LDS users manual V4.8 - cersa-mci.com users manual … · CERSA-MCI – LDS – User’s manual Thursday, March 04, 2010 Page 3 Contents 1. RELEASE TRACKING LIST .....5

CERSA-MCI Conception Etude et Réalisation de Systèmes Automatisés

Measure and Control Instruments Parc Expobat n° 53

F13 825 CABRIES Cedex, France

Tel: +33 (0) 4 42 02 60 44 Fax: +33 (0) 4 42 02 79 79

e-mail: [email protected]; Web: www.cersa-mci.com

L.D.S (Laser Diffraction Sensor)

Fine wire diameter measurement by laser diffraction

USER’S MANUAL V4.8

CERSA-MCI – LDS – User’s manual Thursday, March 04, 2010

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Contents

1. RELEASE TRACKING LIST .................................................................................................................5

2. A FEW INTRODUCTORY WORDS......................................................................................................6

3. « LASER DIFFRACTION SENSORS » PRODUCT LINE ..................................................................7

4. INSTRUMENT OVERVIEW ..................................................................................................................9

4.1. LDS PRINCIPLE ............................................................................................................................................9 4.2. PHOTO SENSORS CHARACTERISTICS AND CONSTRAINTS .............................................................................11 4.3. GENERAL FUNCTIONS.................................................................................................................................12

4.3.1. Standard instrument functions..........................................................................................................12 4.3.2. Optional interface and accessories of the sensor .............................................................................12 4.3.3. Data processing................................................................................................................................12 4.3.4. Wire ovality control ..........................................................................................................................13 4.3.5. References of the measures...............................................................................................................13

4.4. APPLICATIONS............................................................................................................................................14

5. GENERAL SPECIFICATIONS ............................................................................................................15

5.1. METROLOGY ..............................................................................................................................................15 5.2. REFERENCE WIRES .....................................................................................................................................16 5.3. ENVIRONMENT ...........................................................................................................................................16 5.4. STANDARD INTERFACES .............................................................................................................................16

5.4.1. Length counting interface.................................................................................................................16 5.4.2. Serial links ........................................................................................................................................17 5.4.3. Power supply ....................................................................................................................................17

5.5. OPTIONAL INTERFACES ..............................................................................................................................17 5.5.1. Digital inputs/outputs (I option) .......................................................................................................17 5.5.2. Local display (DI option) .................................................................................................................18 5.5.3. Local keyboard (K option)................................................................................................................19 5.5.4. Analog opto-coupled output (A option) ............................................................................................20 5.5.5. Wire sample rotation (WSR or WSR-F option).................................................................................20 5.5.6. Label printer (LP option) .................................................................................................................22 5.5.7. Portable version (P option) ..............................................................................................................28 5.5.8. Oscillating support (OS option)........................................................................................................31

5.6. DIMENSIONS AND WEIGHT.........................................................................................................................32 5.6.1. One-axis version ...............................................................................................................................32 5.6.2. Two-axes version ..............................................................................................................................33

6. IMPLEMENTATION.............................................................................................................................34

6.1. DESCRIPTION. ............................................................................................................................................34 6.1.1. Single axis case: ...............................................................................................................................34 6.1.2. Two-axes case: .................................................................................................................................34

6.2. IN LINE DUST PROTECTION ACCESSORY:.....................................................................................................35 6.2.1. Single axis case (optional): ..............................................................................................................35 6.2.2. Two-axes case: .................................................................................................................................35

6.3. INTERFACES. ..............................................................................................................................................36 6.4. INSTALLATION ...........................................................................................................................................36

6.4.1. Support .............................................................................................................................................36 6.4.2. Electrical connections ......................................................................................................................39

6.5. UTILIZATION..........................................................................................................................................40 6.6. SPOOL LENGTH SELECTION.........................................................................................................................40 6.7. SPOOL CHARACTERISTICS ..........................................................................................................................41 6.8. WIRE ALIGNMENT ADJUSTMENT.................................................................................................................41


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6.9. OPERATION ................................................................................................................................................41

7. CHECKS..................................................................................................................................................41

7.1. MECHANICAL AND OPTICAL CHECK ...........................................................................................................41 7.2. LENSES CLEANING......................................................................................................................................41 7.3. SENSOR CLEANING .....................................................................................................................................42

8. MAINTENANCE ....................................................................................................................................42

9. SECURITY RULES................................................................................................................................42


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1. Release tracking list

Software version Modifications User’s manual version

December 2003 Version 2.7 plus regression curve for linearization, recording

of several linearization tables, WSR upgrade, display and

recording of the ovality on the PC using WSR, statistics on

portable option, display in inches

Version 3.0

March 2004 Version 3.0 plus portable direct data transfer to Excel file. Version 3.1

May 2004 Include linearization on average diameter using WSR Version 3.2

May 2004 Portable recording extension to 200 measures per machine Version 3.3

July 2004 Changing the use of the portable joystick. Version 3.4

July 2004 Last updates, plus Label printer, Dust protection Version 3.5

October 2004 Use of the switch-unit for mill-inches display Version 3.6

December 2004 Last update for Label Printer use. Version 3.7

June 2005 Analog output scheme Version 3.8

July 2005 Using LP with the computer. Version 3.9

October 2005 Using the Foot pedal Version 4.0

January 2006 Integration of the LDSN 2 axes Version 4.1

August 2006 Jack alimentation 5 volts portable version in d2.5mm Version 4.2

September 2006 Clarification on SubD9 connection Pins (Page 37) Version 4.3

March 2009 Modification of Alarm codes list Version 4.4

October 2009 LDSN renames LDS Version 4.5

January 2010 Modification of the LDS references Version 4.6

February 2010 New LDS error codes Version 4.7

March 2010 New LDS error codes and performance updates Version 4.8


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2. A few introductory words CERSA has more than 20 years experience in high technology and innovative products for different fields

of application. Since 1987 we have undertaken an extensive development and production of non-contact,

high performance measuring instruments for fine wire and fibre optic industries, acquiring a worldwide

reputation through the integration of new measurement methods and the latest technologies.

The « Laser Diffraction Sensors » were initially developed in 1987 for the measurement of small and very

small wire diameters on production lines : steel cord, stainless steel, tungsten, copper, and non-transparent

to IR light fibers. Today they are also widely used in laboratories too, due to their easy use and their

outstanding metrology performances.

The measures are non-sensitive to wire vibration in production. As the uncertainty of the measures is

proportional to the diameter, the LDS offer a very high repeatability for very fine wire diameters.

The LDS is part of the new range of LxS design instruments constructed for large industrial measurement

applications, such as covering the measurement of diameters from 5 microns to 80mm, with the advantage

of highly integrated latest technology. The instrument includes all the functions for delivering the

measurements: dimensions, wire length counting and wire speed, statistics, directly through a serial link and

optional display, I/O and analog interfaces, all included in a compact and water proof casing (IP 55). The

device only uses long lifetime static components (laser diode, CCD).

They are used either in production lines or in laboratories (die shops). The LxS line can be used as a stand

alone, connected to an associated electronic, a PLC or a personal computer, for data display and recording.

