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User guide
This manual must not be circulated or copied, or its contents utilized and disseminated, without our express written permission. Persons misusing this manual are subject to prosecution. All rights reserved, especially in cases of granting a patent or registering a utility model. Subject to modifications. Carl Zeiss does not grant any warranty on this material and no implied warranties on commercial quality and the suitability for a certain purpose. Carl Zeiss cannot be held liable for errors included in this document, accidental damage or damage resulting from the provision, function or use of this manual. All product names are registered trademarks or trademarks of the corresponding proprietors.
CALYPSO User guide Revision: 4.0 Date: 04/04 Order number: 61212-2010602
Preface
The Calypso User guide is designed for users who want to learn to use Calypso or have a task to complete and want to find out how to accomplish it in Calypso. This guide contains examples and step-bystep instructions. Consequently, it enables new and experienced users to find the information they need. The reference information on windows and dialog boxes is in the Calypso dialog reference in the Online Help.
Overview of Topics
Included in this User guide: Chapter 1 Introduction on page 1-1 Hints for working with Windows NT, and provides background information illustrating Calypsos basic procedures and general concepts. Chapter 2 Dynalog and Dynalog P control consoles on page 2-1 Describes how to operate Calypso using the Dynalog P control panel. Chapter 3 Working with the CAD window on page 3-1 Describes the possibilities of the CAD window and how to use them. You also get information on how to work with CAD data. Chapter 4 Preparing the measurement plan on page 4-1 Describes how to open a measurement plan and the prerequisites necessary before you can run a measurement plan automatically. Chapter 5 Defining features on page 5-1 Describes the definition of the measurement features (e.g. a plane or cylinder), explains how to create a measurement strategy and how to work with scanning. Chapter 6 Defining characteristics on page 6-1 Describes the principles of the fitting methods that Calypso uses and shows how to define characteristics. Chapter 7 Editing the measurement plan on page 7-1 Explains how to manage a test measurement plan, work with the toolbox options, customize presentation protocols and work with the routes of the CMM. Additionally, this chapter describes the use of the probe changer and audiovisual user information.
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Chapter 8 Running a measurement plan on page 8-1 Describes how to start CNC runs and how to work with the measurement results. Chapter 9 Viewing, presenting and editing measuring results on page 9-1 Describes which types of protocols are available and how to work with them. It also describes how to save the measurement results as files of different formats. Chapter 10 Duplex mode on page 10-1 Contains the instructions for preparing, performing and evaluating measurements with dual horizontal-arm CMMs. Chapter 11 Managing Calypso on page 11-1 Shows how to install Calypso, how to view and modify all of Calypsos system settings. Chapter 12 Auto-Run interface on page 12-1 Explains how the system administrator sets up an Auto-Run interface and how users work with Auto-Run. Chapter 13 DMIS import (option) on page 13-1 Explains the basics and the procedure for importing DMISprogrammed measurements into Calypso. Chapter 14 DMIS export (option) on page 14-1 Explains the basics and the procedure for exporting Calypso measurement plans as DMIS-programmed measurements. Chapter 15 Parameter-coded measuring runs (option) on page 15-1 Explains the basics of the PCM programming language. It also provides directions for and examples of using PCM with Calypso, with formulas, input and output parameters, conditions and loops. Chapter 16 Curve measurement (option) on page 16-1 Contains the basics of curve measuring, how to set up curve features and characteristics, and how to operate on the results. Chapter 17 Qualifying the RDS with CAA (option) on page 17-1 Describes how to calibrate an RDS on a system with the RDS-CAA option (Computer Aided Accuracy). A small number of physical probings is all that is needed to calibrate all 20 736 possible angular positions of an RDS. Chapter 18 Determining measuring uncertainty (OVCMM) (option) on page 18-1 Describes the configuration and use of the OVCMM. This is used to calculate the measurement reliability of the measurement plan results.
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Chapter 19 Characteristic input (option) on page 19-1 You can use the Characteristic Input option without a connected CMM to import suitable CAD data, convert this data into a measurement plan, test and correct this measurement plan and output it as a Calypso measurement plan. Chapter 20 Stylus simulation and stylus system library (option) on page 20-1 If you have used the stylus system library to copy the styli of your CMM virtually, Calypso is able to simulate the stylus movements in the CAD window. Chapter 21 VAST Navigator (option) on page 21-1 With the VAST Navigator, you can achieve maximum precision during high-speed scanning thanks to the refined equipment technology, control technology and algorithms. Tangential probing and helical scanning now become possible. Chapter 22 Automation (option) on page 22-1 Describes the Automation option, with which automation projects can be realized in combination with the CMM OS.
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Supplementary literature
Simply Measure And what you should know to do it right, A metrology primer Carl Zeiss, Industrial Metrology Division, order number: 612302-9002
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Text conventions
The following text conventions and symbols are used in this manual: Example Features Comment C:\windows\w.ini Description Textual element of graphical user interface. The Comment button on the screen. The file w.ini in the directory windows on drive C:\.
Guide your actions... A passage containing important information. Welcome to Cross-reference. If the book is displayed Calypso on page 1-2 online, you can click on the cross-reference to follow the link. Plan CNC-Start CNC-Start Ctrl-a The CNC-Start item in the CNC-Start submenu of the Plan menu. Press and hold down the Ctrl key and press lowercase letter a.
Symbols
Three special icons are used in this book; they always contain important information. The icons appear in the margin, beside the associated text.
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Danger Special care is necessary in this case. The warning triangle warns the user about potential danger of injury. Failure to comply with the warning could result in injury to the user. Important This symbol calls attention to a situation that could result in incorrect measurements, disruptions in the measurement process, collisions or damage to the equipment and the workpiece. This symbol represents important and helpful additional information.
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Contents
Chapter 1 Introduction
Welcome to Calypso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 How to start Calypso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Calypso user desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Working with Calypso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Restructuring, saving and loading toolbars . . . . . . . . . . . . . . . . . . 1-9
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Chapter 4
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Chapter 5
Defining features
Defining features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Definition template for features . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Automatic feature recognition and automatic feature end . . . . . . 5-5 Importing features from CAD files . . . . . . . . . . . . . . . . . . . . . . . . 5-9 How to import features from the CAD model to the measurement plan 5-13 Multiplying features by patterns . . . . . . . . . . . . . . . . . . . . . . . . . 5-14 Copying properties of features . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Color-coding of features buttons . . . . . . . . . . . . . . . . . . . . . . . . 5-18 Tips and tricks for defining features . . . . . . . . . . . . . . . . . . . . . . 5-19
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Sphere Point feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Angle point feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40 General surface feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 General curve feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Additional features Holos and Gear . . . . . . . . . . . . . . . . . . . . . . 5-43 Free Form Surface additional feature . . . . . . . . . . . . . . . . . . . . . 5-45 Turbine Blade additional feature . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 Greater accuracy by gage correction qualification . . . . . . . . . . . . 5-47
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Chapter 6
Defining characteristics
Basics about characteristics . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Calculation of geometric elements . . . . . . . . . . . . . . . . . . 6-3
Best-fit methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
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Adding features or characteristics to a measurement plan . . . . . . 7-5 How to edit features or characteristics . . . . . . . . . . . . . . . . . . . . . 7-5 How to copy features or characteristics . . . . . . . . . . . . . . . . . . . . 7-6 How to move features or characteristics . . . . . . . . . . . . . . . . . . . . 7-7 How to delete features or characteristics . . . . . . . . . . . . . . . . . . . 7-7 How to work with the Waste Basket . . . . . . . . . . . . . . . . . . . . . . 7-8 Grouping and ungrouping characteristics . . . . . . . . . . . . . . . . . . . 7-8 How to rename features, characteristics and groups . . . . . . . . . . . 7-9 How to undo changes in the measurement plan . . . . . . . . . . . . . . 7-9 How to find a measurement plan feature . . . . . . . . . . . . . . . . . . 7-10
Toolboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Creating and using custom toolboxes . . . . . . . . . . . . . . . . . . . . . 7-26 How to work with a custom toolbox . . . . . . . . . . . . . . . . . . . . . 7-27 Deleting a custom toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28 Sizing and moving toolboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
