SICK VMS6200 Operating instructions

OPERATING INSTRUCTIONS

VMS6200

Track and trace systems

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Product described

VMS6200

Document No.

8025140

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

www.sick.com

Legal notes

This work is protected by copyright. The associated rights are reserved by SICK AG.

Reproduction of this document or parts of this document is only permissible within

the limits of the legal provisions of copyright law. Any modification, abridgment, or

translation of this document is prohibited without the express written permission of

SICK AG.

The trademarks mentioned in this document are the property of their respective

owners.

Original documents

This document is an original document from SICK AG.

CONTENTS

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Contents

1 About this document ........................................................................................................ 5

1.1 Limitation of liability ............................................................................................. 5

1.2 Purpose of this document .................................................................................... 5

1.3 Target groups........................................................................................................ 5

1.4 Further information .............................................................................................. 6

1.5 Other relevant technical documentation/information ....................................... 6

1.6 Document conventions ........................................................................................ 6

2 Safety information ............................................................................................................ 7

2.1 Intended use ......................................................................................................... 7

2.2 General safety notes ............................................................................................ 7

2.3 Requirements for the qualification of personnel................................................ 8

2.4 Protective devices ................................................................................................ 8

2.5 System warranty ................................................................................................... 8

2.6 RoHS Directive...................................................................................................... 8

2.7 Safety conventions ............................................................................................... 9

2.8 Warning symbols on the system components ................................................. 10

2.9 Mandatory symbols ........................................................................................... 10

2.10 Safety notes ....................................................................................................... 11

3 System description ........................................................................................................ 12

3.1 Scope of delivery ............................................................................................... 12

3.2 System components.......................................................................................... 13

3.2.1 LMS500 2D LiDAR sensors ............................................................... 14

3.2.2 Trigger photoelectric sensor .............................................................. 15

3.2.3 Incremental encoder .......................................................................... 16

3.2.4 Cabinet ............................................................................................... 17

3.3 Operating principle ............................................................................................ 18

3.3.1 Automated operating mode ............................................................... 18

3.3.2 Recording of measured values and data processing ...................... 20

3.3.3 Data output ........................................................................................ 21

3.3.4 Expanding the system with a reading and weighing station............ 22

3.4 System requirements ........................................................................................ 23

3.4.1 Requirements on the ambient conditions ........................................ 23

3.4.2 Requirements on the conveying equipment..................................... 23

3.4.3 Object requirements .......................................................................... 24

3.4.4 Mounting requirements ..................................................................... 25

4 Mounting ........................................................................................................................ 27

4.1 Mounting volume measurement devices ........................................................ 27

4.1.1 Mounting components ....................................................................... 28

4.1.2 Fastening the mounting plate to the frame ...................................... 29

4.1.3 Screwing the volume measurement device plus adapter plate

to the mounting plate ........................................................................

29

4.2 Mounting the photoelectric retro-reflective sensor ......................................... 30

4.3 Mounting the incremental encoder .................................................................. 30

4.4 Mounting the cabinet ........................................................................................ 31

5 Electrical installation .................................................................................................... 32

5.1 Connection overview ......................................................................................... 33

5.2 Connection to the voltage supply ..................................................................... 34

5.3 Factory connections .......................................................................................... 35

CONTENTS

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5.4 Connecting the volume measurement devices ................................................36

5.5 Connection for the photoelectric retro-reflective sensor .................................37

5.6 Connecting the incremental encoder ...............................................................38

5.7 Connecting to the customer interface ..............................................................39

6 Commissioning ...............................................................................................................40

6.1 Switching on the system ....................................................................................40

6.2 Checking the operational readiness of the system components ....................41

6.3 Configuring the system with SOPAS ..................................................................42

6.3.1 Installing SOPAS ET ............................................................................42

6.3.2 Installing SOPAS .................................................................................43

6.3.3 Assigning IP addresses .......................................................................44

6.3.4 Opening the configuration interface ..................................................50

6.3.5 Configuring the LMS500 and VMC800 .............................................51

6.3.6 Configuring basic settings for the MSC800 ......................................52

6.4 Checking system readiness ...............................................................................52

6.5 Testing the configuration ...................................................................................53

6.6 Optimizing the measurement results ...............................................................55

6.7 Saving the configuration ....................................................................................56

7 Maintenance and repair ................................................................................................57

