PRIMESOperating Manual

Translation of the Original Instructions

BeamControlSystem
BCS
Hardware and Software Interface PROFIBUS

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BeamConrolSystem BCS PROFIBUS

PRIMES

Contents
1

BASIC SAFETY INSTRUCTIONS

52SYMBOL EXPLANATIONS

73PRIMES – THE COMPANY

84INTRODUCTION

95SYSTEM DESCRIPTION

106CONDITIONS AT THE INSTALLATION SITE

11

7

CONNECTIONS

12INSTALLATION

13

8

8.1
8.2
8.3
9

MECHANICAL CONNECTIONS
9.1
9.2

10

11.4

12

13

14

34

Measuring procedure.............................................................................................................................. 34
Measuring procedure in detail................................................................................................................ 35

LASER DIAGNOSTIC SOFTWARE (LDS)
14.1
14.2
14.3
14.4

30

Establishing a connection to PC............................................................................................................. 31
Changing the IP address........................................................................................................................ 31
Automatically obtain the IP-address....................................................................................................... 33

MEASURING OPERATION
13.1
13.2

23

Interface description................................................................................................................................ 23
Device database file (GSD-file)............................................................................................................... 23
Bus address............................................................................................................................................ 24
11.3.1
Changing the bus address by means of the PLC software.................................................... 24
11.3.2
Changing the bus address by means of the LaserDiagnosticSoftware................................. 25
Profibus register structure of the BeamControlSystem........................................................................... 27
11.4.1
Output register control (Command Register)......................................................................... 27
11.4.2
Input register control: status................................................................................................... 27
11.4.3
Error register.......................................................................................................................... 28
11.4.4
Input register: results............................................................................................................. 29

ETHERNET CONFIGURATION
12.1
12.2
12.3

19

PROFIBUS Data..................................................................................................................................... 19
PROFIBUS power supply....................................................................................................................... 20
PROFIBUS Status-LEDs........................................................................................................................ 20
PRIMES Bus........................................................................................................................................... 21
Ethernet connection................................................................................................................................ 21
External safety circuit.............................................................................................................................. 22

PROFIBUS
11.1
11.2
11.3

17

Cooling circuit system............................................................................................................................. 17
9.1.1
Conditions.............................................................................................................................. 17
9.1.2
Connection............................................................................................................................. 17
Compressed air...................................................................................................................................... 18

ELECTRICAL CONNECTIONS
10.1
10.2
10.3
10.4
10.5
10.6

11

Installation into the Laser System........................................................................................................... 13
Alignment to the beam axis.................................................................................................................... 14
Mounting................................................................................................................................................. 15

37

User level................................................................................................................................................ 37
Evaluation function.................................................................................................................................. 39
Storage location of the measuring values............................................................................................... 40
Automated script procedure.................................................................................................................... 40

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BeamConrolSystem BCS PROFIBUS

Editing the configuration file................................................................................................... 41
Global settings....................................................................................................................... 41

15

REMOVAL FROM THE LASER SYSTEM

43

16

MAINTENANCE

43

17

MEASURES FOR THE PRODUCT DISPOSAL

43

18

DIMENSIONS

44

19

TECHNICAL DATA

46

20

DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY48

APPENDIX

49

21

21.1
21.2
21.3
21.4
21.5
21.6

4

LDS installation for an automated measuring mode............................................................................... 49
21.1.1
Installation process................................................................................................................ 49
21.1.2
Configuration of the LDS for the communication with the device........................................... 54
Presettings for the measurement programs............................................................................................ 56
Configuration of the laserds.ini............................................................................................................... 60
Configuration of measuring programs..................................................................................................... 62
Configuration of the evaluation parameters............................................................................................ 64
21.5.1
Show the evaluation file......................................................................................................... 66
Automatic run.......................................................................................................................................... 67

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1PRIMES

Basic safety instructions

Intended use
The BeamControlSystem (BCS) is exclusively intended for measurements carried out in or near the optical
path of high power lasers. Other forms of usage are improper. To ensure a safe operation, the BCS must
only be operated according to the terms stipulated by the manufacturer.
Improper usage of the BCS is strictly prohibited and could lead to health endangering or even deathly injuries.
When operating the BCS it must be ensured that there are no potential hazards to human health.
The BCS itself does not emit any laser radiation. During the measurement, however, the laser beam is guided
through the device which may cause scattered radiation. That is why the applying safety regulations are tobe observed and necessary protective measures need to be taken.
Observing applicable safety regulations
Please observe valid national and international safety regulations as stipulated in ISO/CEN/TR standards
as well as in the IEC-60825-1 regulation, in ANSI Z 136 “Laser Safety Standards” and ANSI Z 136.1 “Safe
Use of Lasers”, published by the American National Standards Institute, and additional publications, suchas the “Laser Safety Basics”, the “LIA Laser Safety Guide”, the “Guide for the Selection of Laser Eye
Protection” and the “Laser Safety Bulletin”, published by the Laser Institute of America, as well as the“Guide of Control of Laser Hazards” by ACGIH.

Taking necessary safety measures
If there are people present within the danger zone of visible or invisible laser radiation, for example nearlaser systems that are only partly covered, open beam guidance systems or laser processing areas, thefollowing safety measures need to be taken:
•
•
•
•
•

Please wear safety goggles adapted to the laser wave length that is in use.
Please protect yourself from direct laser radiation, scattered radiation as well as from beams generated
from laser radiation (for example by using appropriate shielding walls or by weakening the radiation toa harmless level).
Please use beam guidance – or beam absorber elements which do not emit any hazardous particles assoon as they get in contact with laser radiation and which resist the beam sufficiently.
Please install safety switches and / or emergency safety mechanisms which enable an immediate closure of the laser shutter.
Please ensure a stable mounting of the measuring device in order to prevent a relative motion of thedevice to the beam axis. This reduces the risk of scattered radiation and is also necessary to ensure an
optimal performance for the measurement.

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Employing qualified personnel
All users must have been trained in the installation and operation of the device and they need to have abasic knowledge about the work with high power lasers, beam guidance systems as well as focussing units.
Modifications
The BCS must not be modified, neither constructional nor safety-related, without our explicit permission.
Modifications of any kind will result in the exclusion of our liability for resulting damages.
Liability disclaimer
The manufacturer and the distributor of the measuring devices do not claim liability for damages or injuries
of any kind resulting from an improper use or handling of the devices or the associated software. Neither
the manufacturer nor the distributor can be held liable by the buyer or the user for damages to people ormaterial or financial losses due to a direct or indirect use of the measuring devices.

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2PRIMES

Symbol explanations

The following symbols and signal words indicate possible residual risks:

DANGER
means that death or serious physical injuries will occur if necessary safety precautions are not taken.

WARNINGmeans that death or serious physical injuries can occur if necessary safety precautions are not taken.

CAUTIONmeans that a slight physical injury can occur if necessary safety precautions are not taken.

NOTICEmeans that property damages can occur if necessary safety precautions are not taken.

On the device itself, the following symbols indicate possible dangers:

Warning of hand injuries

Read and observe the operating instructions and safety guidelines before the startup!

Further symbols that are not security relevant:Here you can find useful information and helpful tips.

With the CE marking the manufacturer guarantees that his product is inconformity with the EC guidelines.

Calls for action

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PRIMES – The company

PRIMES is a manufacturer of measuring devices used for the characterization of laser beams. These devices
are used for the diagnostics of high power lasers that range from CO2 lasers to solid-state lasers or diodelasers. The wavelength range is covered from infrared to near UV. A great variety of measuring devices forthe determination of the following parameters is available:•

The laser power•

The beam dimensions and beam position of an unfocussed beam•

The beam dimensions and beam position of a focussed beam•

The beam propagation ratio•

The polarisation of the laser beam

Both the development and the production of the measuring devices are effected by PRIMES. This is how weensure an optimal quality, excellent service and a short reaction time which is the basis to meet our customers’ requirements fast and reliably.

