304 Laser Probe 4500 English

LaserProbe4500
CNC-STEP
"LaserProbe4500"
3D laser scanning system
Instruction manual
LaserProbe4500 3D laser scanning system
Hylewicz CNC-Technik
Siemensstrasse 13-15
D-47608 Geldern
Fon.: +49 (0) 2831 133236

E-Mail: info@cnc-step.com
Website: www.cnc-step.de
Contents
1. Safety .......................................................................................................................................................4
1.1. Symbols used................................................................................................................................4
2. Purpose ...................................................................................................................................................4
3. Basic technical data and characteristics .................................................................................................4
3 3.1.
3.2.
3.3.
Scanning parameters ...................................................................................................................4
Allowable synchronization methods .............................................................................................4
Series LA901 laser sensor ..........................................................................................................5
3.4. Synchronization unit.....................................................................................................................6
3.5. Optical isolation unit .....................................................................................................................7
4. Delivery set............................................................................................................................................7
5. Operation principle.................................................................................................................................8
6. Connection versions ..............................................................................................................................8
6.1. Connection to machines with direct stepper control .....................................................................8
6.2. Connection to Beaver 9A/12A/12AV/18A/24A/26A machines......................................................8
6.3. Connection to machines with encoder impulse signals ................................................................9
6.4. Connection to machines with command signal pulses or with differential output encoder
(for example, Beaver 26AVST with servo-controller) ...................................................................9
6.5. Connection to machines with sinusoidal encoder signals (3 wires)..............................................9
6.6. Connection to machines with sinusoidal and differential encoder signals (5 wires) ...................10
7. Connection of the optical isolation unit.................................................................................................10
7.1. Block diagram .............................................................................................................................10
7.2. Designation of contacts...............................................................................................................11
7.3. Connection to the synchronization unit .......................................................................................12
8. Selection of the synchronization option................................................................................................12
8.1. Connection to machine with direct stepper control .....................................................................12
8.2. Connection to machine with encoder impulse signals ................................................................13
8.3. Connection to machines with impulse differential encoder signals.............................................13
8.4. Connection to machines with analog encoder signals ................................................................14
8.5. Connection to machines with analog differential encoder signals ..............................................14
9. The «Dorgonia» software .....................................................................................................................15
9.1. Basic functions ............................................................................................................................15
9.2. Program start...............................................................................................................................15
9.3. Settings........................................................................................................................................16
9.3.1. Positioning of the sensor ....................................................................................................16
9.3.2. Setting-up of the laser sensor parameters .........................................................................16
9.3.3. Setting-up of program filters ...............................................................................................17
9.3.4. Setting-up of the scanning parameters ..............................................................................18
9.4. Generating scanning file for CNC ...............................................................................................18
9.5. Scanning of the item ...................................................................................................................18
9.6. Generate result file ......................................................................................................................18
10. Example of filter operation ...................................................................................................................19
11. System requirements ...........................................................................................................................21
12. Warranty ...............................................................................................................................................21
13. Example of the scanning result............................................................................................................21
14. Troubleshooting ...................................................................................................................................22
1. Safety
Avoid metal chips getting into the optical isolation unit.
Check earth before connecting the system to a machine. Keep the 3D system in clean
condition. The handling of the system assumes knowledge of the instruction manual.
4 1.1. Symbols used
«Attention» symbol: Pay attention to the warning to avoid typical mistakes when
working with the 3D system.
«Information» symbol: Information that can be useful.
2. Purpose
The “LaserProbe4500” system is intended for non-contact laser scanning of items for the purpose
of obtaining three-dimensional computer model and formation of model files suitable for subse-
quent use in CNC system. The system is designed for mounting onto working machines with
any type of control.
3. Basic technical data and characteristics

3.1. Scanning parameters
Name Value
Materials to be scanned Any except transparent or
reflecting materials
Scanning grid for XY arbitrary
Scanning field for XY arbitrary
Scanning depth, mm 100 or customized*
Average scanning speed, points/s 4500
Table 1: Scanning parameters
3.2. Allowable synchronization methods

