operating instructions are for giving technical personnel of the machine manu‐
facturer or operator instructions on the mounting, configuration, electrical installation,
commissioning, operation, and maintenance of the MLG-2 measuring automation light
grid.
These operating instructions do not provide information on operating the machine into
which a measuring automation light grid is integrated. For information about this, refer
to the operating instructions of the particular machine.
ABOUT THIS DOCUMENT 1
1.2
Scope
These operating instructions apply to the MLG-2 Pro measuring automation light grid.
1.3 Target group
These operating instructions are intended for planning engineers, developers, and
operators of plants and systems into which one or more MLG-2 measuring automation
light grids are to be integrated. They are also intended for people who integrate the
MLG-2 into a machine, carry out its commissioning, or who are in charge of mainte‐
nance.
1.4 Information depth
These operating instructions contain information about the MLG-2 measuring automa‐
tion light grid on the following topics:
Mounting
•
Electrical installation
•
Commissioning and configuration
•
Care
•
When planning and using a measuring automation light grid such as the MLG-2, techni‐
cal skills are required that are not covered by this document.
The official and legal regulations for operating the MLG-2 must always be complied
with.
Fault diagnosis
•
Part numbers
•
Conformity and approval
•
NOTE
Please also refer to the SICK AG website: www.sick.de.
1.5 Symbols used
Recommendation
Recommendations are designed to assist you in the decision-making process with
respect to the use of a certain function or a technical measure.
NOTE
Notes inform you about special aspects of the device.
O, Ö, o
LED symbols describe the status of a diagnostics LED. Examples:
O
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The LED is illuminated continuously.
7
1 ABOUT THIS DOCUMENT
Ö
ôKõ
o
Take action ...
b
Instructions for taking action are indicated by an arrow. Carefully read and follow the
instructions for action.
CAUTION
Warning!
A warning indicates a specific or potential hazard. This is intended to protect you
against accidents.
Read carefully and follow the warnings!
s r Sender and receiver
In figures and connection diagrams, the symbol s indicates the sender and r indi‐
cates the receiver.
1.6 Abbreviations used
BNB Beam Number (x) Blocked
BNM Beam Number (x) Made
CBB Central Beam Blocked
CBM Central Beam Made
FBB First Beam Blocked
FBM First Beam Made
IDI Inner Dimension
LBB Last Beam Blocked
LBM Last Beam Made
MDA Minimum Detectable Absorption
MDO Minimum Detectable Object
MLG-2 Measuring automation light grid 2
MOL Minimum Detectable Object Length
MSB Most Significant Bit
NBB Number of Beams Blocked
NBM Number of Beams Made
NCBB Number of Consecutive Beams Blocked
NCBM Number of Consecutive Beams Made
ODI Outer Dimension
RLC Run-length code
SDD SOPAS Device Description
PLC Programmable logic controller
The LED flashes evenly.
The LED flashes briefly.
The LED is off.
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2 Safety information
2.1 Requirements for the qualification of personnel
The MLG-2 measuring automation light grid must only be mounted, commissioned, and
maintained by authorized personnel.
NOTE
Repair work on the MLG-2 may only be performed by qualified and authorized service
personnel from SICK AG.
The following qualifications are necessary for the various tasks:
Task Qualification
Mounting
Electrical installation and
device replacement
Commissioning, operation, and
configuration
Table 1: Authorized personnel
Basic practical technical training
•
Knowledge of the current safety regulations in the work‐
•
place
Practical electrical training
•
Knowledge of current electrical safety regulations
•
Knowledge of the operation and control of the devices
•
in their particular application (e. g., industrial robots,
storage and conveyor systems)
Knowledge of the current safety regulations and of the
•
operation and control of the devices in their particular
application
Knowledge of automation systems
•
Knowledge of how to use automation software
•
SAFETY INFORMATION 2
2.2 Correct use
The MLG-2 measuring automation light grid is a measuring device which is manufac‐
tured according to the recognized industrial regulations and which meets the quality
requirements stipulated in ISO 9001:2008 as well as those relating to environmental
management systems as defined in ISO 14001:2009.
The measuring automation light grids are solely intended for the optical and non-con‐
tact detection of objects, animals, and persons.
A measuring automation light grid is designed for mounting and may only be operated
according to its intended function. For this reason, it is not equipped with direct safety
devices.
The system designer must provide measures to ensure the safety of persons and sys‐
tems in accordance with the legal guidelines.