It has also been designed for network applications, where a larger number of units are necessary, with

centralized data for production control.

CERSA-MCI has developed two PC software for LxS instruments. The first is for the connection of a

single one instrument, the second for several instruments connected in a network. Both software control the

instruments through a serial link (and the network) to acquire and display data. The network software

controls production quality as well as the machinery according to the production volume of each reference

of products.

A « portable » version, battery powered, is available to get the measures on the flight, with a dated data

acquisition per machine and the software for the direct data transfer to Excel file with automatic data and

graph update.

The present document describes the functions and characteristics of the LDS instruments as well as their

use. It is recommended that it be read completely. For a quick start, please refer to § 5.

Our representatives and technicians will assist you in running our instruments in your facilities.

Our laser diffraction sensors do not demand a constraining light radiation protection. Please refer to chapter

9 for maintenance rules.

Our Web site: www.cersa-mci.com, more than presenting our products and activities, offers our customers

the access to the very latest documentation through an access code delivered by CERSA-MCI. We invite

you to visit our web site, to send us your comments and remarks about it, the use of our instruments, and

your particular needs.


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3. « Laser Diffraction Sensors » product line

Metrological overview:

Diameter measurement range: From 5 to 2000 µm.

Instantaneous repeatability: ±±±±0.03% of the diameter.

How to build your reference:

InstrumentType Range – Axis number – Application – Options

Example: LDS0650-1-S-DI

LDS 0650 - 1 - S - DI

• Laser diffraction instrument

• Range is 15µm to 650µ

• One axis measurement

• Application is “Standard”

• Options are Display + Binary Input/Output.

Axis number: The instrument can be built in one or two axes:

1 axis 2 axis Remark : portable version can’t be built in 2 axes configuration.

Application : Standard: Measurement frequency is 400Hz. (since May 14

th, 2010)

Suitable for laboratory and also inline in case of stable diameter

(drawing machine for example), exposure time 10ms.

CCD1 is used (refer to chapter 3.2)

High speed : Measurement frequency can reach 800Hz. Exposure time 10µs.

Suitable for inline in case of non-stable diameter (enameling

machines, extrusion…).

CCD2 is used (refer to chapter 3.2)

Portable : Measurement frequency is 100Hz.

Axis numberApplication Options

LDS Laser Diffraction Sensor 0200 5µm to 200µm 1 S Standard T Wire tilting independancy

0650 15µm to 650µm 2 H High speed D Display

2000 50µm to 2000µm P Portable I Digital Input/Output

Av Analog output (Volt)

Aa Analog output (Ampers)

K Keyboard

Instrument type Range


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Delivered with batteries, it doesn’t need external power.

Including a memory, it can store measures and statistics for

exporting to the computer.

Options : Wire tilting independency: It makes the instrument less sensitive to the wire

tilting, and the laser beam is focused in a very fine line which gives

a very punctual measure (no optical averaging). Used fo H option

and 2 axes mainly.

Display: Local 4 numeric LED display. It shows the instant diameter

measure.

Digital Input/Output:

Inputs can control the instrument (for WSR or Foot Pedal…)

Outputs can generate alarms (out of tolerances, wire brake…)

Analog output (Av or Ai): Av is a voltage output (+/-4V)

Ai is a current output (0-20mA or 4-20mA).

Keyboard: Used to configure locally the tolerances.

In line dust protection accessory:

CERSA-MCI has developed a very efficient dust and vapor protection system for inline

applications of all its instruments, using clean airflow.

Wire ovality measurement system: o Fine wire sample rotation at constant tension. LDS-0200 or 0650 for WSR and

WSR-F Laboratory applications. o 180° oscillating support (OS). LDS, LPS production applications.

Label printer: An industrial label printer can be connected directly to the instrument, either for single

measure printing (foot pedal), or for WSR (ovality) results.

It also can be connected directly to the PC when a PC is used.

Applications to die shops, final wire control, etc…

PC softwares: Sensor operation and maintenance (single sensor). Centralized production management (sensors in a network).


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4. INSTRUMENT OVERVIEW

4.1. LDS Principle

The light ray deviation due to a material tangential effect creates a diffraction phenomenon. When a

wire is placed in a collimated monochromatic laser light source, two symmetrical effects appear on each

side of any wire diameter, like two new sources of coherent light, producing interferometric fringes

perpendicular to the wire. The period of the fringes is a direct function of the wire diameter.

An optical system concentrates the fringe signal on a linear CCD sensor. Due both to the phenomenon

and to the optical system, the sensor signal is wire position independent, provided the wire remains perpendicular to the sensor plane.

The fringe signal comes from the angular deviation of the rays. All the parallel rays from the laser

source are focused on the center of the CCD where the optical mask is placed. All the rays deviated by

the wire, reflection and diffraction, in the same angular direction are focused at the same position on the

CCD sensor. Then when the wire vibrates, the fringe signal does not change position or fringe periods.

Measurement head Serial link RS232C

or RS485

18-36V DC, 5VA electric supply

DSP Computing electronic board

Fine wire

Diffraction effect

CCD sensor Laser diode

Diffraction fringes


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Typical diffraction signal for a 30µm wire diameter with LDS200 model (5 to 200µm), "scope function

of the PC software”. We notice the perfect symmetry and regularity of the fringes which gives such

an accurate measurement.

Typical signal of a 650µm wire diameter on LDS650 (15 to 650µm), “scope function of the PC

software”. The fringe frequency is about proportional to the diameter.


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4.2. Photo sensors characteristics and constraints

The instrument benefits different CCD sensor characteristics used according to the application.

The signal produced by the diffraction effect is concentrated by the optical system in a line of fringes on

the CCD sensitive surface, perpendicularly to the wire. According to the width of the CCD sensing

surface, the tolerance of the sensor to the wire tilting changes.

In the above scheme, the width of the CCD1 (500µm) sensing area is much larger than CCD2 (200µm).

Then, when tilting the wire angularly, the fringe signal, always perpendicular to the wire, is tilting too.

At both ends of the CCD the signal would have more space for tilting on CCD1 than on CCD2. But in

the case of CCD1, the light sensitivity is much lower than for CCD2. It needs an exposure time of about

10ms. We generally use it for laboratory applications or off line, when the tolerance to the wire curbing

and tilting is of greater benefit. In the case of CCD2, the light sensitivity is much better and only 1ms

exposure time is sufficient. It needs more alignment constraints on the wire, but in line, the wire is

straight and the wire tilting is quite limited. As the instrument is not sensitive to the wire position and

vibration parallel to its main axis, we can use the CCD2 more efficiently on machines.

When measuring the diameter, the tilting introduces an error equal to (1-cosA)*∅. For CCD1, A is 1°,

about -0.015%. For CCD2 A is 0.4°, about -0.0025%.

When drawing, the wire tilting should oscillate. Then if we temporary loose the signal we will catch it

again at the next correct position. Most of the time the wire vibrates parallel to itself and therefore no

signal is lost.

