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Newton NM200UW User Manual

Nuclear underwater laser scanner
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NM200UW
Nuclear Underwater Laser Scanner
User Manual
Version 2.1
January 30, 2014

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Summary of Contents for Newton NM200UW

  • Page 1 NM200UW Nuclear Underwater Laser Scanner User Manual Version 2.1 January 30, 2014...
  • Page 2 NM200UW Nuclear Underwater Laser Scanner User Manual (THIS PAGE IS BLANK) Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...

  • Page 3: Table Of Contents

    3.1. Scanner Application Language Selection The NM200UW user interface has two language options: English and French. The scanner user interface will load in English by default when first started. To choose a language, the “Languages” dropdown menu in the taskbar located in the upper left corner of the scanner user interface may be used.
  • Page 4 NM200UW Nuclear Underwater Laser Scanner User Manual 4. DEPLOYMENT 4.1. Pre-Deployment Data Gathering and Scan Program Generation 4.2. Scanner Field of View and Scan Distance 4.3. Equipment Checkout and Preparation Functional Test FME Fastener Challenge Procedure Optional Step – On-Site Qualification 4.4.
  • Page 5 NM200UW Nuclear Underwater Laser Scanner User Manual APPENDIX B - SYSTEM BLOCK DIAGRAMS APPENDIX C – NM200UW 3D IMAGING COVERAGE MAP (ICM) Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...

  • Page 6: Introduction

    Newton Labs to ALARA enhancement tools. In this manual, the hardware and software components of the NM200UW system will be described in detail. Additionally, the necessary steps and actions required to deploy the NM200UW during an outage will be covered, along with a troubleshooting guide to address the handling of non-standard situations.

  • Page 7: Hardware

    NM200UW Nuclear Underwater Laser Scanner User Manual 2. HARDWARE The NM200UW hardware consists of a camera head, a cable, and a ruggedized control box. A substantial amount of research and development has gone into the technologies contained within the hardware, with each of the three major components (described below) having been purpose-built for the nuclear environment.

  • Page 8: Scanner Head

    NM200UW Nuclear Underwater Laser Scanner User Manual Scanner Head The waterproof camera head contains a high-resolution camera, a tuned laser and support optics, mechanical structure for laser alignment and motion, and an LED lighting array. The scanner head camera is filtered to admit only light at the wavelength of the LEDs, to avoid ambient light interference in scanning.

  • Page 9: D-Adapter (Deployment Hardware)

    NM200UW Nuclear Underwater Laser Scanner User Manual D-Adapter (Deployment Hardware) Mounting bracket designed to allow the camera to be positioned statically in various positions in increments of 45 degrees. This is a non-powered, manual alternative to the Pan- Tilt module for J-Hook pole deployment. D-Adapters are not serialized and are interchangeable.
  • Page 10 PC power cable with the correct plugs to switch between them. The maximum current draw of the combined system is 2.6A. NOTE: The Newton NRL-R2000 Control Unit is incompatible with some brands of ground fault circuit interrupter (GFCI) equipment. If the control box does not power on, replace the GFCI equipment.

  • Page 11: System Power Up

    NM200UW Nuclear Underwater Laser Scanner User Manual data storage, and an easy method of transferring scanning results out of containment. If the provided USB memory stick is missing, use a standard 4-16GB replacement. 2.3. System Power Up All electrical and data connections need to be completed before the system is powered on.

  • Page 12: System Disassembly/Breakdown

    NM200UW Nuclear Underwater Laser Scanner User Manual 2.5. System Disassembly/Breakdown System disassembly is the reverse of assembly. All electrical and data connections must remain connected until system is fully powered off. 1. Remove the scanner head from its deployed location in accordance with appropriate site-specific procedures.

  • Page 13: Scanner Hardware Maintenance And Turn-Around Procedures

    Cleaning of NM200UW 50mm and 75mm Windows The windows of the NM200UW are to be cleaned using water based optical cleaning fluid and disposable wipes. The following primary method should be used: 1. Place the Scanner Head on a clean, dry, flat surface with the windows pointing upward.
  • Page 14 “head power” switch to the off position and remove the scanner from the water. A scanner with suspected casing integrity failure should be examined by Newton Labs or an authorized service representative before being used again.