In the event of any other usage or modification to the MLG-2 measuring automation
light grid (e.g., due to opening the housing during mounting and electrical installation)
or in the event of changes made to the SICK software, any claims against SICK AG
under the warranty will be rendered void.
Foreseeable misuse
The MLG-2 is not suitable for the following applications, among others:
As a safety device to protect persons, their hands, or other body parts
•
Under water
•
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2 SAFETY INFORMATION
In explosive environments
•
Outdoors, without additional protection
•
2.3 General safety notes
CAUTION
Observe the following to ensure the safe use of the MLG-2 as intended.
The measuring automation light grid must be installed and maintained by trained,
qualified personnel with knowledge of electronics, precision engineering, and
control programming. The relevant technical safety standards must be observed.
All persons entrusted with the installation, operation, or maintenance of the devices
must follow the safety guidelines:
The operating instructions must always be available and must be followed.
•
Unqualified personnel must stay away from the system during installation and
•
maintenance.
The system must be installed in accordance with the applicable safety regulations
•
and mounting instructions.
The work safety regulations of the employers' liability insurance associations and
•
trade associations in the respective country must be observed during installation.
Failure to observe the relevant work safety regulations may lead to physical injury
•
or cause damage to the system.
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3 Product description
2
5
1
34
1110
4
7
6
5
9
3
2
1
8
3.1 Type labels of the MLG-2 Pro
The MLG-2 Pro senders and receivers each have a type label.
Figure 1: Type label of sender
Figure 2: Type label of receiver
Type code
1
Part number for the individual sender or receiver
2
Part number of the entire MLG-2
3
Symbol for sender or receiver
4
Firmware version
5
Required power supply
6
Maximum output current
7
Serial number
8
2D matrix code, contains the order numbers of the sender/receiver, the order number of
9
the MLG-2, and the serial number
Diagram of the M12/5-pin or M12/8-pin male connector
ß
Pin assignment of the M12/5-pin or M12/8-pin male connector
à
Diagram of the M12/4-pin female connector
á
Pin assignment of the M12/4-pin female connector
â
PRODUCT DESCRIPTION 3
3.2 MLG-2 Pro type code
Example
MLG-2 with 5 mm beam separation, type Pro, detection height 145 mm, 1 input, 1
switching output and 2 analog outputs, no options, 5 m sensing range and pre-configu‐
ration for NBB,LBB,object detection and teach-in.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
M L G 0 5 A - 0 1 4 5 B 1 0 5 0 1
Table 2: Example of an MLG-2 Pro type code
Position Meaning
1 … 3 Product family MLG
4 and 5 Beam separation 02 = 2.5 mm
05 = 5 mm
10 = 10 mm
20 = 20 mm
25 = 25 mm
30 = 30 mm
50 = 50 mm
Table 3: Meaning of the positions in the type code
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3 PRODUCT DESCRIPTION
Position Meaning
6 Type 0 = Special type
7 Hyphen –
8 … 11 Detection height 0000 = Special detection height
12 Interfaces, I/O see table 5, page 13
13 Options 1 = none
14 and 15 Optical properties see table 6, page 13
16 and 17 Preconfiguration of the I/O con‐
Table 3: Meaning of the positions in the type code
3.2.1 Monitoring height
Monitoring height
Table 4: Monitoring height [mm]
[mm]
A = Pro
see table 4, page 12
see "MLG-2 Pro preconfigurations",
nections and the software
page 13
Type
MLG02… MLG05… MLG10… MLG20... MLG25… MLG30... MLG50…
145 145 140 140 – – –
295 295 290 280 275 270 250
445 445 440 440 425 420 400
595 595 590 580 575 570 550
745 745 740 740 725 720 700
895 895 890 880 875 870 850
1045 1045 1040 1040 1025 1020 1000
1195 1195 1190 1180 1175 1170 1150
– 1345 1340 1340 1325 1320 1300
– 1495 1490 1480 1475 1470 1450
– 1645 1640 1640 1625 1620 1600
– 1795 1790 1780 1775 1770 1750
– 1945 1940 1940 1925 1920 1900
– 2095 2090 2080 2075 2070 2050
– 2245 2240 2240 2225 2220 2200
– 2395 2390 2380 2375 2370 2350
– 2545 2540 2540 2525 2520 2500
– – 2690 2680 2675 2670 2650
– – 2840 2840 2825 2820 2800
– – 2990 2980 2975 2970 2950
