SICK LOAD VOLUME MEASUREMENT SYSTEM - Profiling systems Operating instructions

S U P P L E M E N T A R Y O P E R A T I N G I N S TR U C T IO N S

Load Volume Measurement System

Profiling systems

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Subject to change without notice

Described product

Load Volume Measurement System

Document no.

8026099

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 a translation of the original document from SICK AG.

CONTENTS 
 

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S U P P L E MEN T A RY   O P ER A T ING   I NS T RU C T I O NS  L| Load Volume Measurement System 
Contents 
About this document ................................................................................................ 5 
1  Limitation of liability ..................................................................................... 5 
2  Purpose of this document ........................................................................... 5 
3  Target groups ................................................................................................ 6 
4  Abbreviations used....................................................................................... 6 
5  Further information ...................................................................................... 6 
6  Other relevant technical documentation/information............................. 7 
7  Document conventions ................................................................................ 7 
Safety information..................................................................................................... 8 
1  Intended use ................................................................................................. 8 
2  General safety notes .................................................................................... 8 
3  Requirements for the qualification of personnel ..................................... 9 
4  Warranty......................................................................................................... 9 
5  RoHS Directive .............................................................................................. 9 
6  Safety conventions ....................................................................................... 9 
7  Sources of danger ......................................................................................10 
8  Warning symbols on the system components ........................................11 
9  Mandatory symbols ....................................................................................11 
System description .................................................................................................12 
1  Overview.......................................................................................................12 
2  The measurement site ...............................................................................13 
2.1  Sensor layout of 2D LiDAR sensors for vehicle tracking .......13 
2.2  Sensor layout of 2D LiDAR sensors for recording profiles ....14 
3  The system components in detail ............................................................16 
3.1  LMS511 SE 2D LiDAR sensor ...................................................16 
3.2  Application Processing Unit (APU) ............................................17 
4  The operating principle ..............................................................................18 
4.1  Determining the measuring points...........................................18 
4.2  Processing of sensor data in a 3D point cloud.......................19 
4.3  Calculating the volume ..............................................................21 
4.4  Dealing with gaps and cavities and hidden surfaces ............22 
5  Requirements..............................................................................................24 
5.1  General system requirements ..................................................24 
5.2  Measurement site requirement................................................25 
6  Interfaces.....................................................................................................26 
6.1  Overview of interfaces ...............................................................26 
6.2  Integration into IT infrastructure...............................................28 
6.3  System extension .......................................................................29 
Mounting...................................................................................................................30 
1  Mounting 2D LiDAR sensors .....................................................................30 
1.1  Mounting positions of the 2D LiDAR sensors 
for recording profiles ..................................................................31 
1.2  Mounting positions of 2D LiDAR sensors  
for vehicle tracking .....................................................................33 
2  Mounting the control unit ..........................................................................34 

CONTENTS

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5 Electrical installation .............................................................................................36

6 Working in TEMS Manager....................................................................................38

6.1 System start ................................................................................................38

6.1.1 System start-up...........................................................................38

6.1.2 Connecting to TEMS Manager ..................................................38

6.1.3 Initial commissioning .................................................................39

6.2 Checking system status.............................................................................39

6.2.1 Checking operational readiness ...............................................39

6.2.2 Displaying measurement points ...............................................40

6.2.3 Displaying the device status .....................................................41

6.2.4 Displaying system parameters in edit mode...........................42

6.2.5 Running the configuration .........................................................43

6.3 Checking measurement operation...........................................................44

6.3.1 List of recorded vehicles............................................................44

6.3.2 Detailed view ...............................................................................44

7 TEMS Analyzer .........................................................................................................45

8 Technical data..........................................................................................................46

8.1 LVM data sheet ...........................................................................................46

8.2 APU data sheet (excerpt) ...........................................................................47

8.3 2D LiDAR sensor data sheet .....................................................................48

ABOUT THIS DOCUMENT 1

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1 About this document

These supplementary operating instructions for the Load Volume Measurement System

(LVM):

 Contain 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

These supplementary operating instructions are designed to give technical personnel

instructions on the safe integration, configuration, electrical installation, commissioning,

operation, and maintenance of the LVM.

These supplementary operating instructions do not provide information on operating

the customer system into which the LVM has been or is going to be integrated.

The supplementary operating instructions for the Load Volume Measurement

System are only valid in conjunction with the main operating instructions

for the Free Flow Profiler (8020775 DE / 8020776 EN).

