Operating Manual-1.

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Metrology LAB LTD
©2018-2021

SkyBlue – Operations
Purpose of the system .................................................................................................................................. 4
Parameters .................................................................................................................................................... 4
System Architecture and cabling .................................................................................................................. 4
Measurement sensor (Head) .................................................................................................................... 5
Controller .................................................................................................................................................. 5
HMI Display ............................................................................................................................................... 7
Cabling....................................................................................................................................................... 7
Head to Controller ................................................................................................................................ 7
HMI to Controller .................................................................................................................................. 7
Robot to Controller ............................................................................................................................... 7
SkyBlue Client................................................................................................................................................ 8
Starting the client...................................................................................................................................... 8
Visualization of results and parameters adjustment ................................................................................ 8
Parts of visualization screen ................................................................................................................. 9
Title bar ............................................................................................................................................. 9
Control buttons ............................................................................................................................... 10
View ............................................................................................................................................................ 10
VIEW – OBJ .......................................................................................................................................... 11
Image................................................................................................................................................... 12
Presets..................................................................................................................................................... 12
Joint types ........................................................................................................................................... 12
Standard parallelogram plates ........................................................................................................ 13
Filet ................................................................................................................................................. 13
Corner ............................................................................................................................................. 13
But ................................................................................................................................................... 14
LAP .................................................................................................................................................. 14
Cut parallelogram plate .................................................................................................................. 14

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V groove .......................................................................................................................................... 15
HV groove........................................................................................................................................ 15
Concave parallelogram plate .......................................................................................................... 16
U grove ............................................................................................................................................ 16
J grove ............................................................................................................................................. 16
Global parameters .............................................................................................................................. 16
Preset specific parameters.................................................................................................................. 17
But ....................................................................................................................................................... 17
Measurements ................................................................................................................................ 17
Fillet..................................................................................................................................................... 17
Measurements ................................................................................................................................ 18
Corner ................................................................................................................................................. 18
Measurements ................................................................................................................................ 18
Lap ....................................................................................................................................................... 18
Measurements ................................................................................................................................ 19
Vgroove ............................................................................................................................................... 19
Measurements ................................................................................................................................ 19
Area ................................................................................................................................................. 20
hvgroove ............................................................................................................................................. 20
Measurements ................................................................................................................................ 20
Area ................................................................................................................................................. 21
U groove .............................................................................................................................................. 21
Measurements ................................................................................................................................ 21
J groove ............................................................................................................................................... 22
Measurements ................................................................................................................................ 22
Presets management .............................................................................................................................. 22
System ..................................................................................................................................................... 24
Presets for robot connectors .............................................................................................................. 26
Beckhoff .......................................................................................................................................... 26
Slave operation ........................................................................................................................... 26

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Master operations....................................................................................................................... 27
Abb-egm .......................................................................................................................................... 27
Kuka-rsi............................................................................................................................................ 27
Robot state diagram ....................................................................................................................... 27
Locking policy use case ................................................................................................................... 28
Updating of the system ....................................................................................................................... 29
Setting the client manually ................................................................................................................. 29
Sample Workflows .................................................................................................................................. 30
Start a new welding piece ................................................................................................................... 30
Update the controller ......................................................................................................................... 30
Update the client ................................................................................................................................ 30
Understanding SkyBlue algorithm .......................................................................................................... 30

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Purpose of the system

The purpose of the system is used for seam tracking with welding robots …

Parameters
SB50-2 SB120
Area of measurement 15-65mm from front side of the
sensor
Precision of measurement 0.05 mm 0.1 mm
Repeatability 0.03 mm 0.1 mm
Number of measurements per 100 100
second
Power supply of the system 24V 24V
Number collected frames Up to 100 per second Up to 100 per second
Laser wave length 660nm 660nm
Exposure tiem 100µs – 18 ms 100µs – 18 ms
Gain 1-12db 1-12db

System Architecture and cabling

The system consists of three components Measurement sensor, Controller, HMI Device.

