Programming manual FLOcontrol for FLO-3D ► Programming manual FLOcontrol for FLO-3D 1 Programming manual FLOcontrol for FLO-3D Contents 1 Preliminary note .......................................................................................................................................... 4 1.1 Symbols used .................................................................................................................................................... 4 1.1 Warning signs used ........................................................................................................................................... 4 2 Safety instructions ....................................................................................................................................... 4 3 System requirements .................................................................................................................................. 4 3.1 Hardware ........................................................................................................................................................... 4 3.2 Software ............................................................................................................................................................ 5 3.3 Required accessories (example: standard delivery contents) ........................................................................... 5 4 Functions and features ................................................................................................................................ 5 5 Installation ................................................................................................................................................... 5 6 5.1 Hardware ........................................................................................................................................................... 5 5.2 Software ............................................................................................................................................................ 6 5.3 Factory setting ................................................................................................................................................... 6 5.3.1 Network setting IP address range ............................................................................................................. 6 5.3.2 Network parameters.................................................................................................................................. 6 5.3.3 Verify and set the IP address of the PC .................................................................................................... 6 Basic functions of the program .................................................................................................................... 8 6.1 7 Basics of operation ............................................................................................................................................ 8 6.1.1 User interface............................................................................................................................................ 8 6.1.2 Keyboard functions ................................................................................................................................... 9 6.2 Program start ................................................................................................................................................... 10 6.3 Select user language ....................................................................................................................................... 11 6.4 Connect device to the operating program........................................................................................................ 11 6.4.1 Alternative 1: Bookmark entry ................................................................................................................. 11 6.4.2 Alternative 2: Enter the IP address of the device .................................................................................... 13 6.4.3 Alternative 3: Find IP address of the device............................................................................................ 14 Operating modes ....................................................................................................................................... 16 7.1 Monitor............................................................................................................................................................. 17 7.1.1 Intensity image ........................................................................................................................................ 18 7.1.2 Distance image ....................................................................................................................................... 19 7.1.3 Perspective view ..................................................................................................................................... 20 7.1.4 Segmentation .......................................................................................................................................... 22 7.1.5 Save data ................................................................................................................................................ 22 7.2 7.2.1 Applications ..................................................................................................................................................... 23 Activate application mode ....................................................................................................................... 23 2 Programming manual FLOcontrol for FLO-3D 8 7.2.2 Change sensor name and sensor location.............................................................................................. 24 7.2.3 Configure global sensor settings ............................................................................................................. 25 7.2.4 Define network parameters ..................................................................................................................... 26 7.2.5 Create new application ........................................................................................................................... 27 7.2.6 Activate existing application .................................................................................................................... 28 7.2.7 Edit existing application .......................................................................................................................... 28 7.2.8 Rename an existing application .............................................................................................................. 29 7.2.9 Delete an existing application ................................................................................................................. 29 7.2.10 Upload from device ................................................................................................................................. 29 7.2.11 Download to device................................................................................................................................. 30 7.2.12 Help ........................................................................................................................................................ 30 Create applications and set parameters .................................................................................................... 31 8.1 Navigation........................................................................................................................................................ 31 8.2 Select the sensor program............................................................................................................................... 32 8.3 Image quality ................................................................................................................................................... 33 8.3.1 Parameters ............................................................................................................................................. 34 8.3.2 Filters ...................................................................................................................................................... 