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Defining the RDS geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-47 Setting up the initial stylus system changer configuration . . . . . . 7-49 Defining the master stylus length . . . . . . . . . . . . . . . . . . . . . . . . 7-50 How to add holders to the configuration . . . . . . . . . . . . . . . . . . 7-51 Approach parameters for the stylus system changer . . . . . . . . . . 7-52 How to define the position of a holder . . . . . . . . . . . . . . . . . . . . 7-55 How to define the holder positions of an SCP600 . . . . . . . . . . . . 7-56 How to define the holder positions of an ACR3 . . . . . . . . . . . . . 7-57 How to define the holder positions of an MCR20 . . . . . . . . . . . . 7-58 How to define the holder positions of an SCR200 . . . . . . . . . . . 7-60 How to assign a stylus system to a holder . . . . . . . . . . . . . . . . . . 7-62 How to perform an automatic stylus system change . . . . . . . . . . 7-63 How to perform a semiautomatic stylus system change . . . . . . . 7-63 How to change the stylus system assigned to a holder . . . . . . . . 7-64
Chapter 8
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Chapter 9
Chapter 10
Duplex mode
Duplex mode with Calypso . . . . . . . . . . . . . . . . . . . . . . . 10-2 Preparing for duplex mode . . . . . . . . . . . . . . . . . . . . . . . 10-4
Files for duplex mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
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Chapter 11
Managing Calypso
Installing Calypso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
How to install Calypso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Chapter 12
Auto-Run interface
Basics about Auto-Run interfaces . . . . . . . . . . . . . . . . . . 12-2
Layout of the Auto-Run interface . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Basics about desks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3 Basics about measurement plan icons . . . . . . . . . . . . . . . . . . . . . 12-4 Basics about pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5 Basics about branches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6 Basics about keywords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
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Chapter 13
Configuring DMIS import . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Importing measurement plan from DMIS . . . . . . . . . . . . 13-8
How to import and start a DMIS program . . . . . . . . . . . . . . . . . . 13-8 Evaluating reports about the DMIS . . . . . . . . . . . . . . . . . . . . . . 13-11
Chapter 14
Chapter 15
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PCM functions: Input and output . . . . . . . . . . . . . . . . . . . . . . . 15-57 PCM Functions: File commands . . . . . . . . . . . . . . . . . . . . . . . . 15-60 PCM functions: Measurement-specific functions . . . . . . . . . . . . 15-62 PCM functions: CMM-specific functions and travel commands . 15-64 PCM functions: System commands . . . . . . . . . . . . . . . . . . . . . . 15-68 PCM functions: Custom printout . . . . . . . . . . . . . . . . . . . . . . . 15-70 Overview: Conditions in PCM . . . . . . . . . . . . . . . . . . . . . . . . . . 15-72 Overview: Loops in PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-73
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Chapter 17
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Chapter 18
Chapter 19
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Chapter 20
Chapter 21
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Chapter 22
Automation (option)
Basics about automation . . . . . . . . . . . . . . . . . . . . . . . . . 22-2 Using the AAI interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3
How to configure the AAI interface . . . . . . . . . . . . . . . . . . . . . . 22-3 How to activate the AAI interface . . . . . . . . . . . . . . . . . . . . . . . . 22-5 How to start the AAI interface . . . . . . . . . . . . . . . . . . . . . . . . . . 22-5 Manual mode and automatic mode . . . . . . . . . . . . . . . . . . . . . . 22-5 How to stop the AAI interface . . . . . . . . . . . . . . . . . . . . . . . . . . 22-7
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Introduction
It is well worth recalling what you learned in the Calypso Basics course before you start work. The most important points are starting Calypso, an overview of the Calypso user desk and a short explanation of important terms you need for measuring with Calypso.
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Introduction
Welcome to Calypso
From now on, Calypso will be the tool you use for fast, accurate and convenient measuring. Calypso was developed to make the job of measuring easier for you. To this end, it utilizes the entire know-how pool of Carl Zeiss, the technology leader in the world of metrology.
Straightforward programming
Calypso automatically recognizes the geometric elements you probe and responds by generating probing paths and strategies, retract movements and routes between the elements. In contrast to conventional software, the styli are qualified with the aid of CNC programs. As a consequence you need only perform the first probing of the reference sphere manually, Calypso will perform all of the remaining steps for you. In Calypso, you enter the measurement parameters in accordance with a predefined structure, which means that nothing can be inadvertently omitted. You will find, for example, that the parameters in the input menus offer you default values. There are only a few items that call for manual input, and they are highlighted to draw your attention to them right away. Logical sequences, indicators, prompts for confirmation, and plausibility checks matching the individual characteristics are all in place to make sure that you omit nothing and to make measuring as straightforward as possible.
Calypso offers you a clear view of the workpiece at all times. The CAD model is right in front of you on the screen and you can follow every detail as measurement proceeds. Of course, you also have the option of directly importing CAD data so that you can quickly generate errorfree measurement programs of your own. You can be sure that you'll have the results of measurement without delay, and afterwards you can still depend on Calypso to help. You can customize measurement logs to suit your needs and preferences, for example you can assign colors to tolerance overshoots or select full-graphics display modes for the results. If you want to import the results into other mainstream Windows applications, Calypso can export the result files, so you can present the data as graphics or in table form, or in presentation programs whatever your customer wants.
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The Calypso Light version allows you to use all the standard functions of Calypso. Only a few additional and extended functions cannot be started in Calypso Light.
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Never close Visual Works and ACIS 3D Toolkit when Calypso is running. The Log In dialog box appears on the screen.
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If you click on Memos, the Memo Editor window will open in which you may find information left for you by the operator on the previous shift. 4 Select your user name from the User Name list. 5 Type in your password and click on OK. When you log in for the first time, Calypso prompts you to confirm your password:
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6 Type in your password again and click on OK. Once you have logged in, the Calypso user desk appears on the screen.
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Consult your system administrator if you encounter problems when logging in.
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CAD icons
The user desk and its principal fields are described briefly below: Menu bar The main menu options contain pull down sub-menus with the basic commands for working with Calypso. Toolbar The toolbar contains icons that you can use to run frequently required commands quickly. You can use the Toolbar editor to specify which icons appear in what order in the toolbar.
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Measurement plan area Three main windows can be displayed alternately using the measurement plan icons: Prerequisites This is where you find the dialogs for preparing the measurement plan. Features This is where you create lists of the features and work on their templates. Characteristics This is where you define the characteristics in the order in which they are carried out in the CNC run, and where you work on their templates. CAD window The CAD window contains a three-dimensional model of the workpiece and each feature. The model is constantly updated when you define new features or edit existing ones.
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The view requires a certain period of time to create itself. If you do not require the display of the model in the CAD window, select CAD View Hide CAD View. CAD icons The icons start functions and commands with which you can edit the features in the CAD window.
The table shows which key combinations of a two-button mouse corresponds to the keys of the three-button mouse. Two-button mouse Left button Right button Ctrl + right button Alt + right button corresp. to corresp. to corresp. to corresp. to Three-button mouse Left button Middle button Right button Alt + right button
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Routines
Calypso offers shortcuts that enable you to call functions quickly via the keyboard. If you are unwilling or unable to use the keyboard for entries, you can also make entries using the mouse. The context menu is available in lists and in the CAD window in addition to the menu items in the main menu and submenus.
In the lists of features and characteristics, you can open the definition template for each item which defines the respective element. You can open additional dialog boxes and sub-windows from within the definition template. By clicking another element in the list or "scrolling through the list" by means of the arrow buttons, the open window for the new element is updated. Thus, it is not necessary to close the lower-order windows and to open them again for the other element. Thus, you can first open the strategy window for a feature, for example, and then view and edit the strategy for any other feature desired without having to close the strategy window prior to this.
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All changes made in the open dialog boxes are accepted and saved automatically.
Using shortcuts
If a shortcut is available for a menu item, it is shown next to the menu item in the menu. You can use the following shortcuts in Calypso: Shortcut Ctrl+N Ctrl+O Ctrl+S Ctrl+F Ctrl+A Ctrl+Z Ctrl+C Ctrl+X Ctrl+V F2 Del Esc Return Function Create new measurement plan Open measurement plan Saving measurement plan Open the Search dialog box Select all Undo last action Copy selection to the Clipboard Cut selection Paste selection from the Clipboard Rename selected feature Delete selected feature Close box without applying the changes Close box and apply changes
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Function Open feature and characteristic window for the selected feature Open strategy window for the selected feature Open evaluation for the selected feature Exit Calypso
2 Activate the Use typewriter for inputs check box. 3 Click on Close. The window will be closed. From now on, the Typewriter dialog box will appear on the screen whenever a change is made to an input field.