Horizontal

Wire

Horizontal

Wire

Diffraction

fringes

Diffraction

fringes

Tilted wire Tilted wire

CCD 1 sensing area

for laboratory CCD 2 sensing area

for on line application


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4.3. General functions The sensors measure the wire diameters, check the machineries and deliver production data. Connected

in a network, they offer a real time centralized production management.

4.3.1. Standard instrument functions

Permanent control of the correct operation of the sensor. Blinking green LED (Run).

Continuous measurement of the diameter.

Wire loose detection (Event, Digital output, LED: « Wire »).

Diameter out of tolerance detection (Event, Digital output, LED: « Alarm »).

Wire length pulse counting (direct magnetic detector connection).

Measurement statistics: average, max, min, and standard deviation, related to the wire length.

Dated event memorization between two PC communication transfers (limited to 32).

Serial link communication: RS232C or RS485 (network).

PC software for instrument management, data login, instrument software upgrade.

4.3.2. Optional interface and accessories of the sensor

Four digits LED display and alarm

Binary Input and/or power output opto-coupled:

o Two inputs for machine state (event recording)

o Two outputs for local action on event (see table)

Analog output, tension (±±±±4V) or current (0-20mA)

Local keyboard for parameter adjustment.

Wire ovality management: optional Wire Sample Rotation (WSR) or Oscillating Support.

Portable version, battery powered, for periodic recording (6 hours autonomy).

4.3.3. Data processing

Refer also to the “PC software user’s manual” and the “Serial link communication manual".

The sensors are designed to communicate with external equipment and to be part of automated

systems, either alone (RS232C) or in a network (RS485).

Connected to a PC or to a programmable logic controller (PLC):

Due to the information provided by the sensor, it is possible to obtain the instantaneous, the

average, the maximum, the minimum diameters as well as the standard deviation.

When connected to an external wire length pulse generator, the sensor determines:

o The current wire length on the spool

o The total length produced by the machine

o The instantaneous wire speed.

The statistics refer either to the current wire length or to time according to the software

parameter. It is then possible to determine at any time the average weight ((π/4)x square average

diameter x produced length). A binary output of the instrument could switch off the machine when

the spool is full.


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The event recording is used to track production data for quality assurance.

The communication functions and procedures are described in the communication manual.

4.3.4. Wire ovality control

The true wire ovality cannot be obtained without continuously rotating the measurement axis by 180° around the wire. CERSA-MCI meets such a demand with the following systems:

On a production line : Our Oscillating Support (OS option) rotates the instrument by ±90° around

the wire axis. It is the one single way to permanently detect the true ovality of the wire in line.

In laboratories : Our fine Wire Sample Rotation system (WSR and WSR-F option), with an

adjustable constant wire tension, allows numerous measurements, according to the manual rotation

speed. It is then possible to display the number of measurements, the average, max., min., and

difference of the diameters and to deduct the true ovality. This applies to dies diameter and ovality measurement at a very high resolution.

4.3.5. References of the measures

If the LDS are highly sensitive and reproducible, they are not absolute measurement instruments.

They first need a calibration, done in our laboratory, plus what we call a multipoint “linearization”.

The customers cannot access the calibration which is used to set all the parameters of the instrument

at the start. On the other hand, linearization is the way to compensate the slight measurement

deviation and the non linearity of the diffraction phenomenon applied to the measurement of the

wires. The PC windows below is the tool which comes with the PC software to carry out a

linearization. See PC software manual.


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The graph on the top right side of the above window, enhances the difference between reference

wires and diffraction measures (Y axis) referring to the diffraction measures (X axis). These

differences for each reference wire should be on the same curve (red curve), as diffraction deviation

is a perfectly continuous line. That shows also the uncertainties of the reference wires.

It is the way to get the highest level of accuracy from the instrument. The linearization should be

made by the user with the type of wire to measure (copper, tungsten, gold, etc..). To do that in

CERSA-MCI, we use a set of different reference wires calibrated by several laboratories, covering

the whole range of the instruments. CERSA-MCI proposes different sets of 4 standard stainless steel

reference wires in one box, covering the instrument range, whose uncertainty is given within ±0.2µm

but really within ±0.05µm. The quality of the reference wire (clean, good surface quality, tight) is

very important to get the benefit of the maximum accuracy.

These 4 reference wires are originally used to correct the diffraction measures by linear segments as

shown on the graph here above in blue. It shows the deviation Diffraction - Reference (Y axis)

versus Diffraction (X axis). Between two reference wires the correction is made by interpolation.

Under the smallest and above the largest diameter, the correction is made by extrapolation. Care must

be taken never to have reference diameters too close to each other especially at the limits of the

range. That might introduce significant deviation by extrapolation due to the uncertainties of the

wires. It is possible to include up to 20 reference wires in a linearization.

Since version 3.0, December 2003, we also include:

1. The possibility to use up to 20 reference wires in order to correct the diffraction measures using a

regression curve (red curve) at the place of linear segments (Blue lines). The screen above

shows the very last PC software display for linearization. The red curve is the regression curve.

The main advantage is to reduce the uncertainty of the linearization curve below the uncertainty

of each individual wire. Another advantage of such a graph is to enhance any abnormal

deviation of one reference wire compared to the others.

2. There is the possibility also, to enter the average diameter of a wire, using the WSR, to make

the linearization. That is mainly for companies who want to use the weight method as calibration

of the reference wire. Weight methods refer to an average too.

3. In order to answer several complementary demands, we have introduced the capability for each

LDS, to save different linearization tables of the same instrument on the PC hard disk. Then one

can choose any table from the PC to be downloaded inside the instrument. See PC software

manual for details.

See PC software for the way to proceed.

The display of the diffraction signal produced by the reference wire is important to insure that the

wire is placed properly in the instrument and that the signal is correct. Any defective signal might

come from the position of the wire, the wrong surface quality, a diameter not stable in the

measurement field or wires not tightened.

According to the slight sensitivity of the sensor to large differences of wire surface quality (tungsten

to gold), to benefit from the greatest accuracy, apart from stainless steel, we recommend an

individual linearization per type of wire.

4.4. Applications

High accuracy continuous non-contact diameter and ovality measurement, independently of the high frequency vibrations of the wires.

Centralized data acquisition for production management.

Local digital data acquisition by the instrument (machine status). Two inputs.

Local digital commands from the instrument. Two outputs.

Local analog outputs for analog control loop or data recording.


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5. GENERAL SPECIFICATIONS

5.1. Metrology Measuring range : LDS2000/y model 45 to 2000µm

LDS0650/y model: 15 to 650 µm.

LDS0200/y model: 5 to 200 µm.

Repeatability: ±±±±0,03% of the diameter for instantaneous measures, without any averaging, peak

to peak measure. That fluctuations include:

Slow ambient temperature fluctuations from 10 to 45°C (temperature compensated)

Wire vibration or movement inside the laser field.

The instantaneous repeatability is far better than the general standard. No averaging of the measures

is needed.

Measuring frequency : about 400 measures per second.