36 8.3.3 Trigger..................................................................................................................................................... 37 8.3.4 Restore the factory setting ...................................................................................................................... 38 8.3.5 Test trigger .............................................................................................................................................. 38 8.4 8.4.1 Image zone within the program “Belt weigher”........................................................................................ 39 8.4.2 Image zone within all other programs ..................................................................................................... 44 8.5 9 Image zone ...................................................................................................................................................... 39 IO configuration ............................................................................................................................................... 50 8.5.1 Binary threshold outputs ......................................................................................................................... 50 8.5.2 Current output / voltage output ............................................................................................................... 52 8.5.3 Pulse output for counting pulses ............................................................................................................. 52 8.5.4 Configure the outputs.............................................................................................................................. 53 Update sensor software ............................................................................................................................ 54 10 Exit the program ........................................................................................................................................ 55 10.1 Disconnect ....................................................................................................................................................... 55 10.2 Close the program ........................................................................................................................................... 55 Licences and trademarks Microsoft®, Windows®, Windows XP®, Windows Vista®, Windows 7® and Windows 8® are registered trademarks of Microsoft Corporation. All trademarks and company names are subject to the copyright of the respective companies. 3 Programming manual FLOcontrol for FLO-3D 1 Preliminary note 1.1 Symbols used ► Instruction > Reaction, result […] Designation of pushbuttons, buttons or indications → Cross-reference Important note Non-compliance can result in malfunctions or interference. Information Supplementary note 7.1 Hyperlink – within the online help as well as the PDF version of this document, it is possible to jump by clicking to the indicated cross-reverence. 1.1 Warning signs used Warning of serious personal injury. Death or serious irreversible injuries may result. 2 Safety instructions Please read the operating instructions prior to set-up of the device. Ensure that the device is suitable for your application without any restrictions. If the operating instructions or the technical data are not adhered to, personal injury and/or damage to property can occur. 3 System requirements 3.1 Hardware PC with Pentium III processor or higher, clock frequency min. 500 MHz min. 128 MB RAM min. 40 MB freely available hard disk memory CD-ROM drive XGA compatible graphic card with min. 1024 x 768 pixel resolution Ethernet network card for 10Base-T/100Base-TX, TCP/IP protocol PC mouse 4 Programming manual FLOcontrol for FLO-3D 3.2 Software Microsoft® Windows XP®, Windows Vista®, Windows 7® or Windows 8® operating system 3.3 Required accessories (example: standard delivery contents) Connecting cable for FLO-3D, 10 m / 32, ft for connection to junction box Ethernet cable for FLO-3D, 10 m / 32 ft, for connection to junction box Ethernet cable for FLO-3D, 2 m / 6.5 ft, for connection from junction box to PC Junction box for FLO-3D, 115 / 230 VAC Assembly-kit for FLO-3D, clamp cylinder mounting 14 mm CD with parameter setting software FLOcontrol and documentation You can find more information about the available accessories here: www.emwea.de. 4 Functions and features In conjunction with FLO-3D Sensor II the PC operating program FLOcontrol provides the following: measurement and evaluation of volume, level, distance or throughput creation, administration and deletion of application-specific applications 5 Installation Installation and setting for operation with a fixed assigned IP address are described below (= direct connection to the PC). This is the factory-preset operating mode of the FLO-3D sensor. The figures and texts show the installation process under Microsoft® Windows XP®. In other Windows® versions installation is carried out in the same way. 5.1 Hardware Disconnect the junction box from power supply. Connect the black cable of the junction box with the FLO-3D Sensor and screw together. Connect the green Ethernet cable of the junction box with the FLO-3D Sensor and screw together. Open the junction box. Using the short Ethernet cable, make a connection between the jack in the junction box (10) and the Ethernet port of the PC. Connect the junction box with the power supply again. Only qualified electricians may work with the junction box when opened and under power! 5 Programming manual FLOcontrol for FLO-3D 5.2 Software Insert the included CD into the CD-ROM drive of the compatible PC. The installer assistant shoud start automatically. If the settings of the Windows® operating system prevent autoboot, start the file Setup.exe on the CD manually. Follow the instructions oft the installer on the screen. 5.3 Factory setting 5.3.1 Network setting IP address range The IP address ranges of the device and the PC have to match. Device FLO-3D Sensor II PC Network address 192.168.0 = 192.168.0 Station address 69 ≠ e.g. 10 Description Dynamic Host Configuration Protocol IP address Subnet mask Gateway address Factory setting off 192.168.0.69 255.255.255.0 192.168.0.201 5.3.2 Network parameters FLO-3D Sensor II parameter DHCP IP nETm GWIP 5.3.3 Verify and set the IP address of the PC Changes in the network settings of the PC require extended user rights. Contact your system administrator. Activate the menu “Internet Protocol Properties Version 4 (TCP/IPv4)”. The Windows menu “Internet Protocol Properties Version 4 (TCP/IPv4)” is accessible for example via: Start → Control Panel→ Network and Sharing Center → Change adapter settings → Local Area Connection → Properties. Select the option “Use the following IP address”. Verify and, if necessary, set the IP address (here e.g. 192.168.0.10). Enter the subnet mask (255.255.255.0). Leave default gateway blank. Confirm the settings with [OK]. 6 Programming manual FLOcontrol for FLO-3D 7 Programming manual FLOcontrol for FLO-3D 6 Basic functions of the program 6.1 Basics of operation 6.1.1 User interface Pos. Operating elements 1 Mode Function Applications Create, edit, delete etc. applications. Monitor Display or visualisation o of the detected object resp. bulk material o of the set parameter values o of the result window 2 Status bar 3 Tool bar Buttons (e.g. “Save” or “Connect”) Commands that cannot be selected are displayed in grey. 4 Menu bar Pulldown menus with program functions. 5 Button [About this page...] Information about the currently selected mode or the currently selected application. 