Unless otherwise specified in this document, the information in the main

operating instructions for the Free Flow Profiler will apply.

1 ABOUT THIS DOCUMENT

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1.3 Target groups

The supplementary operating instructions are intended for persons integrating and

operating the LVM. They are also intended for the planners and integrators of the

customer system, as well as the operating entity with responsibility for it.

Target group

Activities

Entity operating the customer system

System user

Operating the system: Site view and display of

the measurement results in TEMS Manager

 The system user reports faults to the system manager.

System manager

Mounting, electrical installation, maintenance,

and replacement of system components.

 The system manager submits support requests to SICK.

SICK

SICK service technician

Commissioning, configuration, and support.

Tab. 1: Target group

1.4 Abbreviations used

APU = Application Processing Unit (central computing and control unit)

Free Flow Profiling System

Laser measurement scanner = 2D LiDAR sensor from SICK AG

Load Volume Measurement System

Traffic enhanced measurement system

Uninterruptible power supply

1.5 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.

APU

FPS

LMS

LVM

TEMS

UPS

ABOUT THIS DOCUMENT 1

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1.6 Other relevant technical documentation/information

The supplementary operating instructions of the LVM are based on the operating

instructions of the Free Flow Profiler.

 Technical system documentation

Technical data

Connection diagram

Terminal diagram

 Operating instructions for the following system components:

Operating instructions

Manufacturer

Document no.

LMS5xx Laser Measurement

Sensors

SICK

8013795 (DE) / 8013796 (EN)

Free Flow Profiler

SICK

8020775 (DE) / 8020776 (EN)

Application Processing Unit

SICK

8022112 (DE) / 8022113 (EN)

1.7 Document conventions

▸

Instructions

Reference to another document.

All measurement units used in this document are metric.

Subject to change without notice.

Figures may differ from the actual design.

2 SAFETY INFORMATION

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2 Safety information

2.1 Intended use

The Load Volume Measurement System measures the load volume on flatbed trailers

or the residual volume of dump trucks with only one pass through the measuring station

and without stopping the vehicle. No comparative measurement with and without load is

required.

Eye-safe 2D LiDAR sensors scan the vehicle up to 100 times a second. The measurement

data recorded is used to calculate a 3D model.

On this basis, the vehicle dimensions are determined, and the load volume or residual

volume is calculated. All information is output to the customer system via a TCP/IP

interface as soon as the vehicle has left the measuring station.

By automatically detecting the loading area, irrelevant vehicle parts and attachments

are detected and not taken into account in the volume calculation.

Precise information on the load volume is relevant, for example, for determining the

dry weight of loads with an indeterminate moisture content. Calculation of the residual

volume of bulk materials in dump trucks is used to optimize loading processes or

(if the dump volume is known) to determine the loaded volume.

NOTE! Intended use also includes observance of this addendum, in particular the safety

notes as well as the repair and maintenance requirements.

2.2 General safety notes

▸

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

information before working on the LVM.

▸

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

driver assistance system.

▸

Follow operating processes.

▸

Follow local regulations.

▸

Follow all local regulations relating to working with electrical components.

 Only authorized persons are permitted access to the LVM.

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.

SAFETY INFORMATION 2

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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 LVM.

 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 Warranty

No warranty claims will be accepted if:

▸

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

▸

Parts or components of the LVM have been installed, mounted or modified without

authorization.

▸

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

2.5 RoHS Directive

This product has been designed for specific applications in industrial environments

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

such environments.

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

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

2.6 Safety conventions

The warnings used in these supplementary operating instructions 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 possibly hazardous situation which may lead to minor or moderate bodily

injuries or material damage if not prevented.

NOTE Important information and useful notes.

2 SAFETY INFORMATION

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2.7 Sources of danger

The Load Volume Measurement System is designed in a way that allows for safe

operation. Protective devices reduce potential risks to the maximum possible extent.

WARNING!

RISK OF INJURY FROM LASER RADIATION

The 2D LiDAR sensors used in the LVM comply with laser class 1 (eye-safe) according

to EN 60825-1:2014.

The radiation emitted in normal operation is harmless to human skin and eyes if the

following points are observed:

▸

Do not open the housing.

▸

Current national regulations regarding laser protection must be observed.

DANGER!

RISK OF INJURY DUE TO ELECTRICAL CURRENT

The LVM is connected to an external voltage source.

Touching live devices, which may still be energized, can lead to death, burns or

electrical shock.

