Z+F PROFILER 6007 duo

How we build reality

Z+F PROFILER 6007 duo

The high-speed laser scanningsystem Z+F PROFILER 6007duo is one of Zoller + Fröhlich’smost innovative develop-ments in the field of 2D laserscanning.

The Z+F PROFILER 6007 duo is theperfect tool for high-precisionsurveying, inspection and analysisof short or long tracks with highresolutions at high velocities. It isspecially engineered and opti-mized for those applicationswhere gathering data fast andefficiently is required like forexample in the rail industry.

Due to its high performance level,measurements can be made with-out taking possession of the track,impairing other rail traffic and jeop-ardizing personnel and equipment.

Mounted onto a moving carriervehicle, accurate topographicmeasurements of whole railwaysystems can be captured within ashort space of time.

The captured two-dimensionaldata can then be processed intoabsolute three-dimensional Carte-sian coordinates, using data ofadditional sensors such as GPS orInertial Navigation Sensors (INS).

This highly accurate informationcan then be used for numerousfurther applications, like forexample clearance analysis orvirtual reality reviews.

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Fast, rugged, highly-accurate

Areas of application Key characteristics Laser scanning principle

· Full 360 ° field of view(no shadowing effects)

· Doubled laser scan perfor-mance due to the integration oftwo laser scanning systemssynchronized in a single casing("single device design"):

- 500 rot./sec., i.e. cross-sections (effective)

- Data acquisition rate of 1,016,000 pixel/sec. (effective)

· User-definable horizontal andvertical resolutions

· Interfaces for synchronizationwith navigation sensors

· Ethernet interface for datatransfer and communication

· Extreme high ruggedness andstability due to its compactarchitecture

· High security level (et al. safetycover for the rotating laserheads, emergency-stop me-chanism, laser safety class 3R)

· System adaptable to customerrequirements

In order to take measurementsalong a specified track, theZ+F PROFILER 6007 duo must bemounted onto a carrier platformof a moving vehicle. The twointegrated laser scanning sys-tems measure helix-shaped scanlines of the surrounding surface.

A measurement consists of anangle and a distance which isdetermined recording the phasedifference between emitted andreflected laser beam.

The rotation speed of the twolaser scanning systems and thevelocity of the carrier vehicledefine the density of measure-ments (vertical and horizontalspacing between scannedpoints).

· Clearance analysis

- Analysing the whole infra-structure and the surroun-dings of the driven track axis

- Analysing tunnels/tunnel walls

- Analysing platform edges - Detecting clearance infringe-

ments - Testing railroad clearances

when operating oversizedloads

· Inventory survey (2D/2.5D/3D)

· Documentation and analysis ofthe railroad network/system

· Ballast profile documentation

· Creating a planning basis forreconstruction work or deploy-ment of new trains/vehicles

· Virtual Reality (2.5D/3D)

Source: Amberg Technologies

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Z+F PROFILER 6007 duo

Data acquisition

Due to the two laser scanningsystems, the overall systemperformance is doubled, allowingthe carrier vehicle to travel withhigh velocities on the railway net,still maintaining high scanresolutions and point densities.

Both laser scanning systems aresynchronized to be able toachieve a data acquisition rateof 2 x 508,000 pixels per secondwith 2,048 points per capturedprofile.

The horizontal and vertical resolutions between two consecutive cross-sections depend on the driven speed:

1) distance between two consecutive measured cross-sections2) distance between two consecutive measured points within one cross-section on a surface which is perpendicular to the measuring direction of the laser beam

Speed v[km/h]/[mp/h]

Rotations persecond[rps]

Max. no. ofpoints percross-section

Horizontalresolution 1)

[mm]

Vertical resolution at adistance of 3.5 m tothe scanner-center 2)

[mm]

50/31 500 2048 27,8 10,7

20/12 500 2048 11,2 10,7

10/6 500 2048 5,6 10,7

5/3 500 2048 2,8 10,7

Synchronization and absolutepositioning

For kinematic laser scanning thecarrier-vehicle's driven trajectoryneeds to be determined, usingexternal navigation sensors. Withthis information the capturedtwo-dimensional measurementscan be processed into georefer-enced, absolute three-dimen-sional Cartesian coordinates.