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2 Click on the command of your choice. Usually, the context menus offer commands that are available in the main user desk menu. Sometimes, however, the context menus offer commands that are available nowhere else. If you are trying to perform a task and cannot figure out how to do it, try clicking the right mouse button to view the options in the context menu, and you may find the function you need.
Context menu for features
In the context menu of a feature, use the Details submenu to open the Clearance Data, Evaluation (Feature) and Strategy dialog boxes. Thus you can edit a feature without opening the feature beforehand.
In every configuration, the right end of the toolbar form the icon group for stylus administration. This stylus group cannot be deleted, and its icons cannot be selected. You can only add icons to the toolbar according to the space available above the user desk. As soon as the space has been used up, the toolbar editor refuses to insert additional icons. You have to remove another icon first.
The toolbar currently used in the user desk is saved on a user-specific basis: After you have logged in under your user name, Calypso automatically displays your toolbar. You can save each toolbar under a separate name and reload them at any time to adopt them as your current toolbar in the user desk. The toolbars are saved as *.config files.
The standard toolbar in its existing form can be restored at any time using Presetting, and activated for your user desk using Accept.
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2 Select the representation of the available icons that is most suitable for you: All buttons: All icons appear successively in a list. Arranged by menu: All the icons appear in a hierarchical list according to menu items of the main menu. 3 Select the desired icon and, if appropriate, enable the check box for the spaces to be inserted. 4 To append the icon at the right end of the toolbar (in front of the stylus group): Click on Insert at end. - or To insert the icon in another position in the toolbar: Select the icon in the upper window afterwards and click on Insert before selection. The toolbar in the upper window is extended accordingly. If there is no more space for the icon to be inserted, a message appears. 5 In order to remove an icon from the toolbar: Select it in the upper window and click on Remove button.
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6 When the toolbar corresponds to your wishes: Save it using Save as ... if you want to adopt it into your user desk later. - or If appropriate, click on Accept to let the toolbar take effect immediately for your user desk. 7 Click on OK to close the two dialog boxes.
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Features
There are two types of feature in Calypso: A physical feature of a workpiece, such as planes (lateral surfaces) and cylinders (holes), etc. A constructed feature that does not physically exist. Features of this nature are needed for lines of intersection and cylinder axes, for example.
Automatic feature recognition
Calypso automatically recognizes most geometric features as you move the CMM stylus to probe them. The softwares measurement algorithm is smart and takes into account the location of measurement points as well as the probing direction. For example, if you take measurements at three points on a workpiece, Calypso will determine whether the feature is a line, plane or circle.
Characteristics
An engineering drawing requirement. You use characteristics to specify the size, shape or location of features along with any applicable nominal and tolerance values (e.g. the diameter of a hole, the perpendicularity of a hole to a plane and the distance between two planes).
Measurement plans
A measurement plan is Calypsos version of what you might be familiar with as a part program or control data. A measurement plan contains the information the system needs to perform a measurement, for example: the characteristics with their tolerances the features the names of the stylus systems the part alignment the clearance planes around the workpiece
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user-defined video clips, if applicable. The measurement plan is displayed as three lists with icons that represent the characteristics, the features and the other components to be evaluated. There are two ways of generating measurement plans: You can begin by using the CMM to define the parts features that you want to measure and the characteristics to evaluate for those features. Or you can create the characteristics first and then measure all the requisite features. Once you have created a measurement plan, you can run it to automatically evaluate the characteristics on a specified workpiece.
Coordinate systems
For exact location definition and reliable performance of measurements, precisely defined and convertible coordinate systems are essential.
Machine coordinate system
The machine coordinate system is the basis of movement commands and measurements of the CMM. For concrete measurements on a workpiece, however, this is very impractical. A coordinate system referred to the workpiece must be used as the user-defined reference coordinate system of a measurement plan. A part alignment is bound to the workpiece. For Calypso and the CMM, it locates the position and alignment of the workpiece on the measuring table. There may be several part alignments for a single workpiece. One of the part alignments is defined as the base alignment for the measurement plan. All other part alignments can be converted to this base alignment. In addition, you can also use the features local coordinate system (FLCS) for each feature; the zero point and alignment of this coordinate system are defined in a specified manner by the feature.
Part alignment
Base alignment
Clearance planes
Six planes define a safe area around a part and any associated fixture where the stylus can move without risk of collision. Outside the cube formed by these planes, the stylus can be moved without risk of collision. Calypso determines the parts clearance planes using only two positions.
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These functions make it easy to generate a measurement plan away from the machine. The Calypso Planner makes it possible to work on a computer without a connected CMM in the Simulation operating mode. Common to all these procedures is the fact that the characteristics and features, once defined, are grouped in the measurement plan. This means that random samples taken from series production can be measured automatically without any need for manual probing.
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This user guide takes you through the process step-by-step, all the way up to the measured results. The diagram below illustrates the path we are going to follow.
Drawing
CAD data
Workpiece
Defining features page 5-2 Defining characteristics page 6-7 Work planning
Preparing the measurement plan page 4-12 Editing the measurement plan page 7-2 Running a measurement plan page 8-1
Quality control Viewing, presenting and editing measuring results page 9-1
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Display
The functions of the individual components on the device surface are as follows: Display: corresponds to a PC monitor. This is where you see the user desk and dialog boxes of Calypso. Keyboard: corresponds to the keyboard of the Calypso computer (American keyboard layout). Function keys: are divided into 2 groups. Group Horizontal keys F1 to F12 Vertical keys Dynalog are assigned to fixed Calypso functions. are only assigned if you have defined a toolbox in Calypso. Dynalog P correspond to the function keys of the computer keyboard. can create direct machine commands.
Touchpad: The touchpad replaces the mouse that you would normally have connected to your PC (see Particularities for the operation of Dynalog P on page 2-4 or Operating the touchpad of Dynalog on page 2-8). Joysticks: The joysticks are used for manual control of the CMM.
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Note that on the Calypso computer the keyboard must be operated with an American keyboard driver, as Dynalog P uses the American keyboard layout (QWERTY). To configure Calypso for Dynalog P: 1 Start Calypso on the Calypso computer and log on. 2 Select Extras Workroom CMM and click on the Panel bookmark. You will see the window for the choice of the control console:
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3 Choose DYNALOGp from the Panel group. 4 Click on the Control bookmark and on Connect. 5 Click on OK to save the setting and close the dialog box. This concludes the installation of the Dynalog P control console on the computer. From now on you can operate Calypso in parallel via Dynalog P.
The touchpad fully replaces the mouse. You move the pointer on the screen by moving a finger of your hand instead of moving the mouse. To familiarize yourself with the touchpad, place the tip of any finger on the control surface of the touchpad and watch the mouse pointer on the screen. When you move your finger across the control surface, the mouse pointer on the screen follows the movement of your finger. You single-click by tapping on the control area once with the tip of your finger. You double-click by tapping on the control area twice in quick succession with the tip of your finger.
Function keys
The horizontal function keys F1 to F12 have the same function as on the PC. Some of the vertical function keys trigger direct machine commands, which are listed on the mask. For example, the vertical function keys on the left initiate the functions Slow / Fast Move, Inverse Move (X<-> -X, Y<--> -Y) etc.
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A special feature is the double shift key: The shift key in the keyboard has the same function as that on the PC. The shift key for the machine commands (on the left above the keyboard) is used both to release the secured joysticks and to switch to the RDS mode. To release the secured joysticks, you have to press the shift key briefly. To switch the joysticks to the RDS mode, you have to press the key for slightly longer (approx. 3 - 4 seconds). In the RDS mode, you can move to RDS angle positions manually with the joysticks.