Source of synchronization signal Signal level value
Signals for direct stepper control along X-axis CMOS/TTL
Encoder on X-axis with impulsed output (differential or 1...30V
non-differential)
Encoder on X-axis with sinusoidal output (differential or 1…30V
non-differential)
Table 2: Allowable synchronization methods
3.3. Series LA901 laser sensor

Name Value
Base distance, mm 140
Range, mm 100
5 Total height from the machine table, mm

Error, mm
Resolution, mm
240
±0,1
0,03
Maximum operation speed, points/s 10000
Laser type 3 mW, wavelength 660 nm
Class of protection IP67
Working temperature, °С -10…+60
Time of continuous operation unlimited
Overall and mounting dimensions, mm Fig.1
Weight, g 100
Table 3: Parameters of the Series LA901 laser sensor
Note: * the system can be equipped with sensor offering different characteristics contact:
info@cnc-step.com
CABLE
RIFTEK
Input window Output window Base distance
Working range
Figure 1. Mounting and overall dimensions of Series LA901 laser sensor

3.4. Synchronization unit

Name Value
PC communication interface USB 2.0
6 Working temperature, °С
Dimensions, mm
Table 4: Parameters of the synchronization unit
-10…+60
Fig.2
1 2 3
30,5
137 60,5
4 5
24,7
4
24,7 56,3
4 125
Figure 2. General view of the synchronization unit
№ Designation
Connector for machine, in case of mounting on Beaver 9A/12A/12AV/18A/24A/26A
1
machines, not used otherwise;
2 Connector for laser sensor;
3 Power connector +5V;
Connector for optical isolation unit (for mounting on Beaver
4
9A/12A/12AV/18A/24A/26A machines – 15-conductor cable to PC);
5 USB-cable for connection of the system to PC.
Table 5: Designation of connectors of the synchronization unit

3.5. Optical isolation unit

Name Value
Working temperature, °С -10…+60
7 Dimensions, mm
Mounting
Table 6: Parameters of the optical isolation unit
Fig. 3
on DIN-rail
158
87,4
16,6 45 36 5
Figure 3. General view of the optical isolation unit
4. Delivery set
The delivery set includes:

LA901 laser sensor - 1 piece
Bracket for mounting sensor on machine - 1 piece
Synchronization unit with USB-cable for connection to PC - 1 piece
Cable for the synchronization unit - 1 piece
Power source - 1 piece
Screw М3x18 - 2 pieces
Compact disc with drivers, software and operation manual - 1 piece
Optical isolation unit (optional) - 1 piece
Cable for the optical isolation unit (optional) - 1 piece
Cable for the synchronization unit «CABLE-001-15» (optional) - 1 piece
Passport for the Series LA901 laser sensor - 1 piece
Packing list - 1 piece
5. Operation principle
The laser sensor is mounted onto the machine movement system. In the scanning mode,
the machine CNC system moves the sensor line-by-line over the item prototype. The sensor
measures the distance (Z coordinate) to the item surface. Data takeoff from the sensor is syn-
8 chronized with the sensor movement (XY coordinates), and the result is communicated to the
PC through the USB-port. Thus, XYZ coordinate array for the surface is formed, i.e. a digital pro-
totype model is created which is saved as a point cloud file as well as in a common STL format
suitable for subsequent use in CNC.
6. Connection versions
6.1. Connection to machines with direct stepper control
~110..220VAC
Power supply
+5V
STEP USB ()to PC

xSTEP+ STEP
STEP
DIR
DIR Synchronization
CNC DIR Optical isolation unit
xDIR+ +5V
machine unit +5V
GND
AGND GND
AGND
Sensor
Figure 4. Connection to machines with direct stepper control
6.2. Connection to Beaver 9A/12A/12AV/18A/24A/26A machines

Power supply
+5V
USB ()to PC
CNC Control Synchronization

unit
Control PC
machine signals signals
Sensor
Figure 5. Connection to Beaver machines through 15-conductor cable (in this case, optical isolation unit
is not required)
6.3. Connection to machines with encoder impulse signals

