TH6D

Tracking Head 6 Dimensions

User's Manual
Revision 1.7,
1. Date of issue: 31/05/2012

Translation of Original Operating and Installation Instructions

 Legal details

Manufacturer Scansonic MI GmbH

Rudolf-Baschant-Straße 2

D-13086 Berlin, Germany

Tel.: +49 (0) 30 / 91 20 74 – 10 E-mail: service@scansonic.de

Fax: +49 (0) 30 / 91 20 74 – 29 Internet: www.scansonic.de

Important Every person in charge of installing, operating or maintaining Scansonic

processing heads must first read and understand the sections of the
manual that are relevant to him or her.

This User's Manual is a key part of the TH6D system and must be kept
throughout the life span of the product. Any supplements issued later by
Scansonic MI GmbH must be filed along with the User's Manual. The
abbreviation UM will be used throughout to specify the User's Manual.

Note Scansonic MI GmbH is not liable for the completeness or correctness of the
information found in this manual. Due to continued development of the
product, the contents of this manual are subject to change without prior
notice at the discretion of Scansonic MI GmbH. Every attempt has been
made to ensure that the information contained in this manual is complete
and correct at the time it is printed.

Reproduction / The contents of the User's Manual are the property of Scansonic MI GmbH.
Copyrights No person or other business divisions or departments of other companies
are permitted to reproduce, distribute or alter this manual in any way or by
any means unless prior written authorization has been given by Scansonic
MI GmbH. Furthermore, it is not permitted to use parts or the whole of this
manual to manufacture or sell anything.

Customer Sales and service partner

service Scansonic IPT GmbH
Rudolf-Baschant-Straße 2
D-13086 Berlin, Germany
Tel.: +49 (0) 30 / 91 20 74 – 10
Fax: +49 (0) 30 / 91 20 74 – 29
E-mail: service@scansonic.de
Internet: www.scansonic.de
 Table of Contents

1. Explanations for this Manual ........................................ 1-1

1.1 Purpose and related documents ................................................... 1-2
1.2 Using the User's Manual ............................................................. 1-2
1.3 Abbreviations and units .............................................................. 1-3
1.4 Symbols, warning levels and notice types ..................................... 1-5

2. Safety........................................................................... 2-1
2.1 General safety instructions ......................................................... 2-2
2.2 Laser safety .............................................................................. 2-4
2.2.1 Dangers posed by class-3B lasers ................................................ 2-4
2.2.2 Retro-reflection ......................................................................... 2-5
2.2.3 Laser aperture on the TH6D sensor head ...................................... 2-5
2.2.4 Operating the laser safely ........................................................... 2-6
2.3 Particular dangers...................................................................... 2-8
2.3.1 Master machines ....................................................................... 2-8
2.3.2 Excessive pressure and emitted substances .................................. 2-8
2.4 Protective safety measures during normal operation ...................... 2-9
2.5 Proper and intended usage ......................................................... 2-9
2.6 Warrantee and liability ............................................................. 2-10
2.7 Information and warning signs on the TH6D sensor head.............. 2-11
2.8 Disposal ................................................................................. 2-12

3. Product Information..................................................... 3-1

3.1 Overview .................................................................................. 3-2
3.1.1 Special characteristics ................................................................ 3-2
3.1.2 Possible applications .................................................................. 3-2
3.1.3 How it works ............................................................................. 3-3
3.1.4 Definition of the coordinate system .............................................. 3-4
3.2 Usage limitations ....................................................................... 3-5
3.2.1 The influence of work piece reflection ........................................... 3-5
3.2.2 Influences from the welding process ............................................ 3-6
3.2.3 The influence of accessibility ....................................................... 3-8
3.2.4 Influences of material thickness and step height ............................ 3-9
3.2.5 Limitations caused by the temperature range ................................ 3-9
3.2.6 Influence of the sensor's orientation in relation to the work
piece surface .......................................................................... 3-10
3.2.7 Limitations caused by the gap dimensions .................................. 3-10
3.2.8 Limitations caused by the operating voltage ................................ 3-10
3.3 Descriptions of modules and components ................................... 3-11
3.3.1 TH6D sensor head ................................................................... 3-11
3.3.2 Safety glass unit...................................................................... 3-12
3.3.3 TH6D process computer ........................................................... 3-13
3.3.4 Mains power supply unit ........................................................... 3-14
3.3.5 Cable ..................................................................................... 3-14
3.3.6 Cooling module ....................................................................... 3-15
3.4 Additional machine-dependent modules...................................... 3-17
3.4.1 Analogue-digital interface (ADF) ................................................ 3-17
3.4.2 Calibration plate ...................................................................... 3-18
3.4.3 Network cable ......................................................................... 3-19
3.5 Status LED for the TH6D system................................................ 3-20
3.5.1 Status LED on the TH6D sensor head ......................................... 3-20
3.5.2 Status LED on the TH6D process computer ................................. 3-22
3.6 TH6D system interfaces............................................................ 3-24
3.6.1 Connections for the TH6D sensor head ....................................... 3-24
3.6.2 Connections for the TH6D process computer ............................... 3-26
3.6.3 Machine interfaces ................................................................... 3-27
3.7 Operating and configuration interface for THxDView..................... 3-28

4. Set-up and Installation ................................................ 4-1

4.1 Included in the delivery .............................................................. 4-2
4.2 Returns .................................................................................... 4-3
4.3 Notes for set-up and installation .................................................. 4-3
4.3.1 Installation guidelines ................................................................ 4-4
4.3.2 Application environment ............................................................. 4-4
4.3.3 Cleanliness and cleaning ............................................................. 4-5
4.3.4 Check-list for set-up and installation ............................................ 4-5
4.4 Set-up and installation ............................................................... 4-6
4.4.1 Tool centre point (TCP) and sensor origin ..................................... 4-6
4.4.2 Tightening torque for screws ....................................................... 4-8
4.4.3 Earthing provisions .................................................................... 4-9
4.4.4 Installation and basic positioning of the TH6D sensor head ........... 4-12
4.4.5 Mounting the safety glass unit on the TH6D sensor head .............. 4-13
4.4.6 Mounting the cooling module on the TH6D sensor head ................ 4-15
4.4.7 Connecting the Ethernet cable to the TH6D sensor head and
process computer.................................................................... 4-16
4.4.8 Connecting the power supply to the TH6D sensor head ................ 4-18
4.4.9 Connection for the cooling and purging air at the TH6D sensor
head...................................................................................... 4-19
4.4.10 Connecting the liquid coolants to the cooling module ................... 4-21
4.4.11 Installing the TH6D process computer ........................................ 4-22
4.4.12 Connecting the power supply to the TH6D process computer......... 4-23
4.4.13 Connecting a user PC for the THxDView configuration software ..... 4-24
4.4.14 Overview of connections without the machine interfaces............... 4-25
4.5 Connecting the machine-dependent auxiliary modules.................. 4-26
4.5.1 Connecting the analogue-digital interface (ADF) .......................... 4-26
4.5.2 Connecting the power supply to the analogue-digital interface ...... 4-28
4.5.3 Connection overview with connected ADF ................................... 4-30
4.5.4 Connecting the Fanuc interface ................................................. 4-31
4.5.5 Connection overview with connected Fanuc interface ................... 4-32

5. Initial Commissioning and Operation ........................... 5-1

5.1 Information about the initial commissioning and operation.............. 5-3
5.2 Switching the TH6D system on and off ......................................... 5-4
5.3 The graphical user interface: THxDView ...................................... 5-5
5.3.1 System requirements for THxDView ............................................. 5-5
5.3.2 Requirements for installing THxDView .......................................... 5-6
5.3.3 Installing THxDView ................................................................... 5-6
5.4 Using THxDView ...................................................................... 5-10
5.4.1 Starting up and exiting the THxDView software ........................... 5-10
5.4.2 Overview of the user interface................................................... 5-12
5.5 Menu bar ................................................................................ 5-14
5.6 Image area ............................................................................. 5-15
5.6.1 "Raw Data" main tab ................................................................ 5-15
5.6.2 "Evaluation" main tab .............................................................. 5-16
5.7 Reports area ........................................................................... 5-17
5.7.1 Errors and warnings ................................................................. 5-17
5.7.2 Events.................................................................................... 5-17
5.8 System Status area ................................................................. 5-18
5.8.1 Status of the network connection............................................... 5-18
5.8.2 Status and change of the operating mode ................................... 5-18
5.8.3 Status of the measurement process ........................................... 5-19
5.8.4 Status of the active job ............................................................ 5-21
5.9 Information area ..................................................................... 5-22
5.9.1 Information area – main tab Measurements ................................ 5-22
5.9.2 Information area – main tab sketch ........................................... 5-23
5.10 Parameter configuration area .................................................... 5-25
5.11 Parameter configuration area – "Profile" tab................................ 5-25
5.11.1 Seam Pattern tab .................................................................... 5-26
5.11.2 Seam Pattern tab – templates with seam pattern profiles ............. 5-27
5.11.3 Seam Pattern tab – parameter description .................................. 5-32
5.11.4 Camera tab ............................................................................. 5-42
5.11.5 Camera tab – parameter description .......................................... 5-42
5.11.6 Calibration tab ........................................................................ 5-43
5.11.7 Calibration tab – parameter description ...................................... 5-44
5.11.8 Process Control tab .................................................................. 5-45
5.12 Parameters area – main System tab .......................................... 5-46
5.12.1 Job List tab ............................................................................. 5-46
5.12.2 Machine Interface tab .............................................................. 5-48
5.12.3 Configuration tab ..................................................................... 5-49
5.13 Interfaces and associated parameters ........................................ 5-52
5.13.1 Machine interface – analogue-digital correction ........................... 5-52
5.13.2 Machine interface – Motoman reference path .............................. 5-54
5.13.3 Machine interface – Fanuc Ethernet ........................................... 5-60
5.13.5 Machine interface – IF UDP Data ............................................... 5-64
5.14 Set-up and configuration of the TH6D system ............................. 5-65
5.14.1 User login ............................................................................... 5-65
5.14.2 Establishing a network connection with a TH6D system ................ 5-67
5.14.3 Selecting the language ............................................................. 5-71
5.14.4 Selecting the set-up operating mode .......................................... 5-71
5.14.5 Positioning the TH6D sensor head .............................................. 5-72
5.14.6 Tool calibration........................................................................ 5-75
5.14.7 Measurement process optimization – changing camera settings ..... 5-79
5.14.8 Optimizing the measurement process – changing parameters ....... 5-80
5.14.9 Setting up profiles and creating jobs .......................................... 5-81

6. Maintenance ................................................................. 6-1

6.1 Safety instructions ..................................................................... 6-2
6.2 Required maintenance................................................................ 6-3
6.2.1 Maintenance intervals ................................................................ 6-3
6.2.2 Diagnosis of the maintenance intervals......................................... 6-4
6.2.3 Overview of maintenance procedures ........................................... 6-5
6.3 Handling the components ........................................................... 6-5
6.3.1 Clean and change the safety glass ............................................... 6-5
6.3.2 Cleaning the TH6D sensor head ................................................... 6-8
6.3.3 Check the hose and cable connections.......................................... 6-9

7. Troubleshooting ........................................................... 7-1

7.1 Notes ....................................................................................... 7-2
7.2 Information, warning and error code tables for THxDView............... 7-3

8. Technical Data and Specifications ................................ 8-1

8.1 Technical data and specifications ................................................. 8-2
8.2 Electrical switching functions of the analogue-digital interface (ADF) ...... 8-7
8.3 Electrical switching functions of the Motoman interface .................. 8-8
8.4 Medium .................................................................................... 8-9
8.4.1 Compressed air specifications ..................................................... 8-9
8.4.2 Coolant specification .................................................................. 8-9
8.5 Ambient conditions .................................................................. 8-10
8.6 Accessories and spare parts ...................................................... 8-11
8.6.1 Base configuration for the TH6D system ..................................... 8-11
8.6.2 Optional components ............................................................... 8-12
8.6.3 Optional components for the ABB and KUKA robots...................... 8-13
8.6.4 Wearing parts – safety glasses .................................................. 8-14

9. Appendix ...................................................................... 9-1

9.1 Annex ...................................................................................... 9-2
9.1.1 List of Figures ........................................................................... 9-2
9.1.2 List of Tables ............................................................................ 9-6
9.2 Check-list for set-up and installation ............................................ 9-7
9.3 Contamination Declaration .......................................................... 9-9
9.4 Condensation point table .......................................................... 9-10
 1. Explanations for this Manual
This chapter contains helpful explanations for working with the User's
Manual.

1.1 Purpose and related documents ...................................... 1-2

1.2 Using the User's Manual.................................................. 1-2
1.3 Abbreviations and units .................................................. 1-3
1.4 Symbols, warning levels and notice types ....................... 1-5

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 Explanations for this Manual

1.1 Purpose and related documents

CAUTION!
You must read all relevant documentation and take additional training in order to
work with the TH6D system!

The user's manual contains the necessary information describing the installation, operation, and
maintenance for the following approved versions of the sensor system: Tracking Head 6
Dimensions:

• TH6D-150-CFxx-yy

• TH6D-150-KFxx-yy
The Tracking Head 6 Dimensions will be subsequently referred to as the TH6D in this document.

Additional training is recommended due to the complexity of the device.

1.2 Using the User's Manual

The complete document must be kept close to where the device is deployed and remain
accessible to all personnel authorized to work with the device. This helps in avoiding errors when
installing and operating the TH6D system, and ensures trouble-free operation.

The illustrations in this manual do not always include all details and do not always depict the
latest components. They show only the most significant information for the reader.

The User's Manual is divided up into chapters arranged according to technical and training topics.

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 Explanations for this Manual

1.3 Abbreviations and units

Some of the German and English abbreviations used in this manual are explained below.

Abbreviations

ADF Analogue-digital interface

Base-T Ethernet version

CCD Charge-coupled device

C-MOS Complementary metal oxide semiconductor

EMC Electromagnetic compatibility

Ex. Example

Fig. Figure

IP Internet protocol

L Direction of beam

LED Light emitting diode

LPC Laser protection class

MD Machinery directive

MPR Maximum permitted radiation (according to 60825-1 (VDE 0837-1): 2008-

05)

n Normal

SP Seam point

PTP Peer to peer (networking connection)

PU Polyurethane

r Direction of reflection

S0 Sensor origin

t Time

TCP Tool centre point

TH6D Tracking Head 6 Dimensions

UDP User datagram protocol (network protocol)

UM User's Manual

v Viewing angle

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 Explanations for this Manual

θL Incidence angle Theta L

θr Angle of reflection

Units

bar Bar – measures pressure (1 bar = 105 Pa)

kW Kilowatt

l/min litre per minute

min Minute

ms Millisecond

m2 Square metre

nm Nanometre

Pa Pascal – measurement unit for pressure

s Second

W Watt

µm Micrometre

µs Microsecond

°C Degrees Celsius

ØA Outer diameter

ØI Internal diameter

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 Explanations for this Manual

1.4 Symbols, warning levels and notice types

The list below explains all symbols, warnings and notices used within this manual. They are used
to increase the safety level, decrease the risk of danger and reduce injury and material damages.

Symbols
The following symbols and icons are used to identify sources of danger. They are in compliance
with the applicable standards at the time this manual was published and may occur at all warning
levels.

Warning for a hazardous area (W000)

Warning for laser beams (W010)

Warning for materials that are dangerous to human health (W018)

Warning for hot surfaces (W026)

Warning for dangers in vicinity of the turning and reaching zone of the industrial
robot (W079)

Warning for excess pressure (W080)

Warning for risk of hearing damage (W084)

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 Explanations for this Manual

General mandatory sign (M000)

Follow the instructions (M018)

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 Explanations for this Manual

Warning levels and notice types

This manual uses the following warning levels. It is important to observe the accompanying
instructions and comments. The warnings are listed in order of priority as indicated by their
colour coding.

DANGER!
This indicates particular dangers to life and limb. Failure to observe these notices will
lead to death or serious injuries.

WARNING
This indicates a situation that may be dangerous. Failure to observe these notices
can lead to death or serious injuries.

CAUTION!
This indicates a situation that may be dangerous. Failure to observe these notices
can result in slight injuries. In addition, there is a risk of considerable damage to
property.

The following notice types are used in this manual

NOTE!
This is used for notices which, if not observed, can lead to a disruption in operating
procedures.

TIP!
This is used for notices which can lead to an improvement in operating procedures if
observed.

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 2. Safety
This chapter describes how to handle the TH6D system safely and
describes its correct and intended usage.

2.1 General safety instructions ............................................. 2-2

2.2 Laser safety .................................................................... 2-4
2.2.1 Dangers posed by class-3B lasers .................................... 2-4
2.2.2 Retro-reflection ............................................................. 2-5
2.2.3 Laser aperture on the TH6D sensor head .......................... 2-5
2.2.4 Operating the laser safely ............................................... 2-6
2.3 Particular dangers .......................................................... 2-8
2.3.1 Master machines............................................................ 2-8
2.3.2 Excessive pressure and emitted substances ...................... 2-8
2.4 Protective safety measures during normal operation....... 2-9
2.5 Proper and intended usage ............................................. 2-9
2.6 Warrantee and liability ................................................. 2-10
2.7 Information and warning signs on the TH6D sensor
head ............................................................................. 2-11
2.8 Disposal........................................................................ 2-12

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 Safety

2.1 General safety instructions

The following points contain general safety information that must be observed when operating
the TH6D system.

Obligations of The TH6D system must only be mounted, operated and maintained by
the facility trained personnel. These personnel must be able to recognize possible
manufacturer, dangers or malfunctions based on pertinent experience gained from
operating operating automated production facilities. They must also have knowledge
company and of all applicable standards and safety measures.
personnel It is the responsibility of the laser safety officer to ensure that personnel
operating the laser system are sufficiently trained. Every person who
installs, operates or services the TH6D system must understand and follow
the contents of the manual. These regulations are also intended to prevent
accidents and must be followed:
• 2006/25/EC "minimum requirements to protect health and safety
of workers from the risks arising from physical agents (artificial
optical radiation)",
• BGV B2 "laser radiation" (formerly VBG 93),
• the standards DIN EN 60825-1 and DIN EN 60825-4 "Safety of
laser equipment".
Also observe the information found in Chapter 2.5, "Proper and intended
usage".

Safety The operator of the system is responsible for labelling the system properly.
equipment The operator must also provide an adequate screening or perimeter to
prevent access to the danger zone. The proper measures should be taken
to ensure that no unauthorized personnel are allowed access to the danger
zone. Please observe the information found in point 5.3 in DIN EN ISO
11553-1 "Carrying out corrective measures" which pertains to safety
equipment. Ensure that automatic operation of the facility is impossible
when safety equipment is open or disabled. The prescribed safety
equipment required for operating this system must be available, installed
and ready for use. Faults and malfunctions, in particular those that impair
safety, must be rectified immediately. You must regularly check the
effectiveness of the safety mechanisms!

Initial The TH6D system should only be commissioned and used when it is in a
commissioning technically flawless condition (refer to Chapter 5, "Initial Commissioning
and operation and Operation"). Incorrect operation or misuse can result in danger to life
and limb. The efficient functioning of the TH6D system can also be
impaired. Damage to the TH6D system and to surrounding property is also
possible. No personnel should be located in the danger zone of the facility
during operations. Danger zones must be cordoned off and inaccessible.

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 Safety

Protective Always wear appropriate BGVB2-compliant (previously VBG 93) laser

clothing safety glasses when working in a designated laser radiation danger area.
When replacing cables or the protective glass on the TH6D sensor head,
allow the processing head to cool down after the work process or be sure
to wear protective gloves.

Accident The accident prevention regulation BGV B2 "Laser radiation" (previously

prevention VBG 93) must be followed when operating the TH6D sensor system. The
according to the employee liability insurance association and the relevant worker's safety
BGV B2 authorities should be notified before you start working with any class-3B
regulation or class-4 laser equipment. You must mark and restrict the laser working
ranges of any class-3B or class-4 laser equipment. The operator of the
sensors must restrict access to the laser's working range.

Cleanliness Contaminated optical elements (the protective glass and integrated

protective glass in the reception and transmission modules) can impair the
functionality of the TH6D sensor head! Therefore you should only work
with clean equipment. Regular inspections and necessary cleaning should
be carried out during servicing. A dirty protective glass should be cleaned
or replaced. Contaminated integrated safety glasses must be replaced. The
TH6D system should then be sent in for repair in such cases.

Maintenance Always be sure that the power supply is disconnected before starting any
and repair maintenance procedures. Also be sure that it cannot be accidentally
switched on during maintenance. This will reduce the risk of dangers such
as laser light, unanticipated robot movements or crushing hazards.
Damaged components or safety glass may have sharp edges. Be very
careful when replacing these parts. Use only genuine (original) spare parts
and genuine expendable (wearing) parts. There is no guarantee that parts
from third-party suppliers will meet construction specifications with regard
to load capability or safety. When ordering parts, specify the exact name,
the article number according to the spare parts list and the serial number
of your device! Follow the information regarding maintenance and repair
found in the DIN EN ISO 11553-1:2009-03 standard.

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 Safety

2.2 Laser safety

Laser class For the purposes of accident prevention regulations, a laser device's class
indicates the radiation-related risk posed by the accessible laser beam.
The following TH6D sensor types are classified as laser equipment in laser
class 3B, according to DIN EN 60825-1 (VDE 0837-1): 2008-05.
• TH6D-150-CFxx-yy
• TH6D-150-KFxx-yy
The TH6D sensor heads use laser diodes with a maximum power of
40 mW at a wavelength of 660 nm. For measuring purposes, they project
three laser lines onto the work piece being processed. The actual output of
the emitted radiation may be reduced depending on the beam shaping
being used and the mode of operation.

Wave length
WARNING!
range and
power Laser radiation is dangerous to human health!

• Laser safety goggles should be worn when working

with and on the TH6D system!

The emitted laser radiation is hazardous to the eyes and can also harm the
skin in certain cases. Please follow the related information found in the
BGV B2 "Laser radiation" (previously VBG 93): § 2, section 3, number 4.

Make sure that all persons in the vicinity of the running TH6D sensor
system are wearing protective safety goggles which guard against laser
radiation.

2.2.1 Dangers posed by class-3B lasers

Overview When operating the TH6D system, specific hazards may be present based
on how the laser beam is used.
Laser equipment can produce extremely intense, highly focused radiation
in the visible, infra-red or ultraviolet spectrum. The laser radiation has
photo-chemical, thermal and opto-mechanical influences which can be
hazardous to your health.

CAUTION!
Please refer to the instructions about accident
prevention regulation found in BGV B2 "Laser
safety" (section 2.1).

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 Safety

Dangers from It is dangerous to look directly into the laser beam or into the beam's
laser radiation reflection (see also section 2.2.2).
). Your eyes could be permanently
damaged. It is essential that you wear safety goggles and maintain a safe
distance from the maximum permissible radiation areas. In order to avoid
accidents, work safety measures must be implemented and followed. The
dangers posed by diffuse reflection from laser radiation are relatively low.
However you should avoid exposure to longer periods of diffuse reflection
(longer than 10 seconds). You should also avoid
avoi observation distances
under 13 cm. Work pieces,
pieces, optical lenses or mirrors which lie in the
beam's path can narrow the beam and actually increase the danger of
directed or reflected laser beams. Make sure that such components do not
lie in the beam's path!
path

2.2.2 Retro-reflection

General hazards
DANGER
Danger from reflected laser beams!

• Do not direct the laser beam towards reflective

surfaces!

Directional retro-reflections
retro reflections can occur when working with reflective
materials. Reflections of the laser beam off of the work material can
damage your skin and eyes.

2.2.3 Laser aperture on the TH6D sensor head

Position The laser aperture is located at the bottom of the TH6D sensor head. (See
Figure 1.)
.) This location is marked with a warning label.

Aperture

Figure 1: TH6D sensor head – laser aperture

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 Safety

2.2.4 Operating the laser safely

Overview Laser devices which are supplied as components for a system are not
subject to IEC 60825-1,
1, since the final product itself is subject to this
standard. If the laser system can be removed and operated separately
from a facility, then the requirements of IEC 60825-1 pertain to the
stand-alone component.

This also applies to TH6D-series laser equipment

uipment that can be operated as
stand-alone
alone devices, especially for the sensor types listed in Chapter 1.1.

Sensor safety According to DIN EN 60825-1 (VDE 0837-1):

1): 2008-05,
2008 every class-3B
laser systems must have a key-operated
operated main switch. The key for the
switch must be removable. It must not be possible to switch
swit on the laser
beam when the key switch is deactivated.

The TH6D sensor head has no dedicated key switch. The TH6D sensor
head has a separate power supply for the diode laser so that the laser can
operate safely. Thus the voltage for the laser diodes (24V_LSK)
(24 is only
applied when the laser safety circuit is closed, when the key is turned in
the switch and when safe operations are ensured. The laser safety circuit
has a safety lock function. No laser radiation is emitted when there is no
laser power supply.
Two redundant orange LEDs are used to signal when the laser power
supply is applied to the TH6D sensor head. (Refer
Refer to section 3.5.1.) This
warning LED indicates
s that laser radiation is being emitted or that the
system is ready to emit laser radiation.

Figure 2:: Location of the warning LED on the TH6D sensor head

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 Safety

The wavelength of the warning LED is 606 nm. When selecting safety
goggles, ensure that you can still see the warning LED clearly with the
goggles on. It the operating personnel cannot see the warning light visible
from their secure positions, then additional acoustic or visual warning
signals should be attached during the installation of the TH6D sensor
system.

When installing the sensor heads listed in section 1.1, make sure that the
laser beam cannot inadvertently expose the skin or eyes over the
allowable limits as specified in EN 60825-1 (VDE 0837-1): 2008-05.

Safety measures Possible safety precautions include setting up supervised access areas and
implementing personal protective measures. Contacts made to the laser
safety circuit (for monitoring the area in which hazardous laser radiation is
present) must be fail-safe or redundant. The installer or commissioning
engineer is responsible for ensuring safe operation for the TH6D system in
compliance with DIN EN 60825-1 (VDE 0837-1): 2008-05.