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In the system setup, you have to perform a one-time initialization of Calypso for using Dynalog. Only after this are the keyboard, function keys and touchpad set for Calypso. To operate Calypso with the Dynalog control console, you must familiarize yourself with the functions of the touchpad (Operating the touchpad of Dynalog on page 2-8). On the Dynalog control console, the horizontal function keys are assigned differently than on the PC (Function keys on the Dynalog control console on page 2-9). When using a toolbox, Dynalog facilitates the integration of toolbox features in your measurement plan (Operating the toolboxes via Dynalog on page 2-10). An additional special feature is the double shift key: The shift key in the keyboard has the same function as that on the PC. The shift key for the machine commands (on the left above the keyboard) is used both to release the secured joysticks and to switch to the RDS mode. To release the secured joysticks, you have to press the shift key briefly. To switch the joysticks to the RDS mode, you have to press the key for slightly longer (approx. 3 - 4 seconds). In the RDS mode, you can move to RDS angle positions manually with the joysticks. The operating sequence with a Dynalog control console is shown in an example (Example: Operating sequence on the Dynalog control console on page 2-11)
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2 Select Extras Workroom CMM and click on the Panel bookmark. You will see the window for the choice of the control console:
3 Choose DYNALOG from the Panel group. 4 Click on the Control bookmark. 5 Click on Connect. 6 Click on OK to save the setting and close the dialog box. You are returned to the Calypso user desk.
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8 Activate the Dynalog keys check box and click on Apply and OK. You are returned to the Calypso user desk. This concludes the installation of the Dynalog control console on the computer. You can now operate Calypso via Dynalog.
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F3 F4 F5 F6 F7 F8 F9 F10 F11
F12
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For additional information about the definition of toolboxes, please refer to Toolboxes on page 7-26 and for information about the assignment of the Dynalog functions keys, please refer to Function keys on the Dynalog control console on page 2-9.
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2. L2 function key
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3 Press the F2 function key to open the definition template. The definition template is opened.
3. F2 function key
4 To go to the Feature button, press the Tab key several times to define a feature. 5 Press the F2 function key to open the selection dialog box. The dialog box appears on the screen.
4. Tab key
5. F2 function key
6 Use the tab key to mark a feature and press the F3 function key. The dialog box will be closed.
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7 Press the F3 function key again to close the definition template. The characteristic has been defined and your settings have been recorded. The measurement plan appears again on the screen.
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Chapter
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3-1
The view requires a certain period of time to create itself. If you do not require the display of the model in the CAD window, select CAD View Hide CAD View. A workpiece shown in this way is called the CAD model. In the CAD window, you can, among other things, rotate, enlarge or move this model depending on the view you require for the respective work step.
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The CAD window is only for viewing a CAD file. You cannot edit the CAD data on which it is based; all you can do is add or remove features and probing points to the loaded CAD model. It is possible to save the displayed CAD model and to process the CAD data created from it in a CAD program (not in Calypso Light).
Load settings
If you do not need the complete CAD model with all functions, you can reduce the amount of data and thus the loading times. Depending on the setting, only one view of the CAD model or only the number of geometric elements is loaded: You can, for example, rotate, move or enlarge the view of the CAD model but you cannot extract any features from it. In the display of the geometric elements, the CAD model is not shown.
Stylus simulation
If you have the stylus simulation and stylus toolbox options, you can display the stylus currently in use in the CAD window and conveniently trace the stylus movements during the CNC run or its simulation (see Stylus simulation and stylus system library (option) on page 20-1). You can include a saved CAD model in your evaluations and, for example, output it as a plot.
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CAD window
CAD buttons
The CAD window buttons allow you to manipulate the model of the workpiece in the CAD window. Most of the functions can also be selected from the CAD menu on the user desk.
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If you are using the Calypso Light version, you cannot use the functions of the CAD menu.
Show selected Feature(s) only Show all Calypso Features Show Solid Model
Zoom out
View
Select rotation
Render
Fit to CAD
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Once you have loaded a CAD file of a workpiece, you can work your way through the preparations without having to use the CMM. You use the mouse to define features and their probing points. You can also generate an entire measurement plan on the basis of the CAD model.
This allows you to add further probing points to existing features. In this case, the definition template of the corresponding feature has to be open. The probing points will be added to the existing point list. You can also define new features in a plane of the part alignment with probing points. The list of features has to be open for this purpose. The mouse takes over the function of the stylus which means that you have the full functionality of automatic feature recognition at your disposal (see How to define features using automatic feature recognition on page 5-7).
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Zoom out
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Function Zooms in for a closer view of the model. Each time you click on this button, the view zooms in a little further.
Use Mouse to Pan Allows you to move (or pan) the CAD model around the CAD CAD Image window. This button remains enabled until you click on either the Use Mouse to Zoom or Use Mouse to Rotate CAD Image . Select Rotation mode Sets the rotational axis of the CAD model to X, Y, Z or free axis (which rotates the model around the center of the CAD window). To rotate the model, click on the Use Mouse to Rotate CAD Image. Rotates the CAD model 10 degrees clockwise about the selected axis. Allows you to rotate the CAD model about the axis selected with the Select Rotation mode button . Rotates the CAD model 10 degrees counterclockwise about the selected axis. Toggles the view of the CAD model as a three-dimensional solid with illuminated surfaces. If you want to create a solid model prior to rendering, first click on the Show Solid Model button, then click on the Render. Fits the CAD model into the CAD window. This is useful if the image is enlarged beyond the window size or shifted out of the window area.
Rotate> by increments / mouse click Use Mouse to Rotate CAD Image Rotate -> by increments / mouse click Render
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Chapter
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4-1
Refer to this section for details How to create a new measurement plan on page 4-4 List of the prerequisites on page 4-12 Defining features on page 5-2 Defining characteristics on page 6-1 Defining the scope of measurement on page 8-2
To define the features and characteristics for a measurement plan, secure the workpiece to the measuring table of the CMM and probe its features. Calypso recognizes the features automatically, but you also have the convenient option of changing the default nominals and tolerance values proposed by Calypso in accordance with the specifications. Note that although it may be the most common way to first define features (step 3) and then define characteristics (step 4), Calypso does not restrict you to this order. You can also lay out the sequence of characteristics first and then begin defining features and associating them to characteristics. Once you have created a measurement plan, you can run it to evaluate the defined characteristics on a specified part automatically (CNC). You can also edit the measurement plan and add characteristics and features or change the order in which they are evaluated.
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NOTE
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Another way to create measurement plans is to use the DMIS Import option. If you have purchased this option, you can import runs programmed in DMIS into Calypso and thereby convert them to a regular Calypso measurement plan (see Chapter 13 DMIS import (option) on page 13-1). Calypso creates evaluations for each measurement plan. You can also combine two or more measurement plans and create combined assessments (Combining several measurement plans on page 7-16). The measurement plans you combine in this way need not necessarily be on the CMM they can be created and run on CMMs at different points in the network. Each measurement plan is saved in a directory of its own in the Calypso file system; the directory bears the name of the measurement plan. The measurement plans themselves all have the same name, inspection. Thus, the path to the measurement plan, for example, is called cylinder block 1: ...\calypso\home\om\workarea\cylinder block 1\inspection. By default, Calypso assigns fixed names to the features, characteristics and utilities that are inserted in the measurement plan, that correspond to the language set. To avoid redundancy, a sequence number is attached to every name. The names given in this manner can still be changed afterwards. Should you desire generally to have other name definitions, you may write these name definitions in a corresponding file and load this file into Calypso (How to load a file with default names on page 4-5).
Evaluations
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3 Enter a name.
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Important Do not use control characters, umlauts or the German letter , even if these characters are supported by Windows NT or Windows 2000. Characters such as umlauts can cause problems when the measured results are saved for qs-STAT, for example. Calypso uses only lowercase letters when it saves files to the hard disk. Bear this in mind, because it means that Calypso does not distinguish between names of measurement plans that differ only in the use of uppercase and lowercase letters. 4 Click on OK to confirm. The Calypso user desk appears on the screen. The title bar contains the name of the new measurement plan.
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2 Select File Open or click on the Open Existing Measurement Plan button.
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In the File menu, the four measurement plans last opened are displayed. Selecting File <Measurement Plan> opens such a measurement plan. 3 Go to the directory containing the measurement plan you want to open (the name of the directory is the same as that of the measurement plan). 4 Click on inspection and then click on OK to confirm. The Calypso user desk appears on the screen. The title bar contains the name of the measurement plan.
When a file with default names is loaded in which not all possible default names are defined, only those names contained in the file replace the names already defined. To load a file with default names: 1 Select Extras Workroom Environment. The Start page is shown at the top in the notebook. The title shows the name of the user.
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2 Click on the Default Name bookmark. The notebook page is displayed for selecting the file with the default names. 3 Click on the Select file button. The Select file with default name window is opened. 4 Change over to the directory in which the file with the default names is located. 5 Select the file with the default names and click on Open. The default names contained in the file are now valid. If the file with the default names does not correspond to the prescribed Format, an error message is generated.