Repeatability limitations : Depends on the instrument range: LDS200 LDS0650 LDS2000

In laboratory ±0.01µm ±0.03µm ±0.09µm

On machine (dirty lenses) ±0.1 ±0.3µm ±0.9µm

In practice, apart from specific cases like gold wires, the roughness and the surface irregularities of

the wires, do not permit such a measurement resolution. Nevertheless, the sensors allow very

accurate comparisons for identical measuring conditions (ovality, dies comparison, elongation, etc..).

Measurement accuracy : Even if the LDS are very sensitive and reproducible, they are not absolute measurement instruments.

They need several points of calibration in order to correct a slight curve in the low diameters. To

increase the accuracy, the standard wire should come from the customer’s production to take into

account the real surface roughness.

CERSA-MCI has worked with international measurement laboratory such as NIST (USA), METAS

(Switzerland) to get reference wires at the top level accuracies, from 30 microns to 2mm.

CERSA-MCI delivers reference wires from 30µm min to 2mm, with a minimum uncertainty of

±0.1µm. See our LDS accuracy certification document.

Important note:

1/ Any optical measure, refers to the diameter of the external envelope of the wire, including its

surface roughness. This effect introduces an error on the average diameter measurement. That might

become especially sensitive for very small diameters.

An efficient measure, should represent the average diameter (weighting) or one useful parameter. In

the case of copper or tungsten wires, the useful parameter is the electrical resistance of the wire. If

the production outlet has a constant surface quality (envelope always proportional to the reference

parameter), it becomes easy to calibrate the instruments with wires whose references correspond

directly to the useful parameter.

2/ When in line the wire is hot, above 80°C, very close to the wire surface, the air index change

disturbs the measures by increasing the diameter. That is the case for all the optical measurement

systems.

That is of negligible influence for fine wire. For larger diameters it is important to control the

cooling of the wires especially for steel and hard materials.


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5.2. Reference wires

On the customer side, CERSA-MCI offers its

customers the capability of calibrating the instrument

for their own reference wires with the benefit of a very

reproducible instrument.

On our side, we propose a box with a set of four

standard high quality stainless steel wires with an

uncertainty of ±±±±0,1µm covering the measurement range of the instruments. The standard wire can be

chosen between the following diameters:

30, 86, 137, 291, 600µm. We expect soon to get a

15µm standard wire as well as 1, 1.5 and 2mm wires at the same accuracy levels.

Below 600µm, each standard wire is fixed on a support especially made for our instruments, which

ensures a constant tension of the wire, a fixed position (ovality) and its mechanical protection.

Nevertheless, it should be handled with care to avoid shocks and to maintain the wire in perfect

quality.

5.3. Environment

Temperature: Storage: -20 to +70°C.

Operation: 10 to 45°C accuracy certified.

Humidity: 80%

Vibration: Permanent: 1g max. from 0 to 100 Hz. Linearly decreasing towards 0 from

100 to 500 Hz.

Shock resistance: 30 g.

5.4. Standard interfaces These interfaces come with the basic instrument when no other interfaces are needed (in line

application connected to a PLC or PC, network applications).

5.4.1. Length counting interface

The standard SUBD9 connector provides pins to directly connect the external pulse length generator.

The external generator could be of any type matching the scheme below:

The interest of this scheme is the possibility of directly connecting a standard magnetic detector. This

detector could be placed in front of the capstan or pulley in which holes passing in front of the

R

Optocoupler

Pin 7

Pin 1

Pin 6

SubD 9 connector on

instrument back plate

External pulse

length generator

Instrument internal scheme

18-36 volts DC power supply


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detector generate pulses. The pulse counting indicates the number of turns and the speed. Then, if we

know the diameter of the capstan or pulley, we can count the wire length of the draw as well as the

wire speed. It could also be any pulse from a coder. Just follow the above connection rules to activate

the internal opto-coupler of the instrument. The internal resistance R is made for voltages from 18 to

36 volts DC.

See chapter 5221 for SubD 9 connector.

See PC software for length counting parameter adjustment (number of pulses per turn, capstan

diameter).

The standard length unit is defaulting metric (meter). The user can change it to any standard when

entering the diameter of the capstan. Then, the number of pulses per turn could represent yards or

others units.

When choosing a magnetic detector, please refers to the brand: Crouzet, ref. 84 717 xxx series PNP

output, NO type. Web: www.crouzet.com, choose “switches”. Or it could be of any similar type.

5.4.2. Serial links

o RS232C, RS485 at 38400 bauds

o Instrument software upgrade through the serial link.

o Calibration, maintenance, data login by PC software

See the communication manual for more details.

5.4.3. Power supply

Instrument : 18-36 volts, 24 Volts nominal direct current, 3 VA.

External power supply : 90-264 Volts AC, 47-63 Hz, 15 Watts maxi. Efficiency : 75%

short circuit protected.

5.5. Optional interfaces

5.5.1. Digital inputs/outputs (I option)

The inputs (I) and outputs (O) are simultaneously available and selectable. It is necessary to choose a

function. The outputs are parallel connected to the inputs.

OUTPUTS: Two opto-coupled static relays.

Maximum switching: 48 volts DC, 1 Amp.

INPUTS: Two opto-coupled inputs.

State on: 24 to 48 volts on I/O+ ; impedance: 4,7 KΩ.


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5.5.2. Local display (DI option)

The “Alarm” comes with a switching display between diameter and alarm code (one second switching period).

• Last measured diameter

• Event code : Exx (values from 0 to 24) It includes :

Four green digits to display the diameter with:

International metric standard: the display is in microns (default option):

2 digits after comma if the diameter is lower than 100 µm. The resolution is 0.01µm

1 digit after comma if the diameter is between 100 to 999.9 µm. The resolution is 0.1µm

0 digit after comma if the diameter is above or equal to 1000 µm. The resolution is then 1µm.

Imperial standard (Inches): the display is in milli inches (Mils):

3 digits after comma if the diameter is below 0.010 mil. The resolution of the display is 0.001 mil

(0.000,001 inches), which is 0.025µm.

2 digits after comma if the diameter is equal or above 0.010 mil. The resolution of the display is

0.01 mil (0.000,01 inch), which is 0.25µm.

System display comparison:

LDS0200: 05.00 to 200.0µm or 0.197 to 7.874 mils (0.007,874”).

LDS0650: 15.00 to 650.0µm or 0.591 to 25.59 mils.

LDS2000: 50.00 to 2000µm or 1.968 to 78.74 mils.

To choose between both unit systems, you can use :

. Either a small unit-switch located at the rear side of the LDS (please specify this function

when ordering). In this case, you can switch manually between both units.