▸

Only qualified specialist personnel are permitted to perform electrical work on the

driver assistance system.

▸

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!

RISK OF INJURY DUE TO EQUIPOTENTIAL BONDING CURRENTS

Due to equipotential bonding currents, incorrect earthing can lead to the following

dangers and faults: Voltage is applied to the metal housing, cable fires due to cable

shields heating up, the product and other devices become damaged.

▸

Generate the same ground potential at all grounding points.

▸

Ground the equipotential bonding via the functional ground connection with a low

impedance.

WARNING!

RISK RESULTING FROM IMPROPER OPERATION

Improper installation and commissioning, damaged components, and unsuitable

ambient conditions such as excessively cold or warm temperatures and high levels

of dust, fog or spray, as well as vibrations and jolts at the measurement site may

cause faults and faulty alarms and may result in a complete system crash.

SAFETY INFORMATION 2

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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

2.9 Mandatory symbols

Symbol

Meaning

Read document

Use head protection

Use foot protection

Disconnect before maintenance or repairs

3 SYSTEM DESCRIPTION

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3 System description

3.1 Overview

Fig. 1: System components

Legend

1

2D LiDAR sensors

Serves to measure the position as well as the contour of the vehicle

and the load.

The number depends on the vehicle type and the application.

2

Application Processing Unit

Assembles the vehicle sections into a 3D model and calculates vehicle

data and load or residual volume

The LVM determines the load volume of flatbed trailers or step deck trailers as well as the

residual volume of dump trucks.

Fig. 2: Vehicle types

Legend

1

Flatbed trailers

2

Step deck trailers

3

Dumpers

Components

Vehicles

SYSTEM DESCRIPTION 3

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3.2 The measurement site

The layout of the measurement site depends on the local conditions and on the vehicles

to be measured.

Basically, the sensor layout consists of 2D LiDAR sensors for vehicle tracking and 2D

LiDAR sensors for generating the vehicle sections accross to the direction of travel.

3.2.1 Sensor layout of 2D LiDAR sensors for vehicle tracking

Fig. 3: Sensor layout of 2D LiDAR sensors for vehicle tracking

Legend

1

2D LiDAR sensor for vehicle tracking at main gantry

2

Additional 2D LiDAR sensor for vehicle tracking on a gantry offset in the

direction of travel

 For reliable tracking and maximum system performance, two 2D LiDAR sensors

are required in the longitudinal direction (direction of travel).

 The first 2D LiDAR sensor is mounted on the main gantry, the second on a gantry

offset in the direction of travel.

 The two 2D LiDAR sensors record the exact position of the vehicle as it enters,

passes through and leaves the measuring station.

3 SYSTEM DESCRIPTION

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3.2.2 Sensor layout of 2D LiDAR sensors for recording profiles

The number of 2D LiDAR sensors used to record the profile the vehicle depends on the

application, vehicle type, and accuracy required.

Fig. 4: Sensor layout for dumpers

Legend

1

2D LiDAR sensor for recording profiles on measuring gantry

2

2D LiDAR sensor for vehicle tracking

 For dumpers where the only view of the load is from above, a 2D LiDAR sensor

mounted overhead is used to record the profile of the vehicle from above.

 The beam of the 2D LiDAR sensor is emitted perpendicular to the road surface.

Sensor layout

for dumpers

SYSTEM DESCRIPTION 3

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Fig. 5: Sensor layout for flatbed trailers

Legend

1

2D sensor for recording profile of the left vehicle side

2

2D sensor for recording profile of the top vehicle side

3

2D sensor for recording profile of the right vehicle side

4

2D LiDAR sensor for vehicle tracking

 For vehicles with an open loading area, three 2D LiDAR sensors are typically required

for recording profiles.

 The 2D LiDAR sensor mounted overhead on the gantry records the top of the vehicle.

 Two 2D LiDAR sensors mounted on the side just above the height of the loading edge

detect the right and left sides of the vehicle to ensure proper loading area detection.

 The beam of the 2D LiDAR sensors for recording profiles is emitted accross to the

direction of travel.

NOTE The 2D LiDAR sensors for recording profiles must be located in the same measuring

plane.

Sensor layout

for flatbed trailers

3 SYSTEM DESCRIPTION

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3.3 The system components in detail

3.3.1 LMS511 SE 2D LiDAR sensor

Fig. 6: Scan plane of the LMS511 SE

 2D LiDAR sensors detect their surroundings by scanning them two-dimensionally

using the time-of-flight principle.