  • Page 15: Software

    NM200UW Nuclear Underwater Laser Scanner User Manual 3. SOFTWARE The NM200UW system is provided with one standard software application which is the main User Interface (UI) for the system, and allows the operator to take scans using the system hardware. The NM200UW system can also be loaded with software tools for post-processing;...
  • Page 16 NM200UW Nuclear Underwater Laser Scanner User Manual scanner user interface uses two dropdown menus in the taskbar at the upper left corner of the screen. These menus provide multi-language support and allow access to advanced features. An overview of the functionality accessible in each of the four main sections is provided below: Current View: This provides a visual interface for the user.

  • Page 17: Language Selection

    NM200UW Nuclear Underwater Laser Scanner User Manual Language Selection The NM200UW user interface has two language options: English and French. The scanner user interface will load in English by default when first started. To choose a language, the “Languages” dropdown menu in the taskbar located in the upper left corner of the scanner user interface may be used.
  • Page 18 NM200UW Nuclear Underwater Laser Scanner User Manual Generally during deployment the user will interact with the system using the three basic tabs, with the advanced tab only being used in difficult scanning environments and the registration tab only used during initial setup or software update of the controller. All tabs are described in detail in the sections on the following pages.
  • Page 19 NM200UW Nuclear Underwater Laser Scanner User Manual has no effect on the scan point cloud. The operator adjusts scene exposure and illumination settings to allow them to see the target and thus properly position the scanner. Scene exposure may be coarsely adjusted by moving the slider, finely adjusted by clicking the up and down arrows next to the input box or exactly specified by typing the desired value into the input box.
  • Page 20 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 11: Selected view dropdown prior to scanning, showing disabled menu options Available menu views are as follows. All views except for the Live Camera view are only accessible during the scan review phase of the workflow.
  • Page 21 NM200UW Nuclear Underwater Laser Scanner User Manual Zoom: Right-click and hold and move the trackball or mouse up to zoom in and down to zoom out. Pan: Left-click and hold while holding shift, then move the trackball or mouse to pan the view.
  • Page 22 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 14: Ortho X View Ortho Y – The Ortho Y view is a still image of the scanner point cloud along the scanner +Y axis, which points out of the side of the scanner head opposite to the serial number.
  • Page 23 NM200UW Nuclear Underwater Laser Scanner User Manual User Log Entry Button: The User Log Entry button allows the user to manually input a message that is entered into the user interface’s automatic logging file, generated at any time when the software is running. To use the log entry functionality, press the button at any time during scanning operations.
  • Page 24 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 17: Laser Tab Laser Motion Section – This section of the tab controls motion of the laser line. It is adjusted during the laser position adjustment workflow step. Motor Power Check Box: The motor power check box enables and disables power to the scanner’s internal stepper motor.
  • Page 25 NM200UW Nuclear Underwater Laser Scanner User Manual homing sequence or other startup issue, the laser line position controls will be disabled. The home button may be pressed in this event to re home the laser and allow normal scanning operation to resume. This is the only function of the home button.
  • Page 26 NM200UW Nuclear Underwater Laser Scanner User Manual Laser Line Section – This section of the tab controls the laser line itself as well as software settings associated with the sensitivity of the scanner software to the laser line brightness. These settings are adjusted in the laser line optimization workflow step, which takes place following laser line positioning.
  • Page 27 Newton scanning metrics. This value is the primary metric used to determine the quality of the found laser line during the laser line optimization work flow step. The line quality cannot be the only metric, however, as it increases with laser threshold despite a loss of found laser points at high threshold values.
  • Page 28 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 18: Scan Settings Tab Scan Configuration Section: This section contains controls for scan density and image storage. Scan Density Dropdown Menu: The scan density drop down menu controls the density of the scan, or in more rigorous terms, the scan-axis spacing between each progressive scan line.
  • Page 29 NM200UW Nuclear Underwater Laser Scanner User Manual NOTE: While scan Density does not affect overall Scanner Accuracy, using a low density setting at an unfavorable scan angle may cause a surface to exhibit too few points for an adequate geometric fit, resulting in an apparent loss of accuracy.
  • Page 30 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 19: Load Calibration File Button navigation box Note the calibration file which is being selected in the image above as well as the camera calibration file, which is not selected but must be present in the folder. The scanner software will automatically identify and use the camera calibration file for a given calibration file.
  • Page 31 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 20: Advanced tab Encoder Position Display Window: The encoder position display window provides visual feedback on the current position of the encoder in counts. This may be used for diagnostic or informational purposes.
  • Page 32 Registration Tab: The registration tab is used to set up and manage scanner software licenses. The NM200UW system used a node locked licensing software model in which one software license is provided per controller. Software updates are provided through Newton Labs and may require re-licensing.
  • Page 33 “full” license, which enables all scan functionality, or a “training” license, which does not allow the software to connect to a scanner head. When Newton provides a license, it will be specified as a full or training type.