35,0(6

8

Max-Planck-Str. 2 - 64319 Pfungstadt - Germany - info@primes.de - www.primes.de

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44.1

PRIMES

Introduction
Laser beam measurement

The production with laser beams can be observed effectively by controlling the laser beam parameters. The
laser beam is basically characterized by:••••

The beam power
The beam dimensions and the beam position of the unfocussed beam
The beam dimensions and the beam position in the focus
The polarization of the laser beam

These basic beam parameters have a great influence on the results of laser material processing. In orderto achieve a reproducible process quality it is necessary to detect all changes of the beam parameters.
Changes can be caused not only by:laser internal reasons, for example:••

the aging or pollution of optical components or
the misalignment of the resonatorbut also by:effects in the beam guidance system or the focussing unit, for example:••

the pollution or the misalignment of mirrors or lenses
organic trace gases in the air – thermal blooming

The processing result for the production with lasers is generally dependent on the beam power as well as
the power density in the focussing range. Moreover, the position of the focussing point in relation to the processing zone must be known. Variations to these nominal sizes often lead to a reduced processing speed
or processing quality.
Periodic measurements of the laser beam parameters enable a reliable control of the “tool” laser beam.
This is a basic requirement for a reproducible production with the laser beam and therefore for the quality
assurance.
PRIMES has developed measuring systems that are able to carry out measurements even in an industrial
environment. A connection to the system control is supported and the possibility of a complete documentation of the results is therefore ensured.

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BeamConrolSystem BCS PROFIBUS

System description

The BeamControlSystem consists of the measuring devices FocusMonitor and Compact-PowerMonitor aswell as a PLC-interface-router-combination. These components are integrated in a stable aluminium housing.
A pneumatic shutter protects the inlet.
The measuring devices are intended for a cyclical control of the beam parameters: power, beam position
and beam dimensions as well as the beam pattern in the focus. The PLC connection ensures a smooth,automated measurement.
The enclosed instructions regarding the FocusMonitor and the CompactPowerMonitor describe the operationof the measuring devices in detail.
For the operation of the complete measuring station the safety guidelines that are applicable for the
FocusMonitor and the CompactPowerMonitor apply accordingly.

Fig. 5.1:

10

Components of the BeamControlSystem

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Fig. 5.2:

PRIMES

Principle of the electrical integration of the BCS

To the outside the measuring station is connected via four electrical interfaces:
1. It is connected with the system via PROFIBUS. This is how the power supply as well as the communication between the measuring station and the system control is ensured.
2. The data from the BeamControlSystem to the operating computer are transferred via Ethernet.
3. The interlock signal connection to stop the laser in case of an error.
4. A further connection is the 9 pin D-Sub-connector. It can be used optionally for the communication withthe operating computer by means of RS485-RS232 interface converters.
For the operation of the measuring station, the connection of cooling water as well as compressed air isnecessary.

6
•
•
•

Conditions at the installation site
The BCS must not be operated in a condensing atmosphere. The humidity has to be taken into consideration as well in order to prevent condensates within and outside the BCS.
The ambient temperature must be above freezing.
The temperature of the cooling water must not be beneath the ambient temperature.

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Connections
LED-display
Profibus Run/Stop
Profibus In/Out

Power supply

BC S

BeamControlSystem
PROFIBUS

Power

COM
Run
Stop

In

Out

In

Out

LED
interlock circuit closed
Ethernet

100 MBit

PRIMES-Bus

Interlock

Safety circuit(Connector, 5 pin)

RS 485PRIMES-Bus(D-Sub-connector, 9 pin)

Ethernet connection

Identification plate

Flow∅ 12 mm
Water

In

Out

Pneumatic Air

Inert Gas

Returnflow∅ 12 mm

Cooling
circuitsystemInert gas connection∅ 6 mmCompressed air connection ∅ 6 mm

Fig. 7.1:

12

Overview of connections

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8

Installation

8.1

Installation into the Laser System

PRIMES

1. First of all, the laser source has to be turned off.
2. Ensure that the moving parts, e.g. robot arms, etc. are at a standstill and that they cannot be set in motion unintentionally.
3. Before the installation, please check that there is enough space, especially for the shutter swinging out(see chapter „Dimensions“).
4. The BCS has to be aligned in the beam path of the laser in a way that ensures that the laser hits theaperture centrally.
5. Fasten the BCS in this position and ensure that it is immovable (see „8.3 Mounting“ on page 15).
6. Install all electrical connections.
7. Install the interlock connection with the laser control and check the correct function.
8. Install the water cooling circuit.
9. Connect the compressed air.
10. Connect the inert gas.

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8.2

BeamConrolSystem BCS PROFIBUS

Alignment to the beam axis

First of all, please roughly align the housing with the four adjusting screws (for example by means of a waterlevel).
For a precise adjustment with a dial gauge a plane groove in x- and y – directions was milled into the housing
surface (please see Fig. 8.1).
CrosshairyxAperture

GrooveFig. 8.1:

Groove dimensions and crosshair position, view from above

Please align the housing so that the centres of the laser beam as well as the aperture match each other(see Fig. 8.2).
As an alignment aid a crosshair was engraved in the housing1). The distances of the crosshair to the centreof the aperture (x/y – axis) as well as the distance of the measuring tip in the device (z-axis) are to be foundin the document “Tool centre point-calibration” and on the identification plate. Due to the fact that the xdistance is slightly dependant on the revolution speed of the measuring tip, several x-values for the different
operating speeds are stated here.

1)

14

Depending on customer requirements, other adjustment markings can exist.

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xcrosshairyyxDistances centre of the aperture

Fig. 8.2:i
8.3

Distances centre of the aperture – crosshair

The FocusMonitor is integrated overhead in the BCS. You therefore have to activate the checkbox “turned measuring tip” in the menu “Measurements  Sensor Parameters” of the operating
software (LDS)

Mounting

WARNING
Danger of injury
If the appropriate position of the measuring device is changed, this could cause scatteredradiation during the measurement.
When mounting the device, please ensure that it cannot be moved, neither due to an unintended push or a pull on the cables and hoses.
There are eight tapped holes M6 in the base plate of the BCS-housing which are intended for the customer’s
mounting. Please use at least four screws to fasten the device.
We recommend screws of the strength categor y 8.8 and a tightening torque of 20 N∙m.

NOTICE
Danger of damage
There is a danger of damage for inner components if the screws used are too long.
Please do not screw the fastening screws further into the housing than 15 mm.
The overall length of the screws depends on the customer’s mounting.

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Fig. 8.3:

BeamConrolSystem BCS PROFIBUS

Fixing holes, view from bottom

NOTICE
Danger of damage
There is a danger of damage caused by dirt particles
If you have to remove the eye bolts for reasons of space, please close the tapped holes withsuitable screws (M8) or with appropriate plastic inserts.

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9

Mechanical connections

9.1

Cooling circuit system

9.1.1

Conditions

PRIMES

The hose connections of the BCS are intended for an outer diameter of 12 mm.
For a reliable operation a minimum water flow of 4 l/min and a maximum of 8 l/min are necessary.

There is a block valve in the cooling circuit. In order to switch the valve the compressed airneeds to be connected and the supply voltage has to be turned on.
Please operate the BCS in a non – condensing atmosphere. The temperature of the cooling water may
therefore not be below the ambient temperature.
Only cool the device while carrying out a measurement. We recommend to start the cooling two minutes
before the measurement and to finish it one minute after the completion of the measurement.