6 Result window Selected sensor program (distance, volume, level or beltscale) Result (e.g. 79.05 m³/h) Network status of the device (OFFLINE / ONLINE) Device name Article number, production status and firmware of the connected device Visualised display of the sensor temperature Evaluation time 8 Programming manual FLOcontrol for FLO-3D Pos. Operating elements 7 Tabs A/B/C Ways of selection Function Tabs for the configuration of the parameters Identical commands can be selected in different ways (depending on the program function). A = selection via pulldown menu in the menu bar B = selection via button C = selection via context menu (click with right mouse button) 6.1.2 Keyboard functions The following keyboard functions are provided in the parameter setting module “Program”: Key combination [Shift] + [Tab] Contents [Shift] + [Ins] Duplicate selected image zone. [Shift] + [Del] Delete selected image zone. [Shift] + Arrow key Move the selected image zone by one pixel in the respective direction. Select image zone or cancel selection. If several image zones are defined, the selection will change from one image zone to the next. 9 Programming manual FLOcontrol for FLO-3D 6.2 Program start ► Start the PC operating program FLOcontrol. > The start screen displays the article number, program designation and version number for approx. 5 s. > When the program is started for the first time and the device is as supplied, the neutral user interface will be displayed (on delivery an application with default settings is stored). Status: OFFLINE 10 Programming manual FLOcontrol for FLO-3D 6.3 Select user language ► Select the desired language in the menu bar with [Settings] → [Language] → select the desired language. 6.4 Connect device to the operating program 6.4.1 Alternative 1: Bookmark entry ► Select [Connections] → [IP address] in the menu bar. > User interface changes to the connection settings. > “Saved bookmarks” contains a bookmark entry with the default settings of the device (if this is not the case, continue with 6.4.2 or 6.4.3). 11 Programming manual FLOcontrol for FLO-3D ► Mark the bookmark entry (e.g. “NewSensor”) and click on [Connect]. As an alternative: Double-click on the entry. > Change of status: OFFLINE → ONLINE. The user interface changes to the monitor mode. The [Monitor] button is activated. After a trigger pulse the monitor window displays the current capture of the device. The result field on the right displays the current results. 12 Programming manual FLOcontrol for FLO-3D Establishing the connection may take several seconds. 6.4.2 Alternative 2: Enter the IP address of the device ► Select [Connections] → [IP address] in the menu bar. > User interface changes to the connection settings. ► Enter the IP address of the device in the field “IP address”. ► Assign preset port number 8080. If a firewall is active on the PC, ensure that this port and the port number 50002 have been enabled for image transmission. ► Click on [Connect]. > Change of status: OFFLINE → ONLINE (like 6.4.1). 13 Programming manual FLOcontrol for FLO-3D 6.4.3 Alternative 3: Find IP address of the device ► Select [Connections] → [IP address] in the menu bar. > User interface changes to the connection settings. ► Click on [Find sensors …]. > The window “Network search” opens. > Under “Scan zones” the IP zone set on the PC is automatically assigned (here e.g.192.168.178.0). If you want to search other networks, you have to ensure that the gateways of your PC are correctly set. In case of doubt, contact your network administrator. ► If you want to search other networks, overwrite the IP address range in the field “Network address”. ► Click on [Add]. 14 Programming manual FLOcontrol for FLO-3D > The network address is added to the search list. The fields for the network address and subnet mask are blank so that other entries can be made in the search list. ► Click on [Start scanning]. > The devices found are listed in the “Detection of the sensors” box. ► Click on [Assign]. > All network data necessary for the connection to the device is saved locally on the PC in a bookmark entry with the indicated device name and its location. 15 Programming manual FLOcontrol for FLO-3D ► Mark entry in the search list and click on [Connect]. As an alternative: Double-click on the entry in the search list. > Change of status: OFFLINE → ONLINE (like 6.4.1). 7 Operating modes The device distinguishes two operating modes: Monitor Applications 16 Programming manual FLOcontrol for FLO-3D 7.1 Monitor When you have switched on the unit you are in the monitor mode. Here you can watch the sensor working. Pos. Element 1 Visualisation Function Alternatives for visualising the sensor image 2 Tab [Parameters] 3 Tab [Extended information] Switch and start points Status of the filter Setting of result averaging 4 Sensor image Visualisation of the current sensor image depending on the setting of the visualisation 5 Result window Currently set program Results Outputs Exposure time Dynamics Background Trigger mode Idle time 17 Programming manual FLOcontrol for FLO-3D 7.1.1 Intensity image The intensity image describes the visualisation on the basis of the reflectivity of the object to be displayed. It can be compared with a black and white photo of a camera. This mode is suitable for the following activities: setting the focus of the lens (by means of the setting screw on the back of the unit) adjusting the position of the active image section The active image zone is visualised by a frame. Colour indicators: Blue-shaded image zones: Pixels outside the defined active image zone. Red-shaded image zones: Pixels with too weak a light reflection are visualised in red. Orange-shaded image zones: Pixels with too intense a reflection are visualised in orange (too little distance to the object). Red, orange and blue image zones will not be included in image calculations. Red and orange image zones should be avoided. Corrections are possible when the image quality is adjusted. For visualisation the individual pixels are standardised across the entire image zone. Pixels of high intensity are displayed as light; pixels of low intensity are displayed as dark. If the dynamics of the sensor image is very high, i.e. the difference between the “strongest” and the “weakest” pixels is significant, the zones of little reflection are displayed as very dark, contours at a larger distance can often no longer be recognised. In that case the band width of intensities can be displayed as a logarithm which is almost like a reduction in contrast. ► Select [Linear] or [Logarithmic] display. 18 Programming manual FLOcontrol for FLO-3D 7.1.2 Distance image The distance image describes the object scenario on the basis of the distance to the sensor. In this process each pixel is assigned a corresponding colour from the spectrum depending on the distance to the sensor. Short distances start in the red range and within the spectrum change to shades of blue for larger distances via the yellow and green ranges. Display: When the [Auto] button is activated, the entire range of the distance values is displayed in an optimum way on the colour spectrum available. The assignment of the distances to the colours is shown on the left of the bar graph. Normalisation is carried out on the basis of the first distance values to be visualised and is kept. If the distance values are significantly changed in the course of image visualisation, for example due to major changes in the scenario, normalisation is adapted automatically. When the [Manual] button is activated, you can change the distribution of the colour spectrum. In the input fields you set the minimum and the maximum distance values in whose range the colour spectrum is to be redistributed. The “Background” field stands for the maximum distance value, “Object” for the minimum distance value. Adapt colour spectrum manually: ► Click on [Manual]. > The background and object fields are enabled. ► To determine the current distance of a special pixel, click on the requested pixel with the right mouse button. > The measured distance value is displayed below the sensor image. ► Enter requested values between 0 and 6500 mm for “Background” and “Object”. The input value for “Background” must be greater than the value for “Object”. ► Click on [Assign]. 