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Measurement sensor (Head)

Measurement sensor does the actual physical measurements of objects located in the laser plane

To Controller

Laser safety LED – ON

when laser is ON
Measurement sensor is connected to controller to appropriate connection interface (see below
controller) with high quality cable.

Controller
The controller gets images from the measurement sensor and does the appropriate conversion and
processing to geometric objects of the specified preset.

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TO Robot Preset to 10.0.0.1 TO Sensor

Can be configured from the client Gray or Blue cable

TO HMI (green cable) Debug interface -

net: 172.17.84.1 / 255.255.255.240 DHCP
172.17.84.2 HMI
172.17.84.3.. 172.17.84.14 ext. PC

Power supply 24V

The interfaces of the controller are dedicated for specific purposes from left to right:

1.
2. HMI display or switch to HMI and external pc.
3. Debug interface intended for servicing, remote access etc. The IP configuration is obtained by
DHCP on the network where the controller is connected.
4. OFF
5. Interface to robot. Preconfigured to 10.0.0.1/255.255.255.0. IP configuration can be changed
from the client.
6. SkyBlue sensor connection. 5m gray cable CAT7 and 10m blue cable CAT6A are provided.
7. Not used.

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Sensor interface is POE enabled and controller is powering the sensor. IP address is factory defined and
is not intended to be changed on the field.

HMI Display
Provide user interface to the controller and parameterization of pattern matching for successful seam
tracking.

TO Controller Power supply 24V

Power Supply

Power supply between 8 and 35 V VDC has to be supplied to controller and HMI display (Head is
powered by the controller). Recommended value – 24V. Sample power supplies for controller and HMI
display are provided in the package.

Cabling
Head to Controller
- done by factory qualified cable 5-10m long; CAT 7(5m) and CAT6E(10m) Ethernet cable. Shielding on
both sides is very important (as per the cited standards). The cables are delivered with the system.
White 5m; Blue 10m

HMI to Controller
- sample cable provided by factory with 3m length; CAT5E + Shield minimum

Robot to Controller
- RJ45 connector as defined above (not included in the package).

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SkyBlue Client
Starting the client
To start the client from HMI display a link on HMI screen is provided (2). Before starting the client, it is
advised to start a standard Linux virtual keyboard (1).

On a regular PC, with installed Java, connected with dedicated interface to the controller HMI port you
can start the client by double click of skyblue.jar file.

Visualization of results and parameters adjustment

On startup of the client switches to visualization mode.

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Parts of visualization screen

Title bar

Sensor model Version of controller Current frame No

Version of client Serial number of sensor Time stamp of current frame Locking state

The title bar contains important information about the current system connected:

cl V: - Software version of client operating on a PC or on industrial touch screen (tablet)

Sensor M: - Sensor model – SB50 is the viewing range 001 is the version

SN: - Serial number of the sensor (stored in the sensor). If one connects a sensor to a controller the
specific sensor will be listed here.

Controller V: - Software version of the controller

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It shows as well essential status information about the operation of the system:

xxxxxx[ms] - Timestamp – timestamp of the visualized frame since start of the sensor in milliseconds

fc: (xxxxx) – frame counter of the number of frames since the sensor has been started

Locking state – discussed later in this document

Control buttons

START MEASUREMENT – switches on and off the measurements of

the system. BE CAREFULL THIS SWITCHES ON THE LASER THERE
SHOULD NOT BE ANYBODY IN FRONT OF THE SENSOR LASER BEAM.
The laser is 30 mW optical power laser, which could be harmful for
yeas of operator with direct exposure.

VIEW – Switches to visualization and parameter adjustment screen

PRESETS – Switches to presets management screen.

SYSTEM – Switches to system configuration update and log

collection.

EXIT – closes the client. On close the client switches the

measurements off if they have been switched on by this client (see state diagram and locking later in the
document).

View
Depending on status of the system (measurement on or off) the screen shows parameters of the
selected preset and observed results.

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VIEW – OBJ
Preset selector
Time stamp in ms

Area for measurement

Selected preset
results
parameters editor

Sketch of selected preset with marks

of geometric parameters e.g.
Absolute angle(O) denoted on the
Status result of current
sketch with O
frame
Visualization area (adjusted for the
connected camera) showing
points, segments and found
object. Data is drawn in mm in the
viewing area of the sensor.
Buttons on the left allows
switching on/off the visualisation
of different type of data.