The safety clearance gap (with respect to the range of the unhindered
laser beam) is 3 metres.
A gap of 3 metres must also be maintained from reflected beams that
could come from any other objects. Focusing optical elements may not
intersect the beam path, since this would increase the minimum safety
gap required.
The currently valid MPE values (values of the maximum permissible
exposure according to 60825-1 (VDE 0837-1): 2008-05) are as follows:
• Irradiation of the cornea (exposure time 10 s to 3×104 s):
10 W/m2
• Irradiation of the skin (exposure time 10 s to 3×104 s):
2 kW/m2

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 Safety

2.3 Particular dangers

The particular dangers that can occur while installing, mounting and operating the TH6D system
within a production facility are described below.

Design measures were carefully integrated into the construction of the TH6D system so that
dangers posed by emitted substances ("media") and voltages would be minimized.

Non-approved usage can cause damage to the modules or components.

Your own health and the health of others should be your primary consideration. Ensure that all
voltage sources have been switched off to the facility during set-up or maintenance procedures.
The TH6D sensor system should be switched off and the pneumatic systems should be de-
pressurized. Make sure that the facility cannot be turned on again unintentionally.

2.3.1 Master machines

DANGER!
There is a risk of injury from the master machines!
• Do not stay in the swivel range of master machines when they are turned on!
• Disconnect the power supply before working on any processing device!

Depending on the particular application, the TH6D sensor head may be moved under the control
of master machines. Serious injury or even death can result from being in the swivel range of a
master machine. It is very dangerous and prohibited to work in the operating range of the
master machine (e.g., when setting up the process). You should pay special attention to the
instruction manuals of the other devices in use and their relation to the operation and safety of
the master machines.

2.3.2 Excessive pressure and emitted substances

WARNING
Excessive pressure in the media lines can lead to eye and ear damage or
other injuries!
• Always wear the proper protective eye glasses, ear protection, and clothing
when changing pressurized lines and hoses!!

Forbidden, excessive pressure leads to an increased risk of injury. Follow the pressure
specifications given in the Technical Specifications section in Chapter 8.

Extremely loud noises can occur when changing the pressurized media-supply hoses. Damage to
hearing could result. Always wear proper ear protection while making the change.

Pressurized lines can whip back and forth after they are disconnected. This can lead to eye or
bodily injuries. Always wear proper eye protection and protective clothing while making the
change.

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 Safety

2.4 Protective safety measures during normal operation

Overview The lifespan of the integrated laser diode may be shortened if you are
operating with an enclosure temperature that exceeds the specified
operating temperature. Make sure the temperature stays in the specified
range. Operations outside of the specified temperatures will lead to a
temperature-related decrease in the absolute measurement accuracy.

Protective The following safeguards are available during normal operation:

measures
• Glass panes with anti-reflective coating which have been built into
the TH6D sensor head (refer to section 3.3.1)
• An extra, standard safety glass unit with an additional plastic
safety glass that has been integrated in front of the panes (refer
to section 3.3.2)
• Purging air is supplied to the TH6D sensor head in order to
increase the durability of the plastic safety glasses
• Built-in connections for air-cooling the TH6D sensor head

2.5 Proper and intended usage

DANGER!
Follow the proper and intended use guidelines!
The TH6D system must not be used:

• in facilities which have defective safety equipment.

Follow the specification concerning the surrounding conditions and media as
described in Chapter 8, "Technical Data and Specifications"!

Proper and The TH6D system is used exclusively as a module that is installed as part
intended usage of a production facility. The TH6D system is an optical measuring system
that automatically detects the shape of work pieces. It represents state-
of-the-art technology.
The TH6D sensor head was designed to be mounted on a master machine
(for example, a robot). It may also be used in facilities where the
processing head is fixed in position and the work pieces move. The TH6D
system was designed and manufactured in accordance with recognized
technical safety regulations. The TH6D system should be used for its
intended purpose only.

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 Safety

Proper and Incorrect usage or incorrect operation can lead to danger of death or
intended usage serious damage to health and property. Improper or incorrect usage
- continued absolves the manufacturer from all liability! The TH6D system must only
be operated when in perfect technical condition. During the initial
commissioning, all necessary safety measures must be taken in
accordance with applicable regulations.

You must observe the safety instructions and notices contained in this
manual. The user must read and understand the manual before working
with the TH6D system. We recommend that you take additional Scansonic
training.

2.6 Warrantee and liability

CAUTION!
Please observe the warrantee and liability claims description!

Warrantee and liability claims for personal injury and damage to property are not possible if they
are attributable to one or more of the following causes:

• Improper or incorrect usage of the TH6D system,

• Incorrect installation, commissioning or operation of the TH6D system,

• Operating the TH6D system when safety equipment is defective or not properly
installed, or operating the module when safety and protective devices are not
functioning,

• Failure to observe the notices in the User's Manual regarding installation,

commissioning and operating the TH6D system.

• With all alterations of the TH6D system,

• When operated outside of the specifications given in the configuration data

sheets.

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 Safety

2.7 Information and warning signs on the TH6D sensor head

The illustration below indicates the location of the notices and warning signs on the TH6D
TH sensor
head.

NOTE
Always maintain the signs so that they are in a good, readable condition.

Table 1:: Position of notice and warning signs

Figure Item Description

1 Serial number of the TH6D sensor head

(example)

S/N: 14xxxxxx
Manufacturing date 20xx/xx
1

2 Company logo with configuration

number (example)
2

3
3

4 Labelled connections
4

5 Warning for laser beams (W010)

6

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 Safety

2.8 Disposal

Note The TH6D system can be returned free of charge to Scansonic IPT GmbH
for disposal (excluding delivery charges).
Otherwise, you should dispose of the TH6D system according to
environmental regulations restricting the disposal of electrical waste.

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 3. Product Information
This chapter describes the properties and functions of the TH6D system.

3.1 Overview ........................................................................ 3-2

3.1.1 Special characteristics .................................................... 3-2
3.1.2 Possible applications ...................................................... 3-2
3.1.3 How it works ................................................................. 3-3
3.1.4 Definition of the coordinate system .................................. 3-4
3.2 Usage limitations ............................................................ 3-5
3.2.1 The influence of work piece reflection ............................... 3-5
3.2.2 Influences from the welding process ................................ 3-6
3.2.3 The influence of accessibility ........................................... 3-8
3.2.4 Influences of material thickness and step height ................ 3-9
3.2.5 Limitations caused by the temperature range .................... 3-9
3.2.6 Influence of the sensor's orientation in relation to the
work piece surface ....................................................... 3-10
3.2.7 Limitations caused by the gap dimensions ...................... 3-10
3.2.8 Limitations caused by the operating voltage .................... 3-10
3.3 Descriptions of modules and components ..................... 3-11
3.3.1 TH6D sensor head ....................................................... 3-11
3.3.2 Safety glass unit .......................................................... 3-12
3.3.3 TH6D process computer................................................ 3-13
3.3.4 Mains power supply unit ............................................... 3-14
3.3.5 Cable ......................................................................... 3-14
3.3.6 Cooling module ........................................................... 3-15
3.4 Additional machine-dependent modules........................ 3-17
3.4.1 Analogue-digital interface (ADF) .................................... 3-17
3.4.2 Calibration plate .......................................................... 3-18
3.4.3 Network cable ............................................................. 3-19
3.5 Status LED for the TH6D system .................................... 3-20
3.5.1 Status LED on the TH6D sensor head ............................. 3-20
3.5.2 Status LED on the TH6D process computer ..................... 3-22
3.6 TH6D system interfaces ................................................ 3-24
3.6.1 Connections for the TH6D sensor head ........................... 3-24
3.6.2 Connections for the TH6D process computer ................... 3-26
3.6.3 Machine interfaces ....................................................... 3-27
3.7 Operating and configuration interface for THxDView ..... 3-28

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 Product Information

3.1 Overview
The TH6D system is an optical measuring system that can detect and measure the shape of work
pieces. It is designed for seam tracking during the joining process, but can be used for other
measurement tasks. When integrated in a welding facility with other master machines and
robots, this system can track the seam joint. The TH6D system can also measure the gap width,
the edge offset and the distance of the joint line from the work pieces being welded or soldered.

In addition, the TH6D system measures the orientation of the sensor head over the work piece
surface (the push/drag angles, the lateral angle, the angle of rotation and the vertical axis).
These measurements are used to automatically guide the production facility. The sensor system
records any variations in the work pieces and positions. The weld seam can then be automatically
corrected with high precision and reliability.

3.1.1 Special characteristics

The TH6D system offers the following features and advantages:

• Integrates the latest optical sensor technology

• Three measuring lines are used to guarantee safe seam tracking

• Also works with shiny surfaces such as aluminium or chrome-nickel steel

• Can handle work piece surfaces that have high contrasts

• Not sensitive to splashing or stray light

• Minimal obstructive contour

• Long operating clearance

• Equipped with integrated cooling ducts for heat dissipation

• Easy to operate with an intuitive user interface (GUI)

• Minimizes the set up time required for individual production runs

• Ensures a consistent quality in the process when producing large quantities

The TH6D system is being continuously improved upon and adapted to meet the needs of our
customers. We are also constantly improving the interfaces to available machine controllers. The
TH6D system has proven its usefulness with multiple robot variants in various industrial
reference installations. In these facilities, the seam tracking system ensured that work
piece/positional variances could not impair the welding process.

3.1.2 Possible applications

The TH6D system can be used as a peripheral for automatic seam tracking in the following
processes: laser welding, standard welding, joining processes, brushing and grinding. It can also
be used in other applications requiring sensory guidance along a geometric structure, such as a
robotic welding facility or a welding system that uses custom machines. The corresponding
application interfaces for the TH6D system can be provided.

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 Product Information

3.1.3 How it works

The measurement The laser stripe sensors in the TH6D series provide no-contact detection
mechanism and measurement of work pieces using the principle of laser triangulation.
(As shown in Figure 3.)
A light pattern consisting of three parallel laser lines is projected at an
angle of 20 degrees onto the work piece surface and then scanned
vertically with a digital camera. These light beams are influenced by the
oblique projection at the joint; the beam interruption marks a seam point
along the joint.

1
2
3

4 5

Figure 3: TH6D – The principle of laser triangulation

Description Item Description

1 Laser diode

2 Collimator optics

3 Projection optics

4 Measurement 1 and measurement 2

5 Measured object/work piece

6 Lens / receiver optics

7 Light detector

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 Product Information

3.1.4 Definition of the coordinate system

The directions of movement for the TH6D sensor head are defined as follows:

S0: Sensor origin

+z
Direction Direction of process feed
S0 along the X
axis:
+y +x
Direction Lateral correction
along the Y
axis

Direction Distance (gap) correction

along the Z
axis:

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 Product Information

3.2 Usage limitations

Overview The possible usages for optical seam tracking systems are limited by the
physical environmental conditions present during the welding process. The
reflective properties of the work piece's surface are a major factor, since
all measurements are deduced from the reflected beam pattern. Since the
sensor head works in the immediate vicinity of the welding process,
interference emitted by the process should not be able to impair the
sensor functionality. Welding splatter, smoke, flickering light and EMC
interference are all by-products of arc welding.

3.2.1 The influence of work piece reflection

Overview When using optical sensors for weld-seam tracking, a good understanding
of surface reflectivity is required in order to optimally adjust the laser
brightness and sensor orientation. When working with an ideal reflective
surface (as shown in Figure 4 on left), the light source (a diode laser) is
directed at the work piece surface at an angle of incidence θL so that the
laser beam is completely reflected at the reflection angle θr. No light is
emitted in the direction "n" towards the camera, so there are no laser lines
visible in the camera image. However, for very smooth and shiny work
piece surfaces, only a small fraction of the emitted light is diffusely
reflected (as shown in Figure 4 on right), so that laser lines are faintly
visible (when working with stainless steel and aluminium, for example).

Figure 4: Specular (left) and diffuse (right) reflection

Possible solutions There are two possible ways to improve this situation. The laser output
can be increased or the mounted position of the sensor head can be
changed.

Increasing the laser More powerful laser output is not always available and results in unwanted
output stray light on the work piece and the surrounding clamping mechanisms.

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 Product Information

Changing the If the sensor head is tilted slowly in the direction of travel, the angle θL is
mounting position reduced and thus the maximum of the reflection lobe moves toward the
camera window. The result is a pronounced change in brightness of the
measured lines when the slope of the sensor changes.

The surfaces of real work pieces, particularly for shipbuilding applications,

can be very rough so that the laser beams are scattered diffusely. For
such surfaces, hardly any brightness changes of the measurement lines
should be expected.

Incident beams Reflected beams

Rough surface

Figure 5: Diffuse reflection on work piece with rough surface

3.2.2 Influences from the welding process

Welding splatter, Very strong interference can occur in the sensor camera's field of view
smoke which can then harm the imaging. Welding splashes, smoke and intense
brightness caused by the arc can interfere with the camera's image. The
bright lines visible in Figure 6 represent splatter (molten welding metal)
that extends radially in all directions from the welding process. Metal balls
which have cooled are already present on the surface of the work piece.

Figure 6: Disturbances in the arc welding process

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 Product Information

Solution In the TH6D system, the image is recorded using a camera with an
C-MOS camera extremely broad range of light sensitivity. The brightest areas of the
image can be portrayed equally well as the darkest areas. The master
controller associated with the CCD camera is no longer needed with the
TH6D system. Arc and laser welding tests carried out with the TH6D
system clearly show that the C-MOS technology is superior for these
applications.

Figure 7: MIG process – the inert gas nozzle is clearly visible on the right

Figure 8: Laser welding process – laser focus on right

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 Product Information

3.2.3 The influence of accessibility

Accessibility Another constraint on the use of the TH6D system is the unavoidable
advance of the sensor origin in relation to the TCP. Especially during arc
welding processes, this represents a significant constraint for the robot
programming. Without the TH6D sensor head, the burner can be moved in
any direction. With the TH6D sensor head, the welding tool is forced in a
forward direction. Figure 9 illustrates this restriction using the example of
a laser welding optics with the TH6D sensor head. Since there is a
forward-leading sensor head, the weld seam cannot be processed all the
way up to the vertical wall of the work piece. A closer approach to such a
wall is only possible if the welding optics are put into an increasingly
limited stabbing position.

Figure 9: Accessibility limitations at the end of the seam caused by the

forward-leading sensor

Figure 10: Accessibility limitations in a seam curve caused by the forward-

leading sensor

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 Product Information

3.2.4 Influences of material thickness and step height

Overview Problematic applications may limit the seam tracking system; such limits
can be worked around by changing the position or alignment of the
sensor.

Problem Figure 11 illustrates a recorded measurement from the TH6D system. The
measured area is divided visually into two sections (left and right); the
three laser lines depict the step made by a lap joint. Visually, the number
of laser lines changes from three to six. In this example of a border, the
step height of the lap joint is so large that laser lines 2 and 3 (at left)
coincide with laser lines 1 and 2 (at right).

left right
1

2 1

3 2

Figure 11: Example of a border – the lap joint is too large

Solution By changing the drag angle slightly by five degrees, this unfavourable
situation can be resolved so that reliable detection is again possible. (As
shown in Figure 12.)

left right
1

2 1

3 2

Figure 12: Example of a border – the lap joint is too large – the solution

3.2.5 Limitations caused by the temperature range

Overview Usage of the TH6D system is limited by the permissible temperature

ranges.

Information Follow the specifications concerning the ambient conditions, as described

in section 8.5!

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 Product Information

3.2.6 Influence of the sensor's orientation in relation to the work piece surface

Overview The mounted position of the TH6D sensor head on the tool must be
flexible since the tool itself has precedence over priority positioning. Thus,
the TH6D sensor head may need to be aligned at an angle lateral to the
seam line or at a drag angle. For this lateral angle, limitations to the
mounting positions are imposed by the diminishing reflection, particularly
when working with smooth or specular surfaces. Field-tested lateral angles
are in the range from 15 to 20 degrees. Other angles may be possible
depending on the shape of the work piece (its T-joint). The TH6D sensor
head is mounted in a lancing or drag angle of ± 40 degrees perpendicular
to the work piece. The software will not function if the positioning angle is
outside of this range.

3.2.7 Limitations caused by the gap dimensions

Overview For a butt joint, the lower limit of the gap is dependent on the quality of
the surface, with the following dimensions:
• TH6D-CFxx-yy at 0.2 mm and
• TH6D-KFxx-yy at 1.0 mm.
Preparing the seam can have a significant impact on the seam detection
process. Even minimally rounded edges at the butt joint are very helpful
and can stabilize the seam detection process.
Since the TH6D system only evaluates the work-piece surface, the
measured gap dimension is also strongly dependent on such rounding.

3.2.8 Limitations caused by the operating voltage

Overview Limitations imposed by the operating voltage are necessary for the proper
functioning of the TH6D system.

NOTE!
Make sure that you are using VDE-compliant and certified
power supplies!

Information Please note the voltage specifications as listed in the Technical

Specifications section found in section 8.1!

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 Product Information

3.3 Descriptions of modules and components

3.3.1 TH6D sensor head

Overview The TH6D sensor head consists of the following components:

1 2
9

8
3

6 5 4
Figure 13:: The TH6D sensor head

Components Item Description Function

1 Sensor enclosure • Supports and protects

the sensor components

2 Enclosure cover • Protects the sensor

components

3 Notice and warning signs • Informs and warns of

dangers

4 Safety glass for laser diode • Protects the diode

5 Rod for the safety glass unit • For attaching safety

glass unit

6 Protective glass for sensor • Protects the camera

camera

7 LED showing system status • Displays status

8 LED showing power supply • Displays status

9 Terminal area • Power supply

• Adjusting parameters
• Cooling

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 Product Information

3.3.2 Safety glass unit

Overview The standard safety glass unit uses an extra plastic protective glass to
cover the protective glasses that are built into the TH6D sensor head. This
additional safety glass protects against long-term contamination from
welding splatter and deposits. Thus it is difficult to clean and designed as
a replaceable wearing part.

Increasing the Splatter and deposits reduce the life of the plastic safety glass. This life
life span span can be increased by using clean purge air. A hose for purge air can
be connected to the X1 interface for this purpose (refer to section 4.4.9).

The purge air should be turned on and off in a way that prevents
excessive contamination. You may want to have lead time and follow time
for the purge air. This can be useful when
when you are using a long supply
hose and because deposits and steam require some time to remove.

Construction The safety glass unit consists of a protective plate and the receptacle
which holds the safety glass. (Refer to Figure 14.) The protective plate
shields the unit from radiation coming in from the sides.

3 4

Figure 14:: TH6D safety glass unit

Components Item Description Function

1 Safety glass • Holds the safety glass in place

clamps

2 Protective plate • Protects against process influences

3 Protective plate • Adjusts the opening of the safety

tabs glass unit to the particular process

4 Safety glass • Protects the built-in

built protective
glasses on the TH6D sensor head

5 Receptacle • Holds the safety glass and the

protective plate

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 Product Information

Adjusting the
CAUTION!
protective plate
Do not bend the tabs on the protective plate into the
measurement field.

The safety glass unit can be adapted to various types of applications by

gently bending the tabs on the protective plate. Do not bend the tabs into
the sensor's measurement field. You can check that your positioning is
correct by using the "raw data" image area in THxDView.

3.3.3 TH6D process computer

Overview The controller for the TH6D system runs on the TH6D process computer.

General tasks • Controlling the sequence of the TH6D system

• Controlling and monitoring of the TH6D sensor head
• Processing and output of measurements from the TH6D sensor
head
• Interface for controlling the master machine/robot

The TH6D process computer consists of the following components:

5
2 4

3
Figure 15: TH6D process computer

Components Item Description Function

1 Housing • Supports and protects the

sensor components

2 Connection panel (front) • Connection options

• Status indication

3 Mounting rails • Mounting the TH6D process

computer

4 On/off switch • On/off switch (standby)

5 Connection panel (back) • Connection options

- Mains power supply unit • Power supply

(not pictured)

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 Product Information

3.3.4 Mains power supply unit

Overview The TH6D process computer and the TH6D sensor head require a separate
power supply unit to supply power from the mains.

TH6D process A power supply unit is included in the delivery and is used to supply power
computer to the TH6D process computer. Section 4.4.12 describes the connections.
Power can be supplied to the TH6D process computer using an industrial
top-hat rail.

The TH6D sensor A separate mains power supply (separated from the TH6D process
head computer) should be used for the TH6D sensor head. A suitable mains
power supply is available from Scansonic.

NOTE!
For more information on power supplies, please contact
Scansonic or your local service representative.

3.3.5 Cable

Overview The TH6D system comes with a set of cables. This set consists of one
cable each for the:
• Ethernet connection (see Figure 16)
• Power supply (see Figure 17)
The cable set can be configured to lengths of 10, 15 or 25 metres. The
number of your cable configuration can be found in the list in section 8.3.

Cable for the An Ethernet connection is used as the data link from the TH6D sensor
head to the TH6D process computer.
Ethernet
connection • It supports 100BASE-T Ethernet (Fast Ethernet).
• Section 4.4.7 describes this cable connection.

Figure 16: TH6D system – cable for Ethernet connection

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 Product Information

Power supply A separate power supply unit is used to supply power to the TH6D sensor
cable head. This power supply is built into the production facility. Section 4.4.8
describes this cable connection and pin assignments.

Figure 17: TH6D system – power supply cable

3.3.6 Cooling module

Overview The optional cooling module is made of chrome-nickel

chrome steel. It consists of
a heat shield and a cooling block. The cooling module is mounted to the
housing of the TH6D sensor head. This additional cooling module is
integrated into the facility's cooling circuit. It protects against permanent,
excessive heat build-up
build up during the production process.

Usage The cooling module

module can be used under the following application
conditions:
• An ambient temperature above 45°C (seasonal / location)
• When the workpieces are preheated before welding (must be
verified)
• Longer welding times and with multi-layer
layer welding

ATTENTION!
Refer to section 8.5 for more information on ambient
conditions.

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 Product Information

Construction of The cooling module consists of a heat shield and a cooling block used for
the cooling connecting the cooling liquid. (Refer to Figure 18)
18 The heat shield is used
module to shield against
against lateral radiation and to dissipate the heat. The facility's
cooling circuit is used as the heat exchange mechanism.

1 4

3
2

Figure 18: The TH6D sensor head's cooling module

Components Item Description Function

1 Cooling block • Holds the safety glass and the

protective plate

2 Heat shield • Protects against process influences

3 Screws • Mounts to the TH6D sensor head

4 Coolant connections • Connection for liquid coolant

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 Product Information

3.4 Additional machine-dependent

machine modules

Overview The following auxiliary modules are available for the TH6D system:
• Analogue-digital interface
• Calibration plate
• Network cable (patch cable for Ethernet)

3.4.1 Analogue-digital
digital interface (ADF)

Analogue-digital The analogue-digital

analogue digital interface (ADF) allows you to override and intercept
interface – ADF signals going to or from the TH6D system. A WAGO bus terminal is used
for the ADF. An Ethernet bus coupler is used to communicate with the
TH6D system.
The ADF is also used for the Motoman interface.

Figure 19 shows the standardized construction of the analogue-digital

analogue
interface (ADF). The interface consists of a bus coupler, digital
input/output terminals, analogue output terminals and one end terminal.
ter

Figure 19: TH6D auxiliary module – analogue-digital

analogue interface

Signal input Process parameters are permanently assigned to the analogue outputs in
through the the TH6D system. This means that a particular analogue output is always
facility controller represented by the same process parameter. The user needs to integrate
signals in the production facility's controller
controller which are maintained there as
process records.

Information Section 4.5.1 includes a description of the types of bus terminals and the
ADF connection. Section
Sectio 8.2 contains more information about the
input/output assignments.

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 Product Information

3.4.2 Calibration plate

Calibration plate The calibration plate helps you to calibrate the tool for various machine
interfaces. The TH6D sensor head is aligned to the tool and the sensor
coordinate system is aligned with the machine coordinate system.

Figure 20: TH6D auxiliary module – calibration plate

The following inserts must be ordered specifically:

Item Figure Designation Description

1 Tip insert • Recommended when

using laser optics

2 Cross-hairs • Recommended when

insert using a welding torch

Information Section 5.14 contains more information about setting up and calibrating
the tool.

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 Product Information

3.4.3 Network cable

Overview Network cables (patch cables) are used by the following system
components for Ethernet communications.
• Analogue-digital interface (ADF) to TH6D process computer
• Fanuc interface to TH6D process computer
• THxDView (user PC) to TH6D process computer
The ADF auxiliary module is delivered with a 0.5 metre cable. Network
cables of varying lengths can be ordered from Scansonic for extensions or
re-positioning.

Characteristics • Fully shielded CAT-6A patch cable

• Shielded RJ45 connector
• Oil-resistant
• Suitable for 10GBit Ethernet

Figure 21: TH6D auxiliary module – network cable

Information A listing of possible cable lengths is included in section 8.6.2.

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 Product Information

3.5 Status LED for the TH6D system

3.5.1 Status LED on the TH6D sensor head

Overview
NOTE!
The status LEDs on the TH6D sensor head display
information about the state of the TH6D system.

The LEDs on the TH6D sensor head display the status of the sensor and
the Ethernet connection.

Functions The P1 through P4 LEDs have following functions (refer to Figure 22):

No. Description

P1 Laser supply voltage ON (redundant)

P2 Laser supply voltage ON (redundant)

P3 POWER indicator

P4 Ethernet link status indicator

P2

P1

P3
P4

Figure 22:: Status LEDs on the TH6D sensor head

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 Product Information

Status display The P1 and P2 LEDs only show the status of the supply voltage. The P3 and
P4 LEDs have the following additional functions:

No. Colour Status

P3 Off • Supply voltage is OFF

• or the power cable is not connected

Red • Sensor start-up phase

• or an internal error has occurred

Green • The sensor is trying to establish an

flashing light Ethernet connection

Green • Ethernet link is established

• The sensor is ready for operations

P4 Off • No Ethernet connection

• or cable is not connected

Red • Ethernet link is established but there has

been no communication

Green • Ethernet link is established

flashing light • Communication is established

Green • Laser is ON
rapidly flashing • The status is identical for both the
light automatic and set-up modes

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 Product Information

3.5.2 Status LED on the TH6D process computer

Overview
NOTE!
The status LEDs display information about the state
of the TH6D process computer.