~110..220VAC
Power supply
+5V
9 CNC
A+
B+
xSTEP+
xDIR+
Optical
isolation unit
STEP
DIR
+5V
Synchronization
unit
USB ()to PC
machine
GND
AGND
AGND
Sensor
Figure 6. Connection to machines with encoder impulse signals, including TTL
6.4. Connection to machines with command signal pulses or with differential

output encoder (for example, Beaver 26AVST with servo-controller)
~110..220VAC
Power supply
+5V
F+ (A+) USB ()to PC

xSTEP+ STEP
STEP
F- (A-) Optical
xSTEP- DIR Synchronization
CNC R+ (B+) isolation DIR
+5V unit
machine
xDIR+ unit +5V
R- (B-) xDIR- GND
AGND AGND
GND
Sensor
Figure 7. Connection to machines with command signal pulses or with differential output encoder
6.5. Connection to machines with sinusoidal encoder signals (3 wires)
~110..220VAC
Power supply
+5V
A USB ()to PC
xSTEP+ STEP
STEP
Optical DIR Synchronization
DIR
CNC B isolation unit
xDIR+ unit +5V
machine +5V
GND
AGND AGND
GND
Sensor
Figure 8. Connection to machines with sinusoidal encoder signals (3 wires)

6.6. Connection to machines with sinusoidal and differential encoder

signals (5 wires)
~110..220VAC
Power supply
10
+5V
A STEP USB () to PC
xSTEP+ STEP
A Optical DIR
xSTEP- Synchronization
CNC B isolation DIR
xDIR+ +5V unit
machine unit +5V
B xDIR- GND
AGND GND
AGND
Sensor
Figure 9. Connection to machines with sinusoidal and differential encoder signals
7. Connection of the optical isolation unit

7.1. Block diagram
Figure 10: Block diagram of the optical isolation unit
To decode input signals and convert them to levels used for sensor, the unit contains
“Input decoders”. One of the operation modes of the “Input decoders” is chosen depending on
the position of the "Operation mode selector ".
The input decoder (CPLD) supports the following synchronization signals from different
Sources, such as:
• CMOS/TTL command signals for control of stepper along the X axis;
• Encoder on the X axis with pulsed output;

• Encoder on the X axis with sinusoidal output;
• Encoder on the X axis with differential pulsed output;
• Encoder on the X axis with differential sinusoidal output.
The optical isolation unit forms STEP and DIR signals for the synchronization unit.
11 INFORMATION
The use of CPLD (programmable logic microcircuit) makes it possible to decode practically
all input signals and form output synchronization signals for the laser sensor.
7.2. Designation of contacts
Figure 11. Arrangement of contacts of the optical isolation unit
Contact name Group Designation

+5Vout Input Not used
xSTEP+ Input Adjusted positive input of steps, or A+ signal of encoder
xSTEP- Input Adjusted negative input of steps, or A- signal of encoder
xDIR+ Input Adjusted positive input of steps, or B+ signal of encoder
xDIR- Input Adjusted negative input of steps, or B- signal of encoder
AGND Input Earth relative to which xSTEP+/- xDIR+/- inputs work
+5V Output Power of the input part of the synchronization unit
STEP Output Step signal for the synchronization unit
DIR Output Direction signal for the synchronization unit
GND Output Earth for the synchronization unit
Table 7: Pin assignment of the optical isolation unit
7.3. Connection to the synchronization unit

The optical isolation unit is supplied together with a cable whose 15-conductor connector on
the one end is connected to the synchronization unit while four wires on the other end are con-
nected to the optical isolation unit. Wire designations are shown in Table 8:
12 Wire color
Red
Designation
Power of the input part of the synchronization unit

Terminal on the optical isolation
unit
+5V
Blue Step signal for the synchronization unit STEP
White Direction signal for the synchronization unit DIR
Brown Earth for the synchronization unit GND
Table 8: Designation of wires of the synchronization unit “CABLE-001-15” cable
8. Selection of the synchronization option

Selection of the synchronization option is made by means of micro-switches on the optical
isolation unit.
ATTENTION!
When the “LaserProbe4500” 3D scanning system is ordered for use on a specific machine, the optical isolation
Unit is supplied with pre-set micro-switches.
8.1. Connection to machine with direct stepper control
Diagram of control signals:

5V
S TE P +
0V
5V
DIR+
0V
3D item
Figure 12. Diagram for connection to machine with direct stepper control
To decode the above signals, the micro-switches of the optical isolation unit must be in the
position shown in the following figure:
ON
SW1 SW2
Figure 13. Position of the micro-switches in the mode under consideration

8.2. Connection to machine with encoder impulse signals

5V
13 A+
0V
5V
B+
0V
3D item
Figure 14. Diagram of signals for connection to machine with encoder impulse signals
ON
SW1 SW2
8.3. Connection to machines with impulse differential encoder signals
A+
A-
B+
B-
3D item
Figure 16. Diagram of signals for connection to machine with impulse differential encoder signals
ON
14 SW1 SW2
8.4. Connection to machines with analog encoder signals

A+
B+
3D item
Figure 18. Diagram of signals for connection to machine with analog encoder signals
To decode the above signals, the micro-switches of the optical isolation unit must be in
the position shown in the following figure:
ON
SW1 SW2
8.5. Connection to machines with analog differential encoder signals

A+
A-
B+
B-
3D item
Figure 20. Diagram of signals for connection to machine with analog differential encoder signals
To decode the above signals, the micro-switches of the optical isolation unit must be in
the position shown in the following figure:
ON
15 SW1 SW2
9. The «Dorgonia» software

9.1. Basic functions
The software is intended for:
• Creation of the line-by-line scanning file for CNC system (G-codes), including the de-
fining of the scanning region, discretization interval along the X and Y coordinates
and scanning speed;
• Parametrization of the laser sensor, including adjustment of smoothing filter and filter-
ing of measurement errors;
• Data takeoff from the laser sensor;
• Visualization of data;
• Filtering and smoothing of results;
• Formation of standard format files .stl, .dxf, .txt.
9.2. Program start

After starting, the program checks for availability of the USB cable for connection to the
synchronization unit. If the device is found, availability of the license and its validity are checked,
and the laser sensor is switched on. The emergence of the working window (Fig. 22) shows that
the system is normal operation mode.
E A
A
Figure 22. Main window of the "Dorgonia" program

The window consists of several sections:
• "А" – section for setting of scanning parameters;
• "В" – section for formation of files;
• "С" – section for control and settings;
• "D" – status section;
• "E" – section for imaging of the scanned item.
9.3. Settings.
9.3.1. Positioning of the sensor
The base distance from the Scanner to the object is 140mm and the scanning depth is 100mm (Picture XY).
The Scanner should be positioned so that the bottom is a minimum distance of 140mm and maximum 240mm
16 from the object to be scanned. To determine the correct position you must select „ Test-scanner“ (in section C
of the software window) and the „actual value“ (CV) (in section D of the software window) should show a
value between 0 and 100
To determine the values for „Minimum Z“ and „Maximum Z“ (in section A) you should
perform the following calculation: Min Z = Scan area (100) - CV / Max Z = Min Z + height of the scan object
To ensure that the total object will be scanned, you must subtract +/-1mm from the Min Z value and add +/- 1mm to
the Max Z value. This will increase the scanning area in both directions.
Tip: When scanning objects with large height variations, the scanner should be far away as possible from the object!
Example:
CV = 80mm
Scan object = 40mm
Min Z: 100 – 80 = 20 – 1 = 19mm

Sensor edge
Max Z: 20 + 40 = 60 + 1 = 61mm
Base Distance 140mm
Scan object
Table
Range 100mm
Figure 23. Positioning of the laser sensor
9.3.2. Setting-up of the laser sensor parameters

To change laser sensor settings, call the setting window by pressing the "Settings" but-
ton (Section "С"). The view of the window is shown in Fig. 24. The “Laser settings”
window displays:
1) Unchangeable service information about the sensor: internal divider installed;
type of the device; serial number, working range and base distance; type of
synchronization.
2) Two fields for setting filters implemented directly in the laser sensor. The first
filter deals with the moving average. Maximum allowable value of the filter width is
128. The second filter deals with the result delay time at an interval of 5 ms (see
Description of the Series LA901 laser sensor at www.cnc-step.de
After changing the settings, press “OK” button to save them.
17
Figure 24. Laser settings
9.3.3. Setting-up of program filters