  • Page 34: Information Bar

    This is saved in the “settings.yml” file which is located in the “newton” folder on the desktop. If no calibration file has been loaded, “Not Specified” will be displayed.

  • Page 35: Settings Confirmation Box

    Pan-Tilt: The scanner software will automatically detect the presence or absence of a Newton Labs PT200UW Pan-Tilt Adapter and display the result in this field. If a Pan-Tilt is detected, the user interface will automatically set the view rotation to 180 degrees to match typical Pan-Tilt supported deployment scanner orientation.

  • Page 36: Starting And Exiting The Scanner Software

    Launching the Scanner Software Using Desktop Icons in Ubuntu The NM200UW software is designed to be started by using a desktop icon. A desktop icon will be present on the controller on startup labeled “Underwater Laser Scanner. The scanner software is launched by double clicking on this icon.

  • Page 37: Scanner Software Startup Diagnostic Sequence

    NM200UW Nuclear Underwater Laser Scanner User Manual Scanner Software Startup Diagnostic Sequence Upon startup, the black terminal window will immediately appear, followed by the scanner user interface. During the loading process, a diagnostic window will appear showing startup checks of the hardware and software. Wait while these checks take place and verify that a green check mark is displayed for each step in the process.

  • Page 38: Terminal Window

    Figure 28: Scanner software exit confirmation box Terminal Window The NM200UW software is designed to be operated with the user interface supported by execution of program operations in a terminal window. This is a black window that is displayed behind the main user interface while the software is running. If desired, the operator may observe text output in the terminal window as a supplementary indicator of scanner software operational status, but this is not necessary for operation of the system.
  • Page 39 “1001511_2012_03_23_16_08_00” is the scan taken by head 1001511 at 4:08:00 PM on March 23rd, 2012. NOTE: Newton recommends re-naming the scan directories by target and scan number in the 3D Imaging Coverage Map to aid in post-processing. This re-naming should take place before transferring the scan data off of the control box.

  • Page 40: Scan Files To Copy

    For normal scanning with a properly working NM200UW, all that is required to take measurements is the PLY file. This is indicated in the “3D Data” row of the table below. This should only be used in situations where it is...

  • Page 41: Post-Processing

    NM200UW Nuclear Underwater Laser Scanner User Manual taken such as a critical path evolution, or in a case where ALARA or logistics concerns dictate that the scanner operator will not be able to check the scan quality at the control unit, the before image, after image, and depth images should also be copied.

  • Page 42: Deployment

    4.2. Scanner Field of View and Scan Distance Knowledge of the NM200UW Scanner field of view is important to proper deployment and the acquisition of a high-quality scan set. The field of view of the scanner is generally in the shape of a truncated rectangular pyramid with the apex of the pyramid at the center of the camera lens.
  • Page 43 Optimum scan distance for most targets is 16 in. from the front face of the scanner head. The field of view at this distance is approximately 13.5 in. x 10.5 in. NOTE: Newton recommends using an 8 in. x 8 in. Design Field of View at 16 in. for planning scan sequences.