19 Programming manual FLOcontrol for FLO-3D 7.1.3 Perspective view In principle the perspective view corresponds to the distance image view. There is, however, spatial visualisation. In this process each pixel is assigned a corresponding colour from the spectrum depending on the distance to the sensor. Short distances start in the red range and within the spectrum change to shades of blue for larger distances. Invalid pixels are shown in white. They are either at a distance of more than 6.5 m from the device or they are not included due to their high degree of reflection. When using the “Belt weigher” program, the unit deals with unvalid pixels in a special way (→ chapter 8 Create applications and set parameters). Types of display: ► Select the types of display of the perspective view in the tool bar. Symbol Function Displays the distance data of the sensor as individual coloured pixels. Displays the distance data of the sensor as a coloured bar. Displays the distance data of the sensor as a coloured mesh network. Displays the distance data of the sensor as a coloured perspective model. Shows/hides the coordination grid. Enlarges the perspective view. Reduces the perspective view (standard setting). Display: When the [Auto] setting is enabled, the entire range of the distance values is displayed in an optimum way on the colour spectrum available. The assignment of the distances to the colours is shown in the bar graph on the left. 20 Programming manual FLOcontrol for FLO-3D Normalisation is carried out on the basis of the first distance values to be visualised and is kept. If the distance values are significantly changed in the course of image visualisation, for example due to major changes in the scenario, normalisation is adapted automatically. When the [Manual] button is activated, you can change the distribution of the colour spectrum. In the input fields you set the minimum and the maximum distance values in whose range the colour spectrum is to be redistributed. The “Background” field stands for the maximum distance value, “Object” for the minimum distance value. Using the [Options] button you can show or hide the option field for image adjustment. If the options are suppressed, you will see the result window. Adapt colour spectrum manually: ► Click on [Manual]. > The “Background” and “Object” input fields are enabled. ► Enter values between 0 and 6500 mm for “Background” and “Object”. The input value for “Background” must be greater than the value for “Object”. ► Click on [Assign]. Change the viewing position: You can change the position interactively. ► Left-click into the field of view and move the mouse, keeping the mouse button pressed, into the required direction of rotation. > The object moves around its centre of gravity into the required viewing position. Restore the initial perspective: ► Click on [Default view]. 21 Programming manual FLOcontrol for FLO-3D 7.1.4 Segmentation The segmentation shows what the sensor interprets to be the background and what to be the object. The object is shown in white, the background in black. Noise of the pixels (white pixels in the background or black pixels in the object) should be avoided. Noise can be avoided by a respective setting of the image quality. 7.1.5 Save data The current evaluation image and the current image data can be stored as follows: Symbol Function Saves the current evaluation image as a bitmap file (*.bmp) . ► Indicate the file name and the memory location in the newly opened window. Saves the current image data (intensity, distance or segmentation values) in table format (*.csv) Image data of the perspective view cannot be saved. The values are structured by lines, the individual values are separated by a semicolon so that the data can be imported in standard spreadsheet programs. ► Indicate the file name and the memory location in the newly opened window. 22 Programming manual FLOcontrol for FLO-3D 7.2 Applications The device can save up to 32 applications (= parameter sets). When creating an application, the following parameters have to be taken into account: 1. 2. 3. 4. Program Image quality Image zone IO configuration 7.2.1 Activate application mode ► Click on [Applications]. Pos. 1 2 3 Element Administer applications Application directory General 4 Global sensor settings 5 Network parameters Function New, Activate, Edit, Rename, etc. Overview, structure and selection of the applications. General administration (device-specific names, info about software version etc.). Possible basic settings of the performance and network parameters of the device. Trigger input debouncing (on/off) External selection of the application (on/off) Network parameters (DHCP on/off, IP address etc.) 23 Programming manual FLOcontrol for FLO-3D 7.2.2 Change sensor name and sensor location ► Enter sensor name and sensor location according to the application. ► Transfer the entries to the device with [Assign]. Field Sensor name Sensor location Firmware version Function Any application-specific device name. Location description (e.g. Conveyor 3). Firmware version of the device (cannot be edited and can only be changed via update). 24 Programming manual FLOcontrol for FLO-3D 7.2.3 Configure global sensor settings ► Open the [Global sensor settings] tab. ► Verify and, if necessary, change all entries. Element Trigger input debouncing External selection of the application Funktion Prevents that several pulses occurring shortly after each other cause a trigger process on the unit (mechanical trigger switch). With “On” a stable pulse has to be on the input for at least 3 ms so that it is recognised as a trigger pulse. Shorter pulses are ignored.. If this option is activated, pins 7 and 8 of the process interface are used as inputs 1 and 2 which can externally switch the first four applications. Input 1 (pin 7) is the least significant bit (LSB), input 2 (pin 8) is the most significant bit (MSB). Pin 7: 0, pin 8: 0 -> application on memory location 1 active Pin 7: 1, pin 8: 0 -> application on memory location 2 active Pin 7: 0, pin 8: 1 -> application on memory location 3 active Pin 7: 1, pin 8: 1 -> application on memory location 4 active Belt stop on belt weigher applications (→ chapter 8): When using a belt weigher application, normally it makes sense to use a binary contact on input 1 (pin 7) to distinguish between stopped and running conveyor. For this purpose, setup your belt weigher application completely on memory location 1. Now copy this application to memory location 2. Change the name of application no. 1 into “belt-stop”. Edit the application “belt-stop” and enter a calibration factor of 0.000. Now connect a binary contact with input 1 (pin 7) – this contact should be closed only when the conveyor is running. 25 Programming manual FLOcontrol for FLO-3D 7.2.4 Define network parameters ► Open the [Network parameters] tab. ► Verify and, if necessary, change all entries. ► Transfer the entries to the device with [Assign]. Field DHCP mode IP address Subnet mask Gateway XML-RPC port Video port MAC address Function In the DHCP mode the fields for IP address, subnet mask and gateway are blocked. The sensor is assigned an address by the DHCP server. Currently assigned IP address of the device. Standard setting subnet mask. Default gateway address. The port number for the communication via the XML-RPC protocol (Remote Procedure Call). Port number for the transmission of images. The MAC address of the device (cannot be changed). 26 Programming manual FLOcontrol for FLO-3D 7.2.5 Create new application ► Click on [New]. ► Assign an index number. configure between 0 and 32 ► Enter the name of the new application. length of the name 1...32 characters umlauts allowed (Ä, ä, ... ) no blank or tabulator characters before and after an entry no special characters (&, $, - ...) ► Acknowledge with [OK]. > The new application is created. > The user interface changes to the first application step “Program” (→ Chapter 8.1). 27 Programming manual FLOcontrol for FLO-3D 7.2.6 Activate existing application ► Mark the name/number of the application in the directory structure. ► Click on [Activate]. As an alternative: selection via the context menu (right mouse button). > The colour of the activated folder changes from blue to green. 7.2.7 Edit existing application ► Mark the name/number of the application in the directory structure. ► Click on [Edit]. As an alternative: selection via the context menu (right mouse button) > The user interface changes to the first application step “Program” (→Chapter 8.1). 28 Programming manual FLOcontrol for FLO-3D 7.2.8 Rename an existing application ► Mark the name/number of the application in the directory structure. ► Click on [Rename]. As an alternative: selection via the context menu (right mouse button) ► Enter the new name in the new window “Rename application”. ► Acknowledge with [OK]. 