To change settings of the program filters, call the settings window by pressing the
"Settings" button, go to the «Program settings» tab, set the required width of the
median filter and smoothing filter (Gaussian core), and enable or disable display of the
model. To save the settings, press "ОК".
The "Display model" switch is intended for enabling/disabling of the model
display function. This function is used when RAM is not sufficient.
Figure 25. Settings of the program filters

9.3.4. Setting-up of the scanning parameters

Before scanning is started, it is necessary to use section “A” to define the size of
the scanning field (X - width, Y – field length), discretization interval along the X and Y
coordinates, range of heights of the item to be scanned (Z minimum and Z maximum)
18 and select the type of machine whereto the scanner is connected. After the parameters
are set, the program calculates the allowable scanning speed and displays it in the pa-
rameters windows.
9.4. Generating scanning file for CNC

To form the scanning file for the machine CNC system, it is necessary to set scanning
parameters according to par. 9.3.4, press the "Generate file for CNC» button in the section "В" of
the program working window (Fig. 22), and define the place in the PC memory where the
control file must be written. The output text file contains control G-codes for correct movements of
the machine.
ATTENTION!
The allowable scanning speed is calculated automatically based on the sensor response speed and the scanning
grid specified, its value being set in the formed scanning program. Forced changing of the scanning speed may
cause distortion of the picture obtained.
9.5. Scanning of the item

• To perform scanning it is necessary to:
• use control program for CNC to open the file formed by the “Dorgonia” program according
to par. 9.4;
• position the machine movement system to a point from which scanning must be
started;
• press the "Start session" button in the section "С" of the program working window;
• start the machine to execute the program.
The task execution time depends on the size of the scanning region, speed and step
values with which the carriage moves along the X and Y axes
After the machine has executed the program, it is necessary to switch the scanning
mode off by releasing the "Start session" button.
9.6. Generate result file

The result of scanning is displayed in the section "Е". Control of the item image in this section
is possible with the help of the mouse pointer:
- dragging of the mouse with the left key pressed – rotation of the item;
- dragging of the mouse with the right key pressed – movement of the item;
- scrolling with the mouse – zoom-in and zoom-out of the item (scaling).
To obtain the result file, it is sufficient to press the “Generate result file” button, select the
file type (STL/DXF/TXT) in the emerging window (Fig. 26), enter the file name, select file folder
for saving and press the “Save” button.
To make changes in the region already scanned (discretization interval along the X or Y
axis, length and width of the region), it is necessary to enter new values and press the “Recalcu-
late region” button (section “С” in Fig. 22). To return to the initial view of the model (if filters
were used and limits along Z were set), it is sufficient to switch off the filters and press the “Re-
calculate region” button.
19
Figure 26. The window of result saving
10. Example of filter operation
Figure 27. Initial view of the item directly after scanning
Fig. 27 shows the result of scanning obtained without programmed filtration used. The
peaks in the picture are caused by the influence of vertical walls of the item.
Fig. 28 shows the image of the item in the case where “Median filter” with a width of 9
was used (see par. 9.3.3.). As seen in the picture, the peaks disappeared.
20
Figure 28. The use of median filter with the width of 9.

A substantial reduction of the image noise can be achieved by using programmed
smoothing. Fig. 29 shows the result of programmed smoothing obtained by employing the filter
with the width of 7.
Figure 29. The use of programmed smoothing.