NOTICE
Danger of damage
Concerning the water installation it must be ensured that if you work with sealing tape(e.g. teflon or hemp), no parts get into the turbine! They could constrain the flow or stop it
completely.
Please rinse your line system before connecting it.
The parts of the BCS which are in contact with the cooling water are made of copper, brass or stainlesssteel. The device should therefore not be connected with an aluminium cooling circuit. This could lead tocorrosion of the aluminium due to the different chemical potentials. Do not add any additives to the coolingwater, especially no anti-freeze agents as they could have a significant influence on the thermal conductivity
and could therefore distort the measurement results.
9.1.2

Connection
1.

Please remove the sealing plug of the cooling circuit and keep it save.

2.

Please connect the forward (IN) and return (OUT) circuit of the device.

Operating the device with strongly de-ionized water (DI-water) is only possible if the right connection
pieces are used. We would kindly ask you to inform us before buying the device.

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9.2

BeamConrolSystem BCS PROFIBUS

Compressed air

The compressed air is necessary to open or to close the shutter and the block valve. The supply is effected
via a plastic hose with an outer diameter of 6 mm. A pressure of 4 to 8 bar is required. User-specific modifications are possible.
As an option, a rinsing of the housing with compressed air is possible. A flow rate of typically about 10 to 20
liters per minute should be allowed for. Depending on the application it can be more. Inert gas connection
The connections of the device are intended for hoses with an outer diameter of 6 mm.

NOTICE
There is a danger of damage for the measuring tips due to a plasma ignition or dirt particles
from the environment.
When measuring great power densities1) (YAG: 8 – 10 MW/cm²; CO2: 20 – 30 MW/cm²) it ispossible that a plasma is ignited on the surface of the measuring tip. This could destroy
the measuring tip.
When measuring high power density please rinse the device with inert gas (nitrogen or
helium). The inert gas needs to be dry and oil free.

1)

18

Please also see the manual of our FocusMonitor, chapter “Selection of detectors and measuring tips”.

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10

Electrical connections

10.1

PROFIBUS Data

Pin assignment PROFIBUS, plug IN (top view, plug-in side)
2

1

3
5

4

Plug description

Pin

Function1

unassigned

2Signal A

3

unassigned

4Signal B

5

unassigned

Sensor-/actuator plugs, 5-pole, M12-SPEED-CON,b-coded, front panel- / screw assembly with M16-thread, adjustable,with 0.5 m TPE-cord, 5 x 0.34 mm² (Phoenix Contact 1520013)

Table 10.1: Pin assignment PROFIBUS data plug
Pin assignment PROFIBUS, plug OUT (top view, plug-in side)
1

5

4

3

Socket description2

Pin

Function

1

+5 V

2

Signal A

3

ISOGND

4

Signal B

5

unassigned

Sensor-/actuator plugs, 5-pole, M12-SPEED-CON,b-coded, front panel- / screw assembly with M16-thread, adjustable,with 0.5 m TPE-cord, 5 x 0.34 mm² (Phoenix Contact 1520000)

Table 10.2: Pin assignment PROFIBUS data socket

Suitable cable (male/female): bus system cable, PROFIBUS, 2-pole, PUR halogen-free, violet RAL 4001,
shielded, plug straight M12-SPEEDCON, b-coded, on socket straight M12-SPEEDCON, b-coded, cable
length 2 m (Phoenix Contact 1518135)

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10.2

BeamConrolSystem BCS PROFIBUSPROFIBUS power supply

The device is supplied with power via two 5-pole connectors. The two connectors are internally connected 1:1.
Power In (top view, plug-in side)

Plug description

Pin

Function1

GND Sensor

2

GND Actuator

3

PE

4

+24 V (Sensor)

5+24 V (Actuator)

Sensor-/Actuator-connector, male, 5 pole 7/8“(PhoenixContact 1521452)

Table 10.3: Pin assignment PROFIBUS power supply plug
Power Out (top view, plug-in side)

Plug description

Pin

Function1

GND Sensor

2

GND Actuator

3

PE

4

+24 V (Sensor)

5+24 V (Actuator)

Sensor-/Actuator-connector, female, 5 pole 7/8“(PhoenixContact 1521449)

Table 10.4: Pin assignment PROFIBUS power supply socket

10.3

PROFIBUS Status-LEDs

LED

ColourCondition

Meaning

Run

Green

glowing

PROFIBUS is connected

Stop

Yellow

flashing

PROFIBUS is not connected or there is a disorder

20

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10.4

PRIMES Bus

9-pole D-Sub connector (top view, plug-in side)

5

1

9

6

Pin

Function

1

GND

2

RS-485 (+)

3

+24 V

4

unassigned

5

unassigned

6

GND

7

RS-485 (-)

8

+24 V

9

unassigned

Table 10.5: Pin assignment PRIMES bus

10.5

Ethernet connection

You can either connect the device with the PC via a crossover-cable or with the network via a patch cable.
Connector, 8-pole (top view, plug-in side)
Pin

Function

1

TX+

2

TX-

3

RX+

4

unassigned

5

unassigned

6

RX-

7

unassigned

8

unassigned

Plug description: Phoenix-Contact 1404548 VS-BH-M12FSX-10G-RJ45-90
Table 10.6: Pin assignment Ethernet socket

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10.6

BeamConrolSystem BCS PROFIBUS

External safety circuit

The external safety circuit protects the device from damages. The device could be damaged if••

the water flow rate is too low
the laser is turned on while the shutter is still closed.

If the water flow rate is within the normal range and the shutter is opened, Pin 1 and Pin 3 are connected.
If the device is not ready for operation, Pin 1 and Pin 2 are connected.
The pins of the safety circuit plug are potential-free.

NOTICE
Danger of damage
If the safety circuit is not connected the device could overheat or the closed shutter could
be destroyed by the laser beam.
When connecting the laser control to pin 1 and 3 it has to be ensured that, in case of aninterruption of the connection, the laser is turned off.
5-pole connector (top view, plug-in site)
Pin

Function

1

Reference pin for pin 2 or 3

2

If not ready for operation, connected with Pin 1

3

If ready for operation, connected with Pin 1

4

unassigned

5

unassigned

Plug description

Manufacturer: Phoenix Contact
SACC-E-MS-5CON-M16/0,5 SCO – 1520055

Suitable cable

Phoenix Contact
Sensor-/Actuator-cable - SAC-5P-5,0-PVC/M12FS B-L – 1431717

Table 10.7: Pin assignment of the safety circuit connector

Interlock released(internal signal)

Fig. 10.1:

22

Circuit diagram of the safety circuit

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11

Profibus

11.1

Interface description

PRIMES

The BCS has a PROFIBUS interface. To enable the integration in a line system both the bus interface andthe power supply are duplicated.
All in all there are four interfaces:-

2x Profibus
2x 24 V power supply (24 V ± 5 %, a maximum of 5 ampere of power consumption)

The data is stored in the registers in Motorola format. This means that the highbytes are come first, followed
by lower bytes in the next registers.

11.2

Device database file (GSD-file)

The GSD-file for the BCS has the name PRI_0102.gsd and can be found on the enclosed CD-ROM. Fig.
11.1 shows the integration of the GSD – file under step 7.

Fig. 11.1:

Integration of the GSD – file under step 7

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11.3

BeamConrolSystem BCS PROFIBUS

Bus address

The bus address set by the manufacturer is stated on the connecting plate underneath theProfibus connections. If necessary, this address can be changed with the PLC software or with theLaserDiagnosticSoftware:
11.3.1

Changing the bus address by means of the PLC software

11. Assign a new bus address in the step7 manager (Menu target system  Profibus assigning Profibus
address)Fig. 11.2:

24

Integration under step 7

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11.3.2PRIMES

Changing the bus address by means of the LaserDiagnosticSoftware

1. Please install the LaserDiagnosisSoftware (LDS) on your computer which is connected with the device
via the network connection.
2. Please start the software and open the menu Communication>>Free communication.
3. Select “TCP” in the field Mode.
4. In the field TCP the IP address is to be entered (the IP address can be found on the type plate).
5. Please click on Connect.
6. Please activate the check box Write bus protocol (the protocol can be very useful in case any problems
occur).