– – 3140 3140 3125 3120 3100
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3.2.2 Combinations of MLG-2 Pro inputs and outputs
Position 12 Inputs and outputs, data interface Connection type
B 2 × switching output (Q) and
2 × analog output (QA)
or
1 × input (IN) and
1 × switching output (Q) and
2 × analog output (QA)
I 2 × switching output (Q) and
1 × RS-485 interface
or
1 × input (IN) and
1 × switching output (Q) and
1 × RS-485 interface
R 4 × switching output (Q)
or
2 × input (IN) and
2 × switching output (Q)
Table 5: Possible combinations of MLG-2 Pro inputs and outputs
PRODUCT DESCRIPTION 3
M12/8-pin, A-coded
M12/8-pin, A-coded
M12/8-pin, A-coded
3.2.3 Optical properties
Position
14 and 15
00 Special Special
32 2 m 2.5 mm
05 5 m 5 mm
08 8.5 m 5 mm
Table 6: Sensing range and minimum detectable object length
Sensing range Minimum detectable object length
3.2.4 MLG-2 Pro preconfigurations
Position
16, 17
01 NBB LBB Object detection Teach-in Standard operating
02 NBB LBB Object detection Object detection
03 NBB LBB Object detection Object detection
04 NBB FBB Object detection Teach-in Standard operating
05 NBB FBB Object detection Object detection
06 NBB FBB Object detection Object detection
Table 7: Preconfiguration of MLG-2 Pro with I/O combination B (see table 5, page 13)
QA1 QA2 Q1/C Q2/IN1 Teach-in
(inverted)
(inverted)
(inverted)
(inverted)
mode
Standard operating
mode
Standard & cross
beam operating
mode
mode
Standard operating
mode
Standard & cross
beam operating
mode
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3 PRODUCT DESCRIPTION
Position
16, 17
RS-485
Output
RS-485
Data transmis‐
Q1/C Q2/IN1 Teach-in
sion rate
01 System status
States of the
9600 baud Object detec‐
tion
Teach-in Standard
switching outputs
NBB
LBB
FBB
ODI
IDI
02 System status
States of the
9600 baud Object detec‐
tion
Teach-in Standard
switching outputs
Beam status
03 System status
States of the
9600 baud Object detec‐
tion
Object detec‐
tion (inverted)
switching outputs
Beam status
04 System status
States of the
9600 baud Object detec‐
tion
Teach-in Standard
switching outputs
RLC
05 System status
States of the
9600 baud Object detec‐
tion
Object detec‐
tion (inverted)
switching outputs
RLC
Table 8: Preconfiguration of MLG-2 Pro with I/O combination I (see table 5, page 13)
operating
mode
operating
mode
Standard
operating
mode
operating
mode
Standard
operating
mode
Position
Q1/C Q2/IN1 Q3 Q4/IN2 Teach-in
16, 17
01 Object detection Teach-in Object detec‐
tion
Object detec‐
tion
Standard
operating
mode
02 Object detection Teach-in Object detec‐
tion (inverted)
Object detec‐
tion
Standard
operating
mode
03 Object detection Teach-in Object detec‐
tion
Object detec‐
tion
Standard &
cross beam
operating
mode
04 Object detection Object detection Object detec‐
tion
Object detec‐
tion
Standard
operating
mode
05 Object detection Object detection
(inverted)
Object detec‐
tion (inverted)
Object detec‐
tion (inverted)
Standard
operating
mode
06 Object detection Object detection Object detec‐
tion
Object detec‐
tion (inverted)
Standard &
cross beam
operating
mode
Table 9: Preconfiguration of MLG-2 Pro with I/O combination R (see table 5, page 13)
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3.3 MLG-2 product properties
Different beam separations from 2.5 mm to 50 mm
•
Monitoring heights from 130 to 3,140 mm
•
Operating range up to 2 m, 5 m or 8.5 m
•
Quick response time
•
Convenient configuration using the SOPAS ET software interface
•
Detection of transparent objects
•
Dust- and sunlight-resistant
•
Integrated applications including object detection, height classification, etc.
•
3.4 Setup and function
The MLG-2 is an optical light grid. It comprises a sender and a receiver.
The sender consists of sender optics, several sender elements (LEDs), and actuation
electronics. The receiver consists of receiver optics, several receiver elements (photodi‐
odes) and evaluation electronics.
3.4.1 MLG-2 Pro device components
PRODUCT DESCRIPTION
3
Figure 3: MLG-2 Pro
Receiver
r
Sender
s
Receiver connection
1
Ethernet configuration interface on the receiver
2
Sender connection
3
The receiver has a connection for the power supply, for inputs and outputs, and for syn‐
chronization. It also has an Ethernet connection for configuration via TCP/IP.
