BYK Gardner GmbH wave-scan 3 Robotics for Automation Instruction Manual
Introduction
This instruction manual is an important part of this instrument. It contains essential information about setting up, placing in service and use. If you pass the device on to another user, please ensure that the instruction manual is included with the instrument. The manual must be studied carefully before working with the equipment. Please contact your regional service office if you have any questions or require additional information about the device.
The technology and fittings are based on state-of-the art optic and electronic technology. New developments and innovations are constantly being integrated into the equipment. Thus, the diagrams, dimensions, and technical data used in this manual may have changed as a result of adapting the device to new information and improvements.
© Copyright 2024 BYK-Gardner GmbH
All rights reserved
No portion of the software, documentation or other accompanying materials may be translated, modified, reproduced, copied or otherwise duplicated (with the exception of a backup copy), or distributed to a third party, without prior written authorization from BYK-Gardner GmbH. In any case, this requires the prior written consent of BYK-Gardner.
BYK-Gardner GmbH offers no guarantee that the software will function without error or that the functions incorporated therein can be executed in all applications and combinations selected by you.
No liability other than as provided by law is assumed for direct or indirect damage sustained in association with the use of the instrument, the software or documentation.
BYK-Gardner GmbH reserves the right to update the software and written documentation without prior notice. www.byk-instruments.com
Safety Instructions
No claims of product liability or warranty can be honored if the device is not operated in accordance with the operating instructions and the instructions on the instrument.
The measurement unit is a class 1 laser product. The label shown below is on the base of the measurement unit.
CLASS 1 LASER
DIN EN 60825-1:2015-07
CAUTION!
Since the laser beam used for sampling can penetrate your eye and cause injuries, never dismantle the instrument and never look directly into the measurement aperture when the device is turned on.
If you use the unit and accessories properly, there are no hazards to fear – none of a mechanical nature and none caused by electrical shock.
The following paragraphs contain information about the safe use of the device.
Use only original accessories provided by the manufacturer. See “Delivery Notes” and “Technical Data” for further information.
Avoid exposure to continuous humidity and condensation. See “Technical Data” for further information. Avoid splashing with water, chemicals, or other liquids.
Never attempt to make any repairs to the instrument, neither mechanical nor electrical. Please consult our Technical Customer Service.
Only devices that meet the requirements for low-voltage safety may be connected to the control interface (green).
For operation with the external power supply, care should be taken to ensure the nominal voltage of the power supply unit (see the manufacturer’s plate on the power supply unit) matches the voltage supplied by the power outlet.
The measurement device may be disconnected from the power supply as follows:
- By disconnecting the power plug (black) from the device.
You will find the technical data on the manufacturer’s plate and in the section “Technical Data”.
Defects and extraordinary loads
If safe operation can no longer be presumed, shut down the device and secure it against unintended operation.
The device must be presumed unsafe to operate:
- if visible damage is evident,
- if the instrument is no longer working,
- if it has been stored for long periods under adverse conditions,
- after harsh treatment during shipping.
Additional information on disposal
This symbol means: Do not dispose of this product together with your household waste. Please refer to the information of your local community or contact our dealers regarding the proper handling of end-of life electric and electronic equipment.
Recycling of this product will help to conserve natural resources and prevent potential negative consequences for the environment and human health caused by inappropriate waste handling.
Declaration of Conformity
We,
BYK-Gardner GmbH
Lausitzer Strasse 8
D-82538 Geretsried
declare, that this instrument complies with the requirements of the following EU directives:
- 2014/30/EU – Electromagnetic Compatibility
- 2014/35/EU – Low Voltage
The following harmonized standards were applied:
- EN 60825-1:2007
- EN 61010-1:2010
- EN 61326-1:2013
Geretsried, November 13, 2019
Frank R. Wagner
Managing Director
Handling Instructions
The measurement unit contains sensitive precision optical and electronic parts. Do not drop it and protect it from being bumped or jostled!