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BeamConrolSystem BCS PROFIBUS

7. Please enter the following order in the input field Command (please make sure that the blank character is entered correctly):
se0077xyz
In this case, xyz is a placeholder for the Profibus-address which has to be entered with three digits! The
symbol  is a placeholder for a blank character.

Example: Profibus address is supposed to be 5  Enter: se0077 005
Command

Reply

8. Please click on Send. The answer of the device appears in the bus monitor in the following form:
Adr: 00077 Value: xyz
Hence, the address is preset.
9. Please now turn off the BCS and turn it on again. After the restart the Profibus-address is updated.

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11.4

Profibus register structure of the BeamControlSystem

11.4.1

Output register control (Command Register)

Adr

Byte

Bit

0

PRIMES

Meaning
Commands or status information of the system

0

Status flag: automatic mode 1)

1Opening the shutter

2

Closing the shutter

3

Opening the water valve

4

Closing the water valve

5

Measuring programme: 1 (only power measurement)

6

Measuring programme: 2 (caustic measurement incl. power measurement)

7

Measuring programme: 3 (reserve)

8

Measuring programme: 4 (reserve)

9

Starting the measurement

10

Cancelling the measurement (abort)

11

Open the protective gas valve

12
13
14
15
1)

Must be set whenever procedures or actions are controlled by the system (e.g. opening / closing shutter)11.4.2

Input register control: status

Adr

Byte

0

0

1

Bit

Meaning
Status Information

0

Shutter is open

1

Shutter is closed

2

Shutter is just moved

3

Shutter error (Pos. undefined / Timeout during shutter command)

4

Water valve is open

5Interlock circuit is closed (everything is ok)

6Interlock shutter ok (shutter is open)

7

Interlock CPM ok (there is no CPM error relevant for the interlock)8

LDS idle (script is running, LDS is ready to receive commands)

9

Command to device: Laser on!

10

Measurement is running

11

Measurement completed successfully

12

Measurement completed with error

13

Result ok

14

Result not ok

15

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11.4.3Adr

BeamConrolSystem BCS PROFIBUS

Error register
Byte

Bit

1

Meaning
Error register FM and PM

0
1
2
2

3
4
5
6
7

3

8

Information in register 16 to 18 and CPM error flags are not updated as the statuscollect isdeactivated9

Data valid is set to “false” in the CPM-al-frame

10

Flow rate is too low

11

Temperature of the cooling water at the inlet is too high12Temperature difference of the cooling water is too high13

Temperature of the cooling water at the outlet is too high

14
15

Adr

Byte

Bit

2

Meaning
Error register BCS and LDS

4

0

Automatic Bit is set in case for shutter / water valve command from LDS or
Automatic Bit is not set for shutter /water valve / abort command from device

1

Simultaneous “open shutter” and “close shutter” commands from device

2

Simultaneous “open water valve” and “close water valve” commands from device

3
4
5
6
7
8

Fatal script error

9
10
5

11
12
13
14
15

28

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11.4.4PRIMES

Input register: results

32 bit each – low address contains higher data word
Adr

Byte

Unit

Meaning

4 ... 5

8 ... 11µm

Radius

6 ... 7

12 ... 15

µm

PosX

8 ... 916 ... 19

µm

PosY

10 ...11

20 ... 23

µm

PosZ

12 ... 13

24 ... 27* 1000M2

14 ... 15

28 ... 31

W

Power determined

16 ... 17

32 ... 35

W

Current power

18 ... 19

36 ... 39

1/100 °C

Temperature of cooling water

20 ... 21

40 ... 43

1/100 l/min Flow rate

22 ... 35

44 ... 71

Reserve

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12

BeamConrolSystem BCS PROFIBUS

Ethernet Configuration
The BCS has a stipulated IP address which is given on the identification plate

The PC must also have an IP address in the same subnet, for example:
IP-Address: 192.168.116.80
Subnet mask: 255.255.255.0

192 168 116 80
255 255 255 0

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12.1

Establishing a connection to PC

1. Please start the PRIMES LaserDiagnosisSoftware
2. Choose the mode “TCP” in the menu “free communication” (the option “second IP” must not be
activated!)
3. Enter the IP in the field “TCP”
4. Click on the “connect” button (“connected” appears in the bus monitor)
5. Click on the “save” button (the configuration is saved and does not have to be repeated after a restart)

192 168 116

85

Fig. 12.1:

Establishing a connection in the menu Free Communication

12.2

Changing the IP address

You can change the preseted IP address in the menu Communication>>Free communication by meansof the following commands:
IP-address(Sample address)
Commands

192.

168.

116.

85









se0050xyz

se0051xyz

se0052xyz

se0053xyz

In this case xyz are place holders of the four IP-address bytes (values 1 - 254) which always have to beentered with three digits!
For example, the number 85 has to be entered like this: 085.
For reasons of clarity the symbol  marks a space.
Example: You will change the IP address from 192.168.116.85 to 192.168.116.86.
1.
2.
3.
4.
5.
6.

Please start the PRIMES LaserDiagnosisSoftware.
Open the menu Communication>>Free Communication.
Choose the mode “TCP” (the option “second IP” must not be activated!).
Enter the IP in the field “TCP”.
Click on the “connect” button (“connected” appears in the bus monitor).
Activate the checkbox Write bus protocol (the protocol can be helpful in case of problems).

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7. Enter the following in the field Command (please make sure that the blank character  is entered correctly):
se0053086
8. Click to Send and wait for the confirmation in the bus monitor (in Fig. 12.2 „-> Adr:00053 Wert: 086“)
9. Please turn off the device and turn it on again. After this restart the IP-address is updated.

Confirmation

Fig. 12.2:

32

Changing the IP address in the menu Free Communication

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12.3

Automatically obtain the IP-address

With DHCP (Dynamic Host Configuration Protocol) an automatic integration of a device into a present network is possible without a manual configuration.
In the LaserDiagnoseSoftware you can activate the DHCP funktion with the command:
se0054001
1. Please install the LaserDiagnosisSoftware (LDS) on your computer which is connected with the device
via the network connection.
2. Please start the software and open the menu Communication>>Free communication.
3. Select “TCP” in the field Mode.
4. In the field TCP the IP address is to be entered (the IP address can be found on the type plate).
5. Please click on Connect.
6. Please activate the check box Write bus protocol (the protocol can be very useful in case any problems
occur).
7. Please enter the following command in the input field Command (please make sure that the blankcharacter  is entered correctly):
se0054001
This will activate the DHCP-function.
8. Please now turn off the BCS and turn it on again.

Command

Confirmation

After a newstart of the device with the network connection now the router/server will be asked for an IPaddress. Now the Server will activate a new address which needs to be requested via your router/server.
The function FINDIP over the MAC address (image no.4) is not working than.
In case you turn on your equipment to the router/server with no network connection (meaning no answer
from the DHCP-server), the BCS will use in the meantime the programmed static IP until you turn on andoff again your machine.
The command se0054000 will deactivate the DHCP function.

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Measuring Operation

NOTICE
Danger of damage
Due to obstacles within the reach of the shutter it could be damaged when opening or closing.
First open the shutter before positioning the focusing head over the measuring unit.