The sender has a connection for the power supply, for synchronization, and for a test
input.
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3 PRODUCT DESCRIPTION
3.4.2 Measurement principle
Provided no object is located between the sender and receiver elements, the light
beams from the sender elements will hit the receiver elements.
If an object is located between the sender and receiver elements, the light beams will
be blocked, depending on the size of the object.
Detection area
Figure 4: Detection area of the MLG-2
Monitoring height
1
Beam separation
2
Sensing range
3
The detection area is determined by the monitoring height and the sensing range of the
light grid. The monitoring height is determined by the beam separation and the number
of beams. The sensing range of the light grid is the distance between sender and
receiver.
3.4.3 Synchronizing the MLG-2
The sender and receiver synchronize with each other electronically, thus one electrical
connection between the sender and receiver is necessary.
3.4.4 Beam separations and monitoring height
Beam separations
In order to achieve different levels of measurement accuracy, the MLG-2 is available
with different beam separations.
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PRODUCT DESCRIPTION 3
Figure 5: Schematic depiction of available beam separations (mm)
Maximum and minimum monitoring height
The number of LEDs is limited to 510. This results in different maximum monitoring
heights depending on the beam separation. The minimum monitoring height is deter‐
mined by the beam separation and the smallest module size for this beam separation.
3.4.5 Teach-in
Beam separation Maximum monitoring height Minimum monitoring height
2.5 mm 1195 mm 145 mm
5 mm 2,545 mm 145 mm
10 mm 3,140 mm 140 mm
20 mm 3,130 mm 130 mm
25 mm 3,125 mm 275 mm
30 mm 3,1320 mm 270 mm
50 mm 3,100 mm 250 mm
Table 10: Maximum monitoring heights
During the teach-in process, the switching thresholds for all beams are individually
adjusted for the sensing range and the ambient conditions.
After teach-in has been completed, it must be ensured that the setup is no longer
changed otherwise another teach-in will have to be carried out.
The MLG-2 Pro provides the following options for carrying out a teach-in:
Pressing the teach-in button
•
Automatic teach-in (when switching on)
•
Signal at a switching input
•
SOPAS ET
•
IO-Link
•
Webserver
•
Teach-in quality
The teach-in quality indicates the quality after the teach-in process. The MLG-2 calcu‐
lates this value based on the quality of the light level received. The teach-in quality
depends on the alignment of the MLG-2 and the cleanliness of the front screens.
The value remains constant until another teach-in process is carried out.
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3 PRODUCT DESCRIPTION
Process quality
The process quality indicates the quality of the light level currently being received. The
MLG-2 analyzes the light level received when the light path is unblocked and compares
this to the values after the last teach-in process.
If the received values are getting worse, the process quality drops.
Possible causes of a drop in process quality include:
•
•
•
Retrieving teach-in quality and process quality data
The quality performance indicators can be retrieved in various ways:
•
•
•
•
•
•
Contamination or fogging of the front screen of the sender and/or receiver
Misalignment
Continuous partial blocking of a light beam or several light beams
SOPAS ET
RS485
IO-Link
Integrated web server
switching outputs
Analog outputs
3.4.6 Beam blanking
Individual beams can be blanked.
Figure 6: Detection area with beams blanked
1
2
3
Included beams
Blanked beams
Structural restrictions on the detection area
18
The MLG-2 Pro offers various options for blanking light beams (see "Teach-in",
page 90).
One-off blanking
•
The blocked beams are blanked.
Beam blanking for each teach-in
•
The blocked beams are blanked in every teach-in process.
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NOTE
If this option is selected and an object is located in the detection area during the teachin process, this will not be identified as an error.
3.4.7 Sensing ranges
Operating range
Light grids are generally available with a 2 m range, 5 m range or 8.5 m sensing range.
This is referred to as the operating range, which includes an operating reserve.
Limiting range
It is also possible to operate the MLG-2 up to its limiting range, which goes beyond the
operating range.
Table 11: Limiting range
PRODUCT DESCRIPTION 3
Manual blanking
•
Light beams can be individually selected and blanked using the interface in
SOPAS ET and via IO-Link (see "Representation of the detection area", page 59).
The beams are not taken into account in the measurement, even if they are made
at the time of the teach-in process.