Do not hold the unit by the measurement aperture or allow any foreign objects to get into this opening.
Do not expose the unit to direct sunlight for extended periods of time. Do not store it in a hot or dusty environment. The case that comes with the unit offers the best protection when the unit is being stored.
Avoid prolonged exposure to high relative humidity and do not allow water to form from condensation, see Technical Data [} 31].
Protect the measuring unit from moisture, chemicals and corrosive vapors.
Prerequisites
In order to operate the instrument basic understanding of following topics is recommended:
- Instrument wave-scan 3 / 3 dual for manual measurements (option)
- Software smart-process to monitor the measurement results
- Software smart-robotic to configure and control the device
Hardware
Before operating the instrument for the first time, please read the Operating Instructions and take particular notice of the Safety Instructions. Unpack the instrument and check the delivery for completeness.
Delivery Content
The system comes complete with: Measurement unit, cover, test tile, certificate and safety instructions. Also included are screws and a drawing for the robot mounting board.
The items listed below are contained in the transportation case. Please contact BYK-Gardner, if any item is missing or damaged. See also Delivery Notes [} 28]
Illustration 1: Delivery content
| 1 | Safety instructions and retrace- able certificate | 5 | Drawing for mounting board |
| 2 | Checking tile for instrument test | 6 | Cleaning towel for checking tile |
| 3 | Screws and tool for mounting board | 7 | Measurement unit |
| 4 | USB cable type A / C for initializa- tion | 8 | Protective cap |
The power and communication cables – see Cabling [} 13] – are outside the transportation case, but inside the delivery packaging.
Mounting Board
A mounting board is required to mount the instrument to the robot arm. This board is not part of the delivery. A drawing, that contains all dimensions for the production of the mounting board, is enclosed with each instrument.
Illustration 2: Mounting board with wave-scan 3 ROBOTIC
| 1 | Mounting board |
| 2 | Mounted instrument |
| 3 | Fixing bar |
The measuring instrument is fixed at the mounting board with three screws (part of the delivery) on the position given below.
Illustration 3: Mounting of wave-scan 3 ROBOTIC
| 1 | Mounting position 1 – instrument bottom |
| 2 | Mounting position 2 – instrument bottom |
| 3 | Mounting position 3 – instrument top |
The millings at the fixing bar and a pen matching into the deepening provides for a distinctive attachment.
During the measurement, a distance of 15 mm ± 2 mm to the surface is to be kept.
The angle-deviation of the perpendiculars on the surface can amount to at most 2° to all sides.
NOTICE
The mounting can be done on the left or on the right side of the measurement unit. The protruding element on the side not used can be screwed off (two small screws).
Power Supply
The instrument is supplied by an external AC / DC power adapter, which is not part of the delivery.
Illustration 4: Interface connectors of wave-scan 3 ROBOTIC
| 1 | Power supply is provided via a black 8-pole plug. |
| 2 | Data transmission is provided via a green 4-pole plug. |
In order to connect the measuring instrument, first check the wiring and the matching of the power supply. Subsequently you plug in the black plug and switch on power.
Status LEDs
The instruments has four Light Emitting Diodes (LEDs) for status indication.
Illustration 5: Status LEDs of wave-scan 3 ROBOTIC
| 1 | Lights in green whenever the device detects a valid link.Blinks in green when CRS is active (high) indicating activity. |
| 2 | Lights in blue when the operating speed is 100 Mbps.It is inactive when the operating speed is 10 Mbps or the connection is bro- ken. |
| 3 | Indicates the status of the measurement:
|
| 4 | Lights in green when the power supply is connected. |
If a mistake should happen during the measurement, it is signaled by a red blinking light-emitting-diode (LED-3). The pertinent error code is shown in smart-robotic.
Cabling
The delivery comprises the cables required for initialization and to connect instrument on robot arm with PC:
- Power Cables [} 14]
- Data Cables [} 16]
- USB Cable [} 18]
WARNING!
To avoid instrument damage, only use the cables which are part of the delivery for connecting the instruments!