A file with default names consists of several similarly structured lines. Each line is composed of eight entries that are each separated by a tab. The first line of the file, the header line, contains the following entries (divided by a tab):
Symbol Comment Name1 Name2 Name3 Name4 Name5 IndexColumn
Header line
Name lines
The lines with the default names follow thereafter. A separate line is created for each element type that is supposed to receive an individual default name. A default name can be composed of up to five partial names from which Calypso compiles the name. One of the partial names must contain the start value for the sequential index. Which partial name that is, is defined extra for each line in the IndexColumn (column 8) by input of the column number. An example should illustrate this:
Symbol Circle line2d Comment Name1 Name2 Name3 1 1 Name4 Name5 IndexColumn 5 5
In this example, all features of the Circle type receive the names Table_Bore_x where x is assigned a sequential number beginning with 1.
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The columns have the following meanings: Column Symbol Meaning The internal name used by Calypso for the corresponding feature, e.g., circle for the circle feature. An overview of all the internal names can be found in the online Help by calling up this section. Any comment that, for example, explains the allocation of a feature to the default name. Partial names out of which the default name is composed. One of these columns must contain the start value for the index.
The number of the column that contains the start value for the index. The value range from 3 (Name1) to 7 (Name5) because the Symbol and Comment columns are also counted. In the example above, the index number is in the Name3 column for which reason 5 is entered under IndexColumn. When the first character in the specified column is not a number, the start value 0 is used. If still other characters follow in the specified column of a number, they will be ignored. Example: 42_Circle_2 designates 42 as start value, Circle designates 0 as start value.
Internal name line2d d2Curve bestfit3d line3d d3Curve lengthOfAxis gCurve gSurf width gdtFlat gdtFlatRef gdtProfile
Calypso (Rev. 4.0)
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Feature name Straightness Coaxiality Concentricity Angularity Parallelism Axial Runout True Position Perpendicularity Roundness Radial Runout GDT Symmetry Cylindricity Distance Cartesian Distance 2-D Polar Distance 3-D Polar Distance Distance Symmetry Point Rotation Angle Diameter Diameter Two Plane Plane Feature Angle Ellipse Elliptical Cylinder Erosion Module Form Gear Group Half Cone Angle Holos Cone Cone Angle Cone Addition Angle Of Inclination
Internal name gdtStraightCart gdtCoa gdtCon gdtAngle gdtPar gdtRunFlat gdtPosPol2d gdtPerp gdtRound gdtRunRound gdtSym gdtCyl distance2d distanceCart distancePol2d distancePol3d distance rotationAngle diameter diameter2id plane planeOffset elementAngle ellipse ellipticalCylinder erodingModule form gear setOfTasks apexAngleHalf holos cone apexAngle coneAddition inclinationAngle
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Feature name Alignment Load Alignment Delete Alignment Save Alignment Circle Circle on Cone Circle in contour best fit Sphere Sphere Point Curve Form Length Slot Gage Correction Qualification Perpendicular Maximum Maximum Point Minimum Minimum Point Average Average Offset Plane P6 Alignment Polarposition Height Polarposition Radius Polarposition Angle Projection Projection Angle One Projection Angle Two Point Space Point Distance Radius Measurement Radius Radius Two Radius Point Rectangle
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Internal name coordsys recallPCS deletePCS savePCS circle circleOnCone circleInContour sphere spherePoint ESCurveCurveForm len slot gaugeCalibration perp maximum maxPoint minimum minPoint average averageGeo offsetPlane p6Alignment coordPolHeight coordPolRadius coordPolAngle projection a1id a2id point gdtSpacePoint radiusMeasurement radius radius2id radiusPoint rectangle
Calypso (Rev. 4.0)
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Feature name RPS Alignment Intersection Symmetry Symmetry Point Stylus Qualification Text element Torus Turbine Blade Edge Point Angle between Features Angle Point X Value Y Value Z Value Cylinder
Internal name rpsAlignment intersection symmetry symmetryPoint probeCalib textelement torus CurveBlade edgePoint anglebF anglePoint xValue yValue zValue cylinder
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3 Confirm the displayed dialog box that follows in Excel with OK and Yes. To edit the file with the default names: 1 Load the desired file with the default names into Excel and select Text Files as file type. 2 Accept the defaults in the subsequently displayed Text conversion assistant dialog box with Complete. 3 Edit the file in Excel. 4 After editing, save the file again in the Text (separated tabs) format.
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The prerequisites are described in the following sections: CMM Home Position or Status: This button indicates the status of the CMM and the connection between CMM and Calypso. If the CMM has not yet been initialized and homed, the button is red (see Homing the CMM on page 4-15). Stylus System: By means of this button, the stylus system installed at the moment is qualified (see Installing and qualifying stylus systems on page 4-17). Base / Start Alignment: By means of this button, the part alignment allocated to the measurement plan is defined (see Setting the base / start alignment on page 4-46). Rotary Table (RT): Click on this button to activate a rotary table for the current measurement plan and to define the settings for
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rotary table operation (see Prerequisites for the rotary table on page 4-81). Clearance Planes: Click this button to define a clearance zone around the workpiece for CMM movements. This is required only for CMMs with CNC capability (see Defining the clearance planes on page 4-113). Measurement Plan Settings: Click on this button to check and edit the settings for the result logs (see Editing measurement plan settings on page 4-120). Measurement Plan Editor Features: Click on this button to open the measurement Plan Editor Features (see Editing the measurement plan on page 4-122). Temperature Compensation: Click on this button to have Calypso include the temperature of the workpiece and the X, Y and Z scales of the CMM in the calculations (see Temperature compensation on page 4-123). The buttons in the list of prerequisites are color-coded to indicate their status: Red: This prerequisite must be completed before you can continue with creating the measurement plan. Manual measurements, however, can be performed. Yellow: This prerequisite has not been completed as yet. However, you can proceed with creating the measurement plan (the system will use default settings). Green: The prerequisite is concluded. The Measurement Plan Prerequisites button itself is also colorcoded to reflect the combined status of the individual prerequisites buttons: Red: One or more buttons are red. You must complete the prerequisites in question before you can run the measurement plan. Manual measurements, however, can be performed. Yellow: One or more buttons are yellow. You can still work, however. Green: All prerequisites are completed. If you are performing measurements manually (for example, doing a quick measurement of the diameter of a cylinder), you can proceed even if not all of the prerequisites have been satisfied. It is true that the CMM needs to be homed and the currently installed stylus system must be properly qualified; but, on the other hand, you will not yet need to satisfy the other prerequisites:
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You do not have to define clearance planes unless you want to run measurement plans automatically with Calypso. Whether or not you include the measurement plan settings and temperature compensation depends on the intended application.
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Whenever the CMM is homed, you should also redefine the position of the reference sphere. Even if the reference sphere was not moved, homing might have resulted in a shift of a few micrometers in the machine coordinate system. This shift could result in an error of similar magnitude in measurements with different stylus systems. You can dispense with redefining the position of the reference sphere only when you merely install a new stylus and you are certain that this stylus will not be used in conjunction with styli qualified beforehand. (For further details see Qualifying the reference sphere on page 4-40.)
If you use a rotary table: You must redefine the rotary table axis after the CMM has been homed. (For further details see Prerequisites for the rotary table on page 4-81.)
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Important for SP600 When you install an SP600, you must be careful that the stylus does not touch the workpiece nor come to rest anywhere. The weight of the SP600 itself would, in this case, be determined incorrectly.
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The procedure for connecting to the CMM is as follows: 1 Select Extras Workroom CMM. 2 Click on the Connect button. 3 Click on OK. This closes the CMM notebook.
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If the original stylus system can no longer be used, but you have a stylus system with exactly the same configuration, select Resources Define the stylus system for the current measurement plan to select the suitable stylus system. In the list of the prerequisites, the name of the stylus system is displayed that was most recently used for measuring. When opening an existing measurement plan, it may be that the stylus system required for this measurement plan does not coincide with the one currently installed. To see which stylus system is required, choose Resources Define the stylus system for this measurement plan. A window opens in which the name is given of the required stylus system.
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2 When you want to install an SP600 and change the stylus system (SP600 plate): Remove the stylus system manually from the SP600 and proceed with step 5. 3 When you want to install an SP600 and change the probe (RDS plate), as well as in all other cases: Click on downward-pointing red arrow in the left half of the dialog box. The message appears on the screen: Stylus system will be released in 5 secs.