Operating range Limiting range
2 m 2.8 m
5 m 7 m
8.5 m 12 m
3.5 Scan time
Operation within the limiting range requires the following conditions:
Clean ambient conditions
•
Front screens are cleaned regularly
•
Regular teach-in
•
The following functions cannot be provided when operating within the limiting range:
High level of operating reserves
•
High measurement accuracy
•
Transparent operating mode
•
Dust- and sunlight-resistant operating mode
•
NOTE
The sensing range of the MLG-2 Pro is reduced in certain operating modes (see "MLG-2
operating modes", page 26).
In the MLG-2, not all light beams are active at the same time, instead one light beam is
activated after the other starting from the bottom.
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Number of beams
Scan time
3 PRODUCT DESCRIPTION
Figure 7: Standard scan method
The scan time increases according to the number of beams of an MLG-2.
Figure 8: Scan time in relation to the number of beams
The scan time is used to determine the response times of the outputs, the minimum
presence time of an object and the repeat accuracy of a measurement result (reprodu‐
cibility).
The response time is the time it takes for an output to react following the detec‐
•
tion of an object/gap. The maximum response time is 3 × the scan time plus the
transmission time to the outputs.
The minimum presence time is the time an object or a gap has to be in the detec‐
•
tion area for it to be detected. The minimum presence time is max. 2 × the scan
time.
The repeat accuracy of a measurement result (reproducibility) is the amount of
•
time by which an object detection can differ from a previous or subsequent detec‐
tion. The reproducibility time is 1 × the scan time.
3.5.1 Response time, minimum presence time and reproducibility of the MLG-2
On the MLG-2, the response time, minimum presence time, and reproducibility are dis‐
played via SOPAS ET. Response time and minimum dwell time can be read off in the
diagramsee figure 129, page 122.
3.5.2 Scan time with cross-beam function
When the cross-beam function is enabled, the light beam from a sender LED is
received by three receiver diodes in two scans. This doubles the scan time.
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Figure 9: Cross-beam function
Number of beams
Scan time
1 2
3.5.3 Scan time with high-speed scan on the MLG-2
With high-speed scan, several beams are active in each cycle. This reduces the scan
time by a variable factor.
PRODUCT DESCRIPTION 3
Figure 10: High-speed scan
The scan time is also dependent on the number of beams. Beyond a certain number of
beams, the scan time is reduced because it is possible to use the high-speed scan.
Figure 11: Scan time in relation to the number of beams when using the high-speed scan
High-speed scan with 2 beams active simultaneously
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3 PRODUCT DESCRIPTION
High-speed scan with 3 beams active simultaneously
2
The number of beams that can be activated at the same time depends on the size of
the detection area (sensing range, beam separation, and number of beams). On the
MLG-2, the response time, minimum presence time, and reproducibility are displayed
via SOPAS ET. You can also find the response time and minimum presence time when
using the high-speed scan in the diagrams in these operating instructions (see "Dia‐
grams", page 122).
NOTE
With a beam separation of 2.5 mm, the high-speed scan can only be adjusted in combi‐
nation with the high measurement accuracy function.
3.6 Beam separation and minimum detectable object
The measurement accuracy achieved by the MLG-2 depends on the beam separation.
3.6.1 Minimum detectable object with parallel-beam function
In order for an object to be detected continuously, it must completely cover at least one
beam. This is referred to as the minimum detectable object, or MDO.
Figure 12: Minimum detectable object
Beam diameter
1
Object is not completely reliably detected
2
Object is reliably detected (meets requirements of minimum detectable object size)
3
NOTE
For moving objects, the minimum detectable object depends on the speed of the
object.
Beam separation Minimum detectable object (stationary object)
2.5 mm 3.5 mm
5 mm 9 mm
10 mm 14 mm
20 mm 24 mm
25 mm 29 mm
30 mm 34 mm
Table 12: Minimum detectable object in relation to the beam separation of the MLG-2
12
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PRODUCT DESCRIPTION 3
Beam separation Minimum detectable object (stationary object)
50 mm 54 mm
Table 12: Minimum detectable object in relation to the beam separation of the MLG-2
1
Only if the object also meets the minimum detectable object length requirements.
2
All the values are typical values and can be found in the respective setting modes.
NOTE
The minimum detectable object size is also dependent on the other performance
options, such as the configured response time and operating reserve. The precise mini‐
mum detectable object size is displayed in SOPAS ET on the MLG-2 (see "SOPAS ET
interface", page 54).
3.6.2 Minimum detectable object length
When an object moves through the detection area, it must have a certain length.
12
Figure 13: Minimum detectable object length
Minimum detectable object
1
NOTE
For moving objects, the minimum detectable object length also depends on the speed
of the object.