Application Example
Following picture gives an example how the cables can be placed in a robot cell.
Illustration 6: Example cabling in a robot cell
| Yellow | At robot arm: Torsion capable cable |
| Green | For track chain: Standard cable |
| Red | On the floor: Oil resistant cable |
These three types of cables are provided for both power and data interface.
Power Cables
The power interface is a black 8-pole plug. The power supply input is 24 V 
; max. 0.75 A.
Illustration 7: Polarity diagram for pins M12, 8-pin, A-coded, view pen side
| No. | ROBOTIC Power | Cable Color 4-pin M12-A | Cable Color 8-pin M12-A |
| 1 | Vin | White | White |
| 2 | Vin | Yellow | Yellow |
| 3 | NC | Green | |
| 4 | NC | Brown | |
| 5 | NC | ||
| 6 | GND | ||
| 7 | GND | Green | |
| 8 | GND | Brown | |
| M1 | Shield |
Following power cables are in the delivery.
Illustration 8: Power cables
| 1 | 301 200 143: 8 m for robot – torsion capable |
| 2 | 301 200 144: 10 m for drag chain |
| 3 | 301 200 145: 20 m on floor – oil resistant |
The delivery comprises cables and connectors. If necessary, a coupler can be used to attach plugs on both sides to the floor. The product “Binder 0952400004” is recommended.
Illustration 9: 301 200 142 Power cable complete for 7410
- Products from following vendors are used:
- https://www.binder-connector.com
- https://www.lappkabel.com
ATTENTION!
Please heed tension and pin assignment precisely. The instrument can be damaged without functional connection. No product liability and guarantee claims can be put forward if the instrument is not properly power supplied.
Data Cables
For data communication a proprietary LAN cable is used. The communication interface is a green 4-pole plug.
Illustration 10: Pin assignment M12, 4-pin, D-coded, view socket side
| No. | ROBOTIC Data | Cable Color | 4-pin M12-D | 8-pin RJ-45 |
| 1 | TX+ | Yellow | Pin 1 | Pin 1 |
| 2 | RX+ | Orange | Pin 2 | Pin 3 |
| 3 | TX- | White | Pin 3 | Pin 2 |
| 4 | RX- | Blue | Pin 4 | Pin 6 |
| M1 | Shield |
Following data cables are in the delivery.
Illustration 11: Data cables
| 1 | 301 200 147: 8 m for robot – torsion capable |
| 2 | 301 200 148: 10 m for drag chain |
| 3 | 301 200 149: 20 m on floor – oil resistant |
The delivery comprises cables and connectors.
Illustration 12: 301 200 146 Data cable complete for 7410
- Products from following vendors are used:
- https://www.binder-connector.com
- https://www.lappkabel.com
- https://www.phoenixcontact.com
USB Cable
For initialization the instrument provides an additional USB port.
Illustration 13: Interfaces on wave-scan 3 ROBOTIC
| 1 | Power interface (black) |
| 2 | Data interface (green) |
| 3 | USB type C interface |
Perform following steps:
- Connect the instrument via the USB cable in the delivery with your PC.
- Provide power to the instrument via power cables and black interface.
- Start software smart-robotic for initialization and configuration.
Details for instrument initialization see Device Configuration [} 20]. After initialization and configuration the USB cable can be disconnected. In the productive environment the green data interface is used for communication.
Operation
- The wave-scan 3 ROBOTIC is configured and operated completely via the software smart-robotic, which is installed along with smart-chart:
- Software Installation [} 19]
- Firmware Update [} 19]
- Device Configuration [} 20]
- Productive System [} 24]
The complete configuration usually takes place in a test environment. After successful test the configuration is transferred to the productive system.
Software Installation
Install the software smart-chart as described in:
- Operating Instructions smart-robotic: 300 003 099 (En)
The installation will create following folders: - Program smart-chart
- Program smart-robotic
- Setup for device drivers
- Updates for firmware
After successful installation the software smart-robotic can be started. It is used to configure and test the BYK-Gardner robotic instruments.