4 Click on OK and carefully grip the stylus system that is about to be ejected. After a five-second countdown, the CMM ejects the stylus system. If a trigger probe is involved, you need to deviate the stylus system slightly to be able to remove it from the holder.
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Important Measuring probes are ejected fully automatically, i.e. you must be holding the stylus system in your hand at this time. 5 Click on the red Up arrow on the right-hand side of the window. The Insert stylus? prompt appears on the screen. Do not click OK at this time. 6 Install the new stylus system. Make sure the notch in the adapter plate is aligned with the pin on the underside of the probe. 7 Click on OK. There is an audible sound when the electromagnet engages with the stylus system. If you do not hear anything, gently move the stylus system to assure a proper seat. A popup menu appears listing available, already defined stylus system names. 8 Click on New or select the appropriate name, if the stylus system has already been defined and qualified. If you have just installed a master stylus, select Master Stylus (not for HAMs = Horizontal-Arm Machines, where the first stylus position is taken as the reference). 9 If you have selected New, enter a name for the stylus system in the Create New Stylus window. 10 Click on OK to close the Manual Stylus System Change window. The Calypso user desk will be displayed again. If you install a stylus system that has already been qualified, the name of the stylus system appears in the list of prerequisites alongside the Stylus System button. If this is not the case, the stylus system must be qualified again.
The TP20 from Renishaw is designed for automatic stylus system changes with the MCR20 stylus system changer module, and the same is true of the TP200 with the SCR200 module (see Renishaw MCR20 stylus system changer on page 7-44 and SCR200 stylus system changer on page 7-45). On a VISTA, the TP200 can be secured in the ram with a PH6. On an Eclipse, the TP200 can be secured in the ram with a PH10.
Bear in mind that you can also change styli manually on the TP20 and the TP200 (see the user data on the TP20 / TP200 and RDS).
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Caution: risk of damage! When you change stylus systems manually without the measuring system, the retaining solenoid is deenergized immediately. In order to avoid damage, you must be holding the stylus system in your hand at this time. If there is no measuring system in the TP20 and you are preparing to change the stylus system on the RDS plate manually, remember that the retaining solenoid for the RDS plate will be deenergized immediately, because the switch contact is open. There is a consequent risk of the RDS plate dropping out and suffering damage.
When you use an RDS, the CMM can probe the workpiece from a large number of different directions by adjusting the A and B angles. Every RDS setting that you want to use for probing is considered to be its own stylus and must be qualified separately (exception: you have the RDS-CAA option installed, see Chapter 17 Qualifying the RDS with CAA (option) on page 17-1). Another possibility is to create a list with the angle settings for the probe, which defines the styli at the same time. During qualification, the CMM recognizes the styli in question, and you do not have to qualify these manually. You can learn how to create this list at How to create a stylus list for RDS on page 4-25. Afterwards, you begin the qualification of the stylus system via the Automatic qualification icon.
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2 Click on the Insert new stylus system button. The Create new stylus system dialog box appears on the screen.
3 Enter the names for the new stylus system and the first stylus. Internally, Calypso does not distinguish between upper and lower case characters. 4 Click on OK to close the window.
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The names of the stylus system and the stylus are displayed in the Stylus System and Stylus Name / No. selection lists. If the stylus system has other styli, you now have to add them in Calypso (see How to add further styli to a stylus system on page 4-22).
If you are adding a stylus to a stylus system defined beforehand, the Stylus No. box automatically shows the new number in the sequence. 3 Enter a name for the new stylus in the Stylus field. Internally, Calypso does not distinguish between upper and lower case characters. 4 In the Stylus No. field select the number of the stylus. 5 Click on OK to close the window. The name of the stylus will now appear in the Stylus Name / No. selection list. 6 If you wish to add another stylus, repeat steps 2 through 5. You now have to qualify each new stylus (see How to qualify a stylus manually on page 4-29).
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To rename a stylus: 1 Click on the Stylus System button in the list of prerequisites. The Stylus system qualification window appears on the screen. 2 Select the stylus whose name you want to change from the Stylus Name / No. selection list. 3 Click on the Rename Stylus button. The Rename Stylus dialog box appears on the screen.
4 Enter a new name for the stylus. Internally, Calypso does not distinguish between upper and lower case characters. 5 Click on OK to close the window. As you can see from the Stylus Name / No. list, the stylus has been renamed. It is not necessary to requalify a stylus after renaming it.
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2 Enter the allocation of the sensor system to the machine system and the dimensions (length) of the master stylus: Type CMM XS= YS= ZS= Arm 1 0 / XM RDS Arm 2 / Individ. 0 / XM 55 / ZM 135 / YM Bridge 0 / XM Arm 1 0 / XM DSE Arm2 / Indiv. 0 / XM 73 / ZM 155 / YM
55 / ZM 135 / YM
55 / YM 135 / ZM
73 / ZM 155 / YM
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RST stylus system with a stylus length of 40 mm and a stylus diameter of 3 mm TP6 stylus system with a 20 mm extension, a stylus length of 28 mm and a stylus diameter of 3 mm. 3 Open the Control tab and click on Connect. This activates your settings.
You have already specified the dimensions and installation position of the master stylus (How to enter the data of the master stylus on page 4-24). To create a stylus list for an RDS: 1 Click on the Stylus System button in the list of prerequisites. The Stylus system qualification window appears on the screen.
2 In the upper toolbar, click on the Stylus System Management button. The Stylus System Management dialog will open.
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3 Click on the Catalog tab to bring the tabbed page with the catalog to the front, and select the Create list menu item in the Edit menu (lower right) . The Create list window will open.
4 Enter the data for your stylus system, for the master stylus and for the reference sphere. For more information, see Create list in the Calypso Online Help. Calypso takes the data for the reference sphere (radius, shaft direction, shaft radius) from the Reference sphere notebook (Reference Sphere Management button in the qualification window). 5 Enter a name for the stylus system.
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Important Never use the name of the currently active stylus system. 6 In the Stylus list, enter the stylus name and the corresponding positions of the RDS (A and B angles in degrees): You can insert rows and delete individual rows or the whole table with the context menu. We recommend using stylus names that contain the angular positions that helps you later choose the correct stylus.
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Important Avoid RDS angle positions in which stylus shaft directions are close to the shaft direction of the reference sphere, as there is a relatively high risk of shaft probing in this case. 7 Click on the Save button. The data you entered is saved in an ASCII file and a new stylus system is created in the stylus catalog. Each row of the stylus list creates a separate stylus. The data path and name are assigned by default and can be changed. 8 Close the Stylus System Management dialog. In the Stylus system qualification window, you can now click on the CNC Probing system qualification icon to begin qualifing the RDS positions.
To make the modified data available, however, the stylus system must be selected again.
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The first qualification of a stylus must be done manually. Once the stylus has been qualified for the first time, future qualifications can be done automatically. Using this function, however, you can only qualify the stylus system that is currently located in the probe.
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If the styli you use are very short, reduce the value for Taper Angle accordingly. The smaller the taper angle, the smaller is the section of the surface of the reference sphere which is probed for qualification. 6 Click on the Qualify Stylus button. 7 If you want to perform stylus qualification in the Tensor qualification mode, enter the measuring force in mN that you want to use subsequently with the stylus. If you want to use a particularly long and thin stylus or if the material to be probed is soft, enter a value for dynamic probing in %.
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This information is stored with the stylus data and can be viewed in the Measurement Plan Editor Features and overwritten for individual features. 8 If you perform the qualification in the Tensor or Six Points mode: When prompted, position the stylus over the north pole of the reference sphere and probe it in the direction of the shank. (If your stylus is vertical, therefore, position it over the north pole of the sphere and probe once vertically downwards). 9 If you perform the qualification in Manual mode: After prompting, probe at first a single point in the shaft direction. Manually create the probing points and return points (retract points) in the desired order. These points are assigned to the respective stylus.
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When qualifying a cylindrical stylus, the first three points on the cylindrical stylus must lie in a circle while the next three points need to lie in a circle that is offset with respect to the first circle. After that, you can make any probings that you wish.