Beam separation Minimum detectable object length (stationary object)
2.5 mm 2.5 mm
5 … 50 mm 5 mm
Table 13: Minimum detectable object length with the MLG-2
1
Only if the object also meets the minimum detectable object requirements.
1
NOTE
The minimum detectable object length is also dependent on the other performance
options, such as the configured response time and operating reserve. The precise mini‐
mum detectable object length is displayed in SOPAS ET on the MLG-2 (see "SOPAS ET
interface", page 54).
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3 PRODUCT DESCRIPTION
3.6.3 Minimum detectable object with cross-beam function
The parallel-beam function is used for measuring by default. With the parallel-beam
function, each light beam is received only by the receiver element situated directly
opposite.
With the cross-beam function, a sender LED projects beams to several receiver diodes.
The cross-beam function increases the measurement accuracy and enables the detec‐
tion of smaller objects.
Figure 14: Cross-beam function
A minimum distance between the sender and the receiver is required for the crossbeam function. The minimum detectable object size depends on the position of the
object within the detection area. Detection of the smaller minimum detectable object
size is therefore only possible in the central area (b) of the detection area.
The cross-beam function is only useful for object detection (NBB ≤ 1). For other
•
applications (height classification, object recognition, etc.), the results of the paral‐
lel-beam function are used.
Use of the cross-beam function increases the response time.
•
With the cross-beam function, a minimum distance needs to be maintained
•
between sender and receiver. The minimum distance depends on the aperture
angle of the light grid.
For moving objects for the cross-beam function, the minimum detectable object
•
depends on the speed of the object.
Beam sepa‐
ration
2.5 mm 200 mm – – 2.5 mm 4 mm
5 mm – 110 mm 120 mm 6.5 mm 9 mm
10 mm – 220 mm 240 mm 9 mm 14 mm
20 mm – 440 mm 480 mm 14 mm 24 mm
25 mm – 550 mm 600 mm 16.5 mm 29 mm
30 mm – 660 mm 720 mm 19 mm 34 mm
50 mm – 1110 mm 1200 mm 29 mm 54 mm
Table 14: Minimum detectable object with cross-beam function on the MLG-2
Minimum dis‐
tance
2 m variant
Minimum dis‐
tance
5 m variant
Minimum dis‐
tance
8.5 m variant
Minimum detectable object
(stationary object)
In area B In area A
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PRODUCT DESCRIPTION 3
High-speed scan is not possible.
•
The minimum detectable object size with cross-beam function is also dependent
•
on the other performance options, such as the configured response time and
operating reserve. The precise minimum detectable object size is displayed in
SOPAS ET on the MLG-2 (see "SOPAS ET interface", page 54).
3.6.4 Minimum detectable object with high measurement accuracy from the MLG-2
On the MLG-2, the measurement accuracy can be increased in SOPAS ET (see "Per‐
formance options", page 93). This means that an object can be detected even if it
only covers half of a beam.
Figure 15: Minimum detectable object size with high measurement accuracy
Beam diameter
1
Object is reliably detected (meets requirements of minimum detectable object size)
2
Beam separation Minimum detectable object (stationary object)
1
2.5 mm 2.5 mm
5 mm 5 mm
10 mm 10 mm
20 mm 20 mm
25 mm 25 mm
30 mm 30 mm
50 mm 50 mm
Table 15: Minimum detectable object size with high measurement accuracy
1
Only if the object also meets the minimum detectable length requirements see table 13, page 23).
Minimum detectable object length
Beam separation Minimum detectable object length (stationary object)
2.5 mm 1 mm
5 … 50 mm 2 mm
Table 16: Minimum detectable object length with high measurement accuracy
1
Only if the object also meets the minimum detectable length requirements (see table 12, page 22).
1
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3 PRODUCT DESCRIPTION
When using high measurement accuracy to detect moving objects, the minimum
•
detectable object length also depends on the speed of the object and the other
performance options, such as the configured response time and operating
reserve. The precise minimum detectable object length is displayed in SOPAS ET
on the MLG-2 (see "SOPAS ET interface", page 54).
Sensing ranges larger than the operating range are not possible when using high
•
measurement accuracy.
High measurement accuracy can cause the operating reserve to decrease in the
•
event of large sensing ranges and imperfect alignment.
3.7 Operating reserve
The operating reserve defines the operational safety before contamination, vibrations,
misalignment, temperature fluctuations, etc. cause the MLG-2 to produce incorrect
measurements.