7.1 Monitoring and cleaning work ...........................................................................58

7.1.1 Control measurements .......................................................................58

7.1.2 Visual control ......................................................................................58

7.1.3 Cleaning the volume measurement devices .....................................59

7.1.4 Cleaning the photoelectric retro-reflective sensor ............................60

7.1.5 Cleaning the components of the incremental encoder ....................60

7.1.6 Cleaning the cabinet ...........................................................................61

7.2 Replacing components ......................................................................................62

7.2.1 General notes......................................................................................62

7.2.2 Replacing the volume measuring device ..........................................63

7.2.3 Replacing the MSC800 ......................................................................65

7.2.4 Replacing the VMC800.......................................................................67

7.2.5 Replacing the photoelectric retro-reflective sensor ..........................69

7.2.6 Replacing the components of the incremental encoder ..................70

8 Fault diagnosis ...............................................................................................................71

8.1 Fault indications of the components ................................................................71

8.1.1 Fault indication on the LMS500 ........................................................71

8.1.2 Fault indication on the MSC800 ........................................................72

8.1.3 Fault indication on the photoelectric retro-reflective sensor ...........73

8.2 Fault indication during operation ......................................................................74

8.2.1 Checking the triggering .......................................................................74

8.2.2 Checking the incremental encoder ....................................................75

8.2.3 Checking the CAN cabling ..................................................................76

8.3 Detailed fault analysis .......................................................................................77

9 Technical data ................................................................................................................78

10 Disposal ...........................................................................................................................80

ABOUT THIS DOCUMENT 1

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1 About this document

This document regarding the VMS6200 volume measurement system:

• contains information that is required during the life cycle of the system.

• must be made available to all those who work with the system.

• should be read through carefully, and the contents fully understood before working

with the system.

1.1 Limitation of liability

Applicable standards and regulations, the latest technological developments, and our

many years of knowledge and experience have all been taken into account when

assembling the data and information contained in this document.

The manufacturer accepts no liability for damage caused by:

• Failure to observe this document.

• Non-compliance with notes and regulations.

• Unauthorized mounting and installation.

• Unauthorized technical and other changes.

• Use of unauthorized spare parts, wear and tear parts, and accessories.

• Unauthorized changes, adjustments, and/or manipulations of software.

• Failure to perform and document regular maintenance work.

The actual scope of delivery may differ from the features and illustrations shown here

where special variants are involved, if optional extras have been ordered, or as a result of

the latest technical changes.

1.2 Purpose of this document

This document describes the VMS6200 volume measurement system.

1.3 Target groups

This document is intended for qualified persons who operate the VMS6200.

1 ABOUT THIS DOCUMENT

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1.4 Further information

Special local conditions

The local laws, regulations, technical rules and internal company operating instructions at

the usage site must be observed.

Storage of documents

This document and other relevant technical documentation/information:

• Must be kept available for reference.

• Must be handed over to new system operators/new specialist personnel.

1.5 Other relevant technical documentation/information

• Technical system documentation

– EPLAN E258279

Technical data

Connection diagram

Terminal diagram

• Operating instructions for the following system components:

Operating instructions

Manufacturer

LMS5xx LASER MEASUREMENT SENSORS

SICK

MSC800 modular system controller SICK

WL(F)18-3 compact photoelectric sensors (optional) SICK

DFV60 (optional) SICK

1.6 Document conventions

 Required tools

▸

Instructions

 Result of action

Reference to another document.

All measurement units used in this document are metric.

Subject to change without notice.

NOTE! Illustrations may differ from the actual design.