. Or the LSONE PC software in the “Session” menu. (see PC software manual)

4 digits for the diameter

Sensor OK:

Green blinking

Wire loose:

yellow light

Spool full: yellow

light

Alarm : red light + Code

display: Exx


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The display of the alarm codes Exx:

The instrument gives access to the status codes by a serial link. The status codes are also displayed

on the four digits, alternating every second with the diameter, under the form: Exx, with xx = code

values indicated in the table below:

Old Codes New Codes Signification Action

Instrument internal codes

0 0 Instrument OK

1 300 No wire Place a wire

2 402 Dirty lenses Clean the lenses

3 400 Low signal Check the wire adjustment

°C Internal temperature Wait for T° stabilization

6 507 Maintenance Signal





19 100 Instrument locked Ask CERSA-MCI to unlock it

External production codes

20 Diameter too big Machine intervention

21 Diameter too small Machine intervention

22 Speed too high Machine intervention

23 Speed too low Machine intervention

24 Spool full Replace the spool

Four alarm LED:

o One green LED « RUN » : Sensor OK if blinking.

o One red LED « ALARM » : Measurement problem if lit with Exx display.

o One Yellow LED « WIRE » : Loose wire if lit

o One yellow LED « SPOOL » : Spool full if lit

5.5.3. Local keyboard (K option)

This local keyboard is mainly used in line when the

machines do not have any PLC or PC. Then, associated

with the digital I/O and the display or even the analog

interfaces, it offers the user the possibility to change

locally the instrument parameters in order to control

the machine with a single instrument.

With the same casing as the display, it is placed on the

front part of the instrument. It allows to locally

modifying the operational parameters of the sensor,

after pushing “↑” key to successively access the

parameters. Adjust the values with + and – keys. These

parameters are :


Page 20

Length reset of the counter: Pushing on + or - buttons for 5 seconds resets the counter to zero.

Spool length: Total length of the full spool.

∅∅∅∅: Diameter nominal value, upper and lower diameter.

Speed: Nominal value, upper and lower speed.

The nominal values are thus increased or decreased in increments. The upper and lower variations

refer to the nominal values and are adjusted identically.

5.5.4. Analog opto-coupled output (A option)

It is possible to choose between a voltage or a current analog output when ordering.

Voltage output: ± 4 volts, 100mA. Difference between the nominal and the measured diameter.

Current output: 0-20 mA, maximum 50 volts. The user must provide the external power supply.

See at § 522

From 4 to 20 mA, it delivers the diameter between two current limits.

Option (PC software) : 0 mA : link opened

1 mA : No wire

2 mA : Signal low

3 mA : Other alarms

5.5.5. Wire sample rotation (WSR or WSR-F option)

For fine die and wire diameters and ovality check,

CERSA-MCI has designed a complementary tool for the

LDS line in order to easily fix, tighten and rotate the

wire samples at constant and adjustable tension for

accurate diameter and ovality measurement. The

ergonomic design is made to handle easily and quickly the parts to measure the wire with operator

constraints in mind.

A small printer can also be directly connected to the instrument for stick label printing of the

measures and graph of the diameter.

When the instrument is connected to a PC it also displays the measurements and the graph of the

diameter according to the angle. It is also possible to record the data on a hard disk. Then a complete

data base can be built for dies or wires. See PC software manual.

Rotation

level


Page 21

The image, left, shows the difference of the WSR-F for very fine wires. The yellow cylinders are

covered with adhesive rubbers, which leave no deposit on the wires. Therefore there is no need to use

pincers to fix the wire. When fixed, it is possible to smoothly tighten the wire by rotating the

cylinder. A torque spring limits the tension on the wire.

In the CD Rom provided with the first set of documentation a series of video files show the way

to proceed using WSR’s.

NOTE:

Since version 3.0 one important difference is the number of measures per half turn.

Initially, the internal angular coder of the WSR allowed synchronized measures of 16 angular periods

for one half turn. Even though that satisfies most of the applications, as the wires get closer to a

round shape, a need appears for more measures and a higher ovality resolution.

The instrument measures at maximum speed when the wire rotates. The coder simply locates the

measurements within 16 angular periods. That allows the restoring of the shape of the wire even

without constant wire rotation speed.

The number of measures, and the resolution of the wire shape, depends on the manual rotation speed

of the WSR. It is why the display of the results includes the total number of measures for each turn to

feed back to the operator according to the targeted resolution.

A number of measures from 60 to 80 is quite sufficient for diameters below 100µm.

Rotating the hand level only, as regularly as possible must operate the WSR.

Functions

First insure through the PC software that the instrument is properly configured to work with the WSR

(PC software, menu “session/configuration” with password).

At power on, the instrument is in standard mode, continuously measuring any wire in the

measurement field. The “RUN” light blinks.

When the instrument detects the rotation start, the LED “RUN” and the display becomes fixed. After

¼ of a turn, the recording of the measurements starts for a complete half turn. “RUN” remains fixed

but the display shows “_---_”.

At the end of ¾ of a turn (¼ + ½) the display switches between a mnemonic code and the result of

the measurements in the following way:

Special running conditions

Side red button LED « RUN » Mnemonic display 0,5 s Measures displayed 2 s.

0 pressure Fixed « -___ » D average

1 pressure Fixed « L___ » D mini

2 pressure Fixed « H___ » D maxi

3 pressure Fixed « E___ » E = Dmax – D min

4 pressure Fixed « P___ » Number of measures

5 pressure Blinking Current diameter

6 pressure


Page 22

After a complete record over the half turn, without action from the operator for more than 20

seconds, the instrument returns to initial conditions, measuring. Pressing the red button again allows

access to the last recorded measures in the order indicated above.

If, while measuring, the rotation stops for more than 2 seconds, the measures stop in the instrument

and one returns to the initial conditions. The preceding record is lost.

If, while measuring, some measures are rejected (bad signal), the LED “Alarm” switches on

continuously, but the measurements continue. The complete cycle continues but the results will be

erroneous.

5.5.6. Label printer (LP option)

It is useful to immediately put the measurement results directly on the goods (Die bag or wire spool).

We have chosen the Zebra Technology Corporation label printer TLP2824 (standard) or TLP2844

(photo) for larger labels. Zebra web site: www.zebra.com

These products have all the features needed for easy connection to our instrument or to a PC and also

for its capability to adapt the label design for each customer: name, logo (see label example above).

To work with our instruments they use our specific software interface as well as a specific internal

printer program.

We deliver the printer with all the accessories needed to use it immediately, including paper rolls and

ink ribbons.

It can be used directly connected to the instrument, independently of the PC, for single diameter

printing (foot pedal to activate the printing) or including the WSR option for ovality data printing

It can also be used connected to the PC with the instrument to cumulate hard disk data recording and

label printing.

CERSA-MCI proposes custom made designs: company name, logo, special label sizes.

Please refer to the Zebra TLP2824 user’s manual (delivered in the package) for instructions about

labels and ribbons installation and maintenance.


Page 23

Here below are the sizes and formats which are available today :

• WSR_13x9:

Size: 13mm x 9mm

• WSR_57_32_code39_type1:

Size : 57mm x 32mm

• WSR_57_32_code39_type2:

Size : 57mm x 32mm

• FP_13x9:

Size : 13mm x 9mm

In this case, the first data is the average

diameter,

the second is the ovality.

All data are in µm.

In this case, the first data is the average diameter

of the group

The second data is the difference between

Maximum and Minimum.


Page 24

How to use the label printer and the LDS with WSR connected to the computer :

In this case the WSR is plugged on the LDS. The LDS and the Label printer are both connected to

the PC to 2 different communications ports.