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Image
Image screen is used to adjust the exposure time, gain and point sensitivity (when Points button on the
left is pressed).

Presets
Presets are collection of parameters intended to track specific workpiece. Presets have types and
parameters. There are parameters global for all preset types and parameters specific to the geometry of
the type.

Presets in SkyBlue are designed taking into account the basic welding standards. During welding two
plates are joined with arc welding process. Two types of plates are usually available for welding:

Joint types

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Standard parallelogram plates

This plate can be joined with another plate of the same kind in several different ways:

Filet

Corner

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But

LAP

It is possible to cut one or both of the plates to be joined to increase the quantity of welding material
used.

Cut parallelogram plate

In this case the following additional combinations of shapes are possible

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V groove

HV groove

If the material needed for strong joint is still not enough special cutting of one or both plates is possible

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Concave parallelogram plate

U grove

J grove

Taking in mind this subset of joints defined by ISO welding standard we need to define the following
presets – one for each joint type.

Global parameters
In front of all there are some global parameters not related to the specific shape of a joint:

Exposure time[ms] – the sensor can collect light for different time. The supported time range is 0.1ms to
18ms (to keep the rate of produced frames high enough).

Gain[dB] – in addition to exposure the gain allows making the image lighter. Value can change between
1db and 15db.

Point sensitivity – Controls the collection of points by the algorithm. Range is between 1 and 10. 1 allow
more points 10 reduces the number of points. At 1 a noisy image will give a lot of outliers but a dark
image will deliver points. At 10 the chosen points are reduced and filtering of data takes place.

Line sensitivity – Line sensitivity controls the ease the algorithm produces lines. Value can be changed
from 1 to 100. 1- stands for more lines (more noise). 100 heavy filtering of the lines.

Minimum line – minimum length of accepted line.

Maximum gap – maximum gap between two lines to aggregate them into a single line.

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O - Absolute angle and Absolute angle tolerance – angle of observation of the working pies. Defined
below and on the client as green line.

Preset specific parameters

But

P - butt_minplate – minimum length of plates [mm]

M-maxmismatch – maximum mismatch of plates [mm]

A-butt_maxdistortion – maximum distortion angle [deg]

W-butt_width – width of the gap between plates [mm]

but_track_point A, B, C – supported tracking points: end of right plate-A, center between plates - B, left
plate -C

Measurements
 The following measurements are calculated with this preset:
 Width of but [mm] in GUI; [mm]*100 in robot
 Distortion angle [deg] in GUI; [rad]*100 in ROBOT
 Mismatch [mm] in GUI; [mm]*100 in robot
 Left plate length [mm] in GUI; [mm]*100 in robot
 Right plate length [mm] in GUI; [mm]*100 in robot
 Width of gap [mm] in GUI; [mm]*100 in robot

Fillet

A - fillet_angle and fillet_angle_tol – angle between plates and tolerance of the angle [deg]

P - fillet_minplate – minimum length of the plates [mm]

fillet_track_point A – does not need selection as it is a single option

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Measurements
 Filet measured angle [deg] in GUI; [rad]*100 in robot
 Filet gap [mm] in GUI; [mm]*100 in robot
 Left plate length [mm] in GUI; [mm]*100 in robot
 Right plate length [mm] in GUI; [mm]*100 in robot

Corner

A - corner_angle and corner_angle_tol – angle between plates and tolerance of the angle [deg]

P - corner_minplate – minimum length of the plates [mm]

corner_track_point A – does not need selection as it is a single option

Measurements
 Measured angle [deg] in GUI; [rad]*100 in robot
 Left plate length [mm] in GUI; [mm]*100 in robot
 Right plate length [mm] in GUI; [mm]*100 in robot

Lap

H- lap_stepheight and tolerance – height of lap and tolerance [mm]

A - lap_bending – Maximal angle between plates [deg]

P - lap_minplate – minimum length of the plates [mm]

lap orientation (left/right)

lap_track_point A,B,C

Special comments: Lap preset is defined with 3 segments. All 3 segments should be visible for that
version of the preset.