SAFETY INFORMATION 2

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2 Safety information

2.1 Intended use

The VMS6200 track and trace system is used to solve demanding applications in the area

of object measurement and position determination.

Not only large objects, but also black, foiled or highly reflective objects can be dynamically

and reliably measured on a wide range of conveyor systems (conveyor belts, roller

conveyors).

Two 2D LiDAR sensors determine the smallest rectangular box that fully encloses an

object regardless of its shape, and then use this to derive the length, width and height of

the object.

The VMS6200 may only be operated in an industrial environment. Applications include,

for example, measuring baggage and freight items on conveyor systems in airports,

measuring objects in the incoming and outgoing goods areas in retail and warehousing,

as well as for storage and conveyor systems.

The objects can be measured with or without object carriers, for example pallets.

The modular system construction of the VMS6200 ensures compatibility with existing

solutions from SICK and enables adaptations to customer-specific applications.

NOTE! Intended use also includes observance of this system description, in particular the

safety notes and repair and maintenance requirements as well as proper installation, in

particular for billing operation.

2.2 General safety notes

▸

Please read this document through carefully and observe all the safety notes and

information before working on the VMS6200.

▸

Only qualified persons from the relevant departments are permitted to work on the

VMS6200.

▸

Follow operating processes.

▸

Follow local regulations.

▸

Follow all local regulations relating to working with electrical components.

• Only authorized persons are permitted to access the VMS6200.

System damage/transport damage

Damage to the individual components can lead to malfunctions of the system as a whole.

▸

Do not ignore any damage caused to system components during transport.

▸

In case of damage, contact SICK Service.

2 SAFETY INFORMATION

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2.3 Requirements for the qualification of personnel

Only qualified persons with the relevant technical expertise are permitted to work on the

system.

• Qualified persons have the specialist training, skills, and experience, as well as

knowledge of the relevant regulations and standards, to be able to perform work

assigned to them and to identify and avoid any potential dangers independently.

•

Electricians have the professional training, skills and experience, and knowledge of the

relevant standards and provisions to work on electrical systems and to detect and

avoid any potential dangers independently.

2.4 Protective devices

The volume measurement system is designed in a way that allows for safe operation.

Protective devices reduce potential risks to the maximum possible extent.

2.5 System warranty

No warranty claims will be accepted if:

▸

The safety notes and measures in this document are not observed.

▸

Parts or components of the VMS6200 have been installed, mounted or modified

without authorization.

▸

The VMS6200 has been altered or modified.

▸

The software has been modified, customized, and/or tampered with without

authorization.

2.6 RoHS Directive

This product has been designed for specific applications in large industrial plants

according to Article 2 (4) e, RoHS 2011/65 / EU, and must therefore only be used in such

plants.

The product is neither suitable nor approved for use outside of these plants. SICK

therefore cannot provide any warranty or accept any liability whatsoever for such use.

SAFETY INFORMATION 2

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2.7 Safety conventions

The warnings used in this manual have the following meanings:

DANGER

Identifies an imminent danger, which will lead to death or serious injuries if not

prevented.

WARNING

Identifies a situation presenting danger, which will lead to death or serious injuries

if not prevented.

CAUTION

Identifies a situation presenting danger, which may lead to minor or moderate

injuries if not prevented.

WARNING

Identifies a situation that may lead to property damage to the system or products in its

vicinity if not observed.

Note

Important information and useful tips.

2 SAFETY INFORMATION

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2.8 Warning symbols on the system components

Warning labels must not be removed or covered up. If labels are missing, these must be

affixed. Damaged labels must be replaced.

Symbol Meaning

Hazardous point warning

Hazardous electrical voltage warning

Laser beam warning

Suspended load warning

2.9 Mandatory symbols

Symbol Meaning

Read document

Use head protection

Use foot protection

Disconnect before maintenance or repairs

SAFETY INFORMATION 2

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2.10 Safety notes

DANGER!