Follow the picture bellow for the electric connection.

Important: the original “LP to PC” cable is RS232 type. If your computer doesn’t have a COM Port

available, you can use a USB to RS232 converter or add a RS232 internal board.

When you complete a turn with the WSR, by using the LSONE

software, you can print the label. Please refer to the User’s PC

software manual for more informations.

On the label you will find the following indications:

.

LP power supply Label Printer LP to PC cable

Computer

LDS RS232 + DC cable

LDS power supply LDS + WSR


Page 25

• Serial number: This serial number is composed of a fix string of 8 characters maximum and a

incremental number (maximum 99999). By using the LSONE software, you can initialize

your serial number. Please refer to the user’s PC software manual for more information.

Important : The incremental number will be incremented each time you finish a turn and you launch

the label printing.

• Avg : Average diameter of the wire.

• Min : Minimum diameter of the wire.

• Max : Maximum diameter of the wire.

• Ovl : Ovality of the wire.

• Rnd : roundness of the wire (in %). Rnd = 100 * Ovl / Avg

How to use the label printer directly connected to the LDS with WSR :

In this case the WSR is plugged on the LDS and the Label printer is directly connected to the LDS

communication port, and then the PC is not useful. Follow the picture bellow for the electric

connection.

When you complete a turn with the WSR, by pushing 3 seconds on the WSR red button, you will

print the label directly without using the computer.

Label Printer

LDS + WSR

LDS

power supply

LP power supply

LP to LDS cable

LDS RS232 + DC

cable


Page 26

How to use the label printer and the LDS with Foot Pedal connected to the computer :

In this case the Foot Pedal is plugged on the LDS by the I/O connector. The LDS and the Label

printer are both connected to the PC to 2 different communications ports.

Follow the picture bellow for the electric connection.

Important: the original “LP to PC” cable is RS232 type. If your computer doesn’t have a COM port

available, you can use a USB to RS232 converter or add a RS232 internal board.

LP power supply

Label Printer

LP to PC cable

Computer

LDS RS232 + DC cable

LDSN

Foot Pedal

LDS power supply


Page 27

The foot pedal is used as an interface for the operator.

• One short push on the foot pedal will store the current diameter in the LDS memory. You can

store from 1 to 99 different diameter in the memory.

• One long push (> 2 sec) will close the diameter group, and then the equipment will compute

statistics on this group. On the local display is shown alternatively the average (‘-‘) and the

maximum difference (‘E’).

By using the LSONE software you will be able to display and print all statistics results. Please refer

to the User’s PC software manual.

How to use the label printer directly connected to the LDS with Foot Pedal :

In this case the Foot Pedal is plugged on the LDS by the I/O connector and the Label printer is

directly connected to the LDS communication port, and then the PC is not useful. Follow the picture

bellow for the electric connection.

The use of the Foot pedal is similar to the case with computer connected.

Label Printer

LDS

LDS

power supply

LP power supply

LP to LDS cable

LDS RS232

+ DC cable

Foot Pedal


Page 28

5.5.7. Portable version (P option)

Our instruments, which include in the same

casing, the optical system and the computing

electronics, and which benefit from a power

consumption of only 3 watts, can usefully be

powered by a light battery, without increasing

size and weight excessively but which provide

the same performance as the standard

instruments.

The « portable » is of interest in all industries

where continuous measures on machines are not

needed (copper, steel etc ...), but when it is of

interest to track periodically and accurately in

line the wire diameter with a top level accuracy.

A single portable instrument offers the possibility to measure and to record the wire diameter statistics and up to 200 measures for each for up to 127 machines.

Two cases arise:

Either the customer wants to get the individual measurements of each machine (200

recorded in the instrument per machine at the frequency of 50 Hz) and the diameter

statistics, in that case the transfer is done in a single text file which can easily be imported

within an Excel file,

or the customer wants only to get the diameter statistics. In which case the data is directly

transferred in an Excel file with an automatic graph update. See user’s PC software for

details. Below is an example of one sheet corresponding to one machine of 5 recorded

The diameter statistics include the average diameter, maximum, minimum (in µm or mill inch) and

standard deviation (STD) for the duration of the measures. Each record includes the date and the

time of the record, the diameter statistics, the number of measures (P), the machine number (Mn)

and the measurements.

The operator controls the instrument through a small joystick, thumb activated, placed at the end of

the handgrip. At the end of the recordings, connect the instrument to the PC, our software allows

the transfer of the data from the instrument to the PC. See below


Page 29

Each transfer automatically updates the individual data sheets and graphs per machine. It

automatically includes the new sheet when there is a new machine. The user will need to have

Excel software but not need great knowledge in the use of Excel.

After starting the records, only the measurements with good signals are recorded. After 30 seconds

without an acceptable signal (no wire), the recording automatically stops and the instrument returns

to its initial position.

The Ni-MH battery, which is used (of DR14 type (Duracell)), has a total capacity of 3600 mAh

under 4,8V. It offers on our LxS instrument line an average autonomy of 6 hours.

The portable pack comes with 2 batteries, the external battery charger, the external power supply

for the instrument, the PC communication cable, the PC software for data transfer and processing

and the complete documentation. The instrument does not charge the battery when connected to the

external power supply. Only the external battery charger performs that function.

Nota : The connectione jack for the 5 volt external power supply is of 2.5 mm diameter for the

portable units against 2.1mm for other standard LS instruments. This protect against miss

connection of 24V external supply on 5 volts jack of the portable unit.

The global functions of this instrument are identical to the standard version with:

Missing : No digital I/O or analog interface.

Added : Internal clock for date and time recording and data storage memory.

Detailed procedure for data recording:

The joystick is located at the end of the handgrip and thumb activated:


Page 30

Right side (+) and left side (-) pressures: When you press (+) the valid machine number increases. When you press (-) the valid machine

number decreases. Maintaining a continuous pressure, the machine number change accelerates.

High side pressure (V): First high side pressure, during normal measurement mode, starts the statistic and measures

recordings. While recording the display blinks between current diameter and sign “----“.The

measures are continuously stored in the instrument memory. The measures and recording start when

a wire is in the field.

In “Manual control” mode, a maximum of 200 measures will be recorded, but the statistics

computation continues as long as you stay in this recording mode.

Second high side pressure stops the statistics and measures recordings. Then, return to the

normal measurement mode and then, the display shows permanently (no more blinking) the current

diameter measured while the wire is in the measurement field.

In “Recording automatic stop” mode (See also PC software manual), the recording stops after

getting the number of measures specified (maximum 200), but in any case it can be stopped

prematurely by pressing the high side button.

If you are in the normal measurement mode, when there is no wire measured, the display blinks

alternatively between the last diameter measured and the error code “E1” (no wire).

Caution : When you record the measures, the previous recorded measure in the valid machine is erased by

the new one.

Low side pressure : Pressing the low side once, you enter the recorded measures display mode. Pressing again

several times, scrolls the recorded statistics (max, min diameters, STD and P) in the memory for the

valid machine number.

Low side button Mnemonic display 0,5 s Measures displayed 2 s.