7.2.9 Delete an existing application ► Mark the name/number of the application in the directory structure. ► Click on [Delete]. As an alternative: selection via the context menu (right mouse button) ► Acknowledge the confirmation prompt in the new window with [Yes]. > The application is deleted.. 7.2.10 Upload from device You can save the sensor settings on your PC and transfer them to another device using the [Download to device] function. ► Mark the name/number of the application in the directory structure. ► Click on [Upload from device]. As an alternative: selection via the context menu (right mouse button) or via the tool bar → . ► Define the memory location on the hard disk and assign a file name. ► Acknowledge with [Save]. 29 Programming manual FLOcontrol for FLO-3D 7.2.11 Download to device You can transfer data saved on the PC to the sensor. ► Mark the name/number of the application in the directory structure. ► Click on [Download to device]. As an alternative: selection via the context menu (right mouse button) or via the tool bar → . ► Select the file on the hard disk and click on [Open]. ► Assign an index number. figure between 0 and 32 ► Enter the name of the new application. Length of the name 1...32 characters Umlauts allowed (Ä, ä, ... ) No blank or tabulator characters before and after an entry No special characters (&, $, - ...) > The application is downloaded to the device and can be seen in the directory structure. 7.2.12 Help Opens the by-topic online help. 30 Programming manual FLOcontrol for FLO-3D 8 Create applications and set parameters When a new application has been created or an existing one has been edited, the user interface changes to the first application step “Program”. 8.1 Navigation There are two possibilities to navigate through the process of parameter setting: using the buttons (navigation) [ Back], [Cancel] and [Next]: using the button (module): 31 Programming manual FLOcontrol for FLO-3D 8.2 Select the sensor program In the parameter setting module “Program” you determine the measurement task and the unit of measurement. ► Define the measurement task in the “Program” field. Entry Volume Minimum distance Maximum distance Average distance Function Determines the volume of an object or a medium to be measured on the basis of the surface structure and the distance to the background (unit of measurement: litre). Determines the distance between an object or a medium to be measured and the sensor (unit of measurement mm or inch). The smallest distance value each of the image zone set is used. Determines the distance between an object or a medium to be measured and the sensor (unit of measurement mm or inch). The greatest distance value each of the image zone set is used. Determines the distance between an object or a medium to be measured and the sensor (unit of measurement mm or inch). The distance values on which the measurement is based are averaged across the entire set image zone. 32 Programming manual FLOcontrol for FLO-3D Entry Minimum level Maximum level Average level Belt weigher Function Determines the distance between the object or the medium to be measured and the background on the basis of the distance value across the entire surface of the object This corresponds to the level (unit of measurement mm or inch). The smallest distance value each of the image zone set is used. Determines the distance between the object or the medium to be measured and the background on the basis of the distance value across the entire surface of the object. This corresponds to the level (unit of measurement mm or inch). The greatest distance value each of the image zone set is used. Determines the distance between the object or the medium to be measured and the background on the basis of the distance value across the entire surface of the object or the medium to be measured. This corresponds to the level (unit of measurement mm or inch). The distance values on which the measurement is based are averaged across the entire set image zone. Usage as an “optical belt weigher” for belt conveyors, vibrating chutes or the like with constant speed. Determines the volumetric throughput on the basis of the distance value across the entire surface of the object or the medium to be measured (unit of measurement m³/h). Also counter pulses may be generated. When the function “bulk flow” is activated, the sensor calculates the mass throughput based on a fixed bulk density – in this case the unit of measurement switches automatically to t/h. ► Select the desired unit of measurement in the field “Unit of measurent” (available units of measurement depend on the choosen program). 8.3 Image quality In this module you set the parameters for optimum image capture. ► Optimise the image definition via the setting screw on the back of the device. 33 Programming manual FLOcontrol for FLO-3D Due to the low resolution and the different distances in a scenario manual setting has only little influence on the result of the measurement. 8.3.1 Parameters You define the characteristics of image capture in the [Parameters] tab. Exposure time: The exposure time means the time it takes to capture the sensor image. You can have the exposure time set automatically or you can set it manually. In the following cases it is necessary to change the exposure time: Image quality Many white image zones (overexposure) Setting Many black image zones (underexposure) Increase exposure time White and black image zones (high dynamics due to high-contrast image) Set dynamics to [High] Increase exposure time Considerable noise or flickering of the image Increase exposure time Reduce exposure time Dynamics: For high contrast images, light objects reflect too much light, dark objects, however, too little light. In the “Dynamics” field you can compensate this contrast. The following settings are recommended: Image quality No white and black image zones simultaneously (low dynamics due to low contrasts) White and black image zones (high dynamics due to high-contrast image) Setting [Normal] [High] With the setting [High] the sensor works with double exposure. It measures with a long and then with a second short exposure time. During the short exposure time it fills up extremely overexposed zones. Double exposure prolongs the total exposure time which may cause blurred edges for moving objects / mediums to be measured. Background: Image quality Scene has a defined background. Scene does not have a defined background. The sensor detects objects at a distance greater than 6 m. Setting [Bordered] [Open-ended ] 34 Programming manual FLOcontrol for FLO-3D If the sensor detects objects at a distance longer than 6 m, it only provides meaningful results with the setting [Open-ended] activated. With this setting the measuring range of the sensor is set to longer distances. The exposure time, however, is doubled which may cause blurred edges with moving objects. max. Invalid Pixel: In the “Belt weigher” application, the volume oft the medium – as well as the volumetric or mass troughput – is calculated on the base oft the valid pixels only and then projected onto the full area of the image zone. In all other applications, overexposed pixels will be interpreted as 0 m distance from the sensor and underexposed pixels will be interpreted as the teached or manually entered background distance. Here you can enter how many invalid (over- or underexposed) pixels are maximally allowed for this procedure. If the entered percentage will be exceeded, the resulting throuput will be 0. In most cases you may maintain the default value of 10%. If problems occur i.e. with highly reflecting particles (the throughput will jump sporadically to 0) you may try a higher percentage. Parameter setting: To determine the optimum parameters take the following steps: ► Open the [Parameters] tab. ► Click on [Normal] in the “Dynamics” field. > The overexposed areas are identified by the white pixels. In these areas too much light is reflected. ► Click on [Auto setting]. > The exposure time is calculated and the slider bar in the “Exposure time” field is set automatically. 