11. System requirements
Stable work of the «Dorgonia» software requires the following system:
21 Processor:
RAM:
Disk space:
not lower than Intel Pentium 4 2.0GHz.
not less than 1024 MB (recommended 4096MB).
not less than 20 GB, NFTS file system required.
Video card: ATI/NVidia and not less than 256MB of video memory.
Operating system: Windows 2000/ Windows XP.
Other: USB 2.0 is required.
12. Warranty
Warranty period of the LaserProbe4500 3D laser scanning system is 24 months from the date of
putting in operation. Guaranteed storage time is 12 months.
13. Example of the scanning result

14. Troubleshooting
Problem Cause Solution
The «Dorgonia» program gives an 1. USB drivers not installed. 1. Reinstall drivers from original compact disc
error message: «Error: no scanner 2. USB cable not connected. 2. Check USB cable connection.
22
found»
The «Dorgonia» program gives an 1. Sensor is not connected to 1. Check connection of the sensor to the
error message: «Error: scanner synchronization unit. synchronization unit.
does not respond» 2. Power supply unit (+5V) 2. Check connection of power supply to the
not connected to the synchronization unit.
synchronization unit.
The «Dorgonia» program gives an 1. There are no signals of 1. Using oscilloscope, check for availability of
error message: «Error: data file synchronization with the synchronization signals from the machine
is empty » machine. (if optical isolation unit is in place, this must be
done through the optical isolation unit). It is
possible that no power is supplied to the
optical isolation unit (if available).
The «Dorgonia» program gives an 1. There is a problem with 1. Using oscilloscope, check for availability of
error message: «Erroneous data Synchronization signals STEP/DIR signals
file» (STEP/DIR) coming from
machine (through the optical
isolation unit, if available).

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LaserProbe4500

Fon.: +49 (0) 2831 133236

4 1.1. Symbols used

«Information» symbol: Information that can be useful.

3. Basic technical data and characteristics

3.2. Allowable synchronization methods

3.3. Series LA901 laser sensor

5 Total height from the machine table, mm

Input window Output window Base distance

Figure 1. Mounting and overall dimensions of Series LA901 laser sensor

3.4. Synchronization unit

Figure 2. General view of the synchronization unit

Table 5: Designation of connectors of the synchronization unit

3.5. Optical isolation unit

Figure 3. General view of the optical isolation unit

The delivery set includes:

STEP USB ()to PC

Figure 4. Connection to machines with direct stepper control

6.2. Connection to Beaver 9A/12A/12AV/18A/24A/26A machines

CNC Control Synchronization

6.3. Connection to machines with encoder impulse signals

Figure 6. Connection to machines with encoder impulse signals, including TTL

6.4. Connection to machines with command signal pulses or with differential

F+ (A+) USB ()to PC

6.5. Connection to machines with sinusoidal encoder signals (3 wires)

Figure 8. Connection to machines with sinusoidal encoder signals (3 wires)

6.6. Connection to machines with sinusoidal and differential encoder

Figure 9. Connection to machines with sinusoidal and differential encoder signals

7. Connection of the optical isolation unit

Figure 10: Block diagram of the optical isolation unit

• Encoder on the X axis with pulsed output;

7.2. Designation of contacts

Figure 11. Arrangement of contacts of the optical isolation unit

Contact name Group Designation

7.3. Connection to the synchronization unit

Power of the input part of the synchronization unit

8. Selection of the synchronization option

8.1. Connection to machine with direct stepper control

Diagram of control signals:

Figure 13. Position of the micro-switches in the mode under consideration

8.2. Connection to machine with encoder impulse signals

Diagram of control signals:

Figure 15. Position of the micro-switches in the mode under consideration

8.3. Connection to machines with impulse differential encoder signals

Diagram of control signals:

Figure 17. Position of the micro-switches in the mode under consideration

8.4. Connection to machines with analog encoder signals

Figure 19. Position of the micro-switches in the mode under consideration

8.5. Connection to machines with analog differential encoder signals

Figure 21. Position of the micro-switches in the mode under consideration

9. The «Dorgonia» software

9.2. Program start

Figure 22. Main window of the "Dorgonia" program

Scan object = 40mm

Min Z: 100 – 80 = 20 – 1 = 19mm

Base Distance 140mm

Figure 23. Positioning of the laser sensor

9.3.2. Setting-up of the laser sensor parameters

Figure 24. Laser settings

9.3.3. Setting-up of program filters

Figure 25. Settings of the program filters

9.3.4. Setting-up of the scanning parameters

9.4. Generating scanning file for CNC