HAZARDOUS ELECTRICAL VOLTAGE

Touching live devices can lead to death, burns or electrical shock.

▸

Electrical work may only be performed on the system by qualified specialist

personnel.

▸

Before working on electrical components, observe the five safety rules:

▸

Disconnect.

▸

Secure against being switched back on.

▸

Ensure that there is no voltage.

▸

Ground and short-circuit.

▸

Cover or enclose live parts in the vicinity.

WARNING!

HAZARDOUS LASER RADIATION

The 2D LiDAR sensor of the volume measurement system works with an eye-safe

infrared class 1 laser (IEC 60825-1:2014, EN 60825-1:2014). The laser beam is not

visible to the human eye.

▸

Do not open the housing.

▸

Observe laser safety regulations.

DANGER!

Suspended loads

▸

Never enter the area under suspended loads.

▸

Pay close attention when lifting loads.

▸

Comply with lifting instructions to prevent injuries and accidents.

▸

Use suitable, undamaged lifting tools.

▸

Wear personal protective equipment (safety helmet, safety shoes).

3 SYSTEM DESCRIPTION

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3 System description

3.1 Scope of delivery

NOTE!

▸

After delivery, inspect the system for transport damage and report any such damage

immediately.

▸

Check that the delivery includes all components listed on the delivery note.

System components

• Cabinet with MSC800, VMC800, power supply module, and Ethernet switch

• Two LMS500 2D LiDAR sensors with connecting cables

Optional

• DFV60 incremental encoder (optional)

• WL18 photoelectric retro-reflective sensor (optional)

• Aluminum profiles for setting up the frame (application-dependent as per the order)

• Mounting kits for the cabinet and sensors

SYSTEM DESCRIPTION 3

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3.2 System components

Fig. 1: Components of the VMS6200

Legend

1 2D LiDAR sensor

2 Photoelectric retro-reflective sensor (optional)

3 Incremental encoder (optional)

4 Cabinet with MSC800, VMC800, power supply unit, and Ethernet switch

• The system components are mounted on a customer-specific frame as per the

technical drawing.

NOTE! To avoid dazzling of multiple parallel systems, the field of view in the 2D LiDAR

sensor can be adjusted.

Devices

Mounting

3 SYSTEM DESCRIPTION

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3.2.1 LMS500 2D LiDAR sensors

Fig. 2: LMS500 with adapter plate and mounting plate

Legend

1 Mounting plate for mounting on a frame

2 Adapter plate with adjustment unit for attaching the LMS500

3 System plug with parameter set

4 Status indicators

5 Beam exit

• Two LMS500 2D LiDAR sensors are mounted on the right and left above the conveyor

on a profile.

• The 2D LiDAR sensors have been pre-mounted on an adapter plate with adjustment

unit, and aligned at the factory.

NOTE! The fixing screws must not be loosened by the customer. Otherwise

measurements with the specified accuracy cannot be guaranteed.

• The unit comprising LMS500 and adapter plate is attached to a frame provided by the

customer using a mounting plate.

• The device parameters are permanently stored in the system plug. This makes it easier

to replace components.

• The two LMS500 sensors span a measuring field and detect the contours of objects

transported into the field.

• The acquired measuring points are transmitted to the VMC800 volume measurement

controller for further processing.

Features

Function

SYSTEM DESCRIPTION 3

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3.2.2 Trigger photoelectric sensor

Fig.3: Photoelectric retro-reflective sensor with reflector (e.g., WL18-3)

Legend

1 Photoelectric retro-reflective sensor (e.g., WL18-3)

2 Reflector

• Photoelectric retro-reflective sensor trigger available as an option.

• The emitted light band is reflected back by a reflector.

• Sender and receiver are arranged parallel to one another in the housing.

• Mounted in front of the measuring field.

• Supplies the trigger signal in systems with triggered measurement.

• The trigger signal activates the sensors and opens the internal reading gate.

NOTE! Alternatively, the trigger signal can also be supplied by the customer via the PLC.