CAUTION
Danger of injuries
Danger due to moving and rotating parts.
Do not put your hands near the shutter while it is opening or closing.
Do not put your hands near the aperture.
The operation of the control PC with the corresponding LaserDiagnosticSoftware (LDS) is the basis for every
measurement. This software can be found on the attached CD-ROM.
The control PC (not included in the delivery) is connected with the BCS via Ethernet.
The measurements can either be started manually from the PC or automatically via a script control of thesoftware and the Profibus connection. In both cases the LaserDiagnosticSoftware has to be installed andstarted beforehand. More details are given in the manual „FocusMonitor“

13.1

Measuring procedure

The measuring procedure can be divided into the following steps:
1. Ensuring the readiness for operation
2. Carrying out the measurement
3. Evaluating the measurement

Requirements measuring
programMeasurement running
Laser onWriting results

Fig. 13.1:

34

Simplified timing diagram of the measuring procedureMeasuring procedure in detail

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13.2

Measuring procedure in detail

All signals and I/O definitions are described from the client’s point of view.
SystemFunction

I/O

bit

Script
value

I/O

bit

PLC board
value

Setting „LDS idle“

I

8

1

Resetting „Measurement isrunning“I

100

Resetting „Laser on!“

I

9

0

Activating automatic operation

O

0

1

Waiting till LDS idle is set

I

8

1

Resetting "Closing shutter"

O

2

0

Setting "Opening shutter"

O

1

1

Opens shutter

I/O

bit

value

I

0

1

Opens water valve

I

4

1

If shutter is open and flow rateok, Interlock is resetI

5 to 71

Waiting till shutter is open

I

0

1

Setting "Opening water valve"

O

3

1

Waiting till all Interlocks okI

4 to 7

1

Setting measuring program
requirementsO

5 or 6

1

Setting "Starting measurement"

O

9

1

Resetting „LDS idle“I

8

Reading measuring program
requirementsO

5 to 8

Delets error flagsI

11 to 140Delets result register

Register 4 to 15

0

Setting „Measurement isrunning“

I

10

1

I

9

1

I

9

0

Waiting for the setting of„measurement is running“(remains till „Measurement
finished“ is set)

I

10

1

Resetting measuring program
requirementsO

5 or 6

0

Resetting "Start measurement"

O

9

0

Setting „laser on!“Waiting for „Laser on“ from
BCS

I

9

0

1

Turning on the laser (power is
automatically identified)
Measurement is carried out
Resetting „Laser on!“Waiting for the resetting of„Laser on!“

E

9

0

Table 13.1: Measuring procedure

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BeamConrolSystem BCS PROFIBUS

SystemScriptbit

value

Closes shutter

I

1

1

As soon as shutter is closed,
Interlock is triggeredI

5 to 6

0

I

4

0

I/O

bit

value

I/O

bit

PLC board
I/O

Function

value

Turning off the laser(automatic identification)x

Writing result register

Register 4 to 15

Setting result o.k./n.o.k.

I

13 to 140/1

measurement o.k./n.o.k. is set

I

11 to 12

0/1

Resetting „Laser on!“

I

9

0

Resetting „measurement isrunning“I

100

Waiting for the resetting of„measurement is running

I

10

0

Resetting „opening shutter“

O

1

0

Setting "Closing shutter"

O

2

1

Waiting for „shutter closed“

I

1

1

Setting "Closing water valve"

O

4

1

Closes water valve
Waiting for resetting "water
valve open" and „ Interlock
CPM OK“
System can read flags andresults now
Table 13.1

36

I

4 and 7

Register
0 to 210x

Measuring procedure (continuation)

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14

Laser Diagnostic Software (LDS)The BCS is operated with the PRIMES Software “LDS” or from the laser machine control. A detailed descriptionof the software can be found in the enclosed manuals “FocusMonitor” and “CompactPowerMonitor”.
The software is extented in the following items.

14.1

User level

From version 2.9.034 on, the LaserDiagnosticSoftware is available with a user level control. There are different user levels which are activated with the corresponding password. This enables you to limit the control
options in the software and to adapt them to the requirements of the operation. The following user levels
are defined:
User level
Operator (Op)
Controller (Co)
Expert (Ex)
Professional (Pro)

Password protection
No
Yes
Yes
Yes

Acces to function
Severely limited
LimitedMostly unlimited
Mostly unlimited

Table 14.1: Password protection for user levels

When starting the software you can activate the user level control in the welcoming window (Click on “Change user level”, see Fig. 14.1). If you do not use this option or if a false password is typed in, the software
automatically starts with the lowest authorisation level “Operator”. This also applies for a system control
start-up.

35,0(6
Fig. 14.1:

Change user level

It is also possible to change the user level while the device is in operation (menu „Edit  change userlevel...“). If either no password or a false password is typed in, the system also starts with the user level“operator”.
The user level “operator” is, for example, intended for an application in the production.
In order to ensure an automatic process control the execution of scripts is allowed. Advanced settings forconnected devices or a manual storage of measuring results is, however, not possible.
Table 14.1 shows the allocation of the allowed actions of every user level.
Op = Operator
Co = Controller
Ex = Expert
Pro = Professional

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Software functions

No deviceconnected

Deviceconnected

Measurement Loaded
measurement

File

Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro

New
Open…
Close
Close all
Save
Save as…
Export…

Co, Ex, Pro
Co, Ex, Pro

Load measurement preferences...

Co, Ex, Pro

Co, Ex, Pro

Save measurement preferences…

Co, Ex, Pro

Co, Ex, Pro

Protocol…
Co, Ex, Pro
Print…
Print preview…
Recently opened files
Co, Ex, Pro
Co, Ex, Pro
Exit
Co, Ex, Pro
Co, Ex, Pro
Copy
Edit
Clear plane
Clear all planes
Change User Level…
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Ex, ProMeasure- Environment…
ment
Sensor parameters
Ex, ProBeamfind settings
Ex, ProCCD info…
CCD Settings…
LQM - Adjustment…
Power Measurement…
Single ...
Co, Ex, Pro
Caustic…
Co, Ex, Pro
Start Adjust-Mode
Option…
Co, Ex, Pro
Co, Ex, Pro
Presenta- False colors…
tion
False colors (filtered)…
Isometry…
Isometry 3D…
Review (86%)…
Review (2.Moment)…
Caustic…
Raw-beam…
Symmetry check…
Fixed Contour Lines...
Variable Contour Lines...…
Graphical Review…
System state…
Evaluation Parameter View…
Co, Ex, Pro
Co, Ex, Pro
Color Tables...
Co, Ex, Pro
Co, Ex, Pro
Toolbar
Co, Ex, Pro
Co, Ex, Pro
Position…
Co, Ex, Pro
Evaluation…
0
0
Co, Ex, Pro
Co, Ex, Pro
Commu- Rescan bus
nication Free Communication…
Co, Ex, Pro
Co, Ex, Pro
Scan device list…
Co, Ex, Pro
Co, Ex, Pro
Editor…
Op, Co, Ex, Pro Co, Ex, Pro
Script
List…
Co, Ex, Pro
Co, Ex, Pro
Python…
Op, Co, Ex, Pro Co, Ex, Pro
Activation…
Op, Co, Ex, Pro Co, Ex, Pro
Help
About LaserDiagnoseSoftware… Op, Co, Ex, Pro Co, Ex, Pro

Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Ex, ProEx, ProEx, ProCo, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Ex, ProCo, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Ex, ProCo, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
0
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

0
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro
Co, Ex, Pro

Table 14.2: User access to software functions

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14.2

PRIMES

Evaluation function

The weighting function of the LDS offers different parameters for the evaluation of the power density distribution measured. They are stored in the evaluation file (FocusCaustik.eval) and can be deactivated individually.
The following parameters can be evaluated automatically:
Parameters

MeaningStandardFit

Deviation of the fit to the caustic (%)

PowerStable

Stability of the laser power (W)AstigmatismRatio

Astigmatic difference (%/zr)