 To do so, a laser beam is emitted, and a moving mirror is used to guide it in the required

direction.

 The laser beam is emitted through the front screen of the 2D LiDAR sensor. The scan

plane position is indicated by a housing marking next to the front screen (see the arrow

in the above figure).

 When the laser pulse hits an object, it is reflected and sent back to the receiver of the

2D LiDAR sensor.

 By calculating the time difference between sending and receiving and also the signal

strength, the position of the object is detected exactly and forwarded to the internal

field evaluation unit of the 2D LiDAR sensor.

Properties

SYSTEM DESCRIPTION 3

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3.3.2 Application Processing Unit (APU)

Fig 7: Application Processing Unit (APU)

Legend

1

Application Processing Unit (APU)

2

Control cabinet

 Industrial PC with pre-installed LVM software

NOTE Depending on the application, modules must still be loaded remotely by the

SICK application engineer.

 The APU must be installed by the customer in a control cabinet near the measurement

site.

 The APU is the central computing and control unit of the LVM. It processes all incoming

sensor information.

 The APU generates a three-dimensional vehicle model from the recorded 2D cross-

sections of the 2D LiDAR sensors.

 The vehicle dimensions and the load or residual volume are calculated based on the

3D model.

 The vehicle model with all relevant information is provided to the downstream systems

with its TCP/IP interface.

 The APU is also used for commissiong, calibration, and fault analysis with the aid of

tools.

Features

Function

3 SYSTEM DESCRIPTION

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3.4 The operating principle

3.4.1 Determining the measuring points

Calculation of the load or residual volume is a multi-step process.

First, the vehicle is detected by the 2D LiDAR sensors for vehicle tracking. As soon as

the vehicle passes through the main gantry, the 2D LiDAR sensors record its contour.

The 2D LiDAR sensors do this by establishing the measuring range and using a non-

contact process to scan the vehicle.

Fig. 8: Determination of measurement points

Fig. 9: Operating principle of the profiling sensors

 The beam of the 2D LiDAR sensors for recording profiles is emitted perpendicular

to the road surface.

 The profiling sensor detects the top or sides of the vehicle, depending on the mounting

situation.

 The recording process starts as soon as a vehicle moves into the measuring plane.

 Recording stops when the object leaves the measuring plane.

 After the vehicle has passed through, 2D cross-sections are generated and sent to the

Application Processing Unit.

Operating principle of

the profiling sensors

SYSTEM DESCRIPTION 3

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Fig. 10: Operating principle of tracking sensors

 The beam of the 2D LiDAR sensors for vehicle tracking mounted on each of the two

gantries is emitted in the direction of travel.

 The tracking sensors record the exact position of the vehicle as it approaches,

passes through and leaves the gantry.

 The data from the two tracking sensors is used to calculate the position of the

individual 2D cross-sections.

3.4.2 Processing of sensor data in a 3D point cloud

Fig. 11: Calculation of the 3D point cloud

 The measurement points determined by the 2D LiDAR sensors are cyclically

transmitted to the Application Processing Unit.

 The APU combines the individual 2D sections of the vehicle.

 When the speed and the position of the vehicle on the measured section are taken

into account, a 3D point cloud can be generated and the APU can then use this to

determine the vehicle dimensions.

Operating principle of

the tracking sensors

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The vehicle dimensions are calculated in accordance with the following formulas:

Fig. 12: Calculation of the vehicle dimensions based on the 3D point cloud

Legend

1

Height measurement - Ymax (S)

The maximum vehicle height is determined from the maximum Y value

of the

3D point cloud S.

2

Length measurement - Zmax (S) - Zmin (S)

The maximum vehicle length is calculated by subtracting the minimum

Z value from the maximum Z value of the 3D point cloud S.

3

Calculation of the vehicle width - Max-Si = (Xmax (Si) - Xmin (Si))

To calculate the width of the vehicle, sections (Si) are generated from

the 3D point cloud (S). The width is calculated for each section from

the 3D point cloud. The maximum vehicle width is determined by

considering the maximum width of all sections from the 3D point cloud.

This calculation method makes it possible to compensate for errors

in cases where vehicles follow a slightly curved path through the

measurement site instead of traveling in a perfectly straight line.

Calculating the

vehicle dimensions

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SICK LOAD VOLUME MEASUREMENT SYSTEM - Profiling systems Operating instructions

SICK LOAD VOLUME MEASUREMENT SYSTEM - Profiling systems Operating instructions

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