NOTICE
The software smart-robotic also includes a robot simulation. Using the simulator the configuration can be tested outside the robot cell.
Firmware Update
The firmware of the instrument is updated by BYK-Gardner service team during regular service. The current firmware is also installed along with smart-chart in the folder “C:\Program Files (x86)\BykWare\smart-chart3\Firmware”. Perform following steps:
- Close smart-chart / smart-robotic.
- Connect the device via USB cable to your PC.
- Start the program “Update wave-scan3 <Version-No.>”.
The update program compares the firmware in the update (Package Version) with the firmware in the device (Main Version)
Illustration 14: Firmware update for wave-scan 3 ROBOTIC (7410)
Click the Start Update button. When the update has finished, close the program.
Device Configuration
Before the wave-scan 3 ROBOTIC can be put into operation, following steps have to be performed:
- Driver Installation [} 20]
- Device Connection [} 22]
- Device Test [} 23]
Driver Installation
Installation of device driver is done usually by installing smart-chart. If manual installation is required:
- Locate the files in “C:\Program Files (x86)\BykWare\smart-chart3\Tools\USBBulkDriver”.
- Right click on “dpchooser.exe” and select “Run as administrator”.
- Follow the instructions on the screen.
Illustration 15: USB bulk driver for wave-scan 3 ROBOTIC
After driver installation the device is to be connected via USB cable to your PC to activate the device detection in Windows.
Illustration 16: Cabling for USB device detection1 Instrument wave-scan 3 ROBOTIC 2 USB port on instrument 3 USB port on PC For the installation of the device in the Windows system the USB connection is sufficient. With an active USB connection, the instrument appears in the Windows
Device Manager.
Illustration 17: Instrument in Windows Device Manager
The required entry is BYK-Gardner USB driver. The instrument can now be added as a new device in smart-robotic.
Device Connection
To access the device via smart-robotic, the instrument has be connected to the power supply too.
Illustration 18: Cabling for connection test
| 1 | Instrumentwave-scan 3 ROBOTIC | 2 | USB port on instrument |
| 3 | USB port on PC |
With power supply and USB connection the instrument can now be accessed in smart-robotic in the Devices > Connection tab.
Illustration 19: Connection settings in smart-robotic
Perform following steps:
- Activate the option Work with USB.
- Select the USB identifier from the list (usually “USB0”).
- Click the button Check connection.
- Check if the status is Connected.
With an active USB connection, the IP data – used in the productive environment for the LAN connection – can be sent to the device.
Device Test
With USB connection and power supply the device can be tested. During the test a measurement is performed. The wave-scan ROBOTIC performs a non-contact measurement. A possible test setup is shown below.
Illustration 20: Setup for device test
| 1 | Sample to be measured | 2 | Measurement distance: Max. 15 mm Measurement angel: Max. 2° |
| 3 | Instrument wave-scan 3 ROBOTIC | 4 | Power cable |
| 5 | USB cable |
Go to the tab Device Test.
Illustration 21: Device test in smart-robotic
Perform following steps:
- Initialize: Load device driver.
- Measure: Get measurement data.
- De-Initialize: Unload device driver.
With static sample only the dullness can be measured. To measure the values for the wavelength slowly move the sample (or the instrument) during measurement.
Productive System
The instrument is designed to measure in fully automatic mode. Only requirement is to configure the instrument(s) and the data output interface(s) in smart-robotic.
After successful testing the configuration can be copied from the test system to the productive system and adapted there.
Illustration 22: Robot cell with two robots / Robot arm with two instruments
When the robotic instruments are configured and mounted, the measurements will be done automatically by the robot according to the programming in the PLC.
Illustration 23: Monitoring tab in smart-robotic
Only raw data will be measured – no processing and evaluation takes place. This allows very fast measurements by the robot. To store the measurement results:
- If smart-chart is used, the measurement results will be written into smartchart database – according to existing configuration of color standards and check-zone organizers.