RadiusX

Focus radius X (mm)RadiusY

Focus radius Y (mm)RadiusCombinated focus radius (mm)PositionX

Focus position X (mm)PositionY

Focus position Y (mm)PositionZ

Focus position Z (mm)KValueK

KValueX

Kx

KValueYKy

LaserMinPower

Minimum allowable laser power (W)LaserMaxPower

Maximum allowable laser power (W)LaserMeanPower

Mean laser power (W)BeamParameterProductBeam parameter product (mm*mrad)

MSquareM²

MSquareX

M²x

MSquareY

M²y

BeamDirection

Combinated beam direction (°)

BeamDirectionX

Beam direction to x-axis (°)

BeamDirectionY

Beam direction to y-axis (°)

RayleightLength

Rayleigh length (mm)Divergence

Divergence (mrad)

Table 14.3: Evaluation parameters

Additionally, you can signal the exceed of error limits and also the approach of the limit can be signalized bya warning message. Therefore, additional warning limits are added to the Eval-file (MaxWarnValue).
The BCS evaluates the measuring results and describes them only as good or bad, without thewarning zone. That is why you have to state the minimum and maximum values for warning anderror limits immediately. Otherwise, discrepancies within the evaluation could occur (see Table 14.4)

In order to edit the limit values please open the file “FocusCaustic.eval” with an editor which allows you to
insert a line break (e.g. Notepad++). Each line in the file configures a measurement parameter.

The lines are structured as depicted in Table 14.4. For the configuration the values framed in bold can beadapted to the evaluation, the remaining values either have no influence on the assessment of a measurement with the BCS or they are only used for an automated read-out process.

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PRIMESParameter name

BeamConrolSystem BCS PROFIBUS

Value

Description

bcp:ExtendedParameter
autocalculateWarn=„false“enabled=„true“formatter=„%.2f“id=„StandardFit“

Designation of the parameter

maxValue=„5.00“Maximum value (error limit)

maxWarnValue=„5.00“Maximum value (warning limit)

minValue=„0.10“Minimum value (error limit)

minWarnValue=„0.10“Minimum value (warning limit)

name=„Standard Fit“Designation of the parameter

unit=

„%“

Unit

value=„3.478677“

Value from the measurement

visible=„true“Activation of the parameter

Table 14.4: Parameter error limit / warning limit

After the measurement the data is evaluated automatically via a script control and the result is transferred
via Profibus.

14.3

Storage location of the measuring values

A measurement in an automated operating procedure with the BCS stores the measuring results in thefollowing files:
The measuring files of caustic measurements in “foc” format.
File name: “FocusCaustic_year_month_day_hour_minute.foc”
For each power measurement an individual text file is created. Here, not only every single measurement
for the averaging, including the date and the time, is filed but also the herewith determined average as anecessary value.
File name: “LaserPower_year_month_day_hour_minute_second.txt”

14.4

Automated script procedure

The LaserDiagnosisSoftware offers the possibility to edit scripts and to carry them out automatically. The
following script languages are supported:• Primes-script language• From LDS-version 2.9.035 on: Python (version 2.6) extended by Primes-specific instruction set
For an automated script procedure, the configuration file laserds.ini in the installation directory has to beedited accordingly.
The LDS offers an editor (menu „script  editor“). However, as the configuration file is in ASCII-format, you
can also edit it with an external editor (e.g. Notepad++).

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PRIMES

The scripts can be created and edited by means of an external editor as they are also in ASCII-format.
The standard file-ending for scripts in the Primes language is *.txt, the ones in Python version *.py.
14.4.1

Editing the configuration file

By default, the LaserDiagnosisSoftware is installed in the directory“C:\programs\Primes\LDS v.xxx”. Here, the configuration file “laserds.ini” can be found as well.
		 Open the file “laserds.ini” and search for the section “[Script]”
If you use “Primes-Script”:
		 In order to launch the script, please supplement the command		 line “start file=” with the path and the parameter “/Run;Open Editor” (see Fig. 14.2)
		 With “/run” the script starts immediately after the software has been started, with
		 “Open Editor” the internal editor of the LDS is opened to display the loaded		scripts

Fig. 14.2:

Edit Primes Script

If you use “Python Script”:
In the command line “Start Pythonscript=” the path to the script file is stated without any additionalparameters (see Fig. 14.3)

Fig. 14.3:

Edit Python Script

The procedures written in Python can access self-created libraries. They have to be stored in thesame directory as the launching script or they have to be explicitly described in the script. A further
possibility is to store them in a stated directory “libdir”.
Example:The entry in line “Script libdir=…” in Fig. 14.3 indicates the path to the library directory that is used by
the LDS.
14.4.2Global settings

Adjustable parameters are to be found in the file “GlobalSettings.py”. They are adjustable, for example inorder to change the oscillation time for a power measurement.
The file can be found in the lib-directory of the LaserDiagnosisSoftware. The path to the directory has to beadapted to your computer configuration(standard path “C:\LaserDiagnosisSoftware\pyscript\lib”).
The file “GlobalSettings.py” can be edited with any text editor. Please keep the following points in mind:

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Do not use any tabs, for instance to indent something. Any placeholders or insertions have to consistof 4 spaces.
The order of the parameters in the file can be changed.
Comments can be inserted from time to time. Every comment line has to start with a “#”-symbol.

The following example explains the parameters included in this file. The parameters highlighted in red withthe corresponding comment line are intended for the procedures and measuring tasks of other devices. They
are irrelevant for an application of the BCS.
Example:#Globally valid time-out guidelines for interactions with the device (e.g. the maximum waiting#time for the determination of laser powers); stated in s
giWaitCounter = 100#Number of power measurements by means of which the average of the measurement#is determined; stated in the number of desired measurements
giPowerNumVals = 2#Below this measured laser power the laser is recognised as switched off;#stated in W
giMaxPowerForLaserOff = 50.0
#Power difference for the detection of the switching-on process of the laser: From this#power difference up to zero power, the laser is recognised as switched on;#stated in W
giPowerDiffernceForLaserOn = 40.0
# irrelevant for BCS automatic process
giPlaneListForFastMeasurement = [7, 11]# irrelevant for BCS automatic process
giFocusShiftPowerValues = [10, 20]#irrelevant for BCS automatic process
giProtectionGlassPowerValues = [10, 100]
#irrelevant for BCS automatic process
giSaveZPosFibreMeasurement = 110000#irrelevant for BCS automatic process
giSaveZPosProcessMeasurement = 85000#Thermalization time for the oscillation process of the power measurement; after the detection#of existing laser power this time passes until the actual measurement starts; the duration#refers to the power measurement as well as the complete measurement of the#caustic; stated in s
giThermalizationTime = 10
#Activation of debug outputs during the measuring procedure. This parameter is not relevant#for the productive use of the BCS; stated binarily: 0  no output of the debug message#1  output of the debug message
giDebug = 0#irrelevant for BCS automatic process
giDebugEval = 1
giDebugEvalValue = 2

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15PRIMES

Removal from the Laser System

1.
2.
3.
4.

First of all the laser source has to be turned off.
Close the shutter.
Turn off the voltage supply.
Ensure that moving parts, e.g. robot arms, etc. are at a standstill and that they cannot be set in motion
unintentionally.
5. Remove all connection cables and supply hoses.
6. Remove the device.
7. Empty the cooling circuit completely and seal the connector plugs of the cooling circuit by means of theenclosed sealing plugs.

16

MaintenanceFor service, maintenance and calibration it is recommendable to return the device to the manufacturer on aregular basis (every 12 to 24 months).