5 4 3 1 2 6
The number of probing and support points is displayed in the Qualify Stylus window. With Delete, you can remove the points backwards one after the other. If you do not set a return point after the last probing point, a retraction will be set automatically during the CNC run later. If the sum of the projection angles is greater than 15 degrees, a dialog box automatically appears during the run. You can change the angles and confirm the change with OK in this dialog box. This allows you to adjust the values, so that the shaft direction of the stylus is as close to perpendicular as possible with respect to the
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calculated equatorial plane of the reference sphere and shaft probings are avoided. Calypso qualifies the stylus according to the mode selected. The results are shown in the R, S, X, Y, and Z fields (see About the results of stylus qualification on page 4-39). 10 If you wish to qualify another stylus, repeat steps 2 through 9. 11 Click on OK to return to the user desk. The styli are now qualified and the color of the Stylus System button is green. The qualified stylus system can now be used by all Calypso users.
If the styli you use are very short, reduce the value for Taper Angle accordingly. The smaller the taper angle, the smaller is the section of the surface of the reference sphere which is probed for qualification. 6 Click in the window on the CNC Probing system qualification button.
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7 If you want to perform stylus qualification in the Tensor qualification mode, enter the measuring force in mN that you want to use subsequently with the stylus. If you want to use a particularly long and thin stylus or if the material to be probed is soft, enter a value for dynamic probing in %.
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This information is stored with the stylus data and can be viewed in the Measurement Plan Editor Features and overwritten for individual features. 8 If you perform the qualification in the Tensor or Six Points mode: When prompted, position the stylus over the north pole of the reference sphere and probe it in the direction of the shank. (If your stylus is vertical, therefore, position it over the north pole of the sphere and probe once vertically downwards). 9 If you perform the qualification in Manual mode: After prompting, probe at first a single point in the shaft direction. Manually create the probing points and return points (retract points) in the desired order. These points are assigned to the respective stylus.
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When qualifying a cylindrical stylus, the first three points on the cylindrical stylus must lie in a circle while the next three points need to
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lie in a circle that is offset with respect to the first circle. After that, you can make any probings that you wish.
5 4 3 1 2 6
The number of probing and support points is displayed in the Qualify Stylus window. With Delete, you can remove the points backwards one after the other. If you do not set a return point after the last probing point, a retraction will be set automatically during the CNC run later. If the sum of the projection angles is greater than 15 degrees, a dialog box automatically appears during the run. You can change the angles and confirm the change with OK in this dialog box. This allows you to adjust the values, so that the shaft direction of the stylus is as close to perpendicular as possible with respect to the calculated equatorial plane of the reference sphere and shaft probings are avoided. Calypso qualifies the stylus according to the mode selected. The results are shown in the R, S, X, Y, and Z fields (see About the results of stylus qualification on page 4-39). 10 If you wish to qualify another stylus, repeat steps 2 through 9. 11 Click on OK to return to the user desk. The styli are now qualified and the color of the Stylus System button is green. The qualified stylus system can now be used by all Calypso users.
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The following qualification methods are available (depending on the available options): Mode Application Procedure A total of 30 probings are performed at 15 points on the sphere. Each point is probed twice with different forces each time. The static tensor is determined from the differences between the respective probings. Three great circles are measured on the reference sphere once at very low speed (5 mm/s) and once at very high speed (50 mm/s) and ratio of the two results is determined. You can find more details under Dynamic stylus qualification on page 21-7. Note: The dynamic tensor can be determined only if the static tensor is known. If the static tensor has not been determined yet, the static tensor and then the dynamic tensor will be determined automatically. At first, four points are probed for position determination, followed by six points for stylus qualification. Note: This qualification takes place in clamped mode. Important! For measuring probes, this mode is needed only for special measuring jobs. Slight accuracy reductions are possible! You select the probing points yourself. The first probing point serves to determine the probing direction. The following probings are used to calculate the stylus geometry (results are thus possible as of the fifth probing).
Tensor Determination of the (static) tensor. (standard for measuring probes) The tensor indicates how the stylus bends as a function of the applied force. Dyn. tensor (only with the VAST Navigator option) Determination of the static and the dynamic tensor. As a complement to the static tensor, the dynamic tensor identifies the dynamic behavior of the stylus (i.e., how the stylus bends as a function of the scanning speed).
Initial determination of the stylus geometry. This is suitable for all probes with spherical stylus tips (except for passive styli). It is unsuitable for very short styli and special stylus systems (e.g. angled configurations). Always in the case of manual CMMs. Otherwise, only if automatic qualification is not possible (e.g. due to the shaft geometry). Also suitable for qualification of a temperature stylus or for initial qualification of a cylinder stylus.
Manual
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Mode Dyn. Tensor Repeat Measurement: (only with the VAST Navigator option)
Application Repeat measurement of the dynamic tensor without determination of the static tensor. The static tensor must have been determined in advance. This is suitable for dynamic stylus qualification on the virtual reference sphere (Dynamic stylus qualification on page 21-7). Repeat measurement of the static tensor.
Procedure You will be prompted to probe in the shaft direction. The first four points are used to calculate a sphere. Afterward, the dynamic tensor is determined.
Calypso automatically requalifies the static tensor and the stylus geometry. Any existing dynamic tensor is retained.
Geometry Repeat Repeat measurement of the Measurement: stylus geometry if only this has changed. Any existing static and dynamic tensor is retained.
This is in principle identical to the procedure for the Six Points mode: At first, four points are probed for position determination, followed by six points for stylus qualification. However, qualification takes place in the unclamped mode (after all, there is a valid tensor that is not deleted). This is in principle identical to the procedure for the Manual mode: However, qualification takes place in the unclamped mode (after all, there is a valid tensor that is not deleted). Used, e.g., for disk styli. Four points are first probed for position determination, followed by the required number of points for stylus qualification. The dead weight offset (EGO) is determined by means of the Probe in direction of the stylus shaft prompt.
Repeat measurement of the stylus geometry with manual probings if automatic repeat measurement is not possible.
This is the only possibility to qualify the stylus geometry for passive measuring probes. This is suitable for all styli with spherical stylus tips. At the beginning, the dead weight offset (EGO) must be determined that limits the measuring range of the probe. Read the user guide that is provided.
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If you want to qualify one or more stylus systems, you can accomplish this in the CNC run by means of measurement plans specially conceived for this. During this procedure, you may also use several reference spheres (real or virtual) and carry out rapid repeat measurements. This can be explained by the following example: All styli are qualified in the Tensor mode and should be qualified again once every shift because of possible changes in temperature. In this case, it is not necessary to carry out a complete tensor qualification every time. This is because, even though the geometry of a stylus changes with the temperature, the flexibility does not. For regular qualification, therefore, you can define a measurement plan in which all styli are qualified with only 6 points. Select additionally the Geometry Repeat Measurement mode. In an additional measurement plan, you can select the Tensor mode for the same stylus system, thus making a complete qualification.
If using a virtual reference sphere (VAST Navigator option), it could be helpful to divide the stylus system qualification into several characteristics. In one characteristic, define the geometry specification (tensor, repeat measurement geometry) for all styli as well as the dynamic qualification for those styli that can be qualified on the real reference sphere. Then define in further characteristics the dynamic repeat measurement on virtual reference spheres.
Prerequisites
The following preconditions must be met before you can run the desired measurement plan: The positions of the needed reference spheres must be measured with the master stylus. Virtual positions that may be needed, must be created by being copied in the Reference Sphere Management. All required styli must have been qualified in the desired mode.
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Should virtual positions of reference spheres be needed, they must be created by being copied in the Reference Sphere Management. All required styli must have already been qualified in the desired mode.
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Try to gather all the geometry data on one single reference sphere. Use the second reference sphere or the virtual reference spheres for the dynamic repeat measurement. To create the measurement plan for the automatic qualification: 1 Select File New and enter in the Create new Measurement Plan window a name for the measurement plan, e.g., Stylus qualification. 2 Select Resources Utilities Stylus System Qualification. A new Stylus System Qualification characteristic is created. 3 Create in the same way further Stylus System Qualification characteristics, one for every reference sphere and for every stylus system to be qualified (exception: master stylus). In the CNC run, the position of reference sphere 1 is first measured with the master stylus. 4 Open the first characteristic.
You see the data of the currently used stylus system. In the list on the left, all available (qualified) styli of this stylus system, the current qualification status as well as the respective reference sphere are displayed. On the right side, the styli that are to be qualified with this characteristic are displayed with mode and reference sphere. 5 Select under Stylus System the Master Stylus entry.
