CAVITAR Welding Camera C300 Operating Manual
Contents 1 INTRODUCTION ......................................................................................................................... 1 2 SAFETY INFORMATION .......................................................................................................... 2 3 PROPERTIES ............................................................................................................................... 5 4 INSTALLATION .....................................................................
1 Introduction Thank you for choosing Cavitar Welding Camera model C300 (later: Welding Camera)! Welding Camera is a Finnish quality product developed and manufactured by Cavitar Ltd. We hope that you will be satisfied with your product. Welding Camera is a highly compact and easy-to-use visualization system for the online monitoring of various welding processes, including MIG, MAG and TIG processes. Welding Camera contains several unique features in order to enable highest possible image quality.
2 Safety information PLEASE CAREFULLY READ AND UNDERSTAND THE FOLLOWING SAFETY INSTRUCTIONS BEFORE USING WELDING CAMERA. IT IS OF UTMOST IMPORTANCE TO STRICTLY OBEY THESE INSTRUCTIONS. OTHERWISE SERIOUS DAMAGE TO THE USER OR TO THE DEVICE MAY OCCUR. ONLY A PERSON, WHO HAS CAREFULLY READ AND UNDERSTOOD ALL SAFETY INSTRUCTIONS BELOW AND THE REST OF THIS OPERATING MANUAL, IS QUALIFIED FOR USING WELDING CAMERA. CAVITAR LTD. IS NOT LIABLE FOR ANY DAMAGE CAUSED BY THE IMPROPER USE OF WELDING CAMERA.
Other instructions: o Welding Camera is not certified for medical use o Do not make ANY modifications to the device by yourself o Do not try to repair the device by yourself o It is strictly forbidden to open the cover of the camera unit. Otherwise serious damage or injury to the user or to the device may occur. Camera unit contains gallium arsenide, which is a known human carcinogen o Before powering the system, ensure all connections are made according to this manual and all cables are intact.
CERTIFICATIONS AND COMPLIANCE Cavitar Ltd. is an ISO 9001:2015 certified company CE declaration of conformity o Welding Camera, if installed and operated in accordance with the manufacturer’s instructions, is in conformity with the following European, harmonized and published directives and standards: 2011/65/EU (RoHS 2) 2014/30/EU (Electromagnetic Compatibility) 2014/35/EU (Low Voltage Directive) BS/EN 60825-1:2014 (Laser Safety) Declaration of conformity with 21 CFR 1040.10 and 1040.
3 Properties Welding Camera C300 typically consists of the following components: CAMERA UNIT laser aperture label laser class 3R warning label easy-to-replace protective window mounting threads integrated channels for air or liquid cooling POWER SUPPLY power supply DC 24 V, 25 VA, including 1,2 m long fixed cable CABLES GigE cable (between camera unit and computer), standard length 10 m power cable (between camera unit and power supply), standard length 10 m power supply cable (between pow
Table 3.1. Welding Camera specifications. Camera related Default working distance 200 mm (good image quality within ± 15 mm) Field of view (@ default working distance) approx.
(1) The camera heats up during operation. Please follow these guidelines to ensure proper cooling: a. Heat dissipation measures are needed if the camera temperature (displayed in CAVITAR Capture software) exceeds 55 ºC. A warning message is displayed in CAVITAR Capture if the camera temperature reaches 57 ºC. The maximum camera temperature is 65 ºC and CAVITAR Capture stops image acquisition if this temperature is reached. If the camera temperature reaches 75 ºC, an emergency shutdown will be initiated.
A B C Fig. 3.1. Camera unit (top view, fixed working distance version). A B C Fig. 3.2. Camera unit (top view, adjustable working distance version). D G H I E J F Fig. 3.3. Camera unit (front view). K Fig. 3.4. Camera unit (back view).
In Figs. 3.1-3.4: A Laser aperture label B Laser warning label (laser hazard symbol and explanatory label) C Camera unit device label D Working distance adjustment (optional feature, for more details see the separate document “Working distance adjustment instructions”) E Protective window holder (rotate to change the replaceable protective window) F Mounting threads (2x M4, see Fig. 3.5 for more details) G Power led H Connector for power cable I Connector for GigE cable J Threads (2x M6x0.
CAUTION! Do not connect other than the supplied power supply to the camera unit. Only connect the power supply to a wall socket with protective grounding. Power supply can be disconnected from the mains supply by removing the power supply plug from the wall socket.
4 Installation 4.1 Software installation Recommended computer properties are listed in Table 4.1: Table 4.1. Recommended computer properties.