The MLG-2 is subject to a certain level of contamination depending on its environment
and application. In principle, the MLG-2 must be cleaned regularly and a teach-in
should be carried out after cleaning.
3.7.1 Operating reserves on the MLG-2
On the MLG-2, the operating reserve can be adjusted according to the operating mode.
Standard operating reserve
The standard setting for the operating reserve is the best setting for most applications.
High level of operating reserves
Setting the operating reserve high makes the MLG-2 very resistant to contamination.
However, it is not possible to activate high measurement accuracy in this case.
NOTE
In order to achieve a high operating reserve, the input sensitivity must be increased.
This increases the risk of reflection. If there are reflective surfaces near the detection
area, the light beams from the LEDs may reflect off these surfaces and reach the
receiver, even though there is an object in the detection area.
The high input sensitivity means that only opaque objects can be detected. Transparent
or semi-transparent objects are not detected.
Low operating reserve
Setting the measurement accuracy high reduces the operating reserve. When the oper‐
ating reserve is low, the MLG-2 must be cleaned more frequently and a teach-in proc‐
ess must be carried out.
3.8 MLG-2 operating modes
The MLG-2 has the operating modes Standard, Transparent and Dust and SunlightResistant.
Within the operating modes, the performance options can be used to modify the
response time, minimum detectable object size, minimum detectable absorption (in
Transparent operating mode), and operating reserve.
The configurable performance options depend on the operating mode selected.
•
When the operating mode is changed, a new teach-in process must be performed.
•
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3.8.1 Standard operating mode
Standard operating mode is the mode in which most measuring applications can be
carried out.
Only opaque objects can be detected.
•
There must not be a high level of constant light irradiation.
•
3.8.2 Transparent operating mode
Transparent operating mode enables the detection of transparent objects, such as
those made of glass, PET, etc.
Transparent objects do not completely cover the light beam. In order to detect these
objects, they must have what is known as a minimum detectable absorption (MDA).
NOTE
It is not possible to use the cross-beam function, high operating reserve or high-speed
scan in the Transparent operating mode.
Minimum detectable absorption
In order to detect a transparent object, it must absorb a certain percentage of the
energy from the light beam. Depending on the objects being measured, an object can
be detected with 30% absorption, 15% absorption, or 10% absorption.
PRODUCT DESCRIPTION 3
NOTE
The minimum detectable absorption that an object needs in order to be detected
increases with the sensing range (see "Minimum detectable absorption", page 124).
Examples of the signal attenuation of transparent objects1):
Approx. 10% signal attenuation:
•
Clean PET bottles, clear glass, thin and clear films (e.g., cellophane), household
plastic film, plastic wrapping
Approx. 15% signal attenuation:
•
Clean clear glass bottles, thick films, film and wrapping folded multiple times
Approx. 30% signal attenuation:
•
Green and brown glass, colored glass bottles
The following prerequisites must be met:
The sender and receiver must be aligned precisely with one another.
•
The sender and receiver elements must be kept clean at all times.
•
AutoAdapt
The AutoAdapt function is active in the Transparent operating mode. AutoAdapt adjusts
the switching threshold at which objects are detected in accordance with the level of
contamination on the MLG-2. As a result, the MLG-2 thus becomes less sensitive as the
level of contamination increases.
3.8.3 Dust- and sunlight-resistant operating mode
Dust and sunlight-resistant operating mode is intended for applications when there is a
large amount of dust in the environment or a high level of solar radiation.
Dust and sunlight-resistant operating mode reduces the maximum sensing range
•
1)
Examples are for illustrative purposes only. The signal attenuation and the minimum detectable absorption to be configured must be
determined for each individual application.
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3 PRODUCT DESCRIPTION
•
3.9 Interfaces
The MLG-2 can be used to evaluate the measurements in different ways. The MLG-2
provides various interfaces for data output.
•
•
•
•
The MLG-2 can output the raw data via the interfaces in the form of the beam status or
run-length code, so the user can evaluate the data him/herself.
The MLG-2 can also preprocess the raw data (beam function, e.g., NBB – number of
beams blocked) and output the data via bus or analog interfaces.
The preprocessed data can be assigned directly to the switching outputs via a program‐
mable function logic or via predefined applications.
– To 1.2 m for devices with a 2 m operating range
– To 3 m for devices with a 5 m operating range
– To 5 m for devices with an 8.5 m operating range
This operating mode can only be configured on an MLG-2 with fewer than
240 beams.