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6 Highlight the stylus in the list on the right. 7 Select the mode with which the position of the reference sphere should be determined under Mode. Here, you can also set Geometry Repeat Measurement. The position is measured using only 6 points, not clamped, however. 8 Select the position number of the reference sphere that is supposed to be qualified with this feature under Reference Sphere. 9 Give the characteristic the name Reference sphere 1 and confirm the input with OK. 10 Edit, as in steps 4 through 9, the characteristics for all further (real) reference spheres.
11 Define the characteristics for the qualification of the various stylus systems. Define using Add and Delete which styli should be qualified with the respective characteristic. Example: Only styli 2 and 4 of a star stylus should be qualified. In this case, mark stylus 1, 3 and 5 and click on Delete. For the marked stylus or styli, set the desired qualification mode for this characteristic under Mode. 12 Select File Save to save the measurement plan.
If the measurement plan contains exclusively characteristics for stylus qualification, you need not define any base alignment or clearance plane.
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!
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Important If you have changed the stylus name subsequently after creation of the measurement plan, Calypso does not find these styli and skips them during qualification. In this case, you will have to transfer the respective stylus in the corresponding characteristic from the Stylus Systems Available list on the left back to the Selected styli list on the right. To run the measurement plan for qualifying the stylus systems: 1 Click on the Run Measurement Plan button. 2 Select in the Start Measurement window, under Selection, the Current Alignment, and, under Navigate-Feature To Feature, the Use Position Points Only entry. 3 Start the measurement plan with OK. Calypso carries out the qualification as defined in the characteristics.
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If using more than one (real) reference sphere, Calypso, when changing to another reference sphere, always travels first in +Z to the end of the measuring range, then to the next reference sphere in X and Y. Afterward, the stylus systems are qualified and you may proceed with the desired measurement plan for measuring the workpiece.
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If the results are stable, it probably means that you have reached the limit based on all of the factors mentioned above. In this case, you can regroup the stylus system and possibly increase the rigidity thereby. Qualification with a short, rigid stylus (e.g. the master stylus) can determine possible systematic errors of the CMM.
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Important Never use the master stylus for a normal measurement during operation. The preconditions that have to be satisfied before you can start qualifying the reference sphere are as follows: You have opened a measurement plan. The master stylus is installed. The procedure for installing the master stylus is described in the section entitled How to install a stylus system on page 4-18.
Prerequisites
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To determine the position of the reference sphere: 1 Click on the Stylus System button in the list of prerequisites. The Stylus system qualification window appears on the screen.
2 Make sure that the radius of the reference sphere and the serial number displayed on the screen match the radius and the serial number on the qualification certificate of the reference sphere. These values were entered by the Zeiss customer service engineer. If they do not match the data on the certificate, proceed as described in How to edit the data of the reference sphere on page 4-42. 3 Make sure that the master stylus is displayed in the Stylus Systems selection list.
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4 Click on the Reference Sphere Position button. In case the master stylus has not been inserted, Calypso asks if you really want to determine the position of the reference sphere. If you click on No, the qualification process is discontinued. If you click on Yes, Calypso will use the data of the currently used stylus system. Afterward, you are prompted to enter the orientation of the reference sphere:
5 Select the Orientation of Reference Sphere by clicking on the appropriate button to copy the values automatically into the input fields. The symbol buttons show the view of the reference sphere and the shaft from above (from the Z+ direction) in such a way that the X axis looks to the right and the Y axis is looking up. You can also enter the values freely into the input fields. 6 Probe the reference sphere once in the stylus direction. You do this by positioning the stylus over the north pole of the reference sphere and by probing downwards. Calypso automatically measures the reference sphere for CNCcompatible CMMs. The results are shown in the R, S, X, Y und Z fields (see About the results of stylus qualification on page 4-39). 7 Click on OK, to close the Stylus system qualification window. The position of the reference sphere is now known to the system.
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To edit the data of the reference sphere: 1 Click in the Stylus system qualification window on the Reference Sphere Management button. The Reference Sphere Management is opened with the data of all reference spheres known in Calypso. The number of the currently active reference sphere can be found behind Active Reference Sphere. 2 To add an additional reference sphere: Select New in the menu on the right. An additional column is inserted in the list that initially copies over the values from the previous column. 3 To edit the radius: Highlight the field for the radius. Click on the number in the gray input field at the bottom edge of the dialog box. Enter the number from the qualification certificate. 4 To change the serial number: Highlight the field for the serial number. Click on the number in the gray input field at the bottom edge of the dialog box. Correct the serial number. 5 If necessary, change the clearance planes to suit the type of clamping device you are using (clearance planes for mount) and the position of the stem. The clearance distances define the clearance planes for qualifying the stylus.
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Minimum clearance planes are defined even when the clearances are set to zero; the reference point is an imaginary point slightly outside the reference sphere (depending on the axial direction), not the center of the reference sphere. 6 Confirm your entries with OK. The Stylus system qualification window reappears on the screen.
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4 Click on the data in the list you wish to print. 5 Start printing with OK. The selected stylus data is printed.
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In the first block, the name of the stylus datum appears under name and the key for inclusion in the report appears under available: 1 means in the report, 0 means not in the report In the second block, the setting appears under name and the corresponding value appears under value (column: number of columns in the table, width: column width).
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The known coordinate systems in the measurement plan can be selected and used at various positions of the measurement plan: Features and constructions The start coordinate system for a coordinate system according to the standard method Characteristics True Position, GDT Profile, Simple distance Store erosion module, coordinate system utility Display position and Move in Part Alignment System in the stoplight window Additional features Holos and Gear
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This becomes the case when using features with a pattern or a loop index for a coordinate system determined by the standard method, using the loop index in a special function when defining the coordinate system. The name of the coordinate system is then provided with an index in brackets. For every valid index value, the coordinate system becomes a particular coordinate system of its own.
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The type of brackets selected in the loop is passed along with the index as is the number. n different coordinate systems are calculated for a coordinate system that has a feature with pattern and n positions. When several references contain patterns with varying number of positions, the resulting coordinate system contains exactly as many positions as the reference having the smallest number of positions. Example: A circle and two planes have one pattern with ten features each. If you use these features as references for the coordinate system, a coordinate system with index is formed. This coordinate system can take on from one to ten different positions or alignments depending on the specific index value.
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Important A coordinate system provided with a loop is interpreted as an iterative alignment. For this reason, coordinate systems that should be calculated with an index should have no loop.
Base alignment
The base alignment is a part alignment that defines the position of the workpiece on the CMM. There is only one base alignment in every measurement plan. In order to view, define or change the base alignment, please read How to create a new base / start alignment on page 4-51. The base-alignment parameters correspond to the machine coordinate system. The part alignments inside a measurement plan, on the other hand, correspond either to the base alignment or to other part alignments. They are used for the correct evaluation of the measuring results. When you set the base alignment, you have to decide which features you want to use for defining the workpiece position. If these features have already been measured, the current workpiece position will be calculated and saved.
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Otherwise, with machine-remote programming, for example, the workpiece position cannot be calculated until later. This can be accomplished by loading a saved base alignment (see How to load an existing base alignment/start alignment on page 4-50) or by manually adapting a defined base alignment (see How to adapt a base / start alignment on page 4-54). It is important to differentiate between 2 processes: The assignments of the features to the 5 references of the base alignment are saved in the measurement plan. The results of the calculation of the base alignment are saved in a file.
Start alignment
A part alignment is referred to as a start alignment when it can be used as a provisional base alignment. It must be possible to generate by manual probing and can be permitted only once in a measurement plan.
What is the purpose of a start alignment?
Under certain circumstances, many features are necessary for generating the base alignment. This is the case, for example, when constructions are entered into the base alignments that, in turn, have been formed from several other features. Generating the base alignment through manual probing would, in this case, be relatively complex. This applies also when features difficult to probe are used for generating the base alignment. In these situations, it is recommended to use a start alignment. A start alignment can be built up relatively simple. Depending on the individual case it can, for example, be built by a 3-2-1 alignment, by simple features or also by one point in X, Y and Z each. For a CNC run with manual alignment, it is then sufficient to probe these few points or features. Afterward, Calypso knows the approximate position of the workpiece and can qualify the base alignment in the CNC run.
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Important Always define the base alignment first, and then the start alignment. Otherwise, the offset between the base alignment and the start alignment cannot be correctly calculated. The start alignment is defined and edited in the same manner and with the same