Fig. 4.2. close all other applications and click “Next” to start installation. Fig. 4.3. Click “I Agree” to continue.
Fig. 4.4. Select “Support for two cameras” if two systems will be used with the same computer. Welding Camera has GigE interface, so USB camera drivers are usually not needed. Click “Next” to continue. Fig. 4.5. Choose install location and click “Next” to continue.
Fig. 4.6. Choose start menu folder and click “Install” to continue. Fig. 4.7. After installation is completed, click “Next” to continue.
Fig. 4.8. Select “Reboot now” and click “Finish”. 4.2 Hardware installation Installation of camera unit The camera unit should be mounted or clamped with an appropriate fixture in such a way that the object is located at the working distance of the camera unit. The mounting must enable as efficient conductive (low ambient temperature or heat load from process) or active (high ambient temperature or heat load from process) cooling of the camera unit as possible.
The camera unit must be properly protected from excessive radiation, heat/cold, condensation, vibration or mechanical forces (see Table 3.1 for more detailed specifications). If you feel uncertain about the correctness of the installation and/or about the suitability of the environment, please contact your vendor or Cavitar. Warranty does not cover damage caused by improper installation. Electrical connections The electrical connections shall be made in the following way: connect the power cable (see Fig.
WARNING! Ensure that the locations of all operation and adjustment controls as well as other system components are such that neither the operator nor anybody else can be accidentally exposed to laser radiation. Pay special attention to the placement of camera unit and computer. Ensure that all system components are placed in such a way that the applicable mains plugs are always easily removable from the electrical network.
5 Operation After proper installation Welding Camera is ready for operation. In the following the operation of the system is described in more detail. 5.1 Before operation Before operation the following preliminary issues need to be performed: check that camera unit is properly installed check that the replaceable protective window of the camera unit is clean power up the computer check that the electrical connections are as described in Section 4.2.
5.2.1 Registration When starting CAVITAR Capture for the first time, registration procedure will start (see Figs. 5.1 – 5.5). Proceed by following the instructions and email the registration file to Cavitar. Fig. 5.1. Registration: step 1. Fig. 5.2. Registration: step 2. Fig. 5.4. Registration: file saved notification. Fig. 5.3. Registration: step 3. Fig. 5.5. Registration: final notification.
After receiving the registered file from Cavitar, start CAVITAR Capture. The screen shown in Fig. 5.1 will appear. Click “Load” and select the file sent by Cavitar. After this a notification appears (see Fig. 5.6) and CAVITAR Capture starts after pressing “OK” (see Fig. 5.7). Fig. 5.6. Registration completed successfully. Fig. 5.7. CAVITAR Capture user interface.
5.2.2 Opening the camera When CAVITAR Capture starts for the first time, it has to be connected with the camera. This procedure has to be repeated if a different camera is connected to the computer. However, as long as the same (previously selected) camera is connected to the computer, there should be no need to repeat this procedure. Select “Open Camera…” from “File” menu. This will open the window shown in Fig. 5.8.
5.2.3 Overview of CAVITAR Capture The typical graphical user interface (GUI) of CAVITAR Capture (after Start-button has been pressed) is shown in Fig. 5.10. The actual appearance of the GUI as well as the contents of the menus depend on the software version and selected features. Fig. 5.10. Overview of CAVITAR Capture. In Fig. 5.
The menus contain the following features (available features depend on software version): File Open camera… Close camera Open image… Save as… Exit View Show toolbar Show zoom tools Show preview fps buttons Show statusbar Show capture frame rate Show recording controls Show sources Show camera capture rate tune controls Show histogram View grid Rotate image by 90 degrees Fullscreen mode (Alt + Enter) Autofit image for fullscreen mode Show zoom controls in fullscreen mode Settings Snapshot...
5.2.4 Camera settings After a connection to the camera has been established, it is time to adjust camera settings. To do this, select “Camera…” from “Settings” menu. This will open the window shown in Fig. 5.11 (the window shown in Fig. 5.12 can be opened by clicking “Image” tab). Fig. 5.11. Camera settings (Timing & sync). Fig. 5.12. Camera settings (Image).
“Image” tab (Fig. 5.12) contains the following features: Bit depth (higher bit depth enables larger dynamic range but increases image file size) Mode (different preset resolutions are available) ROI (reducing the region-of-interest reduces image file size) Binning (for reducing image file size and for increasing sensitivity) o Note: if 2x2 binning is applied, the exposure time must be set to at least 8 s in order to see laser illumination in the images.