  • Page 44: Equipment Checkout And Preparation

    NM200UW Nuclear Underwater Laser Scanner User Manual 4.3. Equipment Checkout and Preparation Once a Scan Program and the required procedural support documents have been generated, reviewed, and approved, the scanner system equipment should be checked to ensure that it is functioning properly before use. Standard equipment checks include functionality of the camera head and the pan-tilt adapter if applicable.

  • Page 45: Fme Fastener Challenge Procedure

    Figure 32: Calibration File Location FME Fastener Challenge Procedure This procedure is to be performed prior to the introduction of any NM200UW hardware or equipment into an FME Area without exception. 1. Challenge all fasteners using the following procedure to check tension. Apply the “challenge”...

  • Page 46: Optional Step - On-Site Qualification

    This qualification is done by taking scans of a target object of known dimensions and measuring the result using the post-processing program. Newton factory qualifications are performed on a qualification target consisting of a double ended ball bar with 6”ball spacing and 1”ball diameters. Measurement accuracy is verified relative to the published accuracy specifications of Newton Labs.

  • Page 47: Scanning Procedure Overview

    Below is an overview of the scanning procedure. It is important to understand the work flow of the NM200UW system before exploring the details of features present in the system. 1. Prior to deployment, a 3D Imaging Coverage Map document is generated detailing a scan sequence for each target.
  • Page 48 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 33: Scan Overlay Sequence 8. The scanner sweeps the laser line across the target. As this occurs, a series of laser lines appear on screen in the Live View pane. These lines overlay the target object in real time as the scan progresses.

  • Page 49: Detailed Operation

    NM200UW Nuclear Underwater Laser Scanner User Manual 4.5. Detailed Operation The operation of the NM200UW scanner system in detail is covered in this section. Operation of the scanner in an outage environment should be undertaken only by properly trained and qualified personnel.