35 Programming manual FLOcontrol for FLO-3D As an alternative: Set the exposure time manually by means of the slider bar. Reduce the exposure time if there are overexposed areas (white pixels). Increase the exposure time if there are underexposed areas (black pixels). ► If the image shows overexposed and underexposed areas (white and black pixels), click [High] in the “Dynamics” field. ► If there are white pixels, noise or flickering of the image, optimise the exposure time. White pixels: reduce exposure time. Noise or flickering: increase exposure time. 8.3.2 Filters Select the suitable filter for smoothing noisy data in the [Filters] tab. During filtering the information of neighbouring pixels is used to change the value of the central pixel. Filtering results in smoothing of the surfaces and rounding of the edges. The more a surface is smoothed, the more an edge is rounded. Filters influence the exposure time only insignificantly. Differnet filters can be combined. Filters help improve poor data; however they remain poor data. Therefore optimisation should first of all be effected by exposure. With the spatial filters median and mean, “3x3 averaging” is used. First of all the measured value of a pixel to be filtered is considered. Then it is put into relation with the 8 adjoining pixels. Each filter calculates an average value from the 9 pixels; the calculation conditions for the various filters vary. 36 Programming manual FLOcontrol for FLO-3D Median filter: This filter has excellent smoothing characteristics and influences the edges insignificantly (standard setting). It concludes the 2 extreme values from the 9 pixels (positive and negative outliners) and calculates the average value of the other 5 pixels. Mean filter: This filter has excellent smoothing characteristics and generates very blurry edges. The average value is calculated from the algebraic averaging of the 9 pixels: They are added and divided by 9. Result averaging: Determines the number of images used for calculating an output value. The default setting is 1 image, i.e. the output of the result is calculated on the basis of each individual image. The number of images can be increased for time-uncritical applications, e.g. for level detection. This leads to more precise results; at the same time, however, it also increases the evaluation time (output frequency). Result averaging means smoothing the results with regard to time. Calculation of the output frequency: Output frequency = sampling rate / number of images result averaging. For most of all applications which are not time-critical as well as for most of all belt weigher applications, it is recommended to use a result averaging via 5 images. Select filter: ► Open [Filters] tab. ► Select or deselect requested filter. ► If necessary, increase the number of images in the “Result averaging” field. ► Acknowledge with [Assign]. 8.3.3 Trigger Select the trigger mode and the idle time in the [Trigger] tab. 37 Programming manual FLOcontrol for FLO-3D Trigger mode: The trigger mode describes the trigger source. The following sources are available: Entry Positive edge Negative edge Continuous Function External triggering with positive edge. External triggering with negative edge. Internal triggering, continuos. Idle time: The idle time influences the sampling rate. The sampling rate corresponds to the number of images captured per second in continuous, internally triggered operation. Longer exposure times or higher sampling rates lead to increased heat generation. 8.3.4 Restore the factory setting With the help of this feature you are able to reset the image quality settings of the regarding program to default. ► Restore the factory setting. > The parameter values are reset to Exposure time 10.1 ms Sampling rate: 4 Hz Result averaging via: 1 8.3.5 Test trigger Using the [Release trigger] button you can test the trigger. ► Select the trigger mode in the “Trigger mode” field. external triggering (positive edge) external triggering (negative edge) ► Click on [Release trigger]. > After triggering the captured image and the test results are displayed in the result window. This test will not work with internal triggering. 38 Programming manual FLOcontrol for FLO-3D 8.4 Image zone In this module you select the image zone and set the application-specific parameters. As this module is different in the“Belt weigher” program from all other programs, it is described separately. 8.4.1 Image zone within the program “Belt weigher” Image zone (ROI): In the monitor field you can select one image zone (ROI = region of interest) that is to be evaluated by the sensor. Selection is effected by dragging a selection frame. As default setting a selection frame is already created in the monitor field which you can drag open and move using the mouse pointer. Set-up the image zone in such a way that the medium to be measured is fully located inside the image zone. Except the medium, only the background (normally the rubber belt or the bottom of the chute) should be visible. ► The selection frame can be set-up by taking the following steps: Move the mouse button into the centre of the selection frame until it changes to take the shape of a cross. Press the mouse button and move the selection frame keeping the mouse button pressed. To drag the selection frame open, click on the requested edge using the mouse pointer and drag the selection frame open around the requested object (ROI = region of interest). 39 Programming manual FLOcontrol for FLO-3D ► The selection frame can be modified by taking the following steps: To drag the selection frame open, click on the requested edge using the mouse pointer and drag the selection frame. Repeat the procedure with all other edges if required. 8.4.1.1 “Parameter” tab Here you have to enter he basic data oft the belt weigher application. Field Conveying direction Speed Activate bulk flow Bulk density Calibration factor Function In the field “Conveying direction” you determine if the sensor is mounted vertically or transversely to the conveying direction. The respective mounting direction is shown left beside the sensor image with a double arrow. Conveying speed (i.e. belt speed oft the belt conveyor). The sensor works only with a constant conveying speed. Activate this checkbox to convert the volumetric throughput (m³/h) automatically into a mass throughput (t/h) based on a constant bulk density. The unit of measurement will switch after that from m³/h to t/h. With bulk flow activated you can entert he bulk density here. With bulk flow deactivated the field appears grey and no entry will be possible. Using the calibration factor the gauge may be calibrated additionally if required. The result is multiplied by this factor. 8.4.1.2 “Belt weigher” tab In the [Belt weigher] tab you define the environment scenario of the optical belt weigher as well as additional settings. Field Background Min. object height Min. light intensity Conveyor length in view Function Function to teach the background (zeroing of the optical belt weigher). Any medium below this height will be ignored to avoid zero fluctuation. Pixels with a light intensity below this value will be interpreted as background. Effective length of the choosen image zone (ROI, → chapter 8.4.1) in the conveying direction and initialising function. 40 Programming manual FLOcontrol for FLO-3D Initialization during start-up of the application: ► Run the conveyor empty. ► Click on [Initialise]. ► Respond to the safety query with [Yes]. ► Wait max. 30 seconds until the process is completed. The sensor determines the average distance of each pixel to the background, saves the background profile and determines the conveyor length in view. In the meantime the conveyor has to remain running – otherwise you will have to do the entire process again. > After finishing the initialisation the actual sensor image is displayed again. In the “Background” field “REF” will be displayed. The field “Conveyor length in view” shows the recalculated length of the selected image zone (ROI) in the conveying direction. ► Observe the result window. With the conveyor running empty, the result value should be 0 as stable as possible. If the value fluctuates, increase the value “Min. object height” and click on [Assign] until a stable 0 is achieved. Do not enter a value greater than necessary – any medium below this height will be ignored. Zeroing of the optical belt weigher: If you encounter after a while that the throughput is not stable at 0 m³/h or 0 t/h, it may be necessary to do the zeroing again. This has no effect to the conveyor length in view set. ► Run the conveyor empty. ► Click on [Teach]. ► Respond to the safety query with [Yes]. ► Wait max. 30 seconds until the process is completed. The sensor determines the average distance of each pixel to the background and saves the background profile. In the meantime the conveyor has to remain running – otherwise you will have to do the zeroing again. > After finishing the initialisation the actual sensor image is displayed again. In the “Background” field “REF” will be displayed. 