Switching outputs (Push-Pull)
Analog outputs
RS-485 interface
IO-Link interface
3.9.1 Output of measurement data (raw data)
The MLG-2 provides the status of all beams at its data interface using a data message.
Figure 16: Status of the beams
0 1 1 1 1 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 0
Table 17: Example status for an MLG-2 with 32 beams
0
Beam clear
1
Beam blocked
The data message can be output continuously or in response to particular events.
Run-length code
In order to reduce the volume of data, the run-length code can be output instead of the
complete status of all beams. This code only contains the status change of the beams.
The run-length code indicates how many beams currently have the same status.
0 1 1 1 1 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 1 1 1 1 0 0 0 0 0 0 0
1 4 6 4 6 4 7
Table 18: Example status for the run-length code of an MLG-2 with 32 beams
28
RLC = 1464645
The example shows: 1 beam made, 4 beams blocked, 6 beams made, 4 beams
blocked, 6 beams made, 4 beams blocked, 5 beams made.
The first value always indicates the number of unblocked beams. If the first beam is
blocked, the first value will therefore be zero. The second value indicates how many
beams are blocked; in the example in table 19, this value = 1.
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1 0 0 1 1 1 1 0 0 0 0 1 1 0 0 0 0 0
0 1 2 4 4 2 5
Table 19: Example run-length code with the first beam blocked
NOTE
The run-length code can contain a maximum of 16 values; i.e., 15 status changes. It is
therefore only useful for measuring objects with a small number of parts, e.g., a pallet.
Objects such as pallet cages are not suitable as they involve too many status changes.
3.9.2 Preliminary evaluation
Beam functions for preliminary evaluation
The MLG-2 creates a preliminary evaluation on the basis of the beam status, e.g.:
NBB – Number of Beams Blocked
•
NBM – Number of Beams Made
•
LBB – Last Beam Blocked
•
FBB – First Beam Blocked
•
see table 33, page 107: Table shows all available functions.
The results of the preliminary evaluation can be output via the data interfaces and
processed further externally. Alternatively, they can first be processed in a function pro‐
gramming option in the MLG-2.
PRODUCT DESCRIPTION 3
Function programming for the MLG-2 Pro
Function programming can be used to carry out complex applications with variables,
operands, and functions in SOPAS ET.
1st option:
The beam functions are directly linked with the outputs.
Example:
Q1 = Total number of beams made (NBM) ≥ 30
The output Q1 switches when the total number of beams made is greater than or
equal to 30.
2nd option:
The MLG-2's beam functions are used to define beam function variables first.
Example:
BFVar 1: Total number of beams made (NBM) ≥ 30
BFVar 2: Number of consecutive beams blocked (NCBB) = 5
These can be linked to logical variables.
Example:
LogVar1 = BFVar 1 OR BFVar 2
The logical variables can be linked in turn to the outputs (Q).
Example:
Q1 = LogVar1 = true
The output Q1 switches when the total number of beams made is greater than or
equal to 30 or when the number of consecutive beams blocked equals 5.
3.9.3 Configurable applications of the MLG-2 Pro
The MLG-2 provides predefined applications which are assigned to the outputs. The fol‐
lowing options are available for configuring the applications:
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3 PRODUCT DESCRIPTION
– Via SOPAS ET (see "Configuration with SOPAS ET", page 53)
– Using the integrated web server (see "MLG-2 configuration with the internal web
– Using IO-Link (see "IO-Link", page 110)
Application MLG-2 Pro
Height classification
Object detection/object width
Contamination warning
Object recognition
Hole detection/hole size
Outer/inner dimension
Classification of the object position
Classification of the hole position
Zones
Diagnostics
Table 20: Configurable applications for switching outputs
Application MLG-2 Pro
NBB Object detection
NBM Hole detection
LBB Object height measurement (last beam
FBB Object height measurement (first beam
ODI Measurement of the outer dimension
IDI Measurement of the inner dimension
CBB Measurement of the object position
CBM Measurement of the hole position
– Diagnostics
NBB Zone X
(X = 1, 2, 3
or 4)
NCBB Zone
X (X = 1, 2,
3 or 4)
FBB Zone X
(X = 1, 2, 3
or 4)
LBB Zone X
(X = 1, 2, 3
or 4)
CBB Zone X
(X = 1, 2, 3
or 4)
Table 21: Configurable applications for analog outputs
server", page 108)
blocked)
blocked)
Object detection system within a zone
Object width within a zone
Object height measurement (first beam
blocked) within a zone
Object height measurement (last beam
blocked) within a zone
Object position within a zone
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
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