17

Measures for the product disposal

According to the Electrical and Electronic Equipment Act (ElectroG) PRIMES is obliged to dispose PRIMES
measuring devices manufactured after August 2005 free of charge. PRIMES is registered as a manufacturer with the EAR foundation (German register for electronic waste). Our registry number is the following:
WEEE-Reg. – Nr. DE65549202.
You are welcome to return PRIMES measuring devices that are to be disposed free of charge to ouraddress:
PRIMES GmbH
Max-Planck-Str. 2
D-64319 Pfungstadt
Germany

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Dimensions

X

44

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View X

Measuring tip position and movement range of the z-axis

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19

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Technical DataTypeBCS PROFIBUS

Supply data
Supply voltage, DC
Maximum power consumption

VA

24 ± 5 %5Cooling circuit
Cooling water flow rate, min.
Cooling water temperature Tin1)

l/kW
-

0.8
dew-point temperature < Tin < 30 °C

Pre-pressure, typ.
Maximum temperature gradientbar°C/min2 ... 4
< 0.5

Compressed air (water and oil free)
Minimum pressure
Maximum pressure

bar
bar

4
8

Protective gas (water and oil free)
Maximum pressure

bar

He, N2, Ar
0.5

Power
Min.
Max.

kW
kW

0.5
9

Fokus diameter
Min.
Max.

µm
mm

150
5

Wave-length range

nm

800 ...1100

Measurement range, beneath the top of thedevice
Min.
Max.

mm
mm

10
125

Characteristics measurement

Peak intensity fokus, max.

MW/cm2

10Max. power density in the peak
Beam diameter 0 ... 10 mm
Beam diameter 10 ... 30 mm
Beam diameter 30 ... 55 mm

2

kW/cm
kW/cm2
kW/cm2
kW/cm2105
0.5

Max. mean density
Beam diameter 0 ... 10 mm
Beam diameter 10 ... 30 mm
Beam diameter 30 ... 55 mm

kW/cm2
kW/cm2
kW/cm2
kW/cm25
5
0.5

In the distance underneath the top of thedevicemm

360

Measuring accuracy 2)
PowerFokus position
Fokus radius
Far field divergence
Rayleigh-length
Beam quality (M2)

%
µm
%
%
%
%

3
100 + 10 % of zR
5
5
10
10

1)

Please contact PRIMES in advance in case you intend not to work within this specification.

Apart from the system-related measurement uncertainties is the measuring situation (signal-to-noise ratio, temporal stability of
the laser beam strongly essential for the absolute measuring accuracy and the repeatability. The situation-related measurement
uncertainty can be determined by means of the standard deviation of the hyperbolic fit calculated in the caustic evaluation. Thisvalue (multiplied by 3 for a security of 93.3%) has to be added to the measurement uncertainty as an additive contribution.

2)

46

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BeamConrolSystem BCS PROFIBUSType

BCS PROFIBUS

Repeatability 1)
Power
Fokus position
Fokus radius
Far field divergence
Rayleigh-length
Beam quality (M2)

%
%
%
%
%

1.5
5 % of zR3
3
3
3

Measurement duration with 64 x 64 pixel
Caustik (21 planes)
Power measurement

min
s

3
< 10

Movement range of the z-axis

mm

120

Mbit
-

100
potential-free

Operating temperature range
Storage temperature range°C°C+15 ... +40+5 ... +50

Reference temperature

°C

+22

Permitted relative air humidity%80

l x w x h ((including the pivoting range of the
shutter, without cable and plug)

mm

538 x 242 x 566

Weight, approx.

kg

50

Degree of protection

-

IP52

Protection class-

III

Communication
Ethernet
Profibus
PRIMES-Bus (RS485)
Safety circuit (Interlock)Ambient conditions

Dimensions and weights

Protection

1)

Please contact PRIMES in advance in case you intend not to work within this specification.

Apart from the system-related measurement uncertainties is the measuring situation (signal-to-noise ratio, temporal stability of
the laser beam strongly essential for the absolute measuring accuracy and the repeatability. The situation-related measurement
uncertainty can be determined by means of the standard deviation of the hyperbolic fit calculated in the caustic evaluation. Thisvalue (multiplied by 3 for a security of 93.3%) has to be added to the measurement uncertainty as an additive contribution.

2)

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Declaration of Incorporation of Partly Completed Machinery

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21

Appendix

21.1

LDS installation for an automated measuring mode

The LaserDiagnoseSoftware (LDS) can be configured for an automated measuring process of the
BeamControlSystem. The guidance presumes a connection between the PC and the BCS.
In the setup the program permits everyone a full access, so dedicated administrator rights are not mandatory.
If this is changed afterwards, please make sure the software still has full access rights (otherwise you won’t
get an error when working with Windows®7 but the changed files will be stored in virtual folders of Windows
and will not have any effect on the software).
Operating system requirements :Windows® 7 (64 bit) or Windows® XP

For Windows® XP please replace the directory „Program files (x86)“ with „Program files“.
21.1.1

Installation process

The installation of the software is menu driven and is effected by means of the enclosed medium. Pleasestart the installation by double-clicking the file
“Setup LDS v.2.97.exe”
and follow the instructions.

Fig. 21.1:

Setup window 1

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Fig. 21.2:

Setup window 2

Fig. 21.3:

Setup window 3

Fig. 21.4:

Setup window 4

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Fig. 21.5:

Setup window 5

Fig. 21.6:

Setup window 6

Fig. 21.7:

Setup window 7

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Select configuration "for MechanicalDevices” (important for an automatedfocus measurement) !

Fig. 21.8:

Setup window 8

Fig. 21.9:

Setup window 9

Fig. 21.10: Setup window 10

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Visual Studio Reditributable DLLs
are needed for correct executionof the LDS.

Fig. 21.11: Setup window 11

Fig. 21.12: Setup window 12

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Configuration of the LDS for the communication with the device

Once started, the LDS standard configuration is updated.

35,0(6
Fig. 21.13: Welcome window

1. Select “Change User Level” as shown in Fig. 21.13), type in the password for the user level Expert andclick on OK.
2. Select the menu Communication>>FreeCommunication.

TCP

IP address

Bus protocol

Fig. 21.14: Dialogue window Free Communication

3. Select “TCP” as the communication interface (see Fig. 21.14), activate Write bus protocol (bottom rightcorner) and type in the IP-address (standard is 192.168.116.80, please check the IP given on the typeplate of your device).
4. Click on Connect.

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5. If the BCS is connected to the computer you are using, a “CONNECTED to x.x.x.x” message appears(see Fig. 21.15). Click on Safe Config.

Fig. 21.15: Saving the configuration

A click on Find Primes Devices (see Fig. 21.16) searches the bus for the connected devices. When the
search is successful, the windows for measurement settings are shown.

Fig. 21.16: Button for searching connected devices

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21.2

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Presettings for the measurement programs

The script offers 4 measurement programs. For the programs 2-4 preferences are required:
Program Description
1
2

Measure power only
Measure a whole focus caustic

3*)a) Verify just one plane of an existing measurement (fastcaustic)

4*)b) Measure a whole focus caustic with parameters different toprogram 2
Measure a single plane of an existing measurement

Required files
None
Preferences FocusCaustic1.ptx
Evaluation file FocusCaustic1.eval
Preferences FastCaustic.ptx
Evaluation file FastCaustic.eval
Template measurement FastCaustic.foc
Preferences FocusCaustic2.ptx
Evaluation file FocusCaustic2.eval
Preferences OnePlane.ptx

a or b on customers request

1. When a measurement according to ISO11146 is completed select the menu Presentation>>Caustic
and click on the button Review...
When all terms have green checks in the Presentation>>Caustic>>Review dialogue window, save it
as a master for the automatic mode.
2. Select File>>Save measurement preferences (see Fig. 21.17)

Fig. 21.17: Menu File>>Save measurement preferences

3. Choose the directory of the scripts (in this case c:\Program Files (x86)\Primes\LDS\scripts) and savethe preference files named as shown in Fig. 21.18 on page 57 to Fig. 21.20 on page 57.

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Fig. 21.18: Menu File>>Save as ...