Features

Function

3 SYSTEM DESCRIPTION

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3.2.3 Incremental encoder

Fig. 4: DFV60 incremental encoder

Legend

1 Measuring wheel

2 Spring-loaded mounting arm

• Optionally available measuring wheel system mounted below the conveying equipment.

• Large spring travel and pivot range of the spring arm compensates for unevenness on

measurement surface.

• Measurement of linear movements.

• Detection of position and speed directly on the running surface of the conveyor using

a precision measuring wheel.

NOTE! Alternatively, the speed signal can also be supplied by the customer via the PLC.

Properties

Function

SYSTEM DESCRIPTION 3

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3.2.4 Cabinet

Fig. 5: Components in the cabinet

Legend

1 Air inlet for cooling (with filter mat and cooler)

2 Ethernet switch for connecting the system components

3 VMC800 volume measurement controller

4 Air outlet for cooling (with filter mat)

5 Terminals (24 V DC) and fuse module OUT

6 Power supply unit for supplying voltage to the system components

7 Terminals for voltage supply IN (100–264 V AC / 50–60 Hz)

8 MSC800 system controller

• The power supply unit supplies the voltage to the controllers and connected sensors.

• The VMC800 volume measurement controller receives the measuring points from the

volume measurement devices and uses the 2D sections to calculate a three-

dimensional model. Based on this model, it determines the dimensional values and

transmits these to the MSC800 system controller via CAN bus.

• The MSC800 system controller coordinates all the connected sensors. It processes

the trigger and encoder signals and, via its digital inputs and outputs, provides all the

relevant information for calculating the object dimensions.

The MSC800 receives the measurement results from the VMC800 and outputs these

to the customer system in a defined host telegram.

Function

3 SYSTEM DESCRIPTION

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3.3 Operating principle

3.3.1 Automated operating mode

The VMS6200 runs fully automatically after startup. No manual intervention by the

operator is required.

Fig. 6: Transport conditions – singulated measurement

• The VMS6200 measurement system is capable of identifying singulated box shaped

objects as well as singulated objects of virtually any other shape on flat conveying

systems such as conveyor belts or roller conveyors.

• The objects must pass the VMS6200 with a defined separation distance of 200 mm

(distance between rear edge and leading edge).

• Only one object can be in the measuring range at any given time.

• The VMS6200 can detect the rotation and position of the objects.

Fig. 7: Minimum separation calculation for baggage items with IATA codes

• When measuring baggage items, the IATA code counts as part of the baggage item.

• They must therefore be taken into account when determining the minimum separation.

Transport conditions/

measurement principle

IATA codes

SYSTEM DESCRIPTION 3

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Fig. 8: Minimum separation calculation for palletized freight with straps/wrapping

• Similarly, pallet wrapping or straps need to be taken into consideration when

calculating the separation for objects on pallets.

Fig. 9: No touching, no side-by-side

• The objects must not be located side-by-side

*

.

• The objects must not be touching

*

.

NOTE! Objects are also deemed to be touching if the IATA codes are in contact with one

another.

Pallet wrap/straps

Not allowed!

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3.3.2 Recording of measured values and data processing

Fig. 10: Measuring point determination of the VMS6200

• The measurement process is activated via the trigger signal.

• The volume measurement devices span a two-dimensional measuring range and scan

the surfaces of the object located within this range on the conveying equipment,

without making contact.

• The volume measurement devices transmit the acquired measuring points to the

VMC800 volume measurement controller.

Fig. 11: 3D model generation in the VMC800 volume measurement controller

• There, a spatial model is created taking into consideration the detected conveyor

speed and the specific position of the object on the conveying equipment.

• The VMC800 calculates the volume of the smallest rectangular box that fully encloses

the object and uses this to derive the length, width and height.

• The rotation and position of the object on the conveying equipment is also determined.

• The measurement results are transmitted to the MSC800 system controller for further

processing.

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SICK VMS6200 Operating instructions

SICK VMS6200 Operating instructions

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