- If smart-chart is not used, the measurement results will be written to files on disk for external processing and evaluation.
For more details on operation in the productive environment see Operating Instructions for smart-robotic.
Checking
Due to the underlying measurement principle, no calibration of the instrument is required.
Principle
It is recommended, however, to check the functionality of the instrument at regular intervals (about once every 3 months). The reference tile included with delivery is provided for this purpose.
Illustration 24: Instrument and checking tile
Mounting
Mount the test tile near the robot at the position intended for the instrument test.
The robot is to be programmed to reach the checking tile.
Illustration 25 : Mounting of checking tile
| 1 | Robot arm with rotable adapter |
| 2 | Instrument on rotable adapter |
| 3 | Car body / part in robot cell |
| 4 | Checking tile mounted to wall |
Procedure
Perform a measurement with the robot. The values for a correct reading are printed in the retraceable certificate and on the reference tile. These values can be entered in smart-robotic for a pass / fail check.
Illustration 26: Daily check in smart-robotic
If the value measured on the reference tile is within the printed tolerance range, the requirements are met.
If the mean value is not within the desired tolerance range, try carefully cleaning the test tile. If this produces no improvement, please contact our customer service department.
http://www.byk-instruments.com/contact-infos
Appendix
Cleaning and Maintenance
Cleaning the Test Tile
Since the surface of the test tile is highly sensitive, cleaning must be undertaken with great care.
To clean standards, use a new lint-free cloth, dust-free lens paper or an optical cloth as included with the device.
Apply only slight pressure when cleaning, and ensure the cloth is free of dust or other particles that could damage the surface.
For dirt that is difficult to remove, use a pre-moistened optical cloth. Then wipe the surface with a dry optical cloth.
An exact verification is not possible unless the test tile is in perfect condition. If the condition of the test tile seems doubtful because of its appearance or measurement errors, have it checked by the manufacturer.
Usage of Reference Tile
To ensure a precise instrument test, only original test tiles from the manufacturer should be used. Their surface must not be touched and must be protected against scratches.
Due to environmental influences, however, the values of test tiles can change over the course of time even if they are handled gently.
For this reason, have the test tiles checked by the manufacturer at regular intervals (annual checks are recommended).
Delivery Notes
Product Highlights
- State-of-the-art chip technology with high speed computing power – needed for calculation of scales using e.g. Fast Fourier Transformation
- New LAN interface – today´s industry standard
- New, flexible detachable mount – compatible to predecessor
- New software smart-robotic: Interface software with integration of previous “bykLINK” functions and minimum migration effort
Product Features
- Automatic, non-contact measurement at the line
- Classical LW and SW, modern Wa … We and customer specific scales
- Structure spectrum to analyze appearance changes for optimization
- Dullness and Distinct-of-Image (DOI)measurement independent of the paint system
- Software smart-process for data analysis and documentation
- For flat and curved surfaces (radius > 500 mm)
- Small and light weight sensor
Delivery Content
- Instrument (7410)
- Checking tile (4833)
- Power cable kit (torsion resistant, drag chain, oil resistant)
- Data cable kit (torsion resistant, drag chain, oil resistant)
- USB type C cable for instrument initialization