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Measurements
 Step height [mm] in GUI; [mm]*100 in robot
 Bending angle [deg] in GUI; [rad]*100 in robot
 Upper plate length [mm] in GUI; [mm]*100 in robot
 Lower plate length [mm] in GUI; [mm]*100 in robot

Vgroove

P - vgroove_minplate – minimum length of horizontal part of plates [mm]

W - vgroove_width and tol – Width of V as drawn above [mm]

H - vgroove_height and tol – Height of V as drawn above [mm]

A - vgroove_bending – Maximum angle of distortion of both plates [deg]

G - vgroove_maxgap – Maximum gap of V [mm]

M - vgroove_maxmismatch – Maximum mismatch of both plates [mm]

vgroove_track_point A, B, C, D, E A – left plate cut edge, B – right plate cut edge, C – crossing between
cut parts(bottom of V), D – Middle between A and B, E – centre of A, B, C

Measurements
 Bottom gap [mm] in GUI; [mm]*100 in robot
 Area [mm2] in GUI; [mm2]*100 in robot
 Bending of both plates [deg] in GUI; [rad]*100 in robot
 Top width [mm] in GUI; [mm]*100 in robot
 Height [mm] in GUI; [mm]*100 in robot
 Mismatch [mm] in GUI; [mm]*100 in robot
 Left plate [mm] in GUI; [mm]*100 in robot
 Right plate [mm] in GUI; [mm]*100 in robot

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Area

SkyBlue calculate for V preset a triangular area located between TP. A, B, C

hvgroove

PH - hvgroove_minplatehorizontal – minimum length of horizontal plate [mm]

PV - hvgroove_minplatevertical – minimum length of vertical plate [mm]

W - hvgroove_width and tolerance – Width of the welding groove [mm]

H - hvgroove_height and tolerance – Height of welding groove [mm]

A hvgroove_bending – The expected angle between vertical plate and cut plate is 90 0. This parameter
defines the maximum deviation from this angle 00 in the ideal case. [deg]

G- hvgroove_maxgap – The maximum allowed bottom gap of the object [mm]

orientation (left/right)

hvgroove_track_point A, B, C, D, E

Measurements
 Bottom gap [mm] in GUI; [mm]*100 in robot
 Area [mm2] in GUI; [mm2]*100 in robot
 Bending angle [deg] in GUI; [rad]*100 in robot

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 Width [mm] in GUI; [mm]*100 in robot

 Height [mm] in GUI; [mm]*100 in robot
 Horizontal plate length [mm] in GUI; [mm]*100 in robot
 Vertical plate length [mm] in GUI; [mm]*100 in robot

Area

Please note this version Hv groove expects all 3 segments to be visible.

U groove

P – minimum plate length [mm]

A – Angle of cut plate [deg]

L – Length of bottom part including rounding [mm]

R – Radius of rounding [mm]

B – bending of u groove [deg]

G – Max gap [mm]

Measurements
 Cut-angle [deg] in GUI; [rad]*100 in robot
 Bottom length [mm] in GUI; [mm]*100 in robot
 Bending angle [deg] in GUI; [rad]*100 in robot
 Gap [mm] in GUI; [mm]*100 in robot
 Left Plate [mm] in GUI; [mm]*100 in robot
 Right Plate [mm] in GUI; [mm]*100 in robot

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J groove

P – minimum plate horizontal [mm]

A – Angle of cut plate [deg]

L – Length of bottom part including rounding [mm]

R – Radius of rounding [mm]

B – bending of groove relative to orthogonal position of both plates [deg]

G – Max gap [mm]

Measurements
 Cut-angle [deg] in GUI; [rad]*100 in robot
 Bottom length [mm] in GUI; [mm]*100 in robot
 Bending angle [deg] in GUI; [rad]*100 in robot
 Gap [mm] in GUI; [mm]*100 in robot
 Horizontal Plate [mm] in GUI; [mm]*100 in robot
 Vertical Plate [mm] in GUI; [mm]*100 in robot

Presets management
Presets management screen allows creation of presets and removal of not needed presets.

