STAR-07 Industrial Pattern Projection STAR-07 is a high performance DLP® projector based upon the Texas Instruments micromirror technology and designed to serve in demanding industrial applications. Widely used in multimedia and digital cinema since more than one decade, the well proven DLP technology has become an important tool for industrial solutions as well. The heart of the STAR-07 projector is a 0.7” DLP chip that consists of an array of 1024x768 mirrors. These bi-stable mirrors flip into opposite tilt positions within microseconds to generate the desired patterns. STAR-07 provides precise high-speed control for each individual mirror enabling outstanding flexibility and pattern frame rates of the projection output. The projector is equipped with a high-power LED light source that is the key for the compact and rugged design of the device. Typical use cases are machine vision illumination, 3D scanning, industrial exposure, and additive manufacturing. Beyond that, new emerging applications are well supported by an open SDK interface. STAR-07 comes with two lens options, the standard projection lens with zoom capability and a wide angle lens with fixed focal length. System Architecture The central control unit of STAR-07 is USB2.0 connected and realizes pattern upload, display, and synchronization. An integrated trigger facility supports selectable voltage levels and is software programmable. The digital driver for the LED light source gives convenient access to power setting and temperature reading for thermal management. System Control The ViALUX ALP-4.2 Controller Suite is the central programming tool and provides all necessary functionality for product development. Sequences of patterns are uploaded from PC to the on-board memory via USB2.0 transfer with lossless compression. The properties of the display sequences, e.g. bit depth, picture time, trigger mode, repetitions can be freely defined to meet the respective application requirements. The ALP-4.2 firmware streams patterns from on-board SDRAM memory to the DLP7000 micro mirror array where the input pattern is one-to-one mapped to the mirrors. The patterns are updated in the global reset mode; that means all mirrors are switching simultaneously within a few microseconds. Grey value patterns are generated by controlled ON-time for each mirror yielding exact grey value linearity. The maximum global array switching rate is 22 727 fps; even higher frame rates can be achieved by partial updates of the micromirror array. Multiple STAR-07 devices can be run in parallel, conveniently controlled from the same application program and precisely synchronized by the trigger facility. The ALP-4.2 API is well proven for all Discovery™4100 chipsets; the DLL supports C++, VBasic, .NET, LabView, and other development platforms. Microsoft® operating systems are supported up to the most recent Windows® versions both, 32-bit and 64-bit. The ALP-4 USB2.0 driver is robust, validated, UIF compliant and 24/7 proven in industrial and medical use. Specifications LED options RED Dominant wavelength Spectral bandwidth FHWM STAR-07 output * 613 - 624 nm 18 nm 330 lm 1 450 mW GREEN BLUE VIOLET 528 nm 38 nm 850 lm 1 550 mW 462 nm 21 nm 140 lm 2 550 mW 405 nm 15 nm 2.150 mW WHITE 1100 lm - * Typical value for continuous projection, pulse operation may yield higher output Lens options Standard lens Wide angle lens Length L Diameter D Mass M L = 36 mm D = 35 mm M = 150 g Distortion L = 87mm D = 72 mm M = 580 g 5.5 % Working distance D Throw ratio TR D >0.4 m TR= 1.8 … 2.1 0.2 % Zoom Uniformity (IEC) Contrast FOFO MTF 1.00 – 1.16 +25%/-30% 45% @ 36 lp/mm 2000:1 D > 0.5 m TR = 0.9 none +26%/-23% @D=1m 30% @ 36 lp/mm @ 462 nm 2000:1 Frame rates DMD array (AOI) Bit depth Frame rate 1024 x 768 1024 x 768 1024 x 768 1024 x 768 1024 x 768 8-bit 7-bit 6-bit 5-bit 1-bit 1024 x 512 1-bit 290 fps 569 fps 1 091 fps 2 016 fps 22 727 fps 30 300 fps Greyscale linearity ALP-4 supports precise bit-plane timing enabling outstanding greyscale linearity in connection with synchronized camera recording. Grey value deviations are < 0.06% of the full scale value. General Mass (without lens) 2000 g Input power DC 12-24V 150 W Operating temperature 10°C to 40°C non-condensing Storage temperature -10°C to 50°C non-condensing Dimensions [mm] Standard lens Wide angle lens Regulations LED lifetime CE FCC Class A >10.000 h (ON time) Connections Synchronization Connections (yellow): Pin Signal 1 I/O Limit Description / usage OC Out 1 10mA reserved for future use 2 STAR-07 Cascade OC Out 1 10mA for serializing multiple STAR-07 projectors in a chain 3 Frame Trigger OC Out 1 10mA outputs one pulse per frame, e.g. for synchronizing a slave camera; ALP API commands: AlpSeqTiming (SynchDelay, SynchPulseWidth): relation to frame timing AlpDevControl (ALP_SYNCH_POLARITY) 4 OC Out 1 10mA reserved for future use 5 Device Power VDD Out Vprimary 1A taken from primary STAR-07 projector power supply: 19V, not fused 6 DC 5V + Out 5V 200mA galvanic isolated supply voltage, e.g. for driving opto couplers 7 VDD common VDD 50V common voltage of all trigger outputs OC In 1 3.3 – 24V reserved for future use 8 9 Device Power GND from primary power supply 10 DC 5V GND galvanic isolated supply voltage, e.g. for driving opto couplers 11 VSS common GND common ground of all trigger inputs 12 OC In 1 3.3 – 24V reserved for future use 13 STAR-07 Cascade OC In 1 3.3 – 24V for cascading multiple STAR-07 projectors in a chain 14 Frame Trigger OC In 1 3.3 – 24V triggers next frame in sequence, e.g. for synchronization with a master camera ALP API commands: AlpProjControl: ALP_PROJ_MODE=ALP_SLAVE AlpSeqTiming (TriggerInDelay): relation to frame timing AlpDevControl (ALP_TRIGGER_EDGE) 1 OC – Opto Couplers Min Typical Max Input 5mA 3.3V 6mA 5V 8mA 24V Output - 8mA 10mA 50V / 150mW All input and output signals are driven by opto couplers permitting 250VDC isolation. Inputs are equipped with constant current regulators; therefore no further external resistors are required. STAR-07 Interface Cable Lemo plug internal, soldering side Lemo plug FFA.2C.314.CLAC Lemo: FFA.2C.314.CLAC52Z Lemo: GMA.1B.045.DJ Lemo: 070 140 straight plug, 14-pin, cable collet 4.7-5.1mm for bend relief bend relief, 4.5-4.9mm, YELLOW Multiconductor shielded cable, 7x0.14mm², max. 250V PVC, grey, outer diameter 5.0mm Application Example 1 Driving STAR-07 frame trigger from external source Application Example 2 Trigger external device frame by frame Contact: [email protected] ViALUX GmbH Am Erlenwald 10 09128 Chemnitz Germany phone: +49 (0) 371 33 42 47 0 fax: +49 (0) 371 33 42 47 10 web: www.vialux.de