  • Page 50: Performing A Scan

    NM200UW Nuclear Underwater Laser Scanner User Manual 2: Laser 3: Laser Line Position 1: Scene Setup Optimization Adjustment Idle Idle 4:Settings 5: Scanning 6: Scan Review Specification Figure 34: Scan workflow steps Performing a Scan 1. Begin the scanning work flow process by choosing the “Start Scan” button located in the information bar on the lower left side of the scanner user interface.
  • Page 51 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 36: Scene tab detail showing adjustment of illuminator intensity 3. (Optional Step) – Image Orientation - Depending on the chosen deployment orientation of the scanner head, the image in the current view may be oriented in any one of four orthogonal directions.
  • Page 52 NM200UW Nuclear Underwater Laser Scanner User Manual Interest (ROI) functionality. The purpose of the ROI functionality is to reduce the size of scans for small target objects and also to reduce processing time for this type of object by ignoring portions of the scan area.
  • Page 53 7. Wait for the laser to automatically enable itself and move to the starting middle position of the scan. This middle position is saved in the scanner’s settings.yml file in the “newton” folder on the desktop from the previous scan or scan session. Laser movement should take less than five seconds to complete.
  • Page 54 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 42: Scanner Showing Laser Occlusion. Laser is green plane, camera view is in blue 9. Position the laser in the center of the field of view by pressing the “middle” position shortcut button on the same tab. This should bring the laser to the center of the field of view.
  • Page 55 NM200UW Nuclear Underwater Laser Scanner User Manual 10. Move the laser to the leading edge of the target object using the laser position adjustment slider. The slider is oriented so that the scan proceeds from left to right along the slider, and from the top of the current view screen to the bottom when the scanner view orientation is at zero degrees.
  • Page 56 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 45: User interface during laser position adjustment step showing setting of scan end position NOTE: Why perform the preceding two steps? Restricting the beginning and end of the laser sweep shortens scan time and stops recording of extraneous data.
  • Page 57 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 46: User interface at the beginning of laser line optimization step showing auto-optimizer 14. Wait for the automatic line optimizer to complete its finding process. When the process is complete, if successful, the laser line settings will already be optimized for the target.
  • Page 58 NM200UW Nuclear Underwater Laser Scanner User Manual resulting in laser location errors when the line encounters a discontinuity in the target geometry. This is shown in the interface by a large, fluctuating blue band around the laser line, shown in the following figure. The width of the blue band is the area from which the scanner software extracts the found laser line position.
  • Page 59 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 49: Excessively high laser line threshold The laser line threshold slider should be adjusted so as to allow a complete find of all laser line points, indicated by the “Found Points” display adjacent to the line markup check box, while allowing all available laser line width to be used for line finding.
  • Page 60 Workflow Step 4: Settings Specification 22. Choose a scan density by selecting from the dropdown menu located at the top of the scan settings tab. For the majority of normal scanning operations, Newton recommends using the “medium” density setting. All NM200UW scanner factory qualifications are performed at this setting.
  • Page 61 “Load Calibration” button. a. To use the drop-down menu, simply click and choose from the list of available files. Only files in the “cal” sub-directory of the “newton” directory on the desktop will be shown.
  • Page 62 “Append text to scan directory” input box. Newton recommends entering an underscore as the first character in this box to make the final scan directory name more readable. This entry ensures that the...
  • Page 63 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 55: Scan settings tab lower half showing sample text for settings notes and directory text 27. When satisfied with all scan settings, press the “Begin Scan” button in the information bar to move to the next workflow step. The user interface will pop up a final confirmation window.
  • Page 64 NM200UW Nuclear Underwater Laser Scanner User Manual NOTE: During a scan, user controls are disabled. Scanning is automatic. The Current View pane displays the image taken at the start of the scan. To stop an in-progress scan, use the “Stop Scan” button in the scan controls section of the interface. This terminates the scan, retaining data up to the stop point.
  • Page 65 NM200UW Nuclear Underwater Laser Scanner User Manual Figure 60: User interface during scan review showing depth view of target 29. Select “Scanned Points” from the visualization dropdown menu and review the scanned point cloud. Look primarily for “waves” or oscillations in the data which may indicate that the scanner was moving, vibrating, or subject to “pendulum...

  • Page 66: Repeating Scans

    Removal from Underwater Environment and Decontamination Removal and Decontamination are the responsibility of the end user. Newton recommends that the scanner head, cable, and all deployment tools including but not limited to the Pan- Tilt Adapter, D-Adapter, deployment poles, ropes, hooks, and accessories be wiped down and bagged as they are removed from the water.

  • Page 67: Equipment Storage

    “scan_data” folder inside the “newton” folder on the desktop of the control box PC. Copy all files with the timestamps within the current evolution time period to the USB key provided with the system or to an external data repository accessed via the cat-5 Ethernet jack on the rear face of the camera control unit.

  • Page 68: Data Analysis

    For an in-depth discussion of post-processing tools and methods please see the Post-Processing section in the software section of this manual or the Newton Scanner Registration Guide, available upon request from Newton Labs.

  • Page 69: Advanced Operation

    NM200UW Nuclear Underwater Laser Scanner User Manual 5. ADVANCED OPERATION For advanced users, there are additional operational modes that allow for manipulation of the scanner settings to allow for particularly difficult target objects to be scanned. This type of object may include areas of interest that are very reflective as well as areas of interest that are extremely dark, which must be captured in the same scan.

  • Page 70: Hdr Mode

    NM200UW Nuclear Underwater Laser Scanner User Manual 5.2. HDR Mode This mode allows the user to automatically take several different images at varying levels of camera exposure time. This is useful when a target includes either bright and dark objects or surfaces.

  • Page 71: Troubleshooting

    Settings File Load Failure If no settings file exists in the “newton” folder on the desktop, or an invalid settings file is present, the scanner software will report a settings file failure during the initial startup sequence.