- Mounting kit (hex key, screws, technical drawing)
- Software smart-process (with licenses for 2 PCs)
- Software smart-robotic (communication software)
- Retraceable certificate
- Safety Instructions
- Carrying case
- 2-day training
Download Links
- Instrument Software
- Smart-process (including smart-robotic and device driver)
- Operating Instructions for smart-robotic: 300 003 099
https://www.byk-instruments.com/software#wave-scan
- Instrument Documentation
- Safety Instructions wave-scan 3 ROBOTIC: 301 200 080
- Operating Instructions wave-scan 3 ROBOTIC: 301 200 141
https://www.byk-instruments.com/p/7410
- Accessories List
https://www.byk-instruments.com/c/smart-process/p/4831
Illustration 27 : Additional license for smart-process
https://www.byk-instruments.com/c/p/4833
Illustration 28: Checking tile for wave-scan 3 ROBOTIC
Error Messages
| ID | Message Text |
| 550 | Acquired measurement data is not valid |
| 555 | Measurement timeout |
| 560 | Device temperature too high |
| 561 | Device temperature too low |
| 601 | Initialization error |
| 614 | Component not initialized |
| 1001 | Camera capture timeout |
| 1002 | Camera initialization timeout |
| 1401 | IR laser error detected |
| 1405 | Out of linear range – dullness |
| 1406 | Not measurable – dullness |
| 1407 | Not measurable – dull surface |
| 1408 | Out of linear range – dullness > xx, steep slope |
| 1409 | Out of linear range – steep slope |
| 1410 | Not measurable – dullness > xx, very steep slope |
| 1411 | Not measurable – very steep slope |
| 1413 | Image saturated |
| 1415 | Measurement aborted |
| 1422 | Measurement failed |
System Requirements
| Operating system | Microsoft Windows® 10 v.1607 or later |
| Runtime | Microsoft® .NET core 3.1.0 or later |
| Hardware | i3, 2.5 GHz; i7 recommended, or equivalent |
| Memory | 4-8 GB RAM, 16 GB recommended |
| Hard-disk capacity | 4 GB during installation |
| Monitor resolution | 1280 x 1024 pixel or higher |
Technical Data
Measuring Data
| Light source | Laser Diode LED and IR-SLD |
| Laser diode | Laser Class 1, P ≤ 390 µW, λ=670 nm, DIN EN 60825-1:2015-07 |
| Measure range | Dullness: 1 to 40LW & SW: 0 to 100Wa – We: 0 to 100 |
| Structure spectrum | Dullness: < 0.1 mm Wa: 0.1 to 0.3 mmWb: 0.3 to 1.0 mmWc: 1.0 to 3.0 mmWd: 3.0 to 10.0 mmWe: 10.0 to 30.0 mm |
| Scan length | 5 / 10 / 20 cm |
| Scan speed | 50 to 150 mm/sec |
| Repeatability | du < 40: 4% or > 0.4 (standard deviation)du > 40: 6% or > 0.6 (standard deviation) |
| Reproducibility | du < 40: 6% or > 0.6 (standard deviation)du > 40: 8% or > 0.8 (standard deviation) |
| Distance to surface | 15 ± 2mm |
| Angle to perpendicular | ± 2° |
| Object radius | > 500 mm |
| Smallest sample size | 35 mm x 150 mm |
| Resolution | 375 pixel per cm |
| Memory capacity | n/a – immediate data transfer |
General Data
| Temperature range | Storage: 0° C to 60° COperation: 10° C to 40° C |
| Relative humidity | Up to 85% non-condensing at 35° C |
| Operation altitude | Up to 2000 m (6561 ft) |
| Dimensions (LxWxH) | 112 x 59 x 131 mm (4.4 x 2.4 x 4.8 in) |
| Weight | Ca. 550 g (1.21 lbs) |
| Interface | Initialization: USB-C (USB 2.0)Operation: Ethernet LAN (M12-A) |
| Power supply (input) | Initialization: 5 VDC ; max. 1.75 A (USB-C)Operation: 24 VDC ; max. 0.75 (M12-A) |
Download your manuals from:
https://www.byk-instruments.com/c/p-44798
Download your software from:
https://www.byk-instruments.com/wave-scan
BYK-Gardner GmbH
Lausitzer Strasse 8
82538 Geretsried
Germany
Tel : +49 08171 3493-0
Fax : +49 08171 3493-140
info.byk.gardner@altana.com
www.byk-instruments.com
Documents / Resources
 |
BYK Gardner GmbH wave-scan 3 Robotics for Automation [pdf] Instruction Manual 301 200 141 E, 2401, wave-scan 3 Robotics for Automation, wave-scan 3, Robotics for Automation, for Automation, Automation |