Sensor data as well as scan dataare recorded with unique identifi-ers (time stamps or distancestamps) to be able to synchro-nize both data streams.

Since those external navigationsensors are not defined in acommon standard, they are notintegrated in the Z+F PROFILER6007 duo.

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Therefore suitable interfaces forexternal synchronisation signalsare provided.

Mechanical system overview

The Z+F PROFILER 6007 duo’sintegrated laser scanning sys-tems are each controlled by aseperate laser-PC. The bi-direc-tional communication, as well asdata storage onto removableHDD is realized via LAN-/Ethernet-connection.

External navigation sensors forlater data synchronisation caneither be connected to the laserscanner directly via a RS422interface or via Ethernet.

For power supply the high-speedlaser scanner is connected to thetrain’s power system.

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Schematic system overview

Laser scanner 1

Industrial PC(runs capturing

software)

Navigation Sensors

Laser scanner 2

Laser-PC 1

Laser-PC 2

RS422interface(footpulse,odometer...)

Ethernet

Z+F PROFILER 6007 duo

AC-Power

In addition to the Z+F PROFILER6007 duo a suitable industrial PCfor Profiler-control is required.

While the Z+F PROFILER 6007duo has to be mounted on a fixplatform outside the carriervehicle, the industrial PC isinstalled inside.

High speed laser scanner andindustrial PC are both provided byZoller + Fröhlich.

Higher level custom control

unit

Removable HDD

Ethernet

Software

Zoller + Fröhlich offers already tailor-made capturing andprocessing software solutions. This software was developedin partnership with railway experts from Amberg Technologies(AT). They have intensive business know-how in the railwayindustry and offer various software-packages to process andevaluate laser scan data in this domain.

Capturing

The Z+F PROFILER 6007 duo isoperated by a central capturing-software, which is required toforward commands and data tothe two laser scanning systemsand vice versa.

In addition to the communicationwith the Z+F PROFILER 6007 duothe following tasks are performed:

· Controlling the two laser scanning systems (parameters,etc.)

· Continuous data transfer andstorage (e.g. onto USB-harddrives)

· Real-time creation/calculationof composite cross-sections aswell as referencing them to thecenterline of the running track

· Automatic railhead detection

· Regularly checking and loggingthe status of the scannersystem

Processing

The entire data processing isperformed in the office. Beforeviewing, analyzing and exportingthe captured laser scan data,suitable software is used forpreprocessing:

· Combining the scanner rawdata of both laser scanners andconverting it to the track center-line aligned point clouds

· Storing the scanned data in astandardized data format.

For the actual processing,Amberg’s software products canbe used for:

· Filing of processed scan data inproject-format

· Extensive functions and possibi-lities to process, view, evaluateand analyse the data

· Interfaces for data import andexport

Already during the scanning

process, the captured local data

is referenced to the centerline

of the running track using

automatic railhead detection

and can be displayed on screen

in realtime.

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Both capturing as well as processing software can be customizedindividually. Relevant interfaces for synchronization and customer-specific workflows can be respected.

Results

Results

· Extraction of local and/or globalcoordinates:

- Raw scan data - Scan data, synchronized and referenced to the centerline of the running track - Absolute 3D scan data

· Profile-extraction

- Extraction and storage of profiles and cross-sections (minimum profiles in predefi- ned intervals)

· Clearance-analysis

- Calculation of single profiles (numeric information) - Clearance-analysis on the basis of the absolute rail geometry/driven 3D-tra- jectory

Amberg Rail: Combined View (Clearence Map and Cross-Cut), Offboard

Amberg Rail: Visual Tunnel Map, Offboard

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Results

Results

· Various display-possibilities(depending on the availableinformation):

- 2D view of processed composite cross-cuts, including clearance profile - 3D view of scan data including clearance information - Unwrapped view of data including clearance information

· Virtual reality reviews, showingthe results of the measuring runin a pseudo '3D view', based onthe available information:

- Reflectivity information - 2.5D or 3D information - Clearance information

· Data export in various standar-dized formats (pts, ptx, dwg,dxf, bmp, tif,…)

Amberg Rail: 3D-View, Offboard

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Reference

Reference

Metropolitan TransportationAuthority (MTA), NY, USA

As the operator of the biggesttransportation network in NorthAmerica, MTA is responsible forthe whole public railway traffic inNew York City.