1 pressure « - » D average

2 pressure « H » D maxi

3 pressure « L » D mini

4 pressure « E » Standard deviation (STD)

5 pressure « P » Number of measures (P)

6 pressure

To quit this measurement display mode, you have to press the high side button. Then you return to

the normal measurement mode.

Note : If the portable instrument is powered by its external power supply, and connected to a PC, it is

possible to use it on a machine for continuous diameter recording. In which case it is evidently necessary to

fix it on a support.

After the data is recorded, machine by machine, it can be transferred to the hard disk of the PC by

using the PC software and the transmission cable. It is recommended to use the external power

supply to do this. See also PC software manual.


Page 31

5.5.8. Oscillating support (OS option)

The « oscillating support » gives access to the true wire diameter ovality by continuously

oscillating the instrument on 180° around the wire axe.

For each cycle, the instrument determines: Average Diameter, Max Diameter, Min Diameter,

Ovality (difference Max-Min). The users can access these measures through the serial link (See

communication Manual) and by using the PC software.

On the local screen, the display automatically alternates between the average diameter and the

ovality as below:

‘-‘ : 1 second (previous mean diameter)

‘Mean Diameter’ : 2 seconds

‘E’ : 1 second (previous ovality)

‘Ovality’ : 2 seconds.

The alarm information are displayed normally as described in §452.

The subD9 serial link connector to PC on the connection box, has the same pin connection as the

instrument subD9 connector described at §5221. They connect the same serial link cable and power

supply.

According to the oscillation, the instrument will have its lenses below the wire, in a vertical axis.

To avoid dust falling on the lenses, the OS includes an airflow protection, which blows a cylinder of

airflow around the wire in order to protect any dust from falling on the lenses. Nevertheless, that

supposes a cleaned and dry air pressure connection.


Page 32

The air connection is placed on the fixed part of the OS.

5.6. Dimensions and Weight

5.6.1. One-axis version

Weight : 900g, basic unit.

Dimensions:


Page 33

5.6.2. Two-axes version

Weight : 2200g, basic unit.

Dimensions:


Page 34

6. IMPLEMENTATION

6.1. Description.

6.1.1. Single axis case:

The wires to be measured are placed in the hollowed red central part of the sensor.

The two removable tungsten bars, serve to place the wire in the measuring plane in

the laboratory or, in production, as reference marks in order to align the sensor on

the wire. For the LDS, the tungsten bars are placed in a high position for the

instrument alignment and pulled down to leave the wire contact free. Removable

screwed black cylinders protect the optical systems.

6.1.2. Two-axes case:

Two guiding bars help to the mechanical alignment of the instrument on the machine but also to

support the reference wires and to be used for optical alignment of the CCD sensors at the assembly

stage. These 2 guiding bars have 4 fixed positions:

1. Completely retracted to release the mechanical protection

2. Normal working conditions; the end of the guiding bars are at 8mm of the wire axis.

3. Visual adjustment position; the end of the bars are 1.5mm from the wire axis with the 2

edges at 45° converging on the wire axis.

4. Reference wire support. In that last position, we can use any reference wire or piece of

wire on the bars to measure it in good alignment conditions on both axes.

Wire alignment position.

2 Protection clipping

4 alignment marks

Casing with mechanical protection


Page 35

6.2. In line dust protection accessory:

6.2.1. Single axis case (optional):

The dust protection is fixed on the optical bench (central red part)

from the top, and clips automatically to it.

It aims to create a closed chamber around the optical system and

measurement area. A slight airflow comes inside the chamber either

from the optical bench of the instrument for the last generation, or

from the top opening for the first generation of instrument (before

June 2004).

It has the advantage of maintaining permanently clean air around the

measurement area and pushing away, slight external dusts or vapors.

That eliminates the need for lens cleaning, which increases the lifetime

of the lens system.

To be efficient it needs a clean air supply. The most efficient is to have an independent small air

compressor, getting air from the outside of the factory, and to connect 1 bar pressure on to the

accessory.

The accessory comes with an airflow controller, either placed on the top of the protection, or on the

back of the instrument.

6.2.2. Two-axes case:

This part assures the following points:

• Mechanical protection of the optical system from

external contacts (wires, fingers, tools, dusts).

• Dust protection. It makes a volume of air between the

outside and the optical bank around the lenses. A

clean air pressure connected to the back plate of the

casing, flows through the inner casing, and through

the optical bank to the inside of the volume of the

mechanical protection. The air flow exits through the laser beam pass opening of the

protection in order to avoid flying dusts to enter the volume and so to protect the lenses.


Page 36

6.3. Interfaces. The following elements are available on the back plate:

• SubD 9 connector: used for the supply, the communication and pulse generator connections.

The instrument comes with its own cables and power supply.

• Circular I/O connector with 6 pins: The external connection cable also comes with the option.

• LED light : visualization of the state of the sensor

• Air supply connection for ventilation and dust removal in very harsh environments.

The optional display gives the measure on 4 digits. Four control lights indicate the status of the

instrument.

The optional keyboard permits the local modification of the operational parameters.

6.4. Installation

6.4.1. Support

A supporting structure with a smooth surface, larger than the sensor's dimensions, is recommended to

avoid accidental shocks to the sensor.

The wire should pass in the center and in the middle of the lenses protecting the cylinders. A correct pre-adjustment is obtained when the wire is level with the tungsten bars when they are in

the high position.

When adjusted, the tungsten bars must be pulled down to avoid the wire coming into contact

with them while the machine runs.

The position of the wire may vary in all directions during the operation within ±±±±3 mm provided that the wire keeps parallel to the plane of the tungsten bars.

We also propose the support described below. It is designed around a 26,9x2mm stainless steel tube,

placed perpendicularly to the wire axis, in order to offer an easy way to finely adjust the most critical

angular position of the LxS. The other angular positions are not critical at all.

The rotating support is made of two fixing brackets and of one support plate. The sensor is fixed on

the support plate. The adjustment bracket located between the two fixing brackets, is used to finely

adjust the angular position of the rotating support around the tube. The tube can be easily fixed on the

machine by a rigid support in order to not amplify the vibrations. The distance between the tube and

the wire axis is not critical within ±0.5mm.

The two cylindrical bolts of the adjustment bracket are used to adjust the angular position of the

rotating support. The adjustment bracket should be previously blocked on the tube and the rotating

support should be kept turning. When the angle is adjusted, using the scope function of the PC

software, the fixing brackets must be blocked. Then, one can exchange the instruments without the

need of making new adjustments.


Page 37

A typical application could be as below. The round right angle curved tube offers the possibility of

adjusting the position of the instrument in all directions.

Nevertheless, a straight tube should be sufficient. Then only one linear adjustment is needed. The

height tolerance is not so critical.

Rotating support

Adjustment bracket View 1 View 2

View 3

Wire


Page 38

Instrument

Machine structure

Typical example of application on

machine.


Page 39

6.4.2. Electrical connections

In the case of a single independent utilization, the sensor comes with its own power supply and with

its PC connection cable for maintenance and operation purposes.