NEW button allows creation of new preset. When created the preset gets number (must be unique in
the system) type and label. When created if number of an existing preset is used the existing preset is
overwritten. Type of the preset can be defined only during preset creation. Label is used to allow the
operator easier decision about the purpose of the preset.

DELETE button deletes the selected the selected preset.

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System
System function contains the options needed for robot operations and management of logs and
updates.

Robot IP address – the address of SkyBlue controller used to communicate with robot systems.

Robot Net Mask – the subnet-mask used for the robot connection

The values above apply to the interface of the controller named TO Robot.

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Robot type

Identify the type of the robot connected to SkyBlue. Currently Beckhoff, ABB, KUKA. Currently SkyBlue
support only ethernet connection to robots. To change the used robot types, one should select the type
from the combo box provided in the client, adjust the parameters and press the SET button. The
selected robot type is stored in the controller and will be used in future until changed to another type.

Robot main settings and

type selection Service Functions

Robot type specific

parameters

Simple Robot

Test functions

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Presets for robot connectors

Beckhoff

Slave operation
Beckhoff connector can operate as master and slave. For that purpose, SkyBlue contains an internal PLC
simulator. By default (the settings above) measurements and timing information are redirected to the
internal PLC. The internal PLC support the full set of Beckhoff TwinCat 3 protocol. This include
subscription for variable changes and this way SkyBlue may operate as a slave device to ADS compliant
system. The PLC simulator is accessible through the TO ROBOT port on the defined IP (10.0.0.1 in the
sample) on port 48898.

Two variables are supported controlling SkyBlue:

sbvars.out_sb_track INT32 – when set to 0 measurement is switched to OFF. When set to 1

measurement is switched ON (the laser is powered and SkyBlue start to deliver measurement results.

sbvars.out_sb_preset INT32 – when set the variable define which preset number to be used.

sbvars.sb_data[15] INT32 – results from camera measurements

[0] – actual measurement status 0 – measurement is off 1 – measurement is on

[1] – actual preset

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[2] – time stamp of the frame in ms

[3] – age of the frame in ms. As the processing needs some time after the image has been collected the
age contains that time and can be used on the robot for precise synchronization.

[4] – error code of SkyBlue

– 0 – no error
– 1 – Not enough segments – the expected object has more segments than SkyBlue can see.
E.g. looking for filet but only one segment is found.
– 2 – No candidate segment – The absolute angles do not allow selection of the needed
number of segments.
– 3 – No candidate pair – The relative angles do not fit to the observed object
– 4 – Validation not successful – The distance constraints do not fit. E.g. minimum lengths,
maximum gap etc.
– +100 (e.g. 100, 101, 102, 103, 104) – an attempt to set non existing preset from the robot
has been done. The preset remains the same as before the attempt.

[5] – Tracking point X coordinate in 10microns units (mm * 100). E.g. 1101 is 11.01mm

[6] – Tracking point Y coordinate in 10microns units (mm * 100). E.g. 2101 is 21.01mm

[7]..[14] – Measurement specific to the preset type. The measurements are multiplied by 100 as for the
TP. The angles are presented in radians*100. The distances in mm*100. The areas in mm 2*100. The
order of the measurements is the same as displayed on SkyBlue measurement panel.

Master operations
From timing point of view, it may be more suitable to use SkyBlue as MASTER. This can be achieved by
simple configuration. Adjusting the parameters in Beckhoff connector to appropriate addresses of
Beckhoff PLC will switch SkyBlue to directly send data to actual PLC.

For more details please consult Beckhoff addressing schemes and models.

Abb-egm
TBD

Kuka-rsi
TBD

Robot state diagram

TBD

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Locking policy use case

Locking is needed by the system to avoid occasional operations with SkyBlue from the GUI client. If this
happens during robot operations it may affect the operations of the ROBOT. E.g. if the preset is changed
during welding this may destroy the tracking quality. If this occurs the robot will be “blind” for seam
tracking. Because of this when the measurement is started from the robot the other clients are locked.
They still show the tracking information but it is not possible to switch on/off measurement, change
preset, change parameters in the preset, update the controller etc.