  • Page 72: Microcontroller Failure

    NM200UW Nuclear Underwater Laser Scanner User Manual Microcontroller Failure If the controller cannot communicate with the scanner head over the serial control line, the scanner startup sequence box will report microcontroller failure. The terminal window will also provide error messages that cycle as the scanner software attempts to connect to the head.

  • Page 73: Temperature Alarm

    Press the “q” key repeatedly. If no result, check power, or possible damaged Scanner Head. If a row of Hex numbers appears, head is functioning and camera IP setting problem is likely. Contact Newton Labs to receive procedure to reconfigure Control Box IP settings.

  • Page 74: Scanner Software Crash

    If the scanner software hangs due to any abnormal condition, close the software and re-start. Scan settings and in-progess scans will not be saved in the event of a software crash, but completed scans will be retained in the newton/scan_data folder. Copy the scanner_ui.info file from the session folder and send to Newton Labs.
  • Page 75 NM200UW Nuclear Underwater Laser Scanner User Manual 7: LASER POS. ADJ: MOTOR AND 8 : LASER LINE OPT. - LASER LINE 9 - SCAN SETTINGS - ALL SETTINGS LASER SHOULD FUNCTION SHOULD BE VISIBLE SHOULD BE CONFIGURABLE NO MOTOR MOTION: VERIFY MOTOR...

  • Page 76: Appendix A - Newton Nm200Uw Camera Head

    NM200UW Nuclear Underwater Laser Scanner User Manual APPENDIX A – NEWTON NM200UW CAMERA HEAD Dimensions Height: 4.0 in. (102mm) Width: 4.6 in. (117mm) Length: 9.13 in. (232mm) Weight (in Air): 8 lbs (4kg) Weight (in Water): 2lbs (1kg) + Cable Weight...
  • Page 77 NM200UW Nuclear Underwater Laser Scanner User Manual APPENDIX B - SYSTEM BLOCK DIAGRAMS Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...
  • Page 78 This coverage map is a template for estimating required scan times and placement of the scanner head for deployment of the NM200UW 3D Laser Scanner. The map utilizes two separate coordinate systems: a Cartesian coordinate system used to specify target size and to estimate number of required scans, and a spherical coordinate system used to specify the placement of the scanner head in relation to the target object.
  • Page 79 NM200UW Nuclear Underwater Laser Scanner User Manual figure below for a description of the two systems. “Time” shorthand, e.g. 2:00 o’clock, is used to specify the general location of scans where applicable. For coordinate triads, Cartesian points are labeled (X, Y, Z), while spherical coordinates are labeled (R, Ө, Ф).
  • Page 80 NM200UW Nuclear Underwater Laser Scanner User Manual (THIS PAGE IS BLANK) Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...
  • Page 81 NM200UW Nuclear Underwater Laser Scanner User Manual List of Targets DEPLOYMENT NAME OUTAGE DESIGNATION RWP # DATE AND TIME OF EVOLUTION START TARGET TARGET TARGET NUMBER ESTIMATED DESCRIPTION LOCATION LENGTH, WIDTH, Y DEPTH, SCANNING X (IN) (IN) Z (IN) SCANS...
  • Page 82 NM200UW Nuclear Underwater Laser Scanner User Manual (THIS PAGE IS BLANK) Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...
  • Page 83 NM200UW Nuclear Underwater Laser Scanner User Manual List of Scans Copy this page as needed for each target SCAN LIST TARGET DISTANCE DECLINATION AZIMUTH DESCRIPTION TO CAMERA NOTES ANGLE ANGLE LENS Target Sketch: Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...
  • Page 84 NM200UW Nuclear Underwater Laser Scanner User Manual (THIS PAGE IS BLANK) Newton Labs | 441 SW 41 Street, Renton, WA 98057, USA | 425-251-9600 | www.newtonlabs.com...
  • Page 85 NM200UW Nuclear Underwater Laser Scanner User Manual Scan Layouts Copy this page as needed for all scans. Target Scan Letter Scan Designation Scan Layout Sketch: NOTES Target Scan Letter Scan Designation Scan Layout Sketch: NOTES Target Scan Letter Scan Designation...

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