The total length of the NY subwaysystem covers approximatelymore than 2,057 miles and itserves more than 734 stations.

In 2009 the first tailor-madeZ+F PROFILER 6007 duo wasinstalled successfully at MTA.Since then Z+F's high-speedlaser scanner has been usedregularly.

Main applications at MTA areclearance analysis and 3Dinventory survey.

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MTA symbol ® and Subway Map © Metropolitan Transportation Authority. Used with permission.(In the picture the laser scanner system is the blue box.)

Technical datasheet

Laser measurement system Z+F PROFILER 6007 duo

Methode Phase-shift

Ambiguity interval 79 m

Min. range 1.3 m

Resolution range 0.1 mm

Data acquisition rate 2 x ≤ 508,000 pixel/sec.

Linearity error up to 50 m 1 ≤ 2 mm

Range noise black 10 % grey 20 % white 100 %

Range noise at 5 m 1,2,3 4.0 mm rms 2.5 mm rms 1.0 mm rms

Range noise at 10 m 1,2,3 6.0 mm rms 3.0 mm rms 1.5 mm rms

Range noise at 25 m 1,2,3 16.0 mm rms 9.0 mm rms 3.0 mm rms

Range drift over temperature Negligible due to internal reference

Optical transceiver

Laser visible

Beam divergence 0.22 mrad

Beam diameter at 1 m distance 3 mm

Laser safety class 3R (ISO EN 60825-1)

Deflection unit

Laser deflection system Rotating mirror

Field of view vertical 360°

Resolution vertical 0.18° (at 250 rps scanning speed)

Accuracy ± 0.07° rms

Max. scanning speed 2 x ≤ 250 rps

Miscellaneous

Data storage External HDD

Data interface Ethernet

Communication interface Ethernet

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Power supply

Input voltage 2 x 3 x 400 V AC, 15 A (per scanner)2 x 24 V, 10 A DC (per measurement and control unit)24 V, 20 A DC (cooling system)

Power consumption 5 kVA

Ambient conditions

Operating temperature -10 °C ... +45 °C

Storage temperature -20 °C ... +50 °C

Humidity/air Non-condensing, no rain/snow/hail/visible dust in the air

Illumination Scanning possible during day and night

Dimensions and weight

Scanner (w/d/h) 775 mm x 470 mm x 750 mm

Weight 140 kg

1) Detailed explanation on request - please contact info@zf-laser.com2) Max. data aquisition rate: 508,000 pixel/sec., 2 sigma range noise3) Lambertian retro reflector

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Head office – GermanyZoller + Fröhlich GmbHSimoniusstraße 2288239 Wangen im AllgäuGermany

Phone: +49 7522 9308-0Fax: +49 7522 9308-252

www.zf-laser.cominfo@zf-laser.com

Subsidiary – UKZ+F UK Ltd.5 Avocado CourtCommerce WayTrafford ParkManchester M17 1HWUK

Phone: +44 161 8690 450Fax: +44 161 8690 451

www.zf-uk.cominfo@zf-uk.com

Subsidiary – USAZ+F USA, Inc.700 Old Pond RoadSuite 606Bridgeville, PA 15017USA

Phone: +1 412 2578 575Fax: +1 412 2578 576

www.zf-usa.cominfo@zf-usa.com

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© 2011 Copyright Zoller + Fröhlich GmbH. All rights reserved. The information contained herein may not be reproduced – in whole or in part – without prior written permissionfrom Zoller + Fröhlich GmbH. Subject to errors and technical amendments.