Gain can be applied in order to make the image brighter. However, large gain values will increase the noise in the images. Gain is typically applied if the original image is too dark. This can be the case with very dark or highly reflective metal surfaces. Gamma is a nonlinear correction tool that can increase the visibility of dark regions with respect to the brighter regions. Gamma correction can often improve the visual appearance of the image.
In Fig. 5.14 two bars are shown, but the number of bars can be also 3 or 4 (determined by selecting the desired value from the “Number of bars” field). By using 3 bars one can e.g. assign the actual grayscale range of 0…50 to be displayed on screen as grayscale range 0…150 and the actual grayscale range of 51…150 to be displayed on screen as grayscale range 151…255. With 4 bars even more detailed adjustment of grayscale ranges is possible.
Fig. 5.16. Guideline and grid properties.
Guideline and grid properties window contains the following features: Naming and rotation angle for horizontal guidelines Naming and rotation angle for vertical guidelines Calculation of distances between selected guidelines (up to 4 distances) Options for how to display guidelines, guideline names and calculated distances on the screen Grid spacing and precision Fig. 5.17 shows the view after selecting lines for 1 and 2 and pressing “OK” in Fig. 5.16. Fig. 5.17.
Fig. 5.18. Calibration mode window. In calibration window the desired unit can be set (in Fig. 5.18 “mm” has been set). Calibration can be made based on measurement (as in Fig. 5.18 above) or as a conversion. Calibration based on measurement requires that two vertical and two horizontal guidelines have been placed to their correct positions (e.g. according to a precise calibration pattern or some other object with known dimensions).
Fig. 5.19. Calibration data window. In order to enable the “Calibrate” button (in Fig. 5.19), all fields in the calibration data window need to be filled. When performing calibration for the first time, also the log file path has to be defined by pressing “Change file path” button. After all information has been successfully filled, the “Calibrate” button becomes active and the calibration can be completed. A confirmation window will appear after pressing “Calibrate” button (Fig. 5.20). Fig. 5.20.
Fig. 5.21. View after calibration.
5.2.8 Recording settings To define the recording settings, select “Recording…” from “Settings” menu. This will open the window shown in Fig. 5.22. The actual appearance of the window may depend on the software version in use. Fig. 5.22. Recording settings.
Recording settings contain the following features: Saved images file format: available formats include .jpg, .bmp, .tif, .png and .
Fig. 5.23. Viewing recorded images. The image player controls for viewing recorded images as well as the “Export” button for saving the images to a desired location have been indicated in Fig. 5.23. It is also possible to move the slider with a mouse. If some or all of the recorded images need to be saved on a hard disk, the “Export” button needs to be pressed. This opens the Export window (Fig. 5.24).
Fig. 5.24. Export window. In the export window it is possible to: determine which frames will be saved o pressing “Mark start” will set the current image as the first image to be saved o pressing “Mark end” will set the current image as the last image to be saved choose whether the frames will be saved as separate files or as a video add a folder tag, if desirable view (and modify, if needed) the recording settings 5.2.11 Snapshot Snapshot means the capture of a single frame.
Fig. 5.25. Snapshot settings. 5.3 Starting and stopping laser illumination Laser illumination will start when both conditions below are met: “Laser” is “enabled” in Camera settings Timing & sync window (“Settings menu” “Camera…”) “Start” button (Fig. 5.
5.5 Troubleshooting Below are some instructions for solving certain situations if the system doesn’t appear to function as expected. If these instructions don’t help, please contact your vendor or Cavitar. Camera is not found by Windows check control, power and GigE cables (cables intact and properly connected) check that the system is powered (green led in camera unit is on) ensure that e.g. firewall or virus protection software of the computer is not preventing camera connection.
6 Maintenance and service information Under normal operating conditions the only regular maintenance task is the replacement of the replaceable protective window of the camera unit. If liquid cooling is applied, also the cooling channels need to be checked and cleaned up regularly.
7 Support and end of life Support and contact information It is of utmost importance to Cavitar that Welding Camera will work reliably and offers the greatest possible benefit to our customers. These objectives have guided the design and manufacturing of the product. However, if problems occur despite of our efforts, it will be our first priority to solve these problems as quickly and efficiently as possible. In case of problems please contact your vendor or Cavitar by email or by telephone. Cavitar Ltd.
8 Limited warranty Cavitar warrants to the customer, that the product is free from defects in materials and workmanship and that the product is in good working order. Cavitar does not warrant error free or uninterrupted operation of the product. The warranty is valid only if the serial number plate is on the product (i.e. not removed or defaced). The warranty for the product is one year starting from the date of purchase or delivery (unless the applicable law establishes a longer period).