In case the operator still wants to change some of the above parameters it can explicitly unlock the
client and make the required modifications. If the client has been unlocked with the unlock function the
robot state have to be returned to not-measuring before subsequent switch of measurement-on. This
can be done with SYSTEM SYM_ROB_OFF button in case of slave operation of SkyBlue or in the Real PLC
in case of master operations. Only the change from 0 to 1 of sbvars.out_sb_track is considered as
measurement ON activation.

The same behavior applies to multiple GUI clients but they are not prioritized. The first client locks the
system. When the system is locked by a GUI client the robot will lock it if it switches the measurements
ON.

On the user interface the locking state is shown as last section on the title bar

Sensor model Version of controller Current frame No

Version of client Serial number of sensor Time stamp of current frame Locking state

Type of
locker –
client or
robot

Unique ID of Locking ID of locker

the client Status

The system is locked by the active client.

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- When second client is started the system is still locked by the first client. The
second client can not change parameters and states on the screen but can observe results.

If needed the client [2] can unlock the system

Unlock by pressing
this button

- The client ID is 5 but the robot (ID 6) took over and locked the system. When robot
starts (Including internal robot simulation) it always locks the system. In the client pool the first client
locks. When robot starts it override the client locks and lock the system.

Updating of the system

TBD.

Update of the controller is done by selection of factory distributed xxxxx.deb file. For update of the
client a xxxxxxx.jar file is used (Please use only factory provided update files!)

Setting the client manually

The client is a java application contained in a single jar file.

To start the client on windows:

1. Java 7 JRE has to be installed

2. Double click on the jar file starts the application

The controller should be connected to the “green” cable connector with the PC. IP addresses should be
conformant to spec above.

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Sample Workflows
Start a new welding piece
TBD

Update the controller

TBD

Update the client

TBD

Understanding SkyBlue algorithm

The basic procedure in SkyBlue core includes the following steps on each frame produced by the CMOS
sensor:

1- Collection of the frame – the image collection is done with fast controller located in the sensor
which collects 10bits/pixel images with real time speed of the sensor. Parameters affecting
quality of collected image (frame) are available in all presets:
 Exposure time[ms] – the sensor can collect light for different time. The supported time
range is 0.1ms to 18ms (to keep the rate of produced frames).
 Gain[dB] – in addition to exposure the gain allows making the image lighter. Value can
change between 1db and 15db.
2- Point finding – Includes a procedure for extracting points from the visible object (shown in black
in VIEW-OBJ and in RED in VIEW-IMG). Parameters affecting point finding are available in all
presets:
 Point sensitivity – Controls the collection of points by the algorithm. Range is between 1
and 10. 1 allow more points 10 reduces the number of points. At 1 a noisy image will give a
lot of outliers but a dark image will deliver points. At 10 the chosen points are reduced and
filtering of data takes place.
3- Line finding – uses a transformation of the points known as HOUGH transform to convert them
in linear segments. The following exposed parameters affect the line finding algorithm:
 Line sensitivity – Line sensitivity controls the ease the algorithm produces lines. Value can
be changed from 1 to 100. 1- stands for more lines (more noise). 100 heavy filtering of the
lines.
 Minimum line – minimum length of accepted line.
 Maximum gap – maximum gap between two lines to aggregate them into a single line.
4- Geometric combinations for finding the expected shape – the obtained segments are combined
according to defined geometric parameters in the selected preset. If there is a successful match
the object is “recognized” by SkyBlue and calculations can be done.

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5- Calculation of Tracking point and measurements – If a successful match of object happened on

previous stage tracking point and other measurements can be calculated. In each preset
tracking point is defined as one or more options. Measurements depend on the preset type and
are useful for adapting the robot behavior (welding current, stop of welding, quantity of welding
material, etc.). These parameters allow additional improving of welding quality when used.

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