SICK LOAD VOLUME MEASUREMENT SYSTEM - Profiling systems Operating instructions

SICK
Brand
SICK
Model
LOAD VOLUME MEASUREMENT SYSTEM - Profiling systems
Category
Measuring, testing & control
Type
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.
© SICK. All rights reserved
Original documents
This document is a translation of the 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 ................................................................................................ 6
1.4 Abbreviations used....................................................................................... 6
1.5 Further information ...................................................................................... 6
1.6 Other relevant technical documentation/information............................. 7
1.7 Document conventions ................................................................................ 7
2 Safety information..................................................................................................... 8
2.1 Intended use ................................................................................................. 8
2.2 General safety notes .................................................................................... 8
2.3 Requirements for the qualification of personnel ..................................... 9
2.4 Warranty......................................................................................................... 9
2.5 RoHS Directive .............................................................................................. 9
2.6 Safety conventions ....................................................................................... 9
2.7 Sources of danger ......................................................................................10
2.8 Warning symbols on the system components ........................................11
2.9 Mandatory symbols ....................................................................................11
3 System description .................................................................................................12
3.1 Overview.......................................................................................................12
3.2 The measurement site ...............................................................................13
3.2.1 Sensor layout of 2D LiDAR sensors for vehicle tracking .......13
3.2.2 Sensor layout of 2D LiDAR sensors for recording profiles ....14
3.3 The system components in detail ............................................................16
3.3.1 LMS511 SE 2D LiDAR sensor ...................................................16
3.3.2 Application Processing Unit (APU) ............................................17
3.4 The operating principle ..............................................................................18
3.4.1 Determining the measuring points...........................................18
3.4.2 Processing of sensor data in a 3D point cloud.......................19
3.4.3 Calculating the volume ..............................................................21
3.4.4 Dealing with gaps and cavities and hidden surfaces ............22
3.5 Requirements..............................................................................................24
3.5.1 General system requirements ..................................................24
3.5.2 Measurement site requirement................................................25
3.6 Interfaces.....................................................................................................26
3.6.1 Overview of interfaces ...............................................................26
3.6.2 Integration into IT infrastructure...............................................28
3.6.3 System extension .......................................................................29
4 Mounting...................................................................................................................30
4.1 Mounting 2D LiDAR sensors .....................................................................30
4.1.1 Mounting positions of the 2D LiDAR sensors
for recording profiles ..................................................................31
4.1.2 Mounting positions of 2D LiDAR sensors
for vehicle tracking .....................................................................33
4.2 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
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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
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.
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
Flatbed trailers
Step deck trailers
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.
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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
2D LiDAR sensor for recording profiles on measuring gantry
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
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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
Height measurement - Ymax (S)
The maximum vehicle height is determined from the maximum Y value
of the
3D point cloud S.
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.
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
Brand
SICK
Model
LOAD VOLUME MEASUREMENT SYSTEM - Profiling systems
Category
Measuring, testing & control
Type
Operating instructions
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