41 Programming manual FLOcontrol for FLO-3D Minimal light intensity – specific features with bright mediums on a very dark background: If you have a bright and strongly reflecting medium on a very dark background, an effect may occure with bad influence on the measurement. The bright medium will reflect much of the sensor’s infrared light and the distance to the medium is determined with a high accuracy. The very dark background is reflecting only a small amount of the infrared light – the light received from the sensor contains a high amount of extraneous and flare light. As a result, a too short distance to the background will be determined by the sensor. Observe the dark background (without any medium) in the distance view. Place a bright sheet of paper or the like onto the background and observe the distance view again. The bright paper sheet must not appear significantly higher than the dark background. On all applications like this with a large contrast range, it is recommended to choose the high dynamics in the image quality settings (→ chapter 8.3 Image quality). If the bright sheet of paper is displayed in a greater distance than the background (even at high dynamics), proceed as follows to achieve and enter the “Min. light intensity”. The sensor is interpreting all pixels darker than the “Min. light intensity” as background. ► Stop the empty conveyor. The sensor image should show the dark background as well as the bright medium. ► In monitor mode, click into the sensor image with the right mouse button to show the light intensity for the respective pixel. > The light intensity oft the respective pixel is shown underneath the sensor image in red letters – in this example 3,96. 42 Programming manual FLOcontrol for FLO-3D ► In the same way, click on several different pixels of the dark background and write down the respective light intensity. Try to find out the brightest pixel by clicking onto the brightest regions of the dark background. In this manner, determine the highest light intensity of the dark background. ► Similarly, click onto several different pixels oft he bright medium an write down the respective light intensity. Try to find out the darkest pixel by clicking onto the darkest regions of the bright medium. In this manner, determine the lowest light intensity of the bright medium. The gap between the highest light intensity of the background and the lowest light intensity of the medium should be min. 2.00. ► Calculate the average value of both numers, dividing the sum by two. The result is the value “Min. light intensity” which has to be entered later. The sensor shall interpret each pixel with a lower light intensity as background. Example: Highest light intensity of the dark background: Lowest light intensity of the bright medium: 2,37 5,41 “Min. light intensity” ► Empty the conveyor or move an empty section under the sensor and stop the conveyor again. ► Colour the section of the conveyor in the sensor’s image zone white. ► Activate application mode (→ chapter 7.2.1 Activate application mode). ► Edit the respective application (→ chapter 7.2.7 Edit existing application). ► Activate module [Image zone] (→ chapter 8.4 Image zone). ► Activate [Belt weigher] tab: ► Click on [Teach]. ► Respond to the safety query with [Yes], despite the fact that the conveyor is empty but not running. 43 Programming manual FLOcontrol for FLO-3D ► Wait max. 30 seconds until the process is completed. The sensor determines the average distance of each pixel to the background and saves the background profile. In the meantime the conveyor has to remain stopped and empty – otherwise you will have to do the zeroing with white-coloured background again. > After finishing the initialisation the actual sensor image is displayed again. In the “Background” field “REF” will be displayed. ► Enter the calculated value in the field “Min. light intensity”. ► Click on [Assign]. 8.4.2 Image zone within all other programs Image zone (ROI): In the monitor field you can select one image zone (ROI = region of interest) or several image zones (multi ROI) that are to be evaluated individually by the sensor. Selection is effected by dragging a selection frame and by the requested image zones. The monitor field can be divided into up to 64 selection frames. Overlapping of individual selection frames is possible. As default setting a selection frame is already created in the monitor field which you can drag open and move using the mouse pointer. 8.4.2.1 Build up a new image zone ► Open the [Image zone] tab. 44 Programming manual FLOcontrol for FLO-3D ► Click on [New]. As an alternative: Selection via the context menu (right mouse button), tool bar → or keyboard function. 8.4.2.2 Modify image zone ► To move the selection frame, take the following steps: Move the mouse button into the centre of the selection frame until it changes to take the shape of a cross. Press the mouse button and move the selection frame keeping the mouse button pressed. ► To drag the selection frame open, take the following steps: Click on the requested edge using the mouse pointer and drag the selection frame. Repeat the procedure with all other edges if required. 8.4.2.3 Duplicate image zone ► Open the [Image zone] tab. ► Click into the centre of the selection frame to select it. > The selection frame has a red frame. ► Click on [Duplicate]. As an alternative: Selection via the context menu (right mouse button), tool bar → > The selection frame has been duplicated. 45 or keyboard function. Programming manual FLOcontrol for FLO-3D 8.4.2.4 Delete selection frame ► Open the [Image zone] tab. ► Click into the centre of the selection frame to select it. > The selection frame has a red frame. ► Click on [Delete]. As an alternative: Selection via the context menu (right mouse button), tool bar → or keyboard function. > The selection frame is deleted. 8.4.2.5 Teach sensor In the [Parameters] tab you define the environment scenario (background, object height, reference object). The requested parameters vary depending on the selected program (volume, distance or level). In principle you have 2 options for defining the parameters: Enter values manually into the fields Have the values measured automatically by the sensor Enter the values manually: ► Enter the value into the requested field. ► Click on [Assign]. Teach values: ► Click on [Teach] next to the requested field. One ROI (as a standard always the first or the selected one) can be taught as a reference object for all ROIs. If you have selected several image zones, the result window will display the extreme values irrespective of the set program. The minimum and the maximum measured values are determined across all image zones. If you select the individual image zones, the selected image zone (“Sel. ROI”) is displayed in addition to the measured value. 