The available LEDs display the following functions for the TH6D process
computer.

Status LED Designation Description

PWR Operating state of the TH6D process computer

HDD Activity display for data storage

LNK1 Network connection for THxDView is connected

ACT1 Network connection for THxDView: data being

transmitted

LNK2 Network connection 2 is connected

ACT2 Network connection 2: data being transmitted

On/off switch and supply voltage indicator

Figure 23: Status LEDs on the TH6D process computer

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 Product Information

Status indication The LEDs on the TH6D process computer differ according to their status:

No. Colour Status

PWR Green • TH6D process computer is turned on

Off • TH6D process computer is turned off

HDD Flashing orange • Data memory is active

Off • Data memory is not active

LNK1 Green • A network cable is connected

Off • No network cable is connected

ACT1 Flashing orange • Data is being transferred

Off • No data is being transferred

LNK2 Refer to LNK1

ACT2 Refer to ACT1

Blue • Supply voltage is present;

TH6D process computer is turned on

Red • Supply voltage is present;

TH6D process computer is turned off

Off • No supply voltage

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 Product Information

3.6 TH6D system interfaces

3.6.1 Connections for the TH6D sensor head

Control
NOTE!
The TH6D sensor head is designed so that it cannot
be plugged in incorrectly. It is easy to connect with
existing power supplies.

X3
X2
X1
X5
X4

Figure 24: Connections for the TH6D sensor head

No. Description

X1 Purge air for the safety glass

X2 Cooling air input

X3 Cooling air output

X4 Power supply

X5 Ethernet (process computer)

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 Product Information

Purge for safety • Connection as required for interface X1

glass • Hose diameter: 4 mm
More information on connecting the purge air and the media can be found
in sections 4.4.9 and 8.4.

Air cooling
CAUTION!
The enclosure for the TH6D sensor head is made
of aluminium. Never allow water to run through
the cooling channels: this could lead to corrosion!

NOTE!
When using air to cool the TH6D sensor head, you may
use a branch line with reduced pressure as purge air for
the safety glass (refer to the specifications in section 8.4).

Cooling air input • Connection to the interface X2 (cooling air input)

• Hose diameter: 6 mm
• Max. 6 bar
• Max. amount of air is about 300 litres per minute.

Cooling air outlet • Optional connection to the interface X3 (cooling air outlet)
• Exhaust outlet for the used cooling air

Power supply
NOTE!
The negative terminal for the system supply and laser
supply voltage (0 V) is electrically isolated from the
system ground.

• Connection to interface X4

Plug X4 M12-L, shielded, 4-pin, A-coded

X4 Pin-out Signal Designation Pin

assignments

0V__Power System supply voltage 0V 1

24V_Power System supply voltage 12-36V 2

0V__LSK Laser protective circuit 0V 4

24V_LSK Laser protective circuit 12-36V 3

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 Product Information

Ethernet • Connection to interface X5

T Ethernet (Fast Ethernet) is supported.
• Only 100-BASE-T

Plug X5 M12
M12-L, shielded, 4-pin, D-coded

X5 pin-out Signal Designation Pin

assignments
Tx+ Ethernet transmission line (+) 1

Tx- Ethernet transmission line (-)) 2

Rx+ Ethernet receive line (+) 3

Rx- Ethernet receive line (-) 4

Information Section 4.4 describes the installation.

3.6.2 Connections for the TH6D process computer

Connection The following connections are available on the TH6D process computer.
overview

1 2 3 4 5 6 7
Rear side

8 9 10 11 12 13 14
Figure 25:: Connection overview for the TH6D process computer, rear side

Front side

15

Figure 26: Connection overview for the TH6D process computer, front side

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 Product Information

Connections for Item Description Item Description

the TH6D process
computer 1 Not used 9 COM port (RS232)

2 Power supply 10 Ethernet (data output)

3 Not used 11 Ethernet (TH6D sensor head)

4 Not used 12 Not used

5 Ethernet (data output) 13 Not used

6 Ethernet (THxDView) 14 Not used

7 Not used 15 Not used

8 Not used

3.6.3 Machine interfaces

Communication The following interfaces are available for communicating with the
production facility (especially for the robot and system controls):
• Ethernet TCP/IP
• Analogue/digital/voltage/current interface (ADF)

Currently, communications can be established with the following master

machines or robots:

• Linear axes (via analogue/digital interface)

• Motoman
• Fanuc
• REIS
• ABB

Information More information about connecting and configuring the machine interfaces
can be found in sections 4.5 and 5.9.

The inputs and outputs of the analogue-digital interface and the Motoman
interface are described in the interface assignment tables found in sections
8.2 and 8.3.

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 Product Information

3.7 Operating and configuration interface for THxDView

Interface The PC-based THxDView software can be used as an operating / confi-

guration interface in order to manually configure the TH6D system. The
software should be installed on a PC at the facility. The physical interface
between the facility PC and the TH6D system uses an Ethernet connection.

Functions THxDView has the following functionality:

• Setting parameters
• Monitoring processes

Communication • Ethernet is used for the communication link between the TH6D
system and THxDView.

Installation Section 5.3 describes the installation.

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 4. Set-up and Installation
This chapter describes the set-up and installation of the TH6D system.

4.1 Included in the delivery .................................................. 4-2

4.2 Returns........................................................................... 4-3
4.3 Notes for set-up and installation ..................................... 4-3
4.3.1 Installation guidelines .................................................... 4-4
4.3.2 Application environment ................................................. 4-4
4.3.3 Cleanliness and cleaning ................................................. 4-5
4.3.4 Check-list for set-up and installation ................................ 4-5
4.4 Set-up and installation .................................................... 4-6
4.4.1 Tool centre point (TCP) and sensor origin ......................... 4-6
4.4.2 Tightening torque for screws ........................................... 4-8
4.4.3 Earthing provisions ........................................................ 4-9
4.4.4 Installation and basic positioning of the TH6D sensor
head .......................................................................... 4-12
4.4.5 Mounting the safety glass unit on the TH6D sensor head .. 4-13
4.4.6 Mounting the cooling module on the TH6D sensor head .... 4-15
4.4.7 Connecting the Ethernet cable to the TH6D sensor head
and process computer .................................................. 4-16
4.4.8 Connecting the power supply to the TH6D sensor head..... 4-18
4.4.9 Connection for the cooling and purging air at the TH6D
sensor head ................................................................ 4-19
4.4.10 Connecting the liquid coolants to the cooling module ........ 4-21
4.4.11 Installing the TH6D process computer ............................ 4-22
4.4.12 Connecting the power supply to the TH6D process
computer .................................................................... 4-23
4.4.13 Connecting a user PC for the THxDView configuration
software ..................................................................... 4-24
4.4.14 Overview of connections without the machine interfaces ... 4-25
4.5 Connecting the machine-dependent auxiliary modules .. 4-26
4.5.1 Connecting the analogue-digital interface (ADF) .............. 4-26
4.5.2 Connecting the power supply to the analogue-digital
interface ..................................................................... 4-28
4.5.3 Connection overview with connected ADF ....................... 4-30
4.5.4 Connecting the Fanuc interface ...................................... 4-31

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 Set-up and Installation

4.1 Included in the delivery

Information
NOTE!
Depending on your particular configuration, your TH6D
system may differ from the TH6D system described here.
The ordering documentation sent to you contains a more
detailed overview of your TH6D sensor system
configuration.

Included in the The following components are included in the delivery:

delivery

Base • The TH6D sensor head

• Safety glass unit
• TH6D process computer
• Cable set (two each of: 10 / 15 / 25 m)
• Power supply unit for the TH6D process computer
• CD/DVD with software (THxDView)

The following components are optionally included in the delivery:

Optional • Calibration plate (if required for connecting to ABB or KUKA robots)
• Power supply unit for the TH6D sensor head (Scansonic
recommends using a separate power supply)
• Machine-based auxiliary components (interface hardware that is
specific for your facility: ADF, converter, serial ports, repeaters,
network cables, etc.)
• Cooling module
• Wearing parts (safety glases)

Inspection Check your delivery to confirm that it is undamaged and complete based
on the delivery receipt.

Transportation In the event that there is damage or any discrepancies, please first
damages, etc. contact the shipper.

Storage or Keep the original packaging for storage or for the event that you need to
disposal of send the device back to Scansonic.
packaging If you cannot keep the packaging, please dispose of it in accordance with
the relevant national environmental regulations.

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 Set-up and Installation

4.2 Returns

Information
WARNING!
Hazardous residues!
• Clean the TH6D system before you send it back!
• When shipping the TH6D system back, be sure
that you first package it safely!
• Fill out the Contamination Declaration form.

Be sure to package the TH6D system safely when returning it for service
or repair. Proper packaging will protect service and shipping personnel
from any hazardous residual gases.

Cleaning If the TH6D system is extremely dirty, clean it and all its cable thoroughly.

4.3 Notes for set-up and installation

Overview
DANGER
Danger to life and limb!

The TH6D system should only be mounted and

operated by trained personnel.
Be sure to observe the following:

• You configuration should be installed on the

master machine only after all currents and
pressures are switched off.
• The facility operator should limit access to the
working area (the danger zone).
• Stop the automatic run mode by opening up the
protective disconnect or interlock mechanisms.
• The power supply for the processing devices
should be routed through the facility's emergency-
stop control circuit.
• The emergency-off mechanism and all other
control equipment must fulfil the requirements
stipulated in DIN IEC 60204-1 and DIN EN ISO
13849-1.

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 Set-up and Installation

4.3.1 Installation guidelines

Leave the TH6D By maintaining your Scansonic product in its original condition, you help
system in its us to replace or reproduce it more quickly. Operational malfunctions can
original result when additional components are installed on the TH6D system
condition which deviate from the approved configuration. We recommend avoiding
such additions!

Any structural changes made to the TH6D system will result in the
termination of Scansonic's warranty and liability!

Routing the Make sure that you preserve the motion capabilities of the TH6D system
cables and and master machine when routing the connecting cables and media lines.
media lines

4.3.2 Application environment

Overview
DANGER
Danger from laser radiation!

• Follow the specifications concerning the laser

radiation, as described in section 2.2!
• Always observe the proper safety procedures for
working with lasers!

CAUTION!
When operating in a humid environment, make sure that
the built-in safety glasses do not fog up.

The TH6D system is designed to be used in standard welding facilities or

laser processing cells. Thus it can be considered as a part of a laser
facility. Take all necessary protective measures in the danger zone. Access
to designated laser radiation areas must be restricted properly.
Observe the condensation and moisture specifications for the ambient
temperature and coolant water temperature. Sharp temperature
fluctuations can lead to condensation which can cause damage to the
device. Be sure to observe to information listed in the condensation table
found in Chapter 8 "Technical Data and Specifications".
The TH6D sensor head has a protection degree of IP64. Safety glass panes
in the TH6D sensor head and the safety glass unit provide protection from
dirt or splashed water during processing. Nevertheless, you should design
you processes and work conditions so that contaminants and splashed
water are minimized. Make sure that you use the protective packaging for
the TH6D sensor system when it is not in use (e.g., during maintenance or
storage).

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 Set-up and Installation

4.3.3 Cleanliness and cleaning

Overview
CAUTION!
Before each use of the TH6D system, make sure that the
safety glass unit is securely mounted to the TH6D sensor
head and that it is fitted with a clean safety glass!

NOTE!
As the quality of the seam detection decreases, the
likelihood increases that the optical elements will get dirty.

Dirty optical elements on the TH6D sensor head decrease the quality of
the seam detection. Only use sensor systems with clean built-in safety
glasses. Only use clean glass in the safety glass unit!
Please refer to the instructions for cleaning and replacement in Chapter 6.

Important Contact customer service if the safety glasses built into the TH6D sensor
head become dirty. Only Scansonic service technicians are authorized to
clean and repair the internal sensor modules.

Information The display showing the status of the measurement process (refer to
section 5.8) also provides information about the contamination on the
TH6D sensor head. A lower percentage indicates poorer quality seam
detection and dirtier optical elements.

4.3.4 Check-list for set-up and installation

Function The set-up and installation check-list contains starting points for inspecting
the TH6D system installation before initial use. We assume that you have
followed all safety notices and instructions found in this manual, and that
all training related to the installation was carried out.

The check list covers usage with a robot or master machine.

Check list • The check list is included in section 9.2.

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 Set-up and Installation

4.4 Set-up and installation

Overview This chapter describes how to connect the TH6D system in a production
facility and to a master machine.

Inspection Scansonic strongly recommends conducting a thorough inspection after

you have completely set-up and installed the TH6D system (i.e., before
first use).

Function • Inspecting the set-up and installation steps

• Ensuring that the TH6D system operates smoothly
• The check list for set-up and installation should be used as the
basis of the inspection

NOTE!
Follow the check lists for set-up and installation
found in section 9.2.

4.4.1 Tool centre point (TCP) and sensor origin

Overview The TCP, sensor origin and advanced tracking are used to determine the
tool position in relation to the TH6D sensor head.

TCP The tool position is described by the "tool centre point (TCP)". This is a
theoretical reference point defined at a suitable position on the tool in
relation to the work piece.

Sensor origin The "sensor origin" (S0) is used to specify the desired spatial position of
the TH6D sensor head. The sensor origin describes the centre of the
measuring range.

Advanced tracking The distance from the TCP to the sensor origin is referred to as the
"advanced tracking". This advanced tracking is necessary for determining
the position of the TCP in relation to the sensor origin during measurement
and processing.

Information Section 5.14.6 contains more information about calibration.

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 Set-up and Installation

Position of the The defined position of the sensor origin (S0) is 150 mm from the lower
sensor origin edge of the sensor head. (As shown in Figure 27.)
Please refer to the dimensioning sheet for your TH6D system and the
specifications found in 8.1 for more information.

Advanced
tracking

S0
S0

TCP

Figure 27: Sensor origin for the TH6D sensor head (CF variant)

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 Set-up and Installation

4.4.2 Tightening torque for screws

Overview
NOTE!
The enclosure for the TH6D sensor head is made of
aluminium. Be sure that you use the specified
tightening torques!

The following torque specifications and minimum screw-in depths pertain

to the screws on the TH6D sensor head.

Screw size Screw-in depth Torque

M3 3.5 mm 0.56 Nm

M4 4.5 mm 1.30 Nm

Note Installation screws are not included in the delivery.

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 Set-up and Installation

4.4.3 Earthing provisions

Allgemein
ATTENTION!
The TH6D sensor head must always be properly earthed
(grounded)!

There are two ways to earth the TH6D sensor head:

• Via the robotics interface,
• Or via the power supply.

It is possible to earth the TH6D process computer.

But it is not permitted to earth the TH6D sensor head via the TH6D
process computer. The Ethernet connection does not constitute an
electrical connection to the TH6D sensor head.

Earthing via the Note the following when earthing via the robotics interface:
robotics interface • Make sure that there is a metallic bond between the robot and
the TH6D sensor head. Only then will the TH6D sensor head be
connected to the robot's earth.
• Do not connect the THxD power cable shield to the earth on the
power supply (A) of the TH6D sensor head.

Variant 1

24V_Power
0V_Power
24V_LSK
Shield
0V_LSK

Figure 28: Earthing via the robotics interface, variant 1

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 Set-up and Installation

Variant 2 The robot's earth can also be connected with a cable to the earthing screw
(B) on the TH6D sensor head's housing (refer to Figure 29).

• Connect the TH6D sensor head with the robot.

• You can install an isolator (C) between the TH6D sensor head and
the robot.
• Connect the robot's earth with the earthing screw on the housing
of the TH6D sensor head.
• If this is the case, do not connect the THxD power cable shield
to the earth on the power supply (A) of the TH6D sensor head.

C
B

24V_Power
0V_Power
24V_LSK
Shield
0V_LSK

Figure 29: Earthing via the robotics interface, variant 2

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 Set-up and Installation

Earthing via the

WARNING!
power supply
Electric current can cause damage.
• Connect the welding power source with the
facility's earth.

Note the following when earthing via the power supply:

• If an isolator (C) is installed between the TH6D sensor head and

the robot, then the THxD Power cable shield must be connected
with the earth on the TH6D sensor head's power supply (A).

24V_Power
0V_Power
24V_LSK
Shield
0V_LSK

Figure 30: Earthing via the power supply

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 Set-up and Installation

4.4.4 Installation and basic positioning of the TH6D sensor head

Positioning and The installation of the TH6D sensor head in relation to the process should
installation be positioned as follows:

• In general: The TH6D sensor head should be attached in advance

of the tool (as shown in Figure 31).
• Distance to the surface of the work piece: 150 mm from the
sensor's lower edge (without the safety glass unit! – as shown
in Figure 27).
• The system must be able to travel around interference contours
presented by clamping jigs or other objects without touching them.
• When required, the TH6D sensor head can be mounted to the
master machine at an arbitrary angle to the surface of the work
piece.
• The angular position of the TH6D sensor head must allow sufficient
reflections to be recorded in the sensor measurement field so that
sufficient raw data is visible in THxDView.

Information Section 3.2.1 contains more information about the influence of reflections
on the work piece.

Figure 31 below shows an example of a torch connection. Note the

position of the TH6D sensor head.

5
2

3
4

S0
TCP
+y +x

Figure 31:: Position of the TH6D sensor head (example)

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 Set-up and Installation

Description of Item Description Item Description

components in
Figure 31 1 TH6D sensor head 5 Tool (MIG/MAG torch)

2 Safety glass unit 6 Master machine/robot

3 Simulated laser beams 7 TH6D cable kit

4 Inert gas nozzle 8 Simulated mounting adapter

for the TH6D sensor head

Orientation of the The precise orientation of the TH6D sensor head to the process must be
TH6D sensor head determined using the THxDView configuration software.
Instructions for orientation can be found in section 5.14 " Set-up
and configuration of the TH6D system", following the description
of THxDView.

4.4.5 Mounting the safety glass unit on the TH6D sensor head

Overview
NOTE!
Measurements during the (joining) process should only be
made when a safety glass unit with a clean safety glass
has been attached to the TH6D sensor head!

The safety glass unit (included in delivery) should be attached to the TH6D
sensor head in order to protect the sensor head while it is processing the
work piece. This protective glass unit includes a second protective glass,
which is positioned in front of protective glass panes that are built into the
sensor head.

Installing the • Align the safety glass unit with the shape TH6D sensor head (as
safety glass unit shown in Figure 32).
• Put the safety glass unit on the TH6D sensor head by inserting the
pins (1) into the corresponding holes.
• Press the safety glass unit against the TH6D sensor head until the
retaining springs click in with an audible click.

NOTE!
The safety glass unit is properly seated when its edges are
flush with the TH6D sensor head.

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 Set-up and Installation

Figure 32: Installing the safety glass unit

Protective plate A plate is mounted on the safety glass unit to protect against process
splatter.

NOTE!
You can adapt the plate to your particular application by
manually bending the tabs along the unit's plate so that
the protected area changes.

Caution: Do not bend the plate into the sensor's

measuring range! Check the positioning of the tabs in
the "Raw data" imaging area within THxDView!

Removing the • Pull the safety glass unit out of the TH6D sensor head's enclosure.
safety glass unit Remove in the opposite direction of installation.

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 Set-up and Installation

4.4.6 Mounting the cooling module on the TH6D sensor head

Overview The cooling block and heat sink for the cooling module are delivered as
individual parts. They must be mounted directly on TH6D sensor head.

Installing the
ATTENTION!
cooling module
Be sure that you use properly sized screws!

• Align the heat sink (4), as shown in Figure 33

• Slide the heat sink on the TH6D sensor head.
• Align the cooling block (3) with the holes in the heat sink. Attach
to the TH6D sensor head using the supplied screws and anti- anti
vibration washers (M3x18 (1) above and M3x12 (2) below)
• Torque: 0.6 Nm

2 3 4

Figure 33: Mounting the cooling module

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 Set-up and Installation

4.4.7 Connecting the Ethernet cable to the TH6D sensor head and process
computer

Overview
CAUTION!
Danger of surge voltage!
• Disconnect the power supply before connecting the
cable to the components!

In order to communicate, the TH6D sensor head must be connected with

the process computer via an Ethernet cable. This connection is described
below.

Connection details • Type (TH6D sensor head) M12 device connector (male plug, 4-
4
pole, shielded, D-coded)
• Type (TH6D process computer) RJ45 connector
• Cable designation: Ethernet Mxxxxxx (the number of your cable
configuration can be found in the list in section 8.3).

Figure 34: TH6D system – connecting the Ethernet cable

Connection Connect the cables according to the following assignments (as shown in
Figure 35):

Connection TH6D sensor head TH6D process computer Description

assignments
X5 to 11 Ethernet

X5
11

Figure 35:: Ethernet cable connection

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 Set-up and Installation

Connecting The male and female plugs should be connected in the following way:

To the TH6D sensor • Align the female plug according to the coding and insert into the
head X5 plug. Tighten by turning the coupling nut clockwise.

To the TH6D • Align the male plug according to the coding and insert into the
process computer socket (11) until you hear it click.

Disconnecting The male and female plugs should be disconnected in the following
manner:

From the TH6D • Turn the coupling nut counter-clockwise and pull the socket from
sensor head the plug (X5).

From the TH6D • Press the safety levers on the connector housing towards the plug.
process computer • Pull the plug out of the socket (11).

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 Set-up and Installation

4.4.8 Connecting the power supply to the TH6D sensor head

Overview
NOTE!
The TH6D sensor head is designed so that it cannot
be plugged in incorrectly. It is easy to connect with
existing power supplies.

A separate mains power supply should be used for the TH6D sensor head.
A suitable mains power supply is available from Scansonic. The socket on
the TH6D sensor head is located on the top of the sensor's enclosure.

Connection details
NOTE!
The shield of the power cord should be connected to the
protective earth (PE) terminal on the mains supply.

• Type (TH6D sensor head): M12 device connector (male plug, M12-
L, 4-pole, shielded, A-coded)
• Type (system controller): Open-ended cable for use with main
power supply from Scansonic
• Cable designation: Power Mxxxxxx (the number of your cable
configuration can be found in the list in section 8.3).

NOTE!
Power supply and laser protective circuit (0 V) are
electrically isolated from the system ground.

Power cable pin- Pin Colour Signal Designation

out assignments (M12)

1 Brown 0V_Power • Power supply

2 White 24V_Power • Power supply

3 Green 24V_LSK • Laser protective circuit

4 Yellow 0V_LSK • Laser protective circuit

Black Shield • Shield

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 Set-up and Installation

Connection Connect the cables according to the following assignments. (As shown in
Figure 36.)

Connection TH6D sensor head Customer

Customer-specific mains power
assignments supply unit

X4 to Refer to pin-out
pin

TH6D sensor head

X4

Mains
power
supply
unit

Figure 36:: Power supply on the TH6D sensor head

Connect with the • Align the female plug according to the coding and insert into the
TH6D sensor head X4 plug. Tighten by turning the coupling nut clockwise.

Disconnecting • Turn the coupling nut counter-clockwise

clockwise and pull the socket from
the plug (X4).

4.4.9 Connection for the cooling and purging air at the TH6D sensor head

Overview
WARNING!
Excessive pressure in the media lines can lead to
eye and ear damage or other injuries!
• Always wear the proper protective eye glasses, ear
protection, and clothing when changing
pressurized lines and hoses!!

CAUTION!
Be careful to avoid damaging the equipment!
• Follow the compressed air specifications for the
TH6D sensor head as described in section 8.4.

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 Set-up and Installation

NOTE!
The enclosure for the TH6D sensor head is made of
aluminium. Never allow water to run through the cooling
channels: this could lead to corrosion!

Connection PU 6 and PU 4 hoses (with diameters of 6 and 4 mm) are used to connect
the cooling and purge air to the TH6D sensor head.

• Model type: Quick-lock coupling

• The optimal quantity of purge air is based on the durability of the
safety glass in the safety glass unit. (We recommend max. 1 litre
per minute at max. 2 bar.)

Connection diagram Connect the hoses in the following manner:

X3
X2
X1

Figure 37: Connecting the cooling and purging air to the TH6D sensor
head

Connection Description Diameter

X1 Connection for safety glass purge air 4 mm

X2 Connection for cooling air for advanced 6 mm

tracking

X3 Connection for return of cooling air 6 mm

Description of • Insert the air supply line into the quick-lock coupling.
connections • To disconnect, press the coupling's pressure ring gently towards
the coupling and pull out the hose.

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 Set-up and Installation

4.4.10 Connecting the liquid coolants to the cooling module

Overview
WARNING!
Be careful to avoid damaging the equipment!
• Follow the liquid coolant specifications for the
cooling module as described in section 8.4.

ATTENTION!
The enclosure for the TH6D sensor head is made of
aluminium. Never allow water to run through the
cooling channels in the TH6D sensor head: this could lead
to corrosion!

Connection PU 6 tubing (with 6 mm diameter) should be used to connect the liquid

coolant to the cooling module. Section 8.4 contains more information
informa on
this subject..
subject.

Connection diagram Connect the hoses in the following manner:

X6
X7

Figure 38: Connecting the liquid coolants to the cooling module

Connection Description Diameter

X6 Connection (intake) for liquid coolant 6 mm

X7 Connection (outlet) for liquid coolant 6 mm

Description of • Insert the intake line into the quick-lock

lock coupling.
connections • To disconnect, press the coupling's pressure ring gently towards
the coupling and pull out the hose.

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 Set-up and Installation

4.4.11 Installing the TH6D process computer

Overview
CAUTION!
Pay attention to your cable lengths and
installation options!

The TH6D process computer can be installed at various positions on

mounting rails. (Additional mounting hardware is not included in the
delivery.)

Installation
NOTE!
Do not mount the TH6D process computer on a robot axis;
this could cause damages during operations.

However, a static installation to a robot foot or on a

transport trolley is possible.

• Mounting rails (1) have been pre-assembled

assembled to the bottom of the
TH6D process computer.
• The TH6D process computer should be installed in a clean
environment (e.g. an electrical cabinet) that is protected from
dust, dirt and water.
• For optimal heat dissipation, the TH6D process
proce computer should be
mounted in a vertical position on the mounting rails (be sure to
take the cable lengths into account).
• Make sure that the operating temperatures are not exceeded (refer
to section 8.5).

Figure 39:: Mounting rails for the TH6D process computer

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 Set-up and Installation

4.4.12 Connecting the power supply to the TH6D process computer

Overview
DANGER
Electrical shock danger – risk of injury!

• Disconnect the power supply for the production

facility before working on the TH6D system!

A power supply unit is included in the delivery and is used to supply power
to the TH6D process computer. The connection is located at the rear of the
TH6D process computer's case.

NOTE!
Power can also be supplied to the TH6D process computer
using an industrial top-hat rail. For more information on
power supplies, please contact your local service
representative.

Connection details • Type: DIN connector (female, 4-pin)

Connection Connect the cables according to the following assignment (as shown in
Figure 40):

Connection Mains power supply unit TH6D process computer

assignments
to 2

TH6D process
computer
2

Figure 40: Power supply on the TH6D process computer

Connecting • Align the plug according to its coding and insert in the socket (2).

Disconnecting • Pull the plug out of the socket (2).

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 Set-up and Installation

4.4.13 Connecting a user PC for the THxDView configuration software

Overview
CAUTION!
Danger of surge voltage!
• Disconnect the power supply before connecting the
cable to the components!

The TH6D system is configured with the THxDView software, which must
be installed on a user PC.
An Ethernet cable connecting the TH6D process computer must be
installed so that the TH6D system can communicate with the user PC.
This connection is described below.

Information Chapter 5 contains more information about THxDView.

Connection details • Only 100-BASE-T

T Ethernet (Fast Ethernet) is supported.
• Model type: RJ45 connector
• The number of your cable configuration can be found in the list in
section 8.3.

Connection Connect the cables according

according to the following assignment (as shown in
Figure 41):

Connection User PC TH6D process computer

assignments
Ethernet jack to 6

Ethernet
jack
6

Figure 41: Connecting the user PC for THxDView

Connecting • Align the male plug according to the coding and insert into the
corresponding socket until you hear it click.

Disconnecting • Press the safety levers on the connector housing towards the plug.
Pull the plug out of the socket.

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 Set-up and Installation

4.4.14 Overview of connections without the machine interfaces

Overview The base components should be connected according to Figure 42 and the
installation instructions provided in Chapter 4.

Section 4.4.9
X3

X5

Section 4.4.8
X2
X1

X4
6
Section 4.4.8

Section 4.4.12
11
2
Section 4.4.13

Figure 42: TH6D system – overview of connections without machine interfaces

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 Set-up and Installation

4.5 Connecting the machine-dependent

machine dependent auxiliary modules

4.5.1 Connecting the analogue-digital

analogue interface (ADF)

Overview The communication links for the TH6D process computers and the
customer's Fieldbus can use various implementations.
The analogue-digital
analogue digital interface is required when using analogue and digital
interfaces to communicate with the TH6D process computer.

A list of switchable system functions is included with the delivery of the

product and also provided in section 8.2.

Analogue-digital Figure 43 shows the standardized construction of the analogue-digital

analogue
interface – ADF interface (ADF). The interface consists of a bus coupler, digital and
analogue input/output terminals and one end terminal.

BC DI DO AO ET

Figure 43: TH6D analogue-digital

digital interface (standard)

Bus terminal types The components and the bus terminals types are colour-coded.
colour

Designation Component Colour Bus terminal Inputs/

type outputs

BC Bus coupler - - 1

ET End terminal - - 1

DI Digital In Yellow Digital input (DI) 16

DO Digital Out Red Digital output (DO) 8

AO Analogue Blue Analogue output 4

Out (AO)

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 Set-up and Installation

CAUTION!
Danger of surge voltage!
• Disconnect the power supply before connecting the
cable to the components!

Connection details • Model type: RJ45 connector

• Cable designation: Patch cable Mxxxxxx (the number for a
replacement cable can be found in the list in section 8.3).

Connecting the Connect the ADF to the TH6D process computer using the supplied
ADF Ethernet cable according to the following assignment:

Connection ADF TH6D process computer

assignments
Bus coupler (BC) to 10

TH6D process
computer

10

Figure 44: Connecting the ADF to the TH6D process computer

Connecting • Align the male plug according to the coding and insert into the
socket until you hear it click.

Disconnecting • Press the safety levers on the connector housing towards the plug.
• Pull the plug out of the socket (10).

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 Set-up and Installation

4.5.2 Connecting the power supply to the analogue-digital interface

Overview A connection to a bus coupler module is used to supply power to the

analogue-digital interface. A power supply unit of at least 24-V is required.

Information Appropriate power supplies can be purchased from Scansonic as needed.

Connection There are two connection methods:

options • The bus coupler and the bus terminals are supplied by connecting
two external power sources.
• The bus coupler and the bus terminals are supplied in parallel
(pass through) with one external voltage source.

DANGER
Electrical shock danger – risk of injury!
• Disconnect the power supply before working on
the analogue-digital interface!

Connecting two Connect the two power sources with cables as follows (as shown in Figure
external power 45):
sources

24 V 24 V Earthing
Bus coupler Bus terminals
Figure 45: Power supply on the analogue-digital interface

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 Set-up and Installation

Parallel connection Connect one power source with cable as follows (as shown in Figure 46):
from an external
voltage source

Pass-though
connection of 24 V
to bus coupler

24 V
Bus terminals Earthing

Figure 46: Parallel power supply connection to the analogue-digital

interface

Connecting • Attach wire-end ferrules to the cable ends and insert into the
corresponding socket.

Disconnecting • Pull the cable end out of the socket.

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 Set-up and Installation

4.5.3 Connection overview with connected ADF

Overview The base components should be connected according to Figure 47 and the
installation instructions provided in sections 4.4, 4.5.1 and 4.5.2.
Section 4.4.9
X3

X5

Section 4.4.8
X2

X4
X1

Section 4.5.2
Section 4.5.1
6
Section 4.4.8

10

Section 4.4.12
11
2
Section 4.4.13

Figure 47: TH6D system – overview of connections with ADF

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 Set-up and Installation

4.5.4 Connecting the Fanuc interface

Overview
CAUTION!
Danger of surge voltage!
• Disconnect the power supply before connecting the
cable to the components!

Make sure that each Fanuc robot being used has the proper hardware and
software configuration for sensor management.

Connection details • Ports (Fanuc controller, e.g. RJ-30iA): CD38A or CD38B

• Model type: RJ45 connector
• Cable specification: CAT 6 A
• Cable designation: Patch cable Mxxxxxx (the number of your
cable configuration can be found in the list in section 8.3).

NOTE!
For more information, please contact your Fanuc
service representative.

Connection Connect the cables according to the following assignments.

Connection TH6D process computer Fanuc controller

assignments
5 to CD38A or CD38B

5
5

Figure 48: Connecting the Fanuc interface

Connecting • Align the male plug according to the coding and insert into the
socket until you hear it click.

Disconnecting • Press the safety levers on the connector housing towards the plug.
• Pull the plug out of the corresponding socket.

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 Set-up and Installation

4.5.5 Connection overview with connected Fanuc interface

Overview The base components should be connected according to Figure 49 and the
installation instructions provided in sections 4.4 and 4.5.4.

Section 4.4.9
X3

X5

Section 4.4.8
X2

X4
X1

6
Section 4.4.8

Section 4.5.4

Section 4.4.12
11

CD38A /
CD38B
2
Section 4.4.13

Figure 49: TH6D system – overview of connections with Fanuc interface

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 5. Initial Commissioning and
Operation
This section describes the initial commissioning and operation of the
TH6D system.

5.1 Information about the initial commissioning and

operation ........................................................................ 5-3
5.2 Switching the TH6D system on and off ............................ 5-4
5.3 The graphical user interface: THxDView ......................... 5-5
5.3.1 System requirements for THxDView ................................. 5-5
5.3.2 Requirements for installing THxDView .............................. 5-6
5.3.3 Installing THxDView ....................................................... 5-6
5.4 Using THxDView ........................................................... 5-10
5.4.1 Starting up and exiting the THxDView software ............... 5-10
5.4.2 Overview of the user interface ....................................... 5-12
5.5 Menu bar ...................................................................... 5-14
5.6 Image area ................................................................... 5-15
5.6.1 "Raw Data" main tab .................................................... 5-15
5.6.2 "Evaluation" main tab ................................................... 5-16
5.7 Reports area ................................................................. 5-17
5.7.1 Errors and warnings ..................................................... 5-17
5.7.2 Events ........................................................................ 5-17
5.8 System Status area ....................................................... 5-18
5.8.1 Status of the network connection ................................... 5-18
5.8.2 Status and change of the operating mode ....................... 5-18
5.8.3 Status of the measurement process ............................... 5-19
5.8.4 Status of the active job ................................................ 5-21
5.9 Information area .......................................................... 5-22
5.9.1 Information area – main tab Measurements .................... 5-22
5.9.2 Information area – main tab sketch ............................... 5-23
5.10 Parameter configuration area ....................................... 5-25
5.11 Parameter configuration area – "Profile" tab ................ 5-25
5.11.1 Seam Pattern tab......................................................... 5-26
5.11.2 Seam Pattern tab – templates with seam pattern profiles . 5-27
5.11.3 Seam Pattern tab – parameter description ...................... 5-32
5.11.4 Camera tab ................................................................. 5-42
5.11.5 Camera tab – parameter description .............................. 5-42
5.11.6 Calibration tab............................................................. 5-43

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 5.11.7 Calibration tab – parameter description .......................... 5-44
5.11.8 Process Control tab ...................................................... 5-45
5.12 Parameters area – main System tab .............................. 5-46
5.12.1 Job List tab ................................................................. 5-46
5.12.2 Machine Interface tab ................................................... 5-48
5.12.3 Configuration tab ......................................................... 5-49
5.13 Interfaces and associated parameters .......................... 5-52
5.13.1 Machine interface – analogue-digital correction ............... 5-52
5.13.2 Machine interface – Motoman reference path .................. 5-54
5.13.3 Machine interface – Fanuc Ethernet ................................ 5-60
5.13.5 Machine interface – IF UDP Data .................................... 5-64
5.14 Set-up and configuration of the TH6D system ............... 5-65
5.14.1 User login ................................................................... 5-65
5.14.2 Establishing a network connection with a TH6D system .... 5-67
5.14.3 Selecting the language ................................................. 5-71
5.14.4 Selecting the set-up operating mode .............................. 5-71
5.14.5 Positioning the TH6D sensor head .................................. 5-72
5.14.6 Tool calibration ............................................................ 5-75
5.14.7 Measurement process optimization – changing camera
settings ...................................................................... 5-79
5.14.8 Optimizing the measurement process – changing
parameters ................................................................. 5-80
5.14.9 Setting up profiles and creating jobs .............................. 5-81

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 Initial Commissioning and Operation

5.1 Information about the initial commissioning and operation

General
CAUTION!
information
Follow all the information in Chapter 4 during the
installation and assembly of the TH6D system!

The commissioning and operation have been divided into hardware- and
software-related procedures.

Software The THxDView software must be installed on a PC for the initial

commissioning of the TH6D system. Section 5.3 describes the software.

Hardware Section 5.14 describes the general operation of the TH6D system.

NOTE!
Follow the check lists for set-up and installation
found in section 9.2.

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 Initial Commissioning and Operation

5.2 Switching the TH6D system on and off

Overview
CAUTION!
The THxDView configuration software must be installed on
a separate PC. This user PC and THxDView are thus not
affected when the TH6D system is switched on or off.

The TH6D sensor head and the TH6D process computer can be switched
on/off individually or as a complete TH6D system via the main switch.
Since the interface to the supply voltage can have separated
configurations, it may be possible to use more than one main switch.

Turn on
NOTE!
Three signal beeps can be heard as the TH6D process
computer is booting up. A double beep can then be heard
after the computer has booted up successfully. Any
deviation from this beep tone sequence indicates an error.

Sequence for • In general: Switch on the TH6D sensor head and the TH6D
switching on process computer simultaneously.

Switch-on time • TH6D system: approx. 1 minute

Information about During the initial commissioning, the TH6D process computer may be in
switching on standby mode after the power supply is switched on. Thus it may need to
be switched on manually.

If the status LED on the ON/OFF switch (7) of the TH6D process computer
is red, press the switch briefly to start up.

Section 3.5.2 contains more information on the status displays and

position of the ON/OFF switches.

NOTE!
If the power supply is interrupted to the TH6D process
computer while it is switched on, then you should switch
the TH6D sensor head and the TH6D process computer
back on.

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 Initial Commissioning and Operation

Information The user PC running THxDView can be switched on and off separately
about from the TH6D system. If the TH6D system is switched off before
disconnections THxDView, then you will notice the disconnection in the THxDView
software. The system status displays the message "No System". When
switched back on, THxDView automatically connects to the previously
connected TH6D system. This can be checked with the connection status
in THxDView. (Refer to section 5.8.)

Switching off • Follow the information and instructions about archiving data as
described in section 5.14.9 before you switch off the TH6D
system.
• Then the TH6D system can be turned off using the main switch.

5.3 The graphical user interface: THxDView

Overview The THxDView GUI software is used to set and monitor parameters while
working with the TH6D system.

NOTE!

THxDView is licensed software!

Information Section 5.14 contains set-up instructions.

5.3.1 System requirements for THxDView

Program THxDView, version 1.4.2

PC hardware Standard PC/IPC hardware, Pentium 4 processor or faster, min. 2.0 GHz,
min. 1 GB RAM, screen resolution of 1024 x 768

Operating Windows XP, Vista, Windows 7

systems

Memory 512 MB RAM (1024 MB RAM recommended)

10 MB hard disk space

NOTE!
A local Java application is installed with the software. This
Java application will also be removed if you uninstall
THxDView.

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 Initial Commissioning and Operation

5.3.2 Requirements for installing THxDView

Prerequisites
CAUTION!

Make sure that THxDView is not blocked by any security

programs running on the user PC.

The following are required in order to install and use the THxDView
software:

• Administrative access rights on the user PC

• Compatibility with the firewall and anti-virus software installed on
the user PC
• Establishment of a peer-to-peer connection
• Network connection settings made by the administrator account

5.3.3 Installing THxDView

Overview
NOTE!
The illustrations used here to show the software and
installation may vary visually depending on your operating
system. However the content and functionality will be
similar.

Starting the Insert the installation CD (included in the delivery) in your PC.
installation The installation should start automatically. If automatic start is deactivated
on the PC, you will need to follow the instructions below:

Otherwise • Open up Windows Explorer or click on the My Computer icon.

• Double click on the CD/DVD drive folder.
• Search for the file with the following name:
"THxDView_Setup_x.xx-xxxxxx.exe"
• Double click on the file to start the installation.

Initialization The installation begins with the window shown in Figure 50.

• Choose the language of installation and click on the „OK“ button to

continue

Figure 50: THxDView – initializing the installation

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 Initial Commissioning and Operation

Installation The following window details which software components will be installed.
information (As shown in Figure 51.)

• Click on the "Next" button to continue with the installation or

• Click on "Cancel" to cancel the installation.

Figure 51: THxDView – installation information

License The license agreement comes next. (As shown in Figure 52.)
agreement
• Read the license agreement in its entirety.
• Click on the "I Agree" button in order to accept the terms of the
license agreement and start the installation, or
• Click on "Cancel" if you do not accept the license terms. The
installation will then be aborted.

Figure 52: THxDView – starting the installation

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 Initial Commissioning and Operation

Changing the You can change the pre-set installation directory as follows: (As shown in
installation path Figure 53.)
• Click on the "Browse" button (1).

Figure 53: THxDView – changing the installation directory

Selecting the • Select a directory on your PC or network from the window (as
installation shown in Figure 54) and then click on "OK".
directory • Click on "Install" to continue with the installation (as shown by 2 in
Figure 53).

Figure 54: THxDView – selecting the installation directory

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 Initial Commissioning and Operation

Progress of The required files are now copied to the hard drive. The status bar shows
installation the progress. (As shown in Figure 55.)

Figure 55: THxDView – installation progress

Finishing the The installation ends with the windows shown in the illustration. (As shown
installation in Figure 56.)
• Click on the "Finish" button.

Figure 56: THxDView – installation is finished

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 Initial Commissioning and Operation

5.4 Using THxDView

Overview The THxDView configuration software is used to set and monitor

parameters while working with the TH6D system.

NOTE!
The user PC's subnet must be set to match the IP address
of the TH6D process computer before any connection
between the two computers can be established.

5.4.1 Starting up and exiting the THxDView software

Starting • Start THxDView using the shortcut created on the desktop (as
THxDView shown in Figure 57).

Figure 57: THxDView – the desktop icon

Otherwise • From the Windows Start menu, find THxDView under the following
sub-menu:
scansonic \ THxDView \ THxDView

Start-up window THxDView starts with the following window. (As shown in Figure 58)

Figure 58: THxDView – the start-up window

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 Initial Commissioning and Operation

User login You must first login before you can work with THxDView or change
settings.

Information Section 5.14.1 contains more information about the user login.

Exiting
CAUTION!
THxDView
Data loss is possible!

• Make sure to save any changes you made to the

parameters before you exit THxDView!
• More information can be found in section 5.14.9.

• Click on the "Exit" button (in upper right, as shown in Figure 59)
in the opened window in order to exit.

Figure 59: Exiting THxDView

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 Initial Commissioning and Operation

5.4.2 Overview of the user interface

Overview The user interface is divided into five different areas.

Window areas No. Designation No. Designation

1 Menu bar 4 System status area

2 Image area 5 Information area

3 Reports area 6 Parameter configuration

area

6
1

2 5

3 4

Figure 60: THxDView – user interface

Brief summary The following list gives a brief summary of the user interface areas in the
THxDView software.

Menu bar The menu bar (1) contains options for settings (refer to section 5.5):

• Logging in • Help
• Extras • Selecting a system

Image area The image area (2) allows you to choose between two different methods
for representing the laser beams on the work piece:

• Raw data • Evaluation

(refer to section 5.6.1) (refer to section 5.6.2)

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 Initial Commissioning and Operation

Reports area The report area (3) displays:

• Errors and warnings • Events (section 5.7.2)

(section 5.7.1)

System status The system status area (4) shows the status of the TH6D system. The
area following information is displayed:

• Network connection bet- • Status of the active measure-

ween the TH6D process ment (section 5.8.3)
computer and the user • Active job (section 5.8.4)
PC (section 5.8.1)
• Operating mode (section
5.8.2)

Information The information area (5) informs about system parameters and provides
area help for the configuration. The following information is displayed:

• Measurements • Sketch (section 5.9.2)

(section 5.9.1)

Parameter Parameters can be set in the parameter configuration area (6). This area
configuration is divided into the main tabs:
area

• Profiles (section 5.11) • System (section 5.12)

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 Initial Commissioning and Operation

5.5 Menu bar

Menu bar The following additional THxDView functions can be selected from the
menu bar.

Figure 61: THxDView – menu bar

Login The "Login" option allows you to select an access level for users of the
TH6D system. More information can be found in section 5.14.1.

Extras The "Extras" option allows you to change the language settings.

Help The "Help" option allows you to view the system information. (As shown
in Figure 62.)

Figure 62: THxDView – program information

Selecting a The "Select System" option allows you to manage the sensor systems,
system connect or disconnect to a TH6D system. If multiple TH6D systems are
visible on the network, they will be displayed here. It is not possible to
connect THxDView simultaneously with multiple TH6D systems.

Section 5.14.2 contains more information about selecting the TH6D

system.

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 Initial Commissioning and Operation

5.6 Image area

5.6.1 "Raw Data" main tab

"Raw Data" main The "Raw Data" tab shows the laser lines resulting from the preliminary
tab evaluation in the TH6D sensor head. (As shown in Figure 63.)
The white lines indicate the edges of the work piece. The yellow dots
indicate where a seam has been detected (seam points = SP).
The laser lines are projected from the TH6D sensor head out towards the
camera's field of view. Since the camera in the TH6D sensor head is
protected against extraneous light by a narrow-band optical filter, only
those areas of the work piece surface which are illuminated by the laser
lines are visible.

The coordinates for the "Raw Data" sensor image are defined as follows:
• ∆X = gap between the laser lines
• ∆Y = direction lateral to x
• ∆Z = height

SP
+z

-z

+y -y

Figure 63: Image area – raw data (example with V-seam)

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5.6.2 "Evaluation" main tab

"Evaluation" The "Evaluation" tab shows the results of the analysed raw data. This
main tab provides the user with information on the lateral and vertical positioning
to the joint. (Refer to Figure 64 and Figure 65.)

Possible • Measuring inactive

displays, with • The red lines indicate the
example of V- laser lines recorded by the
camera.
seam

Figure 64: Image area – analysis,

measuring inactive

• Measuring activated
• The green lines indicate
those sections of the laser
lines recorded by the
camera that can be
analysed.
• The measurement points
on the detected seam are
marked in yellow.

Figure 65: Image area – analysis,

measuring activated

Note
NOTE!
Flickering green lines and yellow dots indicate locations
with insufficient seam detection. Fine tuning of the
settings in THxDView can help fix this.

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 Initial Commissioning and Operation

5.7 Reports area

5.7.1 Errors and warnings

Overview The "Errors and Warnings" section of the Reports area can be found in the
lower left part of the THxDView window. This section displays errors,
warnings and additional information. (As shown in Figure 66)

Figure 66: Reports area – Errors and Warnings (example)

Information A list of possible information, warning and error messages is given in

section 7.

5.7.2 Events

Overview Logged system events are displayed in the "Events" section of the
Reports area. This section lists successful and unsuccessful save/delete
actions, for example.

Figure 67: Reports area – Events (example)

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5.8 System Status area

Overview The "System Status" area is located in the lower right of the TXxDView
window. It displays the status of the TH6D system. This area displays the
network connection between THxDView and the TH6D process computer,
the operating mode, the active measurement process and the
composition of the active job.

Figure 68: THxDView – "System Status" area (example)

5.8.1 Status of the network connection

Overview The current status of the network connection between THxDView and the
TH6D process computer is displayed in the left section of the "System
Status" area. (Refer to the marked area in Figure 69.)

Figure 69: THxDView – "System Status", network connection (example)

Possible status • Connection is successful • Could not connect

• Displays the connected with the discovered
TH6D process computer TH6D process
computer

• No TH6D process • Searching for a TH6D

computer found process computer
• No TH6D process • Search is repeated
computer is connected to periodically
the user PC
• Network communication
is blocked by THxDView

5.8.2 Status and change of the operating mode

Overview The current status of the operating mode is shown in the second (from
left) section in the "System Status" area.

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 Initial Commissioning and Operation

Figure 70: THxDView – system status, operating mode

Possible status • Automatic mode • Set-up mode

• No TH6D process computer found

• No TH6D process computer is connected to the user PC
• Network communication is blocked by THxDView

Description of Operating mode Description

operating modes
Automatic • Operations are carried out automatically by the
facility controller (robots).
• System functions can be monitored.
• Functions cannot be manually switched within
THxDView.
• System parameters cannot be changed.
• By default, automatic mode is enabled when
THxDView is started up.
• A reduced number of measured values is trans-
ferred to THxDView.

Set-up mode • THxDView is used to configure the system.

• System functions and parameters can be
changed manually.
• Measurements are displayed within THxDView.

Changing the
CAUTION!
operating mode
It is not possible to change modes during active
processing in automatic mode! Wait until the
program has finished.

The status display is also a button that is used to switch the operating
mode.
• Click on the button to switch back and forth between automatic
mode and set-up mode.

5.8.3 Status of the measurement process

Overview The current status of the measuring process is shown in the third (from
left) section in the "System Status" area. (Refer to the marked area in

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 Initial Commissioning and Operation

Figure 71.)

Figure 71: THxDView – system status, measuring

Possible status • Measuring • Measurement was stopped

activated • Displays the quality of the
measuring process in percent
(in this case 100%)
• Displays the largest contiguous
measurement error, counted
in images (here 0)

• TH6D process computer was not found

• TH6D process computer is not connected to the user PC
• THxDView network communication is blocked

Displays the The displays for the quality of the measuring process and the
quality of the corresponding largest contiguous measurement error depend on the
measuring particular application. Two important factors influencing this are the
process shape of the work piece and the measurement path across the work
piece. A definitive conclusion about measuring quality differences can
only be made by comparing the measurements from identical test pieces
and analysing the measurement data.

Measuring It is only possible to manually activate/deactivate the measuring process

manually while in set-up mode. The status display also serves as a button for this
activated / function.
deactivated • Click on the button to activate or deactivate a measurement
process.

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 Initial Commissioning and Operation

5.8.4 Status of the active job

Overview The status of the active job is shown in the fourth (from left) section in
the "System Status" area. (As shown by the marked area in Figure 72.)
This status is visible in automatic mode and set-up mode.
In this example, the active job includes the seam pattern profile
"a1_seam", the camera profile "a1_camera", the calibration profile
"a1_calibration" and the process control profile "a1_process_control".

Figure 72: THxDView – system status, job

NOTE!
The TH6D sensor head is not activated when the TH6D
system is in automatic mode and receives no job number
from the robot controller.

Possible status • Job is active

• Displays the active job compilation
• Manual mode (P)

• TH6D process computer is in automatic mode

• No job is selected here – so the display is red and
(0)

• TH6D process computer is in automatic mode

• Job is selected (here, job 2)
• Displays the active job compilation ("job
number")

• TH6D process computer was not found

• TH6D process computer is not connected to the
user PC
• THxDView network communication is blocked

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5.9 Information area

Overview The information area contains the main tabs "Measurements" and
"Sketch". These tabs inform about measured results and the system
states of TH6D-sensor system and serve as a guide for setting
parameters. Both tabs are explained in the following chapter.

5.9.1 Information area – main tab Measurements

Overview The main "Measurements" tab summarizes the values measured by the
TH6D system. According to the geometry of the work pieces, the values
change dynamically during the measurement. (As shown in Figure 73.)

NOTE!
The measured values are only displayed while in set-up
mode. No measurements are displayed while in automatic
mode.

Figure 73: Parameters area – display of measurements (example)

Displayed The measured values displayed by the sensor system are related to the
measurements sensor coordinate system which influences the process or the
position/track corrections.
• Process influences: gap width, step height (mismatch), surface
• Position influences: ∆x, ∆y, ∆z,A, B, C (left / right)

Information
CAUTION!
Output data does not need to match the data sent to the
robot! It is transformed based on the defined machine
protocol.

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5.9.2 Information area – main tab sketch

The main The "Sketch" tab in the information area provides graphic support to help
"Sketch" tab in you with parameter changes in the "Parameter configuration area". The
the graphical display can be used as a guide for interpreting the
information area corresponding parameter.

NOTE!
Explanatory diagrams are not yet available for all
parameters.

The example in Figure 74 shows a diagram to explain the angle

parameter setting (on the left).

Figure 74: Information area – diagram (example for adjusting the angle)

Structure The main sketch tab is divided into two sections. In the upper section
examples of the currently selected seam pattern profile are shown. At the
bottom of the section the selected parameter is explained graphically.

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 Initial Commissioning and Operation

By double clicking on the profile or parameter name, a separate window

with an enlarged detail illustration opens.

Figure 75:: Information area - Detailed view of parameters

About the
NOTE!
parameter values
The default values and allowed value ranges are shown
when a parameter is selected.

When selecting or modifying parameters, the default values and the

allowable value range is shown above the tab label as a guide. (Refer to
the example in Figure 76)

Figure 76: THxDView – Information about parameters

Information Sections 5.11 and 5.12 describe the parameters and their functions.

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 Initial Commissioning and Operation

5.10 Parameter configuration area

Overview The "Parameter configuration area" (as shown in Figure 77) consists of
three tabs:

• Profile • System

Figure 77: THxDView – parameter configuration area

These main tabs allow you to specify and change parameters in order to
optimize the seam tracking. The functions of each main tab and their
associated sub-tabs are described below.

5.11 Parameter configuration area – "Profile" tab

"Profile" tab The seam detection is configured in THxDView using four profiles. They
can be selected using the "Profile" tab within the parameter configuration
area. Specific parameters can be activated, deactivated, or assigned
values for each of these profiles. (As shown in Figure 78)

Profiles No. Designation Description

1 Seam pattern Setting the seam parameters

2 Camera Setting the camera parameters

3 Calibration Setting the calibration data

4 Sequence Setting the machine data

controller

1 2 3 4

Figure 78: THxDView – parameter configuration area – profiles

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5.11.1 Seam Pattern tab

Overview The "Seam Pattern" tab allows you to select pre-defined seam pattern
profiles (templates). These templates contain specific parameters for
recording the seam shape.

By changing the parameters in the pre-designed templates, it is possible

to create custom seam pattern profiles.

Figure 79: THxDView – Seam Pattern tab

Information Section 5.11.3 describes the parameters contained in the seam pattern
profiles.

More information about creating and saving custom stitch patterns can be
found in section 5.14.9.

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 Initial Commissioning and Operation

5.11.2 Seam Pattern tab – templates with seam pattern profiles

Overview
NOTE!
Pre-defined seam pattern profiles are marked with the
word "(template)" in their profile names. Saved
customized profiles contain the name of the template on
which they were based.

THxDView has various templates for different seam patterns. The user
can select a template that matches his particular application. The
parameter settings for the selected template can then be used to create
the customer-specific seam pattern profile. This profile must be saved
under a unique suitable name.

NOTE!
Changed seam pattern templates must be saved under a
different name! When restarting the TH6D system, the
default values are re-loaded into the pre-defined
templates.

Templates for the A drop-down list in the "Seam Pattern" tab allows you to select from the
seam pattern following templates for seam pattern profiles. (As shown in Figure 80)
profiles
• Open edge • V-Area • TB-Area
• Overlap seam • HY-seam • M-Depth
• Tailored blank • U-Seam
• V-seam • HU-seam

Figure 80: THxDView – selecting the seam pattern profile

Information
NOTE!
The "Sketch" information area contains helpful information
describing the parameters.

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 Initial Commissioning and Operation

Open edge The "open edge"" seam pattern profile specifies a special form which can
be used for all processes that run parallel to a work piece edge.

Example After cutting glass, the edge can be ground or an adhesive can be applied
application to the work piece edge in parallel.

Figure 81: THxDView – seam pattern template for an open edge

Overlap seam The "overlap seam"" seam pattern profile can be used in a process where
the work piece edges overlap. Figure 82 shows an example of the overlap
joint.

Figure 82: THxDView – seam pattern template for an overlap seam

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 Initial Commissioning and Operation

Tailored blank The "tailored blank" seam profile is an all-purpose template for other
seams that are not defined here. All parameters in this seam pattern
profile can be changed.

a
Gap a Offset d

Example with gap a

Figure 83: THxDView – seam pattern template for a tailored blank

TB-Area The seam sample profile "TB-Area" is suitable for geometries which are
not defined as a standard seam pattern.

Figure 84: THxDView – seam pattern template for a TB-Area

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 Initial Commissioning and Operation

V-seam The seam sample profile "V-seam" can be used in applications where the
seam has been prepared or where V-shaped
shaped work pieces are positioned
next to each other.

Figure 85: THxDView – seam pattern template for a V-seam

V

Information Shiny surfaces reflect in multiples directions so that there is some

ambiguity when the images are evaluated. Section 3.2.1 contains more
information about avoiding
g such multiple reflections.

V-Area The seam pattern template "V area" is suitable for applications of thick
sheet metal, and for the multi-pass
pass welding where the seam area is
needed to calculate the number of layers.

Figure 86: THxDView – seam pattern template for a HV-seam

HV

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 Initial Commissioning and Operation

HY-seam Pending

Figure 87: THxDView – seam pattern template for a HY-seam

U-seam Pending

Figure 88: THxDView – seam pattern template for a U-seam

HU-seam Pending

Figure 89: THxDView – seam pattern template for a HU-seam

M-Depth The seam pattern template "M-depth" is suitable for applications where
only the distance measurement is needed to create an even surface. This
stitch pattern template is not part of the standard software.

Parameter
NOTE!
The "Sketch" area contains helpful information describing
the parameters for the seam pattern profiles.

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 Initial Commissioning and Operation

5.11.3 Seam Pattern tab – parameter description

Parameter
NOTE!
The particular parameters contained within a seam pattern
profile vary according to each profile.

The parameters described below can be used and changed in order to

optimize a seam pattern profile. Not all parameters are included in each
seam pattern profile.

Line quality Depending on the roughness of the work piece surface, there may be
interruptions in the laser lines shown under the "Raw Data" tab. The "line
quality" parameter is adapted to the surface roughness and influences the
analysis and representation of the reflected laser lines.

You can use the illustration in the "Evaluation" area to evaluate the
importance of changing this parameter. The parameters are selected
using a drop-down list. The following values can be selected:

• Standard (baseline value):

The "standard" baseline value is somewhere between fine and
medium; it is a good compromise for many typical applications.
• Fine:
Can be set when the work piece has a very smooth surface and
the laser lines (based on the surface reflection and the TH6D
sensor head) have few or no interruptions.
• Medium, coarse or very coarse:
Can be set when working with less smooth surfaces, when
interruptions in the laser line are being created by a rough surface
so that non-aligned segments are being shown in THxDView.
The example (refer to Figure 90: A, B and C) illustrates the line quality
function.

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 Initial Commissioning and Operation

Example of the line In Figure 90, the "Evaluation" image area shows (A) the raw image of a
quality of a overlap rough surface of the work piece. No changes to the parameters are made
seam here.
In Figure 90, a line quality of "fine" has been selected (B) for this work
piece surface. There are many scattered line elements visible here. This
makes the seam detection more difficult.
In Figure 90, a line quality of "very coarse" has been selected (C) for this
work piece surface. Multiple line elements have been merged together so
the seam detection is functioning well.

A
Raw data

B C
Evaluation – "Fine" line quality Evaluation – "Coarse" line quality

Figure 90: THxDView – line quality parameters (examples)

Used for seam • Open edge • V-seam • U-Seam

pattern profiles • Overlap seam • V-Area • HU-seam
• Tailored blank • HY-seam • TB-Area

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 Initial Commissioning and Operation

Pattern location "Pattern location" describes the arrangement of work pieces (sheets) at
the joint. It determines which side the upper sheet is on. The value "any"
is suitable for a first test run. It should, however, be limited by the
specification "upper sheet is right" or "upper sheet is left".

Used for seam • Open edge • HY-seam • TB-Area

pattern profiles • Overlap seam • U-Seam
• Tailored blank • HU-seam

Reference area A "reference area" is specified to determine an area to the left and right
of the joint line where the measured values can be calculated. The
reference area is also required for measuring the angle information.
By default, the "sensor" setting does not have a reference area specified.
The measured mismatch and gap width values are evaluated in the
sensor coordinate system. So when the TH6D sensor head is aligned
diagonally to the work piece surface, these measurements do not match
up with reality.

Information on the For the "overlap seam" pattern, if the TH6D sensor head is aligned
overlap seam diagonally to the joint (as shown in Figure 91 A and B), then the
measured mismatch is specified as the gap. If this gap is greater than 0.5
mm, then a reference area must be selected. Otherwise there will be no
seam detection.

A B

Gap

+z +z
+y +y
+x +x

Figure 91: THxDView – reference area parameter at the overlap seam

Used for seam • Overlap seam • V-Area • HU-seam

pattern profiles • Tailored blank • HY-seam • TB-Area
• V-seam • U-Seam

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 Initial Commissioning and Operation

TCP alignment "TCP alignment" is used to specify the precise position of the seam point.
The point may lie on the left or right end, or between the end points and
the laser lines.

left middle right

Figure 92: THxDView – TCP alignment parameters

Used for seam • Open edge • V-seam • U-Seam

pattern profiles • Overlap seam • V-Area • HU-seam
• Tailored blank • HY-seam • TB-Area

Depth "Depth" is used to specify the distance from the top edge to the bottom
edge of the work piece. The depth parameter must be specified so that
the TH6D system can properly calculate the area.

Information on the When using the "HV-seam" pattern and when the TH6D sensor head is
HV-seam aligned diagonally to the joint, the seam is not detected over the entire
depth of the work piece joint. Instead, the detection is carried out until
the start of mutually parallel work piece edges of the joint.

+z
+y
+x

Figure 93: THxDView – depth parameter, with the example of an HV-

seam

Used for seam • HY-seam • TB-Area

pattern profiles • U-Seam
• HU-seam

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 Initial Commissioning and Operation

Angle The "angle" setting (left/right) is used to help avoid detecting false joints
left/right on the work piece. You can eliminate multiple reflections in the evaluation
by specifying the correct inclinations of the laser lines. This results in a
more stable seam detection process.
It must be possible to distinguish between the left and right angle since
the angle is being measured from the joint line to the adjacent level. In
the lines "angle left/right", the left value represents the smallest border
while the right value
e represents the largest border of the angular range.

Note The "angle left/right" parameters refer to the two

two-dimensional
representation of the seam profile in the "Evaluation
Evaluation" image area. The
"Measurements" parameter range does not display the measured lateral
angle C (left and right) for the seam profile.

Figure 94: THxDView – angle left/right parameters

Used for seam • Open edge • V-seam • U-Seam

pattern profiles • Overlap seam • V-Area • HU-seam
• Tailored blank • HY-seam • TB-Area

Opening angle In addition to the "angle left/right" parameters,

parameters the "opening angle"
between the edges of the seam can be specified. This is useful when you
cannot define a boundary with "angle left/right" because the orientation
of the sensor to the work piece has changed. If the TH6D sensor head is
pivoted laterally from the joint line, this changes the inclination of the
laser lines in the camera image. The angle constraint then becomes a
hindrance. The opening angle, however, remains unchanged.

Used for seam • V-seam

pattern profiles • V-area

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 Initial
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Interference at When working with reflective surfaces (aluminium or CrNi steel), the joint
the seam line is brightened by multiple reflections of the laser beams. This
interferes with the measurement and evaluation for the seam tracking.
The "interference at seam" (left/right) parameter
ameter indicates an area of the
seam that cannot be evaluated.

Used for seam • V-seam

pattern profiles • V-area

Mismatch "Mismatch" is determined by the thickness of the work piece and any
possible air gap. The "Mismatch" is the vertical distance from the
reference area to the nearest edge of the second work piece. You can
limit this value when you know the thickness of your work pieces in order
to avoid faulty detection (refer to Figure 95).
). A large air gap between the
overlapping work pieces can also be detected.

Note It is very important is to limit the "Mismatch" whenever ambiguities arise

in the camera image (i.e. if two similar seam shapes are visible). This
could occur, for example, when there is a clamp positioned next to an
actual seam.

Figure 95: THxDView – Mismatch parameter at the overlap seam

Used for seam • Overlap seam • U-Seam

pattern profiles • Tailored blank • HU-seam
• HY-seam • TB-Area

Gap "Gap" defines a gap at the joint between the work pieces. When using the
seam shape "tailored blank",, it is possible (and sometimes desired) that
there will be a gap at the joint line. (As shown in Figure 96.)

Note The parameters "Mismatch" and "gap" are very helpful for eliminating
visual ambiguities in the camera image.

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 Initial Commissioning and Operation

Figure 96: THxDView – "gap" parameters (example of tailored blank)

Used for seam • Tailored blank • HU-seam

pattern profiles • HY-seam • TB-Area
• U-Seam

Interpolation An isolated seam point is designated as the base point. The "Interpolation
point tolerance point tolerance" parameter is used to expand the tolerance range of the
(l,v) seam point in the side (S) and height (H) directions. It is used to
calculate and evaluate the seam tracking. This is useful when there is
minor damage to work piece edges which could cause an excessive
excessi gap at
the joint line (for example, on an overlap seam).

Example In the example shown in Figure 97,, the end point of the left middle line of
the joint line (vertical with red dashes) is too far away which corresponds
to a gap.

Figure 97: THxDView – "Interpolation point tolerance"

tolera parameter - 1

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 Initial Commissioning and Operation

Example – For example, by specifying a value of 1 for the "side" parameter (S), the
continued algorithm accepts this deviation and recognizes the overlap seam
flawlessly. Figure 98

Interpolation point tolerance"

Figure 98: THxDView – "Interpolation tolerance parameter - 2

Used for seam • Overlap seam • U-Seam

pattern profiles • Tailored blank • HU-seam
• HY-seam • TB-Area

Search area The parameter "search area" is used if there is major interference (i.e.
left/right caused by reflections) in the proximity of the selected joint line. Such
interference occurs less often in the edge region of the V-seam.
V
Therefore, it is often useful to define a search area for these points.

The search area for the "overlap seam" shape is defined by starting at the
joint on the left and right.
For "tailored blank" and "v-seam",, you can define minimum and
maximum limits for the search area independently of the joint. The
search area to the right
ght and left of the seam position can be defined by
entering the minimum and maximum limits.

For the seam pattern "open edge",, the position of the search area can
only be defined to one selected edge.

(The search area can be defined as an area or only as a line for all seam
shapes.) It must be possible to reliably detect all three laser lines in this
case.

Used for seam • Open edge • V-seam • U-Seam

pattern profiles • Overlap seam • V-Area • HU-seam
• Tailored blank • HY-seam • TB-Area

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 Initial Commissioning and Operation

Line length By specifying the length of line,, only line elements for the joint detection
(left/right) are selected which are contained in the specified range.

Used for seam • Open edge • V-seam • U-Seam

pattern profiles • Overlap seam • V-Area • HU-seam
• Tailored blank • HY-seam • TB-Area

Line diff. The "Line diff. (A, L)" parameter is used for smoothing those line ele-
ele
(A, L) ments that do not lie precisely on the theoretical line direction (angle =
A).
). It is also used to merge small gaps (gap = L).

L W

Figure 99: THxDView – " Line diff. (A, L)"

L) parameter

Used for seam • Tailored blank • HY-seam • TB-Area

pattern profiles • V-seam • U-Seam
• V-Area • HU-seam

Preferred joint The "preferred joint position" parameter allows you to manually define
position the seam position so you can eliminate ambiguities during the seam
detection. This eliminates the risk of faulty detection. It can be used, for
example, when an additional edge is located under the selected work
piece
ce edge or when a clamp causes two steps of equal height to be
visible.

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 Initial Commissioning and Operation

Examples of Figure 100 shows two overlapping overlap seams; the position of the
preferred joint upper sheet is not clear in such a case. Unambiguous detection is only
position possible after the "preferred seam position" parameter has been
specified.

Figure 100: THxDView – "preferred seam position" parameter (example)

Left/Right By choosing the parameter "joint is on the left" or " joint is on the right",
the detection of the seam position occurs in the middle position between
the two higher or two lower lying surfaces. (As shown in Figure 101)

Position of the seam – on the left Position of the seam – on the right

Figure 101: THxDView – "preferred joint position" parameter (example)

Used for seam • Open edge • HY-seam • TB-Area

pattern profiles • Overlap seam • U-Seam
• Tailored blank • HU-seam

Information Sections 5.11 and 5.14.9 contain more information on the various
templates for the seam pattern profiles and on creating additional
profiles.

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 Initial Commissioning and Operation

5.11.4 Camera tab

Overview The "Camera" tab allows you to select a pre-defined profile (template)
which contains specific parameters for configuring the camera imaging in
the TH6D sensor head. It is also possible to create custom profiles by
changing the parameters in the existing templates.

Figure 102: THxDView – Camera tab

Camera profiles Templates and custom camera profiles can be selected from the drop-
down list.

5.11.5 Camera tab – parameter description

Parameter The following adjustable parameters influence the camera imaging:

Dynamic range The "dynamic range extension" parameter can be used with extreme
extension brightness to reduce the over-exposure of the camera. The "slight"
setting is the default.

Exposure time
NOTE!

Usually a short exposure time is recommended.

The "exposure time" controls the function of the shutter in a camera.

Shorter intervals (smaller parameter values) mean that less light is
registered by the photographic layer in the camera chip. This parameter
can help you when movements of the camera are causing the image to
blur. A shorter exposure time also helps to filter out traces of welding
splatter, which show up on the image as points of light.

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 Initial Commissioning and Operation

Laser power The "Laser power" parameter affects the power of the laser diode. At
higher power, the intensity of the laser light is increased. The actual
setting of this value must be tested on the work piece. There is no
recommended value for this parameter, since there are many variable
factors for each situation (the sensor orientation, shape of the work piece
surface, reflective properties or the surface, etc.). The brightness should
only be set as bright as required. Unnecessary brightness would shorten
the lifespan of the laser diode.

5.11.6 Calibration tab

Overview
CAUTION!
The calibration depends on the machine in use. It is only
required when the TH6D system is used with linear axes
and Kuka robots.

Calibration data must be specified in order to define the advanced

tracking compensation between the sensor origin and TCP. This is
accomplished by assigning the measured data in the sensor coordinate
system to the tool.
The "Calibration" tab allows you to select a pre-defined profile
(templates) which contains specific parameters for calibrating the TH6D
sensor head. By changing the parameters in the pre-designed templates,
it is possible to create custom calibration profiles. (Refer to Figure 103).

Figure 103: THxDView – Calibration tab

Note Section 5.14.6 contains more information about carrying out the
calibration.

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 Initial Commissioning and Operation

5.11.7 Calibration tab – parameter description

Parameter The following parameters influence the calibration:

+z

+x
+y
B C

TCP
S0

∆xs

Figure 104: THxDView – parameters for calibration

S/N sensor Serial number of the TH6D sensor head (automatic entry)

Orientation Orientation of the calibration plate in the robot/machine coordinate

system (manual entry)

Offset ∆xs Gap between TCP and the centre of the "tip" or "cross-hairs" insert of the
calibration plate (manual entry)

Tool ABC Tool orientation in the robot coordinate system (manual entry)

S0 position Sensor origin S0 in the robot coordinate system (calculated)

S0 orientation Sensor orientation in the robot coordinate system (calculated)

Advanced Gap between the sensor origin and the TCP (calculated)
tracking

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 Initial Commissioning and Operation

5.11.8 Process Control tab

Overview
CAUTION!

The parameters and parameter functions in the "Process

Control" tab depend on the selected machine interface.

The "Process Control" tab allows you to select pre-defined profiles

(templates) which contain specific parameters for the machine-dependent
process control of the TH6D sensor head. By changing the parameters in
the pre-designed templates, it is also possible to create custom profiles.

Example Figure 105 shows an example of the process control of the overall A/D
corrective interface. The analogue voltages can be scaled here and also
assigned an offset. The user can check off which parameter should be
sent as a voltage value to the controller.

Figure 105: THxDView – Process Control tab A/D-IF

Information The interface can be chosen from the main "System" tab and then the
sub-tab "Machine Interface" (section 5.12.2).

Section 5.9 describes the interface-specific parameters.

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5.12 Parameters area – main System tab

Main tab The "System" tab allows you to configure a job list and select the
"System" machine interface. This is also where the operating range of the analysis
software can be configured.

Tab No. Name Description

1 Job list Manage and create jobs

2 Machine Interface Select the interface

3 Configuration Sets the operating range for the analysis

software

1 2 3

Figure 106: THxDView – parameters area – system

5.12.1 Job List tab

Overview The "Job List" tab can be used to create jobs from the parameter profiles
that have already been defined in the "Profile" main tab.
The user can create jobs for specific applications. These are then saved
on the TH6D process computer. For the actual processing, the facility
controller invokes the job needed for that particular application. This is
achieved using the job number assigned by the sequence program.

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 Initial Commissioning and Operation

Jobs
NOTE!
For more information on setting up profiles and creating
jobs, refer to section 5.14.9.

A job consists of four customer-specific profiles: "seam pattern",

"camera", "calibration" and "process control". (Refer to 1 in Figure 107.)
More information about configuring the custom profiles can be found in
section 5.11.

Figure 107: THxDView – job list

Information The System Status area shows the job compilation that is currently being
used. (Refer to 2 in Figure 108.)
Sections 5.8.4 and 5.14.9 contains more information about Jobs, their
status and creation.

Figure 108: THxDView – job compilation in the System Status area

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5.12.2 Machine Interface tab

Overview The "Machine Interface" tab is used to select which machine interface is
connected to the TH6D system.
This selection must be specified because each interface provides different
machine-dependent parameters for configuring the user interface.

Interfaces Interface Description

A/D correction General interface for control of two auxiliary axes via
the control voltage

Motoman Interface to the Motoman robot controller, whereby the

reference path track-specific correction takes place in the lateral (Y)
and height (Z) directions. This is derived by comparing
the current measurement with the stored reference
value at one measurement point on the reference path.

Fanuc Ethernet Interface to Fanuc controller: transmits the measured

values in the sensor coordinate system without
advanced tracking compensation. This requires that the
tool is calibrated using the 10-point method, as
described in the Fanuc manual.

IF UDP data General interface for transmitting the measurements to

an external receiver; interface for use with non-
standard protocols.

Changing the
NOTE!
interface
The system is rebooted after the machine interface is
changed.

• Select the interface to use from the drop-down list (as shown by 1
in Figure 109).
• Click on "Save" (2).
• After changing the machine interface, the system automatically
restarts.
• The system then starts with the newly selected configuration.

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 Initial Commissioning and Operation

Figure 109: THxDView – selecting the interface

NOTE!
When an interface is changed, the assigned process
control is loaded which provides the relevant parameters.

Information For more information about the available interfaces and their parameters,
refer to section 5.9.

5.12.3 Configuration tab

Overview The "Configuration" tab allows you to configure the settings for playing
back the recorded image from the camera in the TH6D sensor head. (As
shown in Figure 110.)

Parameter Parameter Description

Search window X Rows of the exposure field in the X direction

Search window Y Rows of the exposure field in the Y direction

In the "Evaluation" area, you can restrict the camera image to width X
and height Y so that areas of interference can be ignored.
If a welding process has a strong influence on the optical characteristics
and image analysis, then you remove the problematic image area by
defining a number of image rows (e.g. 0, 200). Rows outside of this
specified range are ignored by the evaluation algorithm and no longer
shown in the "Evaluation" image are.

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 Initial Commissioning and Operation

Configuration
CAUTION!
This configuration does not change the size of the TH6D
sensor head's measuring field. Adjustments only affect the
"Evaluation" image area.

The only visual change in the "Evaluation" image is that the laser lines
are shorter. The size of the visual frame remains unchanged. (As shown
in Figure 110.)

Figure 110: THxDView – configuring the "Evaluation" image area

Example The change to the parameter "search window x and y" (as shown in
Figure 111) has the following influence on the "Evaluation" image area:

x
20
751

100
400
y
Figure 111: THxDView – configuring the "Evaluation" image area
(example)

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 Initial Commissioning and Operation

Example – The changes have no effect on the sensor's field of measurement, as can
continued be seen in the "Raw data" image area. (As shown in Figure 112)

Figure 112: THxDView – configuring the "Raw data" image area

(example)

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 Initial Commissioning and Operation

5.13 Interfaces and associated parameters

5.13.1 Machine interface – analogue-digital correction

A/D correction This general "analogue-digital (A / D) correction interface" provides digital

status signals and is controlled via digital input signals. The correction
values for lateral and vertical deviation, Mismatch and gap width are
output as analogue voltages (e.g. for controlling auxiliary axes).

Machine- The machine interface "analogue-digital correction" only works with the
dependent auxiliary module "analogue-digital interface (ADF)." More information and
auxiliary modules the installation instructions can be found in sections 3.4.1 and 4.5.1.

NOTE!

Voltages are only output during automatic mode.

Digital The status of digital inputs and outputs is shown by fields (1). (As shown
inputs/outputs in Figure 113.)
• Check mark in box: Digital I/O high
• No check mark: Digital I/O low

Analogue The "Analogue On/Off" field is divided into four analogue inputs (2) and 4
inputs/outputs analogue outputs (3). In the "Analogue Out" field (3), four analogue
outputs are displayed for each default voltage value. The four analogue
inputs (2) are by default not operated.

2 3

Figure 113: THxDView – analogue-digital correction interface

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 Initial Commissioning and Operation

Corresponding After the analogue-digital interface is properly selected, the parameters

process control shown in Figure 114 are available for the process control. The user can
check off which parameter should be sent as a voltage value to the
controller. It is also possible to scale the parameter values and set an
offset.

Figure 114: A/D interface – process control

Parameter Parameter Description

description
Filter width Mean value of the measured data for the specified
number of images

∆x (scale, offset) Scaling factor for the output of the measured value
on the gap between the laser lines; added to the
measured value

∆y (scale, offset) Scaling factor for the output of the measured value
on the position in lateral direction; added to the
measured value

∆z (scale, offset) Scaling factor for the output of the measured value
on the position in height; added to the measured
value

A (scale, offset) Not used in this machine interface

B (scale, offset) Not used in this machine interface

C (scale, offset) Not used in this machine interface

C (left) (scale, offset) Not used in this machine interface

C (right) (scale, offset) Not used in this machine interface

Gap (scale, offset) Scaling factor for the output of the measured value
on the gap width; added to the measured value

Mismatch (scale, offset) Scaling factor for the output of the measured value
on the step height; added to the measured value

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 Initial Commissioning and Operation

5.13.2 Machine interface – Motoman reference path

Motoman This section explains how to use the "Motoman reference path" machine
reference path interface.

Figure 115: THxDView – Motoman reference path interface

Machine- The "Motoman reference path" machine interface only works with the
dependent auxiliary module "analogue-digital interface (ADF)." More information and
auxiliary module the installation instructions can be found in sections 3.4.1 and 4.5.1.

Prerequisites There are prerequisite conditions from Yaskawa/Motoman for two

versions of the robot controller:

DX100 controller Requirements for adapting the TH6D system to a Motoman DX100
controller:

Hardware • YCP02-E board with plug for CN120 (analogue sensor card,
complete)
• Possibly: adapter for high-speed inputs (DIN adapter and cables)
when using the analogue search function
• Four digital inputs and eight digital outputs to control the TH6D
• An additional XIO02 card (I/O card) may be needed

Software • DS1.42-32

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 Initial Commissioning and Operation

X100 controller • Sensor parameters that deviate from the initialization values:

Sensor parameter S1E021 = 2 S1E070 = 1

S1E022 = 3 S1E072 = 30
S1E027 = 100 S1E073 = 60
S1E028 = 100

NX100 controller Requirements for adapting the TH6D system to the Motoman NX100
controller:

Hardware General sensor card for analogue inputs:

• Sensor board: NCP 02 • Connector: (3M-10136)

• Analogue board: NSL02-2 • Cover: (3M-10336)

Operating modes The "Reference Path" field in the "Machine Interface" tab (as shown in
– basic settings Figure 116) shows the currently selected operating mode (1) and the
current controller mode (2).
The display field (2) is also a control field in set-up mode used to specify
whether the robot controller ("via robot" mode) or the operator (manual
mode) control the operating modes of the TH6D system. In the "with
robot" mode, the robot controller automatically switches between the
"record", "ref. mode" and "correction" operating modes. When in manual
mode, the toggle field (2) can be pressed repeatedly to switch modes.

The default is the control mode "via robot" using the auto-switched
operating modes shown below.

1 2

Figure 116: Motoman reference path – operating modes

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 Initial Commissioning and Operation

The robot selects If the control mode "via robot" is activated, the field "operating mode"
the operating (1) is assigned to the field "selection" (2) in THxDView as follows:
mode
Operating Selection Description
mode

• Records the seam points in the sensor

coordinate system with imaging
frequency (IN 3 = 0, IN 4 = 0)

• Transmits the difference between the

current measured value and the
measured value of the reference path
(IN 3 = 1, IN 4 = 0)

• Not used

Changing the
CAUTION!
control mode and
manually The operating mode can only be changed manually while

changing the in set-up mode.

operating mode
• While the control mode "via robot" is activated, click once on the
"choice" button (2) to switch to manual mode (as shown in Figure
117).
• By switching to manual mode, the "record" (1) mode is
simultaneously activated, which is also displayed in the control
field (2) (as shown in Figure 118).

1 2 3 4

Figure 117: Manually switching the control mode

Figure 118: Control mode "manual" – operating mode "record"

• Click once more on the "choice" field (2) to switch to the next
operating mode.
• The operation mode that has been selected is displayed in the
field (1) after the switch.
• After switching through the three manually selectable operating
modes, the system will return to the "via robot" control mode.

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 Initial Commissioning and Operation

• Click on the button "Save" (3) to change the default boot

configuration permanently. The new configuration will then be
loaded at the next system boot.
Click on the button "clear" (4) to reset to factory default settings.

Manually selecting If the control mode "manual" is activated, the field "operating mode" (1)
the operating is assigned to the field "selection" (2) in THxDView as follows. The
mode assignments are listed in the order they are activated and displayed when
manually changed:

Operating Selection Description

mode

• Records the seam points in the sensor

coordinate system in imaging
frequency

• Transmits the difference between the

current measured value and the
measured value of the reference path

• Not used

Set up with the

CAUTION!
robot
Automatic mode and the "via robot" selection mode must
both be activated in order to set up the robot.

NOTE!
During the reference movement, the seam points are
saved in the TH6D process computer and assigned to the
active job. Each processed section of a work piece has its
own job number and thus its own reference data.

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 Initial Commissioning and Operation

Set up with the Function Display Bit

robot –
continued The robot's path is initially programmed on a sample Field (1) shows: IN3=0
work piece (the teach-in). IN4=0
Then the reference path is recorded as soon as the
robot sets off (controlled by the program) on the Field (2) shows:
learned path at its processing speed. It is important
that the activation and deactivation of the TH6D
sensor head occurs automatically in the
programming.

During the recording of the reference path, no

corrective values are transmitted to the robot.

When the work pieces are processed, the TH6D Field (1) shows: IN3=1
sensor head provides analogue corrective path-based IN4=0
signals for lateral and height directions as differential
values for the reference path. This requires that the Field (2) shows:
robot switch to the "ref. mode".

Information field
NOTE!
The speed needed for calculating the path length must be
specified in the "Process Control" tab.

The "Info" shows a brief summary analysis of the recorded reference

path.

Example In the example (in German language, as shown in Figure 119), a path of
100.6 mm was recorded. In this case there was an interruption in the
seam detection of 0.3 mm at the seam position 47.9 mm.

Figure 119: THxDView – Motoman reference path – information field

Analogue and
NOTE!
digital
inputs and In the operating mode "record", no corrective values are

outputs output to the analogue outputs.

The functions of the "Analogue On/Off" and "Digital I/Os" areas are the
same as those of the analogue-digital interface (refer to section 5.13.1).
The corresponding interface assignment table can be found in section 8.3.

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 Initial Commissioning and Operation

Corresponding After the Motoman interface has been selected in the "Machine Interface"
process control tab, the parameters shown in Figure 120 are available for the process
control.

Figure 120: Motoman interface – process control

Parameter The following parameters are used to optimize the measurement process.
description
Parameter Description

Speed Speed value of the robot movement during the

(Rec, Track) recording (Rec.) of the reference path

Speed value of the robot movement during the seam

tracking (Track)

Speed (Scale, Offset) Not used

Filter length Selectable range for smoothing the measured values

(moving average)

Caution: Only use filter width OR filter length!

Measurement data without Not used

advanced tracking

Filter width Mean value of the measured data for the specified
number of images

Caution: Only use filter width OR filter length!

∆x (scale, offset) Scaling factor for the output of the measured value
on the gap between the laser lines; added to the
measured value

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 Initial Commissioning and Operation

Parameter Parameter Description

description –
∆y (scale, offset) Scaling factor for the output of the measured value
continued on the position in lateral direction; added to the
measured value

∆z (scale, offset) Scaling factor for the output of the measured value
on the position in height; added to the measured
value

A (scale, offset) Not used in this machine interface

B (scale, offset) Not used in this machine interface

C (scale, offset) Not used in this machine interface

C (left) (scale, offset) Not used in this machine interface

C (right) (scale, offset) Not used in this machine interface

Gap width (scale, offset) Scaling factor for the output of the measured value
on the gap width; added to the measured value

Mismatch (scale, offset) Scaling factor for the output of the measured value
on the step height; added to the measured value

5.13.3 Machine interface – Fanuc Ethernet

Overview
NOTE!
Consult Fanuc's documentation when carrying out the
machine-side integration.
Caution: Scansonic MI GmbH is not responsible for
the content and maintenance of third-party
documentation!

Prerequisites The following prerequisites are needed for the Fanuc system configuration
[source Fanuc]:

Hardware • Controller (hardware):

RJ30iA robot controller with RJ45 network input, numbered as
CD38A

Software • The proper Fanuc system software for communicating with the
TH6D sensor head
• Software packages for sensor communication and seam tracking:
R691 universal sensor interface
R648 user socket messaging

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 Initial Commissioning and Operation

Fanuc Ethernet The TH6D process computer communicates with the Fanuc robot
controller using a separate PTP connection with a fixed IP address.
• Refer to instructions for setting up the Ethernet link found in the
Fanuc documentation.

Changing the IP
NOTE!
address of the
TH6D systems The robot and the TH6D system must be in the same IP
address range.

After selecting the Fanuc interface, you must enter another IP address.
The following steps should be taken to change the IP address using
THxDView:

• The "Eth1" option (1 in Figure 121) must be selected: it

corresponds to the TH6D communication port used with the Fanuc
controller.
• Enter the desired IP address in the box (2).
• The subnet mask (3) must always be 255.255.255.0.
• Click on the "Save" button (4) to apply the change.
• Restart the TH6D process computer by clicking the “Yes” button in
the confirmation dialog box
• OR select "Restart" from the menu bar, under "Extras"

2 3 4
1

Figure 121: Fanuc Ethernet interface – changing the IP address

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 Initial Commissioning and Operation

Calibration A job must be specified in order to calibrate with the Fanuc robotics
controller. This job must be designated as job number 1, since the Fanuc
controller automatically invokes this number for the calibration.

Our This job should consist of configurations (profiles) specifically set up and
recommendation designated for the calibration.

Creating the Create the profile and the first job according to the example below and
calibration job the information found in section 5.14.9.

Creating and Select the "Lap joint" template for the seam pattern.
saving a profile • Specify the "TCP position" parameter so that the TCP is positioned
either to the left of right of the upper workpiece edge (upper
plate) (refer to Figure 122 and section 5.11.2)
Adjust additional parameters if necessary. Save the profile under
a specific name (for example, "fanuc_calibration").

Figure 122: Fanuc Ethernet interface – creating a calibration profile

• Select the existing template for the camera profile. Change the
parameters if necessary and save the profile under a specific
name (as described in section 5.14.7)
The profiles for "Calibration" and "Process Control" (refer to sections
5.11.6 and 5.11.8) should not be set. When compiling the job, you can
use the system files or the place holders syscalib.xml (calibration) and
syspctrl.xml (process control).

Creating a
ATTENTION!
calibration job
Do not delete the calibration job after the calibration has
been carried out!
Addition information about this calibration can be found in
the documentation from Fanuc.

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 Initial Commissioning and Operation

Make sure that the calibration job is assigned job number 1 (Job 1)!
• Set up Job 1 as a calibration job, using the previously created
profiles (refer to the example in Figure 123)
• OR: you can delete an existing Job 1 and create a new one based
on the previously created profiles.
• OR: you can change the number of an existing Job 1. Then create
a new job as the calibration job with the previously created
profiles. This job will automatically be assigned job number 1 and
will be switched to the top position on the job list.
• Additional information about creating jobs can be found in
sections 5.12.1 and 5.14.9

Figure 123: Fanuc Ethernet Interface – creating a calibration job

(example)

Corresponding The protocol for the Fanuc Ethernet interface to the TH6D system has
process control been specified. Thus, after restarting the TH6D system, the output of
measurements can be either enabled or disabled in the process control.
This is done by setting or removing the check mark (as shown in Figure
124).

Figure 124: Fanuc Ethernet interface – process control

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 Initial Commissioning and Operation

5.13.5 Machine interface – IF UDP Data

IF UDP data
NOTE!
The UDP-machine interface is used for non-standard
applications.

The following customer-specific adaptations can be made when using the

UDP Data machine interface.

• IP address:
• Dead time

Figure 125: THxDView – UDP Data interface

Delay Delay is the system delay time or response time required by the TH6D
system when it outputs a data record. This value is automatically sent to
the robot controller when the communication link is established.

ATTENTION!
You should only change this delay value when the
communication link between the TH6D system and robot
controller times out!
The value can then be adjusted accordingly but may not
be less than 17 milliseconds! (Input value of 17000).

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 Initial Commissioning and Operation

5.14 Set-up and configuration of the TH6D system

Prerequisite The TH6D system must be installed as described in Chapter 4. THxDView

must be installed on the user PC. The network link to the TH6D process
computer must be established and operational.

Initial During the initial commissioning the TH6D process computer may still be
commissioning in standby mode. It must then be manually switched on using the ON/OFF
information switch on the TH6D process computer. Refer to the information about the
status display and the position of this switch as described in section 3.5.2.
After it is booted up, the TH6D system is in automatic mode. Set-up
mode must be activated in order to change parameters.

NOTE!
Parameter changes and other adjustments can only be
carried out while in the set-up mode. In this operating
mode, the laser lines are switched on, unless this is
prevented by the applicable laser safety regulations.

5.14.1 User login

Overview After the THxDView software is successfully installed and started up, the
user must log on to the TH6D system.

THxDView provides different levels of access, each of which is secured by

a password. The default access level is "Parameterization"

General access

Serves the general overview function. Here, no adjustments can be

made.

• Access level: Expanded view

• Password: level1

Parameterization access
Here the parameterization of TH6D system can be made.

• Access level: Adjusting parameters

• Password: level2

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 Initial Commissioning and Operation

User login • Click on the "Login" button (as shown Figure 126).
• Select the desired access level.
• Enter the password in the window that appears and then click
"Login" (as shown in Figure 127).
• The "Login" menu option then changes to show the current access
level.

Figure 126: THxDView – user login

Figure 127: User login – password entry

Login failure • An error message will be displayed if you enter a wrong password
(as shown in Figure 128).
• The password can be re-entered.

Figure 128: Login failure

Changing the
NOTE!
access level
It is possible to switch to a lower access level without re-
entering a password.

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 Initial Commissioning and Operation

After logging in, you can click on the menu bar to change access levels.
You will have to enter a new password if you are switching to a higher
access level.

• Click again on the "Login" option with the name of the current
access level (as shown in Figure 129).
• Select a different access level.
• Enter the password if necessary.

Figure 129: Changing the access level after the login

5.14.2 Establishing a network connection with a TH6D system

Overview
NOTE!
The TH6D system is delivered with the factory default IP
address and port permissions. Only Scansonic service
personnel can change these settings.

The TH6D process computer comes standard with the following default
connection settings for the user PC with THxDView:

• IP address: 192.168.0.201
• Subnet mask: 255.255.255.0

The user PC and the TH6D process computer must be in the same
address range. The fourth number block in the IP address range may
not be 201. The address for the subnet mask must stay as shown above.

Examples of valid • 192.168.0.214

IP addresses • 192.168.0.105

Prerequisite The user PC must be connected to socket 6 of the TH6D process

computer, as described in section 4.4.13.
THxDView must be installed on the user PC, as described in section 5.3.3.

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 Initial Commissioning and Operation

Notes
NOTE!
THxDView must not be blocked by any firewall or anti-
virus programs.

Checking the IP
NOTE!
addresses
All connected TH6D systems will be shown in THxDView,
even if they are in another address range.

You can select the menu option "Select System" in order to display the
TH6D systems connected to the user PC along with their IP addresses.
You can select a system here. A sensor system management option is
available for checking IP addresses and to operate a TH6D system with a
specific serial number.

Open the sensor • Click on the "Select System" button in the menu bar (as shown in
system Figure 130).
management • Select the "Manage Sensor Systems" option.

Figure 130: THxDView – selecting a sensor system (example)

• Refresh the list by clicking on the "Refresh" button (as shown by 1

in Figure 131).
• Check and compare the displayed TH6D systems and their specific
IP addresses with the network settings of the user PC.
• Make any necessary changes on the user PC (as network
administrator).
• Click on the "OK" button (2) to close the "Manage sensor
systems" window.

1
2

Figure 131: THxDView – Manage sensor systems (example)

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 Initial Commissioning and Operation

Establishing a After the network connections have been configured on the user PC, a
connection link can be established to the TH6D system.

• Click on the "Select System" button in the menu bar.

• Click on the TH6D system that you plan to use.
• The connection will then be automatically created.

Figure 132: Establishing the connection to the TH6D system (example)

Status display A successful connection is indicated with green in the "system status"
for the area and the name of the connected TH6D system. (Refer to the marked
connection area in Figure 133.)

Information Section 5.8 contains more information about the status display in the
"system status" area.

Figure 133: THxDView – connected network status (example)

Information The user PC running THxDView can be switched on and off separately
about from the TH6D system. If the TH6D system is switched off before
disconnections THxDView, then you will notice the disconnection in the THxDView
software. The system status displays the message "No System".
When switched back on, THxDView automatically connects to the
previously connected TH6D system. This can be checked with the
connection status in THxDView. (Refer to section 5.8.)

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 Initial Commissioning and Operation

Setting the
NOTE!
automatic
connection You can configure the settings so that a connection is
automatically established between THxDView and the
TH6D system when the software starts up.

The next time you start THxDView, the program automatically tries to
connect to the previously connected TH6D system. This process can be
interrupted within four seconds.

This automatic connection can be configured in the settings:

• Click on the menu option "Extras".

• Select the "Preferences" option (as shown in Figure 134).

Figure 134: THxDView – configuring the automatic connection

• Choose a value from the drop-down list for the automatic

connection setting.

Figure 135: THxDView – choosing a value for the automatic connection

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 Initial Commissioning and Operation

5.14.3 Selecting the language

Overview
NOTE!
Additional languages are being prepared. Please contact
your local sales and service partner.

The standard version of the THxDView is available in German and English.

Changing the • Click on the "Extras" button (as shown in Figure 136).
language • Select the language in "Language" option.
• A reboot is not required when changing the language.

Figure 136: THxDView – changing the system language

5.14.4 Selecting the set-up operating mode

Operating modes
NOTE!
When selecting the operating mode, there must be an
existing connection to a TH6D system and you must be
logged in at the "Parameterization" access level.

In order to set up the TH6D system using THxDView, you must be

connected and logged in to a TH6D system and the "Setup" operating
mode must be activated.

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 Initial Commissioning and Operation

Selecting the
CAUTION!
set-up operating
mode It is not possible to change modes during active
processing in automatic mode! Wait until the
program has finished.

The default operating mode when starting the TH6D system is the
automatic mode.

• Click in the "system status" area on the "Operation" button in

order to switch to set-up mode.
• This button is coloured red while in set-up mode (as shown in
Figure 137).

"Setup Mode" is
activated

Figure 137: THxDView – the set-up operating mode

NOTE!
When "Setup Mode" is activated, the laser lines are
switched on, unless this is prevented by the applicable
laser safety regulations.

5.14.5 Positioning the TH6D sensor head

Prerequisites First, the installation and connection of the TH6D sensor head, TH6D
process computer, facility controller, user PC and THxDView must be
carried out (as described in Chapter 4). The TH6D sensor head can then
be positioned

NOTE!
The emitted laser lines are much longer than the
measuring field of the TH6D sensor head. Thus the sensor
head must be carefully positioned over the joint.

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 Initial Commissioning and Operation

Positioning the Move the tool (e.g. torch) to the desired working position. Align the
TH6D sensor sensor head TH6D sensor head as described below:
head • The TH6D sensor head should be positioned at a gap of 150 mm
above the butt edge of the work piece.

The optimal
NOTE!
setting
Set-up
up mode must be activated in order to carry out
configurations manually.

To optimally adjust the lateral and vertical position of the TH6D sensor
head above the butt edge of the work piece:
• Verify that the position of the sensor is correct by observing the
orientation movements in THxDView.
• Position the butt of the work piece in the centre of the "raw
" data"
image area, as shown in Figure 138.
• The middle line of the three laser lines should be aligned near the
horizontal white line of the "raw data"" image area.
area

Figure 138: Positioning the TH6D sensor

or head – V-seam example

The example illustrations below show different gaps that the TH6D sensor
head can have to the seam area, using an example of a V-seam:
V

• Too far away from the work piece

surface.
• The third laser line is almost gone
from the camera's viewing range.

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 Initial Commissioning and Operation

The optimal • Too close to the work piece surface.

setting – • The first laser line juts out from the
continued camera's viewing range.

• Moved too far laterally to the left.

• The laser lines jut out of the sensor
area.

• The optimal gap to the surface of

the work piece.
• The solid white line shown in the
image area should be used as a
reference.
• The laser line in the middle is
positioned on the reference line.

Active • Optimal positioning for the TH6D

measurement sensor head.
head
• Measuring is activated.
• Yellow dots mark the detected
seam for the active measurement.

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 Initial Commissioning and Operation

5.14.6 Tool calibration

Overview
CAUTION!

The tool must be re-calibrated each time after the

TH6D sensor head is replaced or installed.

You must re-calibrate the tool each time after the tool (e.g. torch) or
TH6D sensor head is installed on a master machine or robot.
This tool calibration is required so that the sensor coordinate system and
the master machine's coordinate system are synchronized to work with
each other. Thus the position and orientation of the TH6D sensor head is
determined in relation to the tool (the tool centre point).

Interface The calibration steps and required accessories depend on the particular
specifications type of interface being used. The calibration of the tool should be carried
and accessories out either on the master machine/robot or on the sensor side, as shown
in the following table:

Interface TH6D system Master machines Accessories

Linear axes x - Calibration

(ADF) plate

Motoman No calibration – reference path principle

Fanuc - x -

KUKA x Calibration
plate

NOTE!
Contact your system partner for assistance in performing
a robot-side calibration.

Tool calibration This section only describes the sensor-side tool calibration for the linear
for linear axes axes (refer to the table above).
(ADF)
Required accessories:
• Calibration plate
• "Tip" or "cross-hairs" insert (depending on the tool)

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 Initial Commissioning and Operation

Prerequisites The following conditions must be fulfilled in order to calibrate the tool.
• The calibration plate must be precisely aligned in relation to the
world coordinate system (the robot's "base coordinate system")
and mounted (preferably in direction +x).
• The TH6D sensor head must be optimally mounted in relation to
the tool and work piece (seam detection must be ensured across
the entire path).
• The TH6D sensor head and the tool must be aligned in the +x
direction in relation to the calibration plate (as shown in Figure
139).
• All cables connecting the TH6D sensor head, process computer,
optional machine interface and the facility controller must be
plugged in securely.
• THxDView must be installed on a user PC which must be
connected to the TH6D process computer.
• A template or existing profile with parameters specifications must
have been selected from the "Calibration" sub-tab of the main
"Profile" tab.

+z

+x
+y
B C

TCP
S0

∆xs

Figure 139: Orientation of the TH6D sensor head in relation to the

calibration plate

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 Initial Commissioning and Operation

Determining the
CAUTION!
calibration data
Before calibrating the tools, it is imperative that the seam
shape "Overlap Seam" is activated from the "Seam
Pattern" tab!

Drive the TCP In the "Calibration" tab, parameters must be specified as the basis of the
tool calibration. (Refer to Figure 140 and Figure 141)

• Move the tool's TCP (1) in direction +x to the centre of the insert
being used ("tip" or "cross-hairs”) (2) for the calibration plate.

2 1

+y

+x

Figure 140: THxDView – specifying the parameters for calibrating - 1

Determine the data • Move the tool from the centre in direction -x until the laser lines
(3) are optimally aligned with the "V" (4) of the calibration plate.
• All three laser lines must jut out over the edges of the "V" (4).
You can check this setting in the "raw data" image area within
THxDView (refer to Figure 142).
• Read out the traversed path ∆xs and the tool angles A, B, C from
the robot controller.

3 1

+y
∆xs
4 +x

Figure 141: THxDView – specifying the parameters for calibrating - 2

Entering the
NOTE!
calibration data in
THxDView The serial number (parameter S/N sensor) will be
automatically imported into THxDView.

In the "Calibration" tab, parameters must be specified as the basis of the

tool calibration. (As shown in Figure 142.)

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 Initial Commissioning and Operation

Entering the • Use the drop-down

down list to select the orientation (1) of the
calibration data in calibration plate in relation to the tool coordinate system
(currently only +x available).
THxDView –
• Enter the calculated values in the boxes (2) and (3) (see the
continued example in Figure 142).
• Click on the "Calibrate" button (5) in order to start the calculation
for the sensor origin coordinates.
• Do not press any other button during the calibration process!
• A successful calibration will be shown in the reports area.
• The calculated parameters "S0 Position", "S0 Orientation"
"Advanced Tracking" and "Basic Sensor" are shown in the area
(4).
• Click on the "Save As" button (7) to save the entries and
calculations in a newly named
ed calibration profile.

V
8
1
2
3
4

5 6 7

Figure 142: THxDView – specifying the parameters for calibrating the tool

NOTE!
Make sure you select the proper profile when compiling
the jobs!

Changing an Customer-specific
specific calibration profiles can be changed after their creation.
existing • Select a profile from the drop-down list (8)).
calibration • Make the changes as previously described.
profile
• Click on the "Save" button (6) to save your changes in the
existing profile.

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 Initial Commissioning and Operation

5.14.7 Measurement process optimization – changing camera settings

Overview
NOTE!
Set-up mode must be activated in order to change
parameters.
Parameters values must be saved in the profile in order to
save the values permanently. (Refer to section 5.14.9.)

The first step in optimizing the measurement processes is adjusting the

brightness of the laser lines and the exposure time of the camera to fit
your particular application. The default values are 70 (laser) and 5
(shutter).

Camera settings In the "Camera" option of the main "Profiles" tab, the value for the laser
brightness (2) should be specified in the input box so that the laser lines
in the "raw data" image area are still faintly visible. This value is very
dependent on the roughness of the work piece surface and its colouration.
For reflective surfaces (such as stainless steel and aluminium), a value of
at least 200 must be specified here.

1
2
0
0

Figure 143: THxDView – changing the camera settings

Subsequently, the exposure time (1) must be reduced to the smallest

possible value at which the laser lines in the "raw data" image area are
still visible.

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 Initial Commissioning and Operation

5.14.8 Optimizing the measurement process – changing parameters

Overview
NOTE!
Set-up mode must be activated in order to change
parameters.
Parameters values must be saved in the profile in order to
save the values permanently. (Refer to section 5.14.9.)

Parameters can be changed in THxDView in order to optimize the

measuring processes for the TH6D system. Parameters should be
optimized in individual steps in order to isolate fault detection.

New values can be specified directly in the corresponding fields located

within the associated tabs. In order to change the parameters, you must
have a connection established to the TH6D system. You must also be
logged in at the "Parameterization" access level and the corresponding
parameter must be activated.

Changing the At the "Parameterization" access level, you can change the corresponding
parameters parameters within their specified value ranges.

Entering • Select a parameter. If necessary, activate it by clicking on the

parameters check box.
• Click in any field in the parameter line and enter a new value.
• Set them according to the range of values which is specified in the
help bar above the tab (as shown by 1 in Figure 144).
• Parameter values that are changed are then highlighted in green
(as shown by 2 in Figure 144).
• All values entered must be confirmed with the "Enter" key before
they are transmitted to the TH6D process computer.
• The parameter values are shown in black after they have been
successfully transmitted.

Figure 144: THxDView – changing parameters (example)

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 Initial Commissioning and Operation

Input incorrect • If an invalid value is entered, the initial value is displayed in red
(as shown by 4 in Figure 145).
• The help bar will show the wrong entry by marking it with a red
circle and white X (as shown by 3 in Figure 145).

Figure 145: THxDView – incorrect parameter entry (example)

5.14.9 Setting up profiles and creating jobs

Overview
NOTE!
Jobs cannot be created using profile templates. They can
only be created from customer-specific profiles.

A job is composed of four profiles. Existing profile templates cannot be

used to create jobs. Thus before a job is defined, you must first create,
set-up and save a specific profile for it.

Creating a • From the main "System" tab, select one of the tabs "Seam
custom Pattern", "Camera", "Calibration " or "Process control " (as shown
by 1 in the example in Figure 146).
(customer-
• Choose a template that is suited to your processing task, or
specific) profile
choose an existing profile from the drop-down list (2) of the
selected tab.

Setting up a new • Change the parameters necessary for your optimizations (3).
profile • Save the newly created profile using the following specifications.
• If needed, repeat these steps for the other tabs (1).

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 Initial Commissioning and Operation

Setting up a new
profile – continued

1
2

4 5

Figure 146: THxDView – setting up a profile

Saving a new
NOTE!
profile
Tabs containing changed but unsaved parameters are
marked with an "*" before the tab name. (Refer to 1 in
Figure 146.)

• Click on the "Save As" button (5 in Figure 146) after you have
finished optimizing the parameters. You can then save your
customization to a new profile.
• Give the profile a clear name and click on "Save" (6 and 7 in
Figure 147).

Figure 147: THxDView – saving a profile

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 Initial Commissioning and Operation

Changing an Customer-specific profiles can be changed after they are created.

existing profile • Select a profile from the drop-down list (2 in Figure 146).
• Make the changes as previously described.
• Click on the "Save" button (4) to save your changes in the
existing profile.

Information • The "Reports” area shows when the profile has been saved
about saving successfully.
• The profile that you created is now in the drop-down list (as
shown by 8 in Figure 148) and can be selected when compiling a
job.

Figure 148: THxDView – selecting the profile from the drop-down list

Creating a job The profile can be compiled into application-specific jobs after the set-up
is complete. These are created in the "Job List" tab under the main
"System" tab. (As shown in Figure 149.)

Figure 149: THxDView – job list

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 Initial Commissioning and Operation

Creating jobs – Jobs can be assigned a unique job name. Each job is assigned a unique
continued number by which it is saved in the TH6D process computer. For the
automated processing, the machine controller invokes the desired job
using the job number. This job is uploaded to the TH6D process computer
and executed. The machine controller cannot change this job during an
active measurement.

Creating a new job • Click on the "Create Job" button (9) in the "Job List" tab.
• A new row (10) will appear in the job list with fields that you need
to fill in.

10
00

9
0
Figure 150: THxDView – creating a new job

Assign a job name • Click in the column (11) and enter a unique job name (as shown
and profiles in Figure 151).

11

Figure 151: THxDView – entering a job name

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 Initial Commissioning and Operation

• Then assign the desired profile to each profile type from the drop-
down lists (as shown by 12 in Figure 152).
• All four profile types must be assigned profiles in order to save the
job.
• Templates cannot be selected.

12

Figure 152: THxDView – assigning a profile

Saving the created

CAUTION!
job
Data loss is possible!
Don't forget to save the new jobs! Unsaved data will be
lost if the voltage drops or the TH6D system restarts.

The reference text "new" will appear under the assigned job number after
you have named it and assigned a profile. (Refer to Figure 153.) This
indicates that the job has been created but not yet saved.
• Create as many jobs as you need based on these specifications.
• Click on the "Save" button (13) to save the new jobs.
• A message about the save status will appear in the reports area.

13
00

Figure 153: THxDView – saving a new job

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 Initial Commissioning and Operation

Changing of The composition and name of created jobs can be changed after the jobs
deleting a job have been created. The assigned job number remains the same.

• Click on the row of the job you wish to change – the job entries
can now be edited.
• Change the job name or assign different profiles to the profile
types.
• The reference text "changed" will be displayed under the job
number.
• Click on the "Save"" button to apply the changes.

Figure 154: THxDView – changing the content of jobs

Information The name of the template is based on the corresponding profile and
shown in parentheses after the profile name. (Refer to 14 in Figure 155.)

14

15

Figure 155: THxDView – notes on the job list

The current job and its contents can be seen in the "System State" (15)
area.

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 6. Maintenance
This section describes the process of servicing the TH6D system.

6.1 Safety instructions .......................................................... 6-2

6.2 Required maintenance .................................................... 6-3
6.2.1 Maintenance intervals..................................................... 6-3
6.2.2 Diagnosis of the maintenance intervals ............................. 6-4
6.2.3 Overview of maintenance procedures ............................... 6-5
6.3 Handling the components ............................................... 6-5
6.3.1 Clean and change the safety glass ................................... 6-5
6.3.2 Cleaning the TH6D sensor head ....................................... 6-8
6.3.3 Check the hose and cable connections .............................. 6-9

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 Maintenance

6.1 Safety instructions

You must observe and obey the following safety instructions during maintenance and servicing to
the TH6D system. These relate to the use of the TH6D system in a production facility.

DANGER!
There is a risk of injury from the master machines!
• Do not stay in the swivel range of master machines when they are turned on!
• Disconnect the power from the master machines before starting to work on
the TH6D system!

WARNING
Danger of getting stuck!
• When the power supply is turned on, keep hands, hair, pieces of clothing and
tools away from the moving parts of the processing equipment.
• Disconnect the power supply before beginning work on the TH6D system.

WARNING
Danger to health through harmful gases and fumes!

• Never inhale the gases resulting from the work process!

• Always be sure that there is sufficient ventilation and extraction for gases!
• After a process has completed, wait for the gases to be sucked away before
entering the work/laser cell.

WARNING
Loud noises can be dangerous!
The loud noises caused by emitted media can damage your hearing.

• Always wear protective gear for your ears when changing pressurized hoses!!
• Or make sure that you de-pressurize all facility components!

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 Maintenance

WARNING
Danger from excessive pressure!
There is a risk of head, eye or hearing injury.
• Always wear protective gear for your eyes and ears when changing
pressurized hoses!
• Or make sure that you de-pressurize all facility components!

WARNING!
Risk of injury from hot components!
There is a risk of burn injury from hot components when carrying out maintenance
work immediately following the work process.
• Allow the work pieces to cool down or wear suitable protective gloves!

6.2 Required maintenance

Some components or work pieces in the TH6D system must be regularly maintained.
Maintenance may only be carried out by trained personnel in observance of the safety
information stated in this document.

6.2.1 Maintenance intervals

The frequency of the maintenance depends on the work load of the TH6D system and will vary
according to the facility.

Normally, a maintenance interval after every eight hours of processing time is adequate.
Scansonic recommends a diagnosis of the maintenance intervals in order to determine more
precise intervals.

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 Maintenance

6.2.2 Diagnosis of the maintenance intervals

Overview Depending on the application (e.g. for large-batch

large productions), the
durability of the safety glasses should be determined empirically in cycles.
This provides a more precise estimation of when the safety glass should
be replaced.

NOTE!
If the quality of the seam detection deteriorates (as
indicated by the value in THxDView), this indicates that
you need to replace or clean the safety glass. (As shown
in Figure 156.)

A reference point here is the seam detection value provided in the

"System Status" section THxDView. If the percentage value specified for
the seam detection continually decreases while measuring the same
sample work piece, this may indicate significant contamination
co or deposits.
(Refer to the marked area in Figure 156.)

In this case, the safety glass should be checked and replaced if necessary.

Figure 156:: Preventive maintenance and diagnosis

After the safety glass is changed, the percentage value for the seam
detection should return to the proper range. (As shown in Figure 157.)

Figure 157: Changing the safety glass – improved seam detection

(example)

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 Maintenance

6.2.3 Overview of maintenance procedures

CAUTION!
The maintenance information in the table below is a recommendation but does not
guarantee error-free functionality.

Table 2: Maintenance procedures

Component / Maintenance procedure Hours of Section Page

module operation

Safety glass • Cleaning 8 6.3.1 6-5

• Glass may need changing

TH6D sensor • Cleaning the TH6D sensor When 6.3.2 6-8

head
head necessary

Hose connections • Check that the input and When 6.3.3 6-9
output sides are connected
necessary
firmly and that there are no
leaks or damage.

Cable connections • Check that the input and When 6.3.3 6-9
output sides are connected
necessary
firmly and that there is no
damage.

6.3 Handling the components

This section describes how to handle the individual components and modules during the
maintenance procedures.

6.3.1 Clean and change the safety glass

Overview
NOTE!
The TH6D system may only be used for welding processes
together with a TH6D sensor head and an attached safety
glass unit with a clean safety glass!

The safety glass unit with the built-in safety glass protects the optical
elements in the TH6D system from mechanical contamination, process
splatter and deposits.

Maintenance • Check regularly that the safety glass is clean (check for deposits or
procedure splatter) and undamaged.
• Clean the safety glass.
• Replace the safety glass if it is scratched.

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 Maintenance

Removing the
NOTE!
safety glass unit
The TH6D sensor head and the safety glass unit may be
heated up during the thermal processing. Allow the
modules to cool down before removal, or wear suitable
protective gloves!

• Pull the safety glass unit out in the opposite direction of

installation. Pull down and out of the enclosure for the TH6D
sensor head.
• Section 4.4.5 contains more information about the disassembly
process.

Remove the • In order to replace the safety glass, take hold of it with your thumb
protective glass and forefinger at the red marks (as shown in Figure 158). Gently
lift the safety glass up and pull out diagonally.

Figure 158: Replacing the safety glass – removing the safety glass

Cleaning the Any contamination of the safety glass from the process should be cleaned
safety glass as follows:

• Use only clean, lint-free cloths for cleaning.

• Clean with ethanol (do not use water or chemically aggressive
cleaning agents)!
• Wear gloves or finger coverlets in order to avoid leaving finger
prints.

Replacing parts Within this module, the following components can or must be replaced:

Item Designation Article no. : Can / must

1 Safety glass unit M001592 Can

2 Safety glass (Refer to Can

section 8.3.)

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 Maintenance

To insert new
CAUTION!
safety glass
Do not touch the unprotected surfaces of the
safety glasses!

NOTE!
Safety glasses are coated on both sides with a protective
foil. These foils must be removed during the insertion,
according to the instructions below.

• Take hold of the sides of the new safety glass using your thumb
and middle finger (hold the marked points shown in Figure 159).
• Carefully remove the protective foil on the bottom side (towards
the safety glass unit).
• Use your forefinger to push down on the safety glass so that it is
positioned between the spring strips.
• After it snaps into place, peel off the foil from the top side of the
safety glass.

Figure 159: Replacing the safety glass – inserting the new safety glass

Installing the • Install the safety glass unit (with the new safety glass) so that it is
safety glass unit aligned flush with the TH6D sensor head and until you hear a
clicking sound.
• Section 4.4.5 contains more information about the installation.

Functional testing Check that everything has been installed properly before re-
commissioning. Use a functional test with sample measurements.
• Move the TH6D sensor head manually over the work piece.
• Open up the THxDView program and switch the TH6D system into
set-up mode.
• Activate the measurement function in THxDView. Stop it after
about ten seconds.

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 Maintenance

Function test – • You can check the image by clicking on the "Raw Data" tab and
continued then on "Evaluation" in the image area (refer to section 5.6).
• When compared to measurements taken before the safety glass
was replaced, the new test measurements should exhibit less or no
errors and the percentage values for the seam detection should be
improved.
(Refer to the example in Figure 160.)
• If the seam detection is functioning smoothly, you can switch the
TH6D system to automatic mode and log out of THxDView.
• If the seam detection is still problematic, check that the safety
glass and the safety glass unit properly seated and consider
changing the parameter settings (refer to section 5.14.8).

Figure 160: Maintenance – replacing the safety glass – function test

6.3.2 Cleaning the TH6D sensor head

Overview
CAUTION!
A re-calibration is required after the position of the TH6D
sensor head is changed in relation to the tool or when it is
dismantled. Also check the calibration after cleaning!

The TH6D sensor head may get dirty depending on the nature of your
process. Any such contamination should be removed regularly.

Maintenance • Cleaning the TH6D sensor head

procedure • Cleaning the safety glass unit and the safety glass (and replacing
when necessary, refer to section 6.3.1)
• Cleaning plugs and media connectors

Cleaning
CAUTION!
Disconnect the power supply before cleaning!
Use non-abrasive cleansers when cleaning the
safety glasses on the TH6D sensor head!

• Use only clean, lint-free cloths for cleaning the safety glasses on
the TH6D sensor head.
• You may use a gentle, non-abrasive detergent (never use water or
aggressive chemical agents!).
• You may also use ethanol for cleaning.

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 Maintenance

6.3.3 Check the hose and cable connections

Overview The connections for the media-supply hoses and cables on the input side
of the TH6D sensor head are under heavy stress due to the motions of the
master machine/robot. These connections need to be inspected regularly.

Maintenance Check that the hose and cable connections:

procedure • Are attached firmly
• Do not leak
• Are not damaged

Replace any damaged hoses or cable.

Checking the hose

WARNING!
connections
Your eyes and ears can be damaged by emitted
media!

• Always wear proper protective gear for your eyes

and ears while carrying out maintenance work on
pressurized lines!

• Pressurize the supply circuit.

• Check the hose connections to the TH6D sensor head to make sure
there are no leaks (check for noise and feel for leaks)
• Be sure to de-pressurize (switch off) defective supply circuits!
• Replace the plugs, couplings or hoses.

Checking the • Switch off the electricity to the cable connections.

cable connections • Visually inspect all related cable connections to the TH6D sensor
head and TH6D process computer for possible damages.
• Replace any defective cables.

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 7. Troubleshooting
The chapter describes errors that may occur, along with their causes
and the appropriate measures that can be taken.

7.1 Notes .............................................................................. 7-2

7.2 Information, warning and error code tables for
THxDView ....................................................................... 7-3

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 Troubleshooting

7.1 Notes

We learn from your feedback.

It is not possible to totally exclude the possibility of malfunctions even after proper inspections
have taken place. We do not yet have a comprehensive list of faults and solutions.

Thus we recommend that you contact customer service if you are experiencing malfunctions or
difficulties.

Scansonic Scansonic IPT GmbH

Rudolf-Baschant-Straße 2
D-13086 Berlin, Germany
Tel.: +49 (0) 30 / 91 20 74 – 10
Fax::: +49 (0) 30 / 91 20 74 – 29
E-mail: service@scansonic.de
Internet: www.scansonic.de

Sales and
service partner

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 Troubleshooting

7.2 Information, warning and error code tables for THxDView

These information, warning and error code tables can be used for finding sources of errors in the
TH6D system.

Information

No. Code Description Information

1. I750 Automatic tracking is The TH6D system works in automatic mode.

activated

Warnings

No. Code Description Source of error / possible solution

1. W180 Excessive There is a problem with the TH6D sensor head's cooling
temperature at (air or water).
sensor • Check the coolant connections and coolant lines.
• Check the temperature of the coolant (refer to the
information in section 8.4 Medium)

2. W400 Laser off Status alert indicating that the laser is switched off
(system standby).

Automatic mode: The master machine has tried to turn

on the TH6D system but an error has occurred.

Manual mode: No connection from the TH6D process

computer to the TH6D sensor head; error E100 appears
at the same time.
• Activate the TH6D system using the controller on the
master machine or robot.
• Check the connection between the TH6D process
computer and the TH6D sensor head.
• Check the power supply to the TH6D sensor head.

3. W401 Laser safety circuit The laser safety circuit (LSC) is open.
off • Check that the LSC is closed.
• Check the LSC switch to make sure it is functioning
properly.
• Check the LSC cable. Replace it if it is defective.

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 Troubleshooting

No. Code Description Source of error / possible solution

4. W710 Manual mode The TH6D system is in set-up mode.

• Log in to THxDView (using the parameterization
access level). Switch the TH6D system to automatic
mode (refer to Sections 5.14.1 and 5.8.2)

5. W720 Sensor change The calibration profile for the actual job is no longer
without tool valid because a sensor has been changed.
calibration • Add the current calibration profile for the actual job.
Attention: This warning message can occur after E720
has been fixed when an internal tool calibration has
been carried out but not specified in the job.

Errors

No. Code Description Source of error / possible solution

1. E100 No communication Communication with the TH6D sensor head is not

with sensor possible.
• Check that the Ethernet and power cables and plugs
are undamaged and properly attached.
• Use the status LED on the TH6D system to check for
proper function (refer to section 3.5)

The TH6D sensor head may be defective if you have

ruled out cable connectivity problems.
• Contact your customer support representative and
send in your TH6D sensor head for repair.

2. E105 Sensor The firmware is not properly configured.

is not configured • Contact your customer support representative and
send in your TH6D sensor head for repair.

3. E110 There is an error with The calibration version of the TH6D sensor head does
the sensor not match with the software in the TH6D process
calibration. computer.
• Record the serial numbers of the TH6D sensor head
and process computer. Contact your customer
support representative.

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 Troubleshooting

No. Code Description Source of error / possible solution

4. E120 No reception of the The TH6D process computer is not receiving

measurement data. measurements for one of the following reasons:
Disruption of network communication between the
TH6D sensor head and the TH6D process computer.
• Check that the Ethernet and power cables and plugs
are undamaged and properly attached.
• Use the status LED on the TH6D system to check for
proper function (refer to section 3.5)

The TH6D sensor head is defective.

• Contact your customer support representative and
send in your TH6D sensor head for repair.

The power supply to the TH6D sensor head is too low.

• Check the output of the power supply and ensure

that it is sufficient (refer to section 8.1 Technical
Specifications)

5. E150 Internal sensor error Electronic defect in the TH6D sensor head.

• Record the serial numbers of the TH6D sensor head

and process computer. Contact your customer
support representative.

6. E300 Process interface is The process interface to the master machine (section
not ready 5.9) is not able to communicate because of an
initialization error.
• Record the serial numbers of the TH6D sensor head
and process computer. Contact your customer
support representative.

7. E310 No communication on The connection between the master machine / robot

the process interface and the TH6D process computer is malfunctioning.

• Check that the cables and plugs are undamaged and

properly attached.
• Check the software on the master machine / robot.
• Check the communication between the master
machine / robot and the TH6D sensor system.

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 Troubleshooting

No. Code Description Source of error / possible solution

8. E600 Job is not selected The job was not selected by the master machine /
robot or no job number was sent by the master
machine / robot to the TH6D system.
• Check the programming on the master machine /
robot to ensure that the jobs numbers are assigned
properly.

9. E605 Job number not An improper job number has been selected or sent. The
allowed job number is not assigned in the TH6D process
computer.
• Check the programming on the master machine /
robot to ensure that the jobs numbers are assigned
properly.

10. E610 Error in job profile The TH6D system has a software error.

• First delete the job and then the corresponding

profiles. Then create both again (refer to section
5.14.9)

11. E620 Job profile is missing The TH6D system has a software error.

• First delete the job and then the corresponding

profiles. Then create both again (refer to section
5.14.9)

12. E650 Job internal error The TH6D system has a software error.
• Delete the corresponding job and create a new one.

13. E720 Sensor change has Code indicates that a TH6D sensor head was changed.
been detected When a TH6D sensor head is changed, the TH6D
system automatically switches to manual mode.

When using an internal tool calibration:

• Carry out a new internal tool calibration (refer to
section 5.14.6)
• Integrate the newly created calibration profile into
your created job (refer to section 5.14.9)

When using an external tool calibration:

• Acknowledge this error by switching to automatic
mode (refer to section 5.8.2)
• Run the external tool calibration again.
• Check the tool machine via the machine or robot.

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 8. Technical Data and Specifications
This section lists the technical specifications for the TH6D system.

8.1 Technical data and specifications .................................... 8-2

8.2 Electrical switching functions of the analogue-digital
interface (ADF) ................................................................ 8-7
8.3 Electrical switching functions of the Motoman
interface ......................................................................... 8-8
8.4 Medium........................................................................... 8-9
8.4.1 Compressed air specifications .......................................... 8-9
8.4.2 Coolant specification ...................................................... 8-9
8.5 Ambient conditions ....................................................... 8-10
8.6 Accessories and spare parts .......................................... 8-11
8.6.1 Base configuration for the TH6D system ......................... 8-11
8.6.2 Optional components ................................................... 8-12
8.6.3 Optional components for the ABB and KUKA robots .......... 8-13
8.6.4 Wearing parts – safety glasses ...................................... 8-14

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 Technical Data and Specifications

8.1 Technical data and specifications

TH6D sensor head, Characteristics

in general

Configurations • TH6D-150-CFAA-AB
• TH6D-150-KFAA-AB

Power supply • 12 – 36 V DC (125 mA max. at nominal 24 V)

• Protected against false insertion

Weight • TH6D sensor head 0.53 kg

• TH6D sensor head including safety glass unit: 0.65 kg

Limiting acceleration (mechanical) • 3 g (with or without functional operations)

Laser protection class • 3B

Protection class • IP64 (with plugged-in connectors)

Operating wavelength • 660 nm

Max. laser output • 50 mW

Dimensions • 70 x 121 x 40 mm (L x H x W)

Figure 161: TH6D sensor head – dimensions

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 Technical Data and Specifications

TH6D safety glass unit Characteristics

Dimensions

Figure 162: TH6D safety glass unit – dimensions

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 Technical Data and Specifications

Sensor head TH6D-150-CFAA-AB

Field of measurement • Width: ± 8 mm

(width / height) • Height: ± 12 mm

Optical resolution in the TCP • 0.07 mm/pixel along X axis

• 0.03 mm/pixel along Y axis

Nominal working gap • 150 mm from bottom edge of sensor

(z = 0 mm)

Nominal working gap • 10 mm from rear edge of sensor

(x = 0 mm)

Operating range

S0 S0

Figure 163: Operating range TH6D-150-CFAA-AB

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 Technical Data and Specifications

Sensor head TH6D-150-KFAA-AB

Field of measurement • Width: ± 22 mm

(width / height) • Height: ± 40 mm

Optical resolution in the TCP • 0.1 mm/pixel along X axis

• 0.3 mm/pixel along Y axis

Nominal working gap • 150 mm from bottom edge of sensor

(z = 0 mm)

Nominal working gap • 10 mm from rear edge of sensor

(x = 0 mm)

Operating range

S0 S0

Figure 164: Operating range TH6D-150-KFAA-AB

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 Technical Data and Specifications

TH6D process computer Characteristics

Dimensions • 270 x 200 x 105 mm (L x W x H)

• 270 x 220 x 105 mm (L x W x H) with mounting
attachment

Power supply • 12 – 36 V DC (500 mA max. at 24 V), protected against

false insertion

Weight • Approx. 3.0 kg

Facility and plant integration • Ethernet

• Serial port

Figure 165: TH6D process computer – dimensions

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 Technical Data and Specifications

8.2 Electrical switching functions of the analogue-digital interface (ADF)

Note that the signals of one type are numbered consecutively. The inputs of the second digital
input module, for example, represent the ADF inputs 5 through 8. This principle applies to all
signal types. The assignments listed here are set as the default. It is possible to change these
assignments.

NOTE!
Seam search and measurement will only function when the currently selected job has
been created and activated.

Signal type Sequential no. Designation

1 Laser On/Off The laser is switched on or off

2 Seam search Start/Stop The measurement is started or stopped
-
-
5 Job No. (bit 0)
6 Job No. (bit 1)
7 Job No. (bit 2)
Digital 8 Job No. (bit 3)
input 9
10
11
12
13
14
15
16
1 Automatic mode Automatic mode is activated
2 System is ready Seam tracking system is ready
3 Tracking is activated Tracking has been started
4 Seam is found The seam position is currently detected
5
6
7
Digital 8
output 9
10
11
12
13
14
15
16
1
Analogue 2
input 3
4
1 Seam position Y
Analogue 2 Seam position Z
output 3 Height difference
4 Gap width

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 Technical Data and Specifications

8.3 Electrical switching functions of the Motoman interface

The electrical switching functions of the Motoman Interface are identical with the ADF, except for
the differences which have been marked.