For production applications, it is provided with a cable for connection on the SubD 9 connector and

another cable for the circular connector.

The sensor works with an 18 and 36 volts, 3 VA continuous power supply.

6.4.2.1. SubD9 connection pins:

Pins Designations Type Reference Ground

5 RS485 + Bi-Directional GND (Pin 3)

9 RS485 - Bi-Directional GND (Pin 3)

4 RS232C : RXD (1) Input GND (Pin 3)

8 RS232C : TXD Output GND (Pin 3)

3 GND Internal Ground GND (Pin 3)

7 Power supply : +24 volts (2) Floating Power External 0V (Pin 6)

2 Switch RS232/485 (1) Input GND (Pin 3)

6 Power supply : 0V (2) Floating Power External 0V (Pin 6)

1 Wire length pulse input (3) Floating Input External 0V (Pin 6)

• (1) For RS485 only: Pin 2 and Pin 4 need to be connected to Internal Ground (GND) (Pin 3)

• (2) Power supply Pins 6 and 7 are floating. Never connect any Pin that is normally referenced to

GND (Pin 3) to Pin 6 or Pin 7

• (3) Wire length pulse input (Pin 1) is referenced to External 0V (Pin 6)

6.4.2.2. Circular input/output connector

The state of the inputs (I) is seen through the serial link. See “Communication manual”.

To activate the output relays: see PC software according to the table below.

Configuration 1 2 3 4

Output O1 Opened Closed Opened Closed

Output O2 Opened Opened Closed Closed

Each output relay can switch according to the following cases (PC software): • Diameter out of tolerances.

• Sensor failed

• Wire loose

• Serial link control

• Spool full

• All alarms: sensor failed, wire loose, spool full.

Pins Designations Wire colour

1 Analog + White

2 Analog – Brown

3 I/O1 + Green

4 I/O1 - Yellow

5 I/O2 + Grey

6 I/O2 - Pink


Page 40

The relays are active when closed. I/O schema:

Analog output scheme (current case shown):

6.5. UTILIZATION The instrument can be used on a machine or in a laboratory. Nevertheless, the configuration in a production

line, the calibration and the maintenance will demand the additional use of the PC software or the

communication functions (PLC).

Please refer to the « User’s PC software Manual » for the detailed description of the functions.

Important note: Before any operation of the instruments within their specifications, the machine should be

switched on at least 30 min before. This ensures a thermal stabilization.

6.6. Spool length selection This function is only useful if the wire length pulse generator is connected on the SubD9 connector. It

enters or modifies the wire length per spool, which will generate an alarm and/or activate an output relay

(I/O output activated). This parameter is adjustable from the PC software or from the optional local

keyboard.

Pins 3-5 (+)

Pins 4-6 (-)

Opto-coupled input

LED

Output static

relays

Inside LxSN instrument

DC Power supply

48 Volt maxi

+

Power relay

Maxi 1 Amp.

-

User’s application

Pins 1(+)

Pins 2(-) Inside LxSinstrument

DC Power supply

48 Volt maxi

+

-

User’s application

Resistance R

R 100 Ω 0.01%

I

V = R*I

DAC

Voltage case

Current case


Page 41

6.7. Spool characteristics This function is only useful if the wire length pulse enters the connector. It displays the characteristics of

the wire on the PC: the average diameter, the average speed, the standard deviation and the spool length in

meters with regard to the length count reset. The pulse counting computes the statistical parameters

according to the wire length. That means, the average diameter can be used to evaluate the production

weight.

6.8. Wire alignment adjustment The wire must pass approximately in the middle of the lenses protection. The wire must be straight, tight and clean.

A correct pre-adjustment is obtained when the wire is level with the tungsten bars in their high position.

A fine adjustment is obtained by using the « scope » function of the PC software. The amplitude of the

signal must be maximum at the right and the left end of the "scope" screen. (See §3-1)

6.9. Operation After power-on, the sensor automatically goes into automatic measurement.

In the laboratory: place the wire directly in contact on the tungsten bars in the high position, tighten well.

Be careful not to bend the wire. This could disturb the measurements.

In production: it is necessary to begin with the visual adjustment followed by the fine adjustment of the

orientation and of the position of the instrument with regard to the wire, the wire being tightened as in

production, without blemish or particles of dust.

Use the « scope » function of the PC software to check the sensor adjustment.

Then, enter the operational parameters: number of pulses per capstan revolution, capstan diameter, nominal

diameter to be measured, statistical length, diameter and speed thresholds, spool parameters.

The sensor is now adjusted and ready to operate. Please pull the tungsten bars in to the low position, to

avoid any contact with the wire while drawing.

7. CHECKS The check of the instrument status and alignment on the machine is performed by using the PC software or

through a serial link using a PLC. We recommend you read the following chapter after having the sensor

connected to a PC and the LS software being active.

7.1. Mechanical and optical check By choosing the Utility/Scope function you can check the alignment of the LDS on the wire and the

cleanliness of the lenses. The signal must be symmetrical in amplitude on both sides of the central axis of

the scope.

An excessive dust deposition on the lenses leads to a continuous light which adds to the fringes signal.

7.2. Lenses cleaning The lenses cleaning should be performed regularly depending on the environment.

A period of 3 weeks to one month is correct for wet wire drawing. In a laboratory, a simple dry air blowing

action each month into the lenses protection is sufficient. The user must remember that dust on the lenses

degrades the device’s accuracy. Nevertheless, even dirty, the devices remain quite accurate (±0,3µm).

However, if too dirty, the devices will stop working.

To clean the lenses, unscrew the removable protections. In certain cases of very dirty environments, the

protections can be equipped with a dry air injection system.

To clean the lenses, it is recommended to use specific products like the SINETT cleaning products made of

cloth soaked with dry cleaning and antistatic solutions.


Page 42

7.3. Sensor cleaning The sensor housing can be cleaned with usual cleaning products.

8. MAINTENANCE Maintenance test calibration for the measurements accuracy and for the checking of the signal quality

through the scope function. Only the cleaning of the lenses is to be taken into consideration for the sensor.

The mechanical alignment of the sensor and of the wire will also be checked by the « scope » function. In

case of non-alignment, the ends of the scope signal have a reduced, or even, a non-existent amplitude.

Please adjust the sensor alignment in such a case, with the tungsten bars in the high position as the

reference point..

9. SECURITY RULES There is no particular protection constraint for users in the case of a normal operation of the devices,

without dismounting the sensor.

Low power supply voltage; 18-36 volts direct current.

Class 1 laser device according to the classifications given by the "The Food Administration" of the United-

States, document FDA 81-8140, section 1040-10.

For several reasons, it is forbidden to dismantle the mechanical and electronic elements of the optical bench

inside the sensor. The optical alignment of the components would be immediately lost and the sensor would

not be usable any more. Nevertheless, if this is to be done, unplug the power supply before opening the

sensor.

Documents

LDS users manual V4.8 - cersa-mci.com users manual … · CERSA-MCI – LDS – User’s manual Thursday, March 04, 2010 Page 3 Contents 1. RELEASE TRACKING LIST .....5