46 Programming manual FLOcontrol for FLO-3D Teach process for the “Distance” program: Depending on the preselection either the minimum, maximum or average distance is determined. For the definition of the switch points (IO configuration) at a later point of time there is the option to define the distance value as a percentage value of a reference object. To do so, the distance to a reference object has to be entered or taught. ► To define the distance to a reference object, take the following steps: Position the reference object in the field of view. Click on [Teach]. > The value taught is displayed in the “Reference object” field. As an alternative: Enter a distance value in the “Reference object” field. Click on [Assign]. Teach process for the “Volume” program For the definition of the switch points (IO configuration) at a later point of time there is the option to define the volume value as a percentage value of a reference object. To do so, the volume of a reference object has to be entered or taught. ► Remove all objects to be detected from the field of view. > Only the background area is displayed. ► Click on [Teach] next to the “Background” field. > The distance between the sensor and the background area is determined. > The taught value is displayed as the reference value REF in the “Background” field. > 0 l is displayed in the result window. As an alternative: Enter the requested distance value in the field and assign it. 47 Programming manual FLOcontrol for FLO-3D ► Position the object(s) in the image zone. ► If necessary, define the ROI. ► To define the volume of a reference object, take the following steps: Position the reference object in the field of view. Click on [Teach] next to the “Reference object” field. > The taught value is displayed in the “Reference object” field. As an alternative: Enter the desired distance value in the “Reference object” field and click on [Assign]. ► Click on [Segmentation] under “Visualisation”. > Ideally the object is displayed in white and the background in black. ► If there are black pixels on the object, take the following steps: Enter a minimum height in the “Min. object height” field starting from which an object stands out from the background. Click on [Assign]. > The output screen indicates the real volume value in litres. Teach process for the “Level” program Depending on the preselection either the minimum, maximum or average level is determined. For the definition of the switch points (IO configuration) at a later point of time there is the option to define the level as a percentage value of the max. level. To do so, the maximum level has to be entered or taught. ► Empty the tank (if possible). ► If necessary, define the ROI. ► Click on [Teach] for “Distance to reference level”. > The distance between the sensor and the tank floor is determined. > The taught value is displayed as the reference value REF in the “Distance to reference level” field. As an alternative: Enter the distance between the sensor and the tank floor in the “Distance to reference level” field and assign it. 48 Programming manual FLOcontrol for FLO-3D ► To define the maximum level, take the following steps: Fill the tank up to its maximum. Click [Teach] for the “Max. filling level” field. > The taught value is displayed in the “Max. filling level” field. As an alternative: Enter the maximum level in the “Max. filling level” field and click on [Assign]. ► Under “Visualisation”, click on [Segmentation]. > Optimally, the object appears white and the background appears black. ► If there are black pixels on the object, take the following steps: Enter a minimum height in the “Min. object height” field starting from which an object stands out from the background. Click on [Assign]. > The output screen indicates the real level in mm or inch. 49 Programming manual FLOcontrol for FLO-3D 8.5 IO configuration In this module you configure the analogue output and define the output logic and the switch points of the outputs. Furthermore you are able to configure the pulse output (only in the “Belt weigher” program). All ROIs are monitored for the same switch points. 8.5.1 Binary threshold outputs 8.5.1.1 Terms Abbreviation Term HNO Hysteresis function, normally open HNC Hysteresis function, normally closed FNO Window function, normally open FNC Window function, normally closed Button (icon) 50 Programming manual FLOcontrol for FLO-3D 8.5.1.2 Hysteresis function The hysteresis keeps the switching state of the output stable if the process value fluctuates around the set point. When an object approaches, the output switches when the set point is reached. When the object is removed again, the output does not switch back before the value is below the reset point. 8.5.1.3 Window function The window function enables the monitoring of a defined acceptable range. If the process value is between the set point and the reset point, the output is closed (window function, normally open) or open (window function, normally closed). The window functions also work with switching hysteresis. Set and reset points are fixed and symmetrically arranged around the selected switch point. The hysteresis is the distance between the set and reset points. 51 Programming manual FLOcontrol for FLO-3D 8.5.2 Current output / voltage output These two functions provide an analogue signal on the output which increases or decreases linearly depending on the size of the process value. With the parameters “Analogue start point” and “Analogue end point” you define at which process value the minimum or maximum is reached. Depending on the requested configuration a rising or falling edge can be implemented. The analogue output is available only on output no. 1. Function Button (Icon) Voltage output 0 ... 10 V (rising edge) Voltage output 10 ... 0 V (falling edge) Current output 4 ... 20 mA (rising edge) Current output 20 ... 4 mA (falling edge) 8.5.3 Pulse output for counting pulses Within the “Belt weigher” program, it is possible to generate counting pulses with the help of this function. Each pulse is equal to a certain, adjustable amount of the medium to be measured. By doing this you can e.g. implement an external counter or an external counter reading display in m³ or t. The pulse output is available only within the “Belt weigher” program and only on output no. 2. Function Button (Icon) Pulse output for counting pulses Configuration has to be done within the [Pulse] tab. 52 Programming manual FLOcontrol for FLO-3D In the field “Pulse value” you can define which amount of the medium to be measured equals one counter pulse (in the example above one pulse will be generated every 1000 liters). The “Pulse duration ∆t” field defines the length of each counter pulse. Choose the values in a way that the counter pulses never overlap – even at maximum throughput. Otherwise you may lose counter pulses! ► Click on [Continue] and respond to the safety query with [Yes] in order to save the altered values to the sensor. 8.5.4 Configure the outputs Output no. 1 can be configured as an analogue or binary output, output no. 2 as a binary output or a counter pulse output. In the tabs you can select if the minimum or maximum measured value of all ROIs is to be used in the “Multiarea processing logic” field (corresponds to the “Min.” or “Max.” values). This enables more precise monitoring of overfill or underfill. The field is only active, if more than 1 ROI has been created. ► Click on the requested logic function under “Output 1” and “Output 2”. ► Select the respective [Output 1] or [Output 2] tab. ► Select between the absolute value and indication in percent using the buttons and ► Enter values for output configuration. ► In case of multiple ROIs, select the respective entry in the “Multi-area processing logic” field. ► Click on [Assign] or [Continue] and save the changes. 53 . Programming manual FLOcontrol for FLO-3D 9 Update sensor software The update consists of a file with the extension *.swu which has to be compatible with the FLO-3D Sensor. During the update all data stored on the sensor will get lost. ► Possibly store the data saved on the sensor. ► Save the update file (file extension: *.swu) in a directory of your choice. ► Connect to the requested sensor. ► Change to the [Applications] mode. ► Select [File] → [Sensor firmware update] in the menu bar. ► If the data saved on the sensor have been stored, acknowledge warning with [Yes]. > The user interface changes. ► Select SWU file for the sensor update. > File is transmitted to the sensor. This process will take a while. After successful transmission you receive a message. Then the sensor automatically makes a reset. After initialisation you can connect to the sensor as usual. 54 Programming manual FLOcontrol for FLO-3D When the firmware is updated, the IP address is reset to the factory setting. Do not interrupt the current supply to the sensor during the update process! This results in loss of data and functionality of the sensor. 10 Exit the program 10.1 Disconnect ► Select [Connections] → [Disconnect] in the menu bar. As an alternative: Click on the disconnect symbol in the tool bar → . ► Acknowledge query with [OK]. > The device is disconnected from the program. No connection to the PC is necessary after the configuration of the sensor. 10.2 Close the program ► Select [File] → [Exit] in the menu bar. The FLOcontrol program is not necessary for the usage of the already configured sensor. 55 Programming manual FLOcontrol for FLO-3D 56