NOTE!
Seam search and measurement will only function when the currently selected job has
been created and activated.

Signal Sequential Designation

type number

1 Laser On/Off The laser is switched on or off

2 Seam search Start/Stop The measurement is started or stopped
3 Reference movement 0 = reference recording track, 1 = reference
movement
4 Corrective movement 1 = active (then DI3 has no effect)
5 Job No. (bit 0)
6 Job No. (bit 1)
7 Job No. (bit 2)
Digital
8 Job No. (bit 3)
input
9
10
11
12
13
14
15
16
1 Automatic mode Automatic mode is activated
2 System is ready Seam tracking system is ready
3 Tracking is activated Tracking has been started
4 Seam is found The seam position is currently detected
5
6
7
Digital 8
output 9
10
11
12
13
14
15
16
1
Analogue 2
input 3
4
1 Seam position Y
Analogue 2 Seam position Z
output 3 Height difference
4 Gap width

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 Technical Data and Specifications

8.4 Medium

8.4.1 Compressed air specifications

Compressed air Characteristics

specifications

Type of connections • Purge air:

Quick-lock coupling for Ø Outer = 4 mm
• Cooling air:
Quick-lock coupling for Ø Outer = 6 mm

Required air quality • Oil and water free, filtered, dry

Recommended flow rate for • 1 l/min

purging

Allowable maximum pressure • 6 bar

for cooling

8.4.2 Coolant specification

ATTENTION!
This information is relevant only when using the optional cooling module!
• Do not allow any liquid coolants into the TH6D sensor head!

Coolant specifications Characteristics

Type of connections • Quick-lock coupling for ØOuter = 6 mm

Type of coolant • Suitable for DI water (stainless steel version)

Flow quantity • 2 l/min at 6 bar

Minimum coolant temperature • > 15 °C

Maximum coolant temperature • 25 °C

Maximum pressure • 6 bar

Conductivity • Conductivity to 2 µS/cm

pH value • 5.5 – 8

Maximum particle size • < 50 µm

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 Technical Data and Specifications

8.5 Ambient conditions

Please follow the information about the ambient, environmental conditions for the TH6D system
given in the table below.

Table 3: Ambient conditions

Storage temperature -10 to +60 °C (observe dew point!)

Operating temperature TH6D sensor head: +10 to +50 °C (min. 5 °C above the
condensation point!)
TH6D process computer: +5 to +50°C (min. 5°C above the
condensation point!)

Enclosure temperatures +25 to +45 °C

for achieving the
specified measurement
precision

Permitted relative < 95 % (non-condensing!)

humidity

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 Technical Data and Specifications

8.6 Accessories and spare parts

The following accessories and spare parts are available for the TH6D system.

NOTE
Please specify the article number and name when ordering.

8.6.1 Base configuration for the TH6D system

Item Article No. Designation Description / function Figure

1 M001806 TH6D
TH6D-150-CFAA-AB TH6D sensor head

For thin sheet metal

applications

2 M001879 TH6D
TH6D-150-KFAA-AB TH6D sensor head

For thick sheet metal

applications

3 M001592 Safety glass unit Protection against process

splatter and deposits

4 M001797 TH6D process computer System controller,

with software measurement analysis

5 M001585 THxD cable set [10 m] Consisting of M001704

and M001705

6 M001704 THxD power cable [10 m] Cable for power supply to the
TH6D sensor head

7 M001705 THxD Ethernet cable [10 m] Ethernet cable for connecting

the TH6D sensor head to the
process computer

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 Technical Data and Specifications

Item Article No. Designation Description / function Figure

8 M001587 Power supply unit 24V-3,

24V Power supply
2A TH6D sensor head

9 M001713 THxDView ver. 1.0 CD with configuration

software

10 License agreement Comes with THxDView

(M001713)

8.6.2 Optional components

Item Article No. Designation Description / function Figure

1 M001589 Modbus TCP analogue-

analogue For the ADF and Motoman
digital interface interfaces

2 M001586 THxD cable set [15 m] Consisting of M001706

and M001707

3 M001706 THxD power cable [15 m] Cable for power supply to the
TH6D sensor head

4 M001707 THxD Ethernet cable Ethernet cable for connecting

[15 m] the TH6D sensor head to the
process computer

5 M001618 THxD cable set [25 m] Consisting of M001708

and M001709

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 Technical
ical Data and Specifications

Item Article No. Designation Description / function Figure

6 M001708 THxD power cable [25 m] Cable for power supply to the
TH6D sensor head

7 M001709 THxD Ethernet cable Ethernet cable for connecting

[25 m] the TH6D sensor head to the
process computer

8 M001852 Patch cable (1 m) Cable for the Ethernet

connection

9 M001853 Patch cable (2 m) Cable for the Ethernet

connection

10 M001854 Patch cable (5 m) Cable for the Ethernet

connection

11 M001855 Patch cable (10 m) Cable for the Ethernet

connection

8.6.3 Optional components for the ABB and KUKA robots

Item Article No. Designation Description / function Figure

1 M001799 Calibration plate THxD Tool for calibrating the TH6D

sensor head

2 M001834 Cross
Cross-hairs insert for the Insert for calibration plate, to
calibration plate help calibrate welding
applications (arc welding)

3 M001835 Tip insert for the calibration Insert for calibration plate, to
plate help calibrate laser
applications

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 Technical Data and Specifications

8.6.4 Wearing parts – safety glasses

Item Article No. Designation Description / function Figure

1 M001652 Safety glass Scaled 1–9

2 M001612 Safety glass Scaled 10-24

3 M001610 Safety glass Scaled 25-49

4 M001613 Safety glass Scaled 50-99

5 M001614 Safety glass Scaled 100-499

6 M001615 Safety glass Scaled 500-999

7 M001609 Safety glass Scaled 11000 +

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 9. Appendix
9.1 Annex ............................................................................. 9-2
9.1.1 List of Figures ............................................................... 9-2
9.1.2 List of Tables................................................................. 9-6
9.2 Check-list for set-up and installation............................... 9-7
9.3 Contamination Declaration .............................................. 9-9
9.4 Condensation point table .............................................. 9-10

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9.1 Annex

9.1.1 List of Figures

Figure 1: TH6D sensor head – laser aperture .................................................................... 2-5
Figure 2: Location of the warning LED on the TH6D sensor head.......................................... 2-6
Figure 3: TH6D – The principle of laser triangulation .......................................................... 3-3
Figure 4: Specular (left) and diffuse (right) reflection ......................................................... 3-5
Figure 5: Diffuse reflection on work piece with rough surface .............................................. 3-6
Figure 6: Disturbances in the arc welding process .............................................................. 3-6
Figure 7: MIG process – the inert gas nozzle is clearly visible on the right ............................ 3-7
Figure 8: Laser welding process – laser focus on right ........................................................ 3-7
Figure 9: Accessibility limitations at the end of the seam caused by the forward-leading
sensor .......................................................................................................................... 3-8
Figure 10: Accessibility limitations in a seam curve caused by the forward-leading
sensor .......................................................................................................................... 3-8
Figure 11: Example of a border – the lap joint is too large .................................................. 3-9
Figure 12: Example of a border – the lap joint is too large – the solution .............................. 3-9
Figure 13: The TH6D sensor head .................................................................................. 3-11
Figure 14: TH6D safety glass unit .................................................................................. 3-12
Figure 15: TH6D process computer ................................................................................ 3-13
Figure 16: TH6D system – cable for Ethernet connection .................................................. 3-14
Figure 17: TH6D system – power supply cable ................................................................ 3-15
Figure 18: The TH6D sensor head's cooling module .......................................................... 3-16
Figure 19: TH6D auxiliary module – analogue-digital interface .......................................... 3-17
Figure 20: TH6D auxiliary module – calibration plate ........................................................ 3-18
Figure 21: TH6D auxiliary module – network cable........................................................... 3-19
Figure 22: Status LEDs on the TH6D sensor head ............................................................ 3-20
Figure 23: Status LEDs on the TH6D process computer .................................................... 3-22
Figure 24: Connections for the TH6D sensor head ............................................................ 3-24
Figure 25: Connection overview for the TH6D process computer, rear side......................... 3-26
Figure 26: Connection overview for the TH6D process computer, front side......................... 3-26
Figure 27: Sensor origin for the TH6D sensor head (CF variant) .......................................... 4-7
Figure 28: Earthing via the robotics interface, variant 1 ...................................................... 4-9
Figure 29: Earthing via the robotics interface, variant 2 .................................................... 4-10
Figure 30: Earthing via the power supply ........................................................................ 4-11
Figure 31: Position of the TH6D sensor head (example) .................................................... 4-12
Figure 32: Installing the safety glass unit ....................................................................... 4-14
Figure 33: Mounting the cooling module ......................................................................... 4-15
Figure 34: TH6D system – connecting the Ethernet cable.................................................. 4-16

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 Figure 35: Ethernet cable connection ............................................................................. 4-16
Figure 36: Power supply on the TH6D sensor head ........................................................... 4-19
Figure 37: Connecting the cooling and purging air to the TH6D sensor head........................ 4-20
Figure 38: Connecting the liquid coolants to the cooling module ........................................ 4-21
Figure 39: Mounting rails for the TH6D process computer ................................................. 4-22
Figure 40: Power supply on the TH6D process computer ................................................... 4-23
Figure 41: Connecting the user PC for THxDView ............................................................. 4-24
Figure 42: TH6D system – overview of connections without machine interfaces ................... 4-25
Figure 43: TH6D analogue-digital interface (standard)...................................................... 4-26
Figure 44: Connecting the ADF to the TH6D process computer .......................................... 4-27
Figure 45: Power supply on the analogue-digital interface ................................................. 4-28
Figure 46: Parallel power supply connection to the analogue-digital interface ...................... 4-29
Figure 47: TH6D system – overview of connections with ADF ............................................ 4-30
Figure 48: Connecting the Fanuc interface ...................................................................... 4-31
Figure 49: TH6D system – overview of connections with Fanuc interface ............................ 4-32
Figure 50: THxDView – initializing the installation .............................................................. 5-6
Figure 51: THxDView – installation information.................................................................. 5-7
Figure 52: THxDView – starting the installation ................................................................. 5-7
Figure 53: THxDView – changing the installation directory .................................................. 5-8
Figure 54: THxDView – selecting the installation directory .................................................. 5-8
Figure 55: THxDView – installation progress ..................................................................... 5-9
Figure 56: THxDView – installation is finished.................................................................... 5-9
Figure 57: THxDView – the desktop icon......................................................................... 5-10
Figure 58: THxDView – the start-up window.................................................................... 5-10
Figure 59: Exiting THxDView ......................................................................................... 5-11
Figure 60: THxDView – user interface............................................................................. 5-12
Figure 61: THxDView – menu bar .................................................................................. 5-14
Figure 62: THxDView – program information ................................................................... 5-14
Figure 63: Image area – raw data (example with V-seam) ................................................ 5-15
Figure 64: Image area – analysis, measuring inactive ...................................................... 5-16
Figure 65: Image area – analysis, measuring activated .................................................... 5-16
Figure 66: Reports area – Errors and Warnings (example) ................................................ 5-17
Figure 67: Reports area – Events (example) ................................................................... 5-17
Figure 68: THxDView – "System Status" area (example) .................................................. 5-18
Figure 69: THxDView – "System Status", network connection (example) ............................ 5-18
Figure 70: THxDView – system status, operating mode .................................................... 5-19
Figure 71: THxDView – system status, measuring ............................................................ 5-20
Figure 72: THxDView – system status, job ...................................................................... 5-21
Figure 73: Parameters area – display of measurements (example) .................................... 5-22

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 Figure 74: Information area – diagram (example for adjusting the angle) ........................... 5-23
Figure 75:: Information area - Detailed view of parameters .............................................. 5-24
Figure 76: THxDView – Information about parameters ..................................................... 5-24
Figure 77: THxDView – parameter configuration area ....................................................... 5-25
Figure 78: THxDView – parameter configuration area – profiles ......................................... 5-25
Figure 79: THxDView – Seam Pattern tab ....................................................................... 5-26
Figure 80: THxDView – selecting the seam pattern profile................................................. 5-27
Figure 81: THxDView – seam pattern template for an open edge ....................................... 5-28
Figure 82: THxDView – seam pattern template for an overlap seam ................................... 5-28
Figure 83: THxDView – seam pattern template for a tailored blank .................................... 5-29
Figure 84: THxDView – seam pattern template for a TB-Area ............................................ 5-29
Figure 85: THxDView – seam pattern template for a V-seam ............................................. 5-30
Figure 86: THxDView – seam pattern template for a HV-seam........................................... 5-30
Figure 87: THxDView – seam pattern template for a HY-seam ........................................... 5-31
Figure 88: THxDView – seam pattern template for a U-seam............................................. 5-31
Figure 89: THxDView – seam pattern template for a HU-seam .......................................... 5-31
Figure 90: THxDView – line quality parameters (examples) ............................................... 5-33
Figure 91: THxDView – reference area parameter at the overlap seam ............................... 5-34
Figure 92: THxDView – TCP alignment parameters........................................................... 5-35
Figure 93: THxDView – depth parameter, with the example of an HV-seam ........................ 5-35
Figure 94: THxDView – angle left/right parameters .......................................................... 5-36
Figure 95: THxDView – Mismatch parameter at the overlap seam ...................................... 5-37
Figure 96: THxDView – "gap" parameters (example of tailored blank) ................................ 5-38
Figure 97: THxDView – "Interpolation point tolerance" parameter - 1 ................................. 5-38
Figure 98: THxDView – "Interpolation point tolerance" parameter - 2 ................................. 5-39
Figure 99: THxDView – " Line diff. (A, L)" parameter........................................................ 5-40
Figure 100: THxDView – "preferred seam position" parameter (example) ........................... 5-41
Figure 101: THxDView – "preferred joint position" parameter (example)............................. 5-41
Figure 102: THxDView – Camera tab .............................................................................. 5-42
Figure 103: THxDView – Calibration tab ......................................................................... 5-43
Figure 104: THxDView – parameters for calibration .......................................................... 5-44
Figure 105: THxDView – Process Control tab A/D-IF......................................................... 5-45
Figure 106: THxDView – parameters area – system ......................................................... 5-46
Figure 107: THxDView – job list..................................................................................... 5-47
Figure 108: THxDView – job compilation in the System Status area ................................... 5-47
Figure 109: THxDView – selecting the interface ............................................................... 5-49
Figure 110: THxDView – configuring the "Evaluation" image area ...................................... 5-50
Figure 111: THxDView – configuring the "Evaluation" image area (example) ....................... 5-50
Figure 112: THxDView – configuring the "Raw data" image area (example) ........................ 5-51

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 Figure 113: THxDView – analogue-digital correction interface ........................................... 5-52
Figure 114: A/D interface – process control .................................................................... 5-53
Figure 115: THxDView – Motoman reference path interface .............................................. 5-54
Figure 116: Motoman reference path – operating modes .................................................. 5-55
Figure 117: Manually switching the control mode ............................................................. 5-56
Figure 118: Control mode "manual" – operating mode "record" ......................................... 5-56
Figure 119: THxDView – Motoman reference path – information field ................................. 5-58
Figure 120: Motoman interface – process control ............................................................. 5-59
Figure 121: Fanuc Ethernet interface – changing the IP address ........................................ 5-61
Figure 122: Fanuc Ethernet interface – creating a calibration profile ................................... 5-62
Figure 123: Fanuc Ethernet Interface – creating a calibration job (example) ....................... 5-63
Figure 124: Fanuc Ethernet interface – process control ..................................................... 5-63
Figure 125: THxDView – UDP Data interface ................................................................... 5-64
Figure 126: THxDView – user login ................................................................................ 5-66
Figure 127: User login – password entry ......................................................................... 5-66
Figure 128: Login failure ............................................................................................... 5-66
Figure 129: Changing the access level after the login ....................................................... 5-67
Figure 130: THxDView – selecting a sensor system (example)........................................... 5-68
Figure 131: THxDView – Manage sensor systems (example) ............................................. 5-68
Figure 132: Establishing the connection to the TH6D system (example) ............................. 5-69
Figure 133: THxDView – connected network status (example) ........................................... 5-69
Figure 134: THxDView – configuring the automatic connection .......................................... 5-70
Figure 135: THxDView – choosing a value for the automatic connection ............................. 5-70
Figure 136: THxDView – changing the system language ................................................... 5-71
Figure 137: THxDView – the set-up operating mode......................................................... 5-72
Figure 138: Positioning the TH6D sensor head – V-seam example...................................... 5-73
Figure 139: Orientation of the TH6D sensor head in relation to the calibration plate ............. 5-76
Figure 140: THxDView – specifying the parameters for calibrating - 1 ................................ 5-77
Figure 141: THxDView – specifying the parameters for calibrating - 2 ................................ 5-77
Figure 142: THxDView – specifying the parameters for calibrating the tool.......................... 5-78
Figure 143: THxDView – changing the camera settings..................................................... 5-79
Figure 144: THxDView – changing parameters (example) ................................................. 5-80
Figure 145: THxDView – incorrect parameter entry (example) .......................................... 5-81
Figure 146: THxDView – setting up a profile.................................................................... 5-82
Figure 147: THxDView – saving a profile......................................................................... 5-82
Figure 148: THxDView – selecting the profile from the drop-down list ................................ 5-83
Figure 149: THxDView – job list..................................................................................... 5-83
Figure 150: THxDView – creating a new job .................................................................... 5-84
Figure 151: THxDView – entering a job name .................................................................. 5-84

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 Figure 152: THxDView – assigning a profile..................................................................... 5-85
Figure 153: THxDView – saving a new job ...................................................................... 5-85
Figure 154: THxDView – changing the content of jobs ...................................................... 5-86
Figure 155: THxDView – notes on the job list .................................................................. 5-86
Figure 156: Preventive maintenance and diagnosis ............................................................ 6-4
Figure 157: Changing the safety glass – improved seam detection (example) ....................... 6-4
Figure 158: Replacing the safety glass – removing the safety glass ...................................... 6-6
Figure 159: Replacing the safety glass – inserting the new safety glass ................................ 6-7
Figure 160: Maintenance – replacing the safety glass – function test .................................... 6-8
Figure 161: TH6D sensor head – dimensions ..................................................................... 8-2
Figure 162: TH6D safety glass unit – dimensions ............................................................... 8-3
Figure 163: Operating range TH6D-150-CFAA-AB .............................................................. 8-4
Figure 164: Operating range TH6D-150-KFAA-AB .............................................................. 8-5
Figure 165: TH6D process computer – dimensions ............................................................. 8-6

9.1.2 List of Tables

Table 1: Position of notice and warning signs .................................................................. 2-11
Table 2: Maintenance procedures..................................................................................... 6-5
Table 3: Ambient conditions .......................................................................................... 8-10

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9.2 Check-list for set-up and installation
This check-list for set-up and installation references the information found in sections 4.3 and
4.4.

Item Procedural steps Completed

1 Mechanical mounting

Overview: Please follow the instructions for installing the TH6D system in
Chapter 4.

Mounting: The TH6D sensor head should be mechanically connected to the

master machine. (Refer to section 0.)

Orientation: The TH6D sensor head should be aligned with the work piece
surface so that the edges of the work piece can be detected in the sensor
measuring range. (Raw data in THxDView)

Screws should be tightened by hand. (Caution! Aluminium housing)

Safety glass unit with safety glass should be mounted on the TH6D sensor
head.
(Refer to section 4.4.5.)

The Ethernet cable should connect the TH6D sensor head (plug-in slot X5)
to the TH6D process computer (plug-in slot 5). (Refer to section 0.)

The power cable should connect the TH6D sensor head (plug-in slot X4) to
the mains power supply unit. (Refer to section 4.4.8.)

The power supply cable should be connected to the TH6D process computer
(plug-in slot 2). (Refer to section 4.4.12.)

The TH6D process computer should be mechanically connected to the

master machine.

Strain relief mechanisms should be in place for the individual cables and
hoses.

2 Media supply

The compressed air supply for the cooling air (for the optional cooling air)
should be connected with the TH6D sensor head (plug-in slots X2, X3, X3).
(Refer to section 4.4.9.)

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 Item Procedural steps Completed

There should be sufficient capacity in the hoses to supply the media

(compressed air and purging air). The outer hose diameter should be 4/8
mm.

The quality of the supplied media should be verified.

Optional: For high power applications, an additional heat sink should be

attached to the TH6D sensor head by the customer.

3 Installation and construction

The compressed air supply (cooling and purging air) should be connected
to the proper maintenance unit via a cut-off valve (with filter and de-
humidifier).

The pre-pressure of the cooling air should be ≤ 6 bar.

The pre-pressure of the purging air should be ≤ 3 bar.

4 Software configuration / parameterization

Overview: To ensure smooth operations, follow the instructions for

installing and configuring THxDView as described in Chapter 5.

THxDView should be installed on the user PC (refer to section 5.3).

The user PC running THxDView should have an Ethernet connection to the

TH6D process computer (at plug-in slot 6).

The processing parameters should have been verified and specified when
necessary using THxDView.

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9.3 Contamination Declaration

Notes When returning the TH6D system, please fill out this declaration
completely.
With this declaration, you confirm the correctness and
completeness of the following data.

Adding a device

Configuration number:

Serial number:

Reason for return:

Type of contamination:

Type of medium used:

The device was cleaned by

the customer using:

Other details:

Declaration (legally valid)

Company

Address

Telephone

Contact person:

Date: Signature:

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9.4 Condensation point table
Condensation point temperatures (in °C) at a relative air humidity level of:
Air 45 % 50 % 55 % 60 % 65 % 70 % 75 % 80 % 85 % 90 % 95 %
temperature
2 °C -7.8 -6.6 -5.4 -4.4 -3.2 -2.5 -1.8 -1.0 -0.3 0.5 1.2
4°C -6.1 -4.9 -3.7 -2.6 -1.8 -0.9 -0.1 0.8 1.6 2.4 3.2
6°C -4.5 -3.1 -2.1 -1.1 -0.1 0.9 1.9 2.7 3.6 4.5 5.4
8°C -2.7 -1.6 -0.4 0.7 1.8 2.8 3.8 4.8 5.7 6.5 7.3
10°C -1.3 0.0 1.3 2.5 3.7 4.8 5.8 6.8 7.7 8.5 9.3

12°C 0.4 1.8 3.2 4.5 5.6 6.7 7.8 8.7 9.6 10.5 11.3
14°C 2.2 3.8 5.1 6.4 7.6 8.7 9.7 10.7 11.6 12.6 13.4
15°C 3.1 4.7 6.1 7.4 8.5 9.6 10.7 11.7 12.6 13.5 14.4
16°C 4.1 5.6 7.0 8.3 9.5 10.6 11.7 12.7 13.6 14.6 15.5
17°C 5.0 6.5 7.9 9.2 10.4 11.5 12.5 13.6 14.5 15.4 16.2
18°C 5.9 7.4 8.8 10.1 11.3 12.4 13.5 14.6 15.4 16.3 17.3
19°C 6.8 8.3 9.8 11.1 12.3 13.4 14.5 15.5 16.4 17.4 18.2
20°C 7.7 9.3 10.7 12.0 13.2 14.4 15.5 16.5 17.4 18.4 19.2

21°C 8.6 10.2 11.6 12.9 14.2 15.4 16.4 17.4 18.4 19.3 20.2
22°C 9.5 11.2 12.5 13.9 15.2 16.3 17.4 18.4 19.4 20.3 21.2
23°C 10.4 12.0 13.5 14.9 16.0 17.3 18.4 19.4 20.4 21.3 22.2
24°C 11.3 12.9 14.4 15.7 17.1 18.2 19.2 20.3 21.4 22.3 23.2
25°C 12.2 13.8 15.4 16.7 18.0 19.1 20.2 21.4 22.3 23.3 24.2

26°C 13.2 14.8 16.3 17.7 18.9 20.1 21.3 22.3 23.3 24.3 25.2
27°C 14.1 15.7 17.2 18.6 19.8 21.1 22.2 23.3 24.3 25.2 26.1
28°C 15.0 16.6 18.1 19.4 20.9 22.1 23.2 24.3 25.3 26.2 27.2
29°C 15.9 17.6 19.0 20.5 21.8 23.0 24.2 25.2 26.2 27.3 28.2
30°C 16.8 18.4 20.0 21.4 23.7 23.9 25.1 26.1 27.2 28.2 29.1

32°C 18.6 20.3 21.9 23.3 24.7 25.8 27.1 28.2 29.2 30.2 31.2
34°C 20.4 22.2 23.8 25.2 26.5 27.9 28.9 30.1 31.2 32.1 33.1
36°C 22.2 24.1 25.5 27.0 28.4 29.7 30.9 32.0 33.1 34.2 35.1
38°C 24.0 25.7 27.4 28.9 30.3 31.6 32.8 34.0 35.0 36.1 37.0
40°C 25.8 27.7 29.2 30.8 32.2 33.5 34.7 35.9 37.0 38.1 39.1

45°C 30.3 32.2 33.9 35.4 36.9 38.2 39.5 40.7 41.9 43.0 44.0
50°C 34.8 36.6 38.5 40.1 41.6 43.0 44.3 45.6 46.8 47.9 49.0
(1) Values are rounded off.
The condensation point tables indicates when condensation will occur at different surface temperatures, and
depending on the air temperature and relative humidity.
Example: At an air temperature of 20°C and a relative humidity of 70%, the condensation point will be
reached when the object temperature is 14.40°C.
Our recommendation: Make sure that you choose an operating temperature (cool water temperature) that is
high enough so that there is no chance of condensation even when there are changes in the surrounding
temperature or air humidity. You may need to temper the effect of the coolant water if you are in doubt.
The information is provided here to the best of our knowledge but is not legally binding for any third parties.
The purchase still has an obligation to check the information himself. The user is responsible whenever the
equipment is used at temperatures above the condensation point.

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