Fig. 21.19: File name FastCaustic.ptx

Fig. 21.20: File name One plane.ptx

The preference files for program 2 and 3b are the same (except of the file name). Program 4 uses theconfiguration for plane 0 of its ptx-file. Basically, all 3 different ptx-files can be generated from one (good)measurement.
Also save the measurement as a master foc-file for the program “FastCaustic” (see Fig. 21.21); this is notnecessary for another complete caustic measurement.

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Fig. 21.21: Menu File>>Save measurement preferences...

Fig. 21.22: File name FastCaustic.foc

After this, close the LDS to be able to edit the configuration files, especially the “laserds.ini”.
The script controlled LDS offers the possibility to evaluate several beam parameters to qualify the measurement. The evaluation is controlled by files with the extension “ *.eval ”. One of these files is installed with the
LDS in the script folder (see Fig. 21.23).
1. Using Windows Explorer, go to the directory scripts (“c:\Program F iles(x 86 )\Prim es\LDSv2.97 \scripts”)
2. Copy the file schutzglastest.eval three times inside the directory.
3. Rename the files to:
FocusCaustic1.eval
FastCaustic.eval or FocusCaustic2.eval
OnePlane.eval

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Fig. 21.23: Script directory

To configure the evaluation files, please refer to the accordant documentation in chapter „14.2 Evaluation
function“ on page 39 and „21.5 Configuration of the evaluation parameters“ on page 64.
4. Open the preference file for the program 4 (OnePlane.ptx) with an editor. Make sure that in line 5 “Startebene=” the value is 0.
5. Save and close the file (this will be the measuring plane and will otherwise not work correctly).

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Configuration of the laserds.ini

First you have to copy the required script to the right directory, if it is not installed already.
1. Please save the script file automaticscript.py in
c:\Program Files (x86)\Primes\LDS v2.97\Scripts
This will be the script that is started automatically.
2. Open the laserds.ini file (marked file in Fig. 21.24) with an editor.
3. Please register this file, as shown in Fig. 21.25 (line 170).

Fig. 21.24: File Laserds.ini

Fig. 21.25: Registration in the laserds.ini

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4. In line 43 of Fig. 21.26 you can insert an arbitrary path (make sure, the LDS has the permission to write).

Fig. 21.26: Save path for automatic measurement

5. Save and close the ini-file.
6. Copy the file BeamControls.xsd in the explorer from the script path (Fig. 21.23 on page 59) to thesave directory (BCS_Saves).
7. Start the LDS.

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21.4

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Configuration of measuring programs

Before you start the automated measurement some environment variables have to be configured in the fileglobalsettings.py in the directory c:\Program Files (x86)\Primes\LDS v2.97\lib (Fig. 21.27).

Fig. 21.27: Storage location of the globalsettings.py file

1. Open the file with an editor (e. g. Notepad++) as shown in Fig. 21.28.

Fig. 21.28: Editing the file GlobalSettings.py

In the following passages only the relevant parameters for the BCS in GlobalSettings.py are described.

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PRIMESThe variable giWaitCounter (line 2) is a global timeout for actions like the communication with the robot.
The default value 150 s is reasonable for most cases.
giPowerNumVals (line 4) sets the number of power measurements which are averaged for the program“power measurement only”. A reasonable value would be 15-20. The default is 5 which is a good value fordebugging (fast but not accurate).
The script automatically detects whether the laser is powered on or off after the accordant signal. Both levels
can be declared separately:
giMaxPowerForLaserOff (line 7) is the power level the program will wait for after a measurement is done
and the laser is switched off.
giPowerDifferenceForLaserOn (line 9) is the power level the program will wait for after it set the “laser on”
signal.
Both actions can take several seconds because of the thermalization of the system.
The designation has to be made in watts. Reasonable values would be 50. Default 0.0 watts is only fordebugging without laser.
giThermalizationTime (line 27) declares the time in seconds before a measurement which will be waited
so the CompactPowerMonitor (CPM) as part of the BCS is thermalized.
A reasonable value would be 60-90 seconds (5 seconds for debugging in turn).
The program FastCaustic offers the possibility of measuring just some planes of the complete laser focus(not available for another whole focus measurement).
The plane(s) can be set by the variable giPlaneListForFastMeasurement. Here you can type in the planes
separated by a comma and a space (-> [5, 7] will measure planes 5 and 7).
An example for a reasonable application can be the measurement of one or two planes of the master caustic
again and evaluate the standard deviation (line 12).
2. After customizing the variables for your application save and close the file GlobalSettings.py.

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21.5

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Configuration of the evaluation parameters

This chapter describes the usage of an “evaluation file” in conjunction with the automated measuring mode.
1. To use the evaluation files first open the directory (“c:\Program Files(x86)\Primes\LDS v2.97\scripts”)

Fig. 21.29: Script directory

2. Copy the file “Schutzglastest.eval” twice inside the directory.
3. Rename the files as
FocusCaustic.eval and FastCaustic.eval.
4. Start the program “EvalEditor.exe” stored in the directory (“c:\Program Files(x86)\Primes\LDS v2.97”).
5. Load the file FastCaustic.eval as shown in Fig. 21.30.

Fig. 21.30: File FastCaustic.eval

In Fig. 21.31 a possible configuration of the evaluation file is shown.

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Rename the parameters

Property
mismatch

Change the upper and lower limits
Enable/Disable

Fig. 21.31: Main window of the Evaluation Editor

Name
The name of the parameter can be changed. The selected name will be shown in the LaserDiagnoseSoftware (LDS).
EnableThe required parameters can be selected.
Minimum/Maximum
The upper and lower limits for each selected parameter can be chosen.
Minimum Warn/Maximum Warn
The columns named with “Minimum Warn” and “Maximum Warn” can be used as the limits for the evaluation
test, because there is no warning level implemented in the BCS. Therefore the parameters combined in thetwo blue boxes (see Fig. 21.31) should be the same. A property mismatch is announced by a red squareor asterisk.
6. Save the evaluation file after editing.

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21.5.1

BeamConrolSystem BCS PROFIBUSShow the evaluation fileFor each measurement the system runs, certain documents including the timestamp are saved.
Example:••••FastCaustic _2011_12_16 11_17_58.foc
FastCaustic_2011_12_16 11_17_58.eval
FastCaustic_2011_12_16 11_17_58.ptx
FastCaustic_2011_12_16 11_17_58.txt

1. Start the LDS and open the actual “*foc” file.
2. Open the menu Presentation → Evaluation Parameter View…
3. Load the corresponding “ *.eval ” file.

Fig. 21.32: Evaluation results

Measured parameters out of the given range are marked red.

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21.6

PRIMES

Automatic run

1. Start the LDS.
The welcome dialog is disabled and a text editor with the script appears (script is running automatically).
While the script is already running, the software searches for the devices. For this preparation there is asleep timer in the script. If the BCS is found after this timer, the “BCS idle” signal on the Profibus is set anda measuring program can be requested (BCS idle is also notified in the lower part of the script editor; see
Fig. 21.33).

Fig. 21.33: Script editor

If the BCS isn’t found correctly after the timer has run out, the script will end with an error message like “KeinFM gefunden” (“no FM found”) (Fig. 21.34).

Fig. 21.34: Error message

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If this happens, increase the timer setting.
1.
2.
3.
4.

Go to the editor in the LDS and open the automaticscript.py file.
Search for the line “primes.WaitFor[22000]” (see Fig. 21.35)
Set it to 60,000 ms tentatively (default is 22,000 ms).
Save the script and restart the software.

Fig. 21.35: Wait timer setting

If you still do not get the idle signal after the holding time, there is perhaps an error
1.
2.
3.
4.

68

Check all electrical connections.
Check the power supply (device is switched on?).
Check the directory path of the software.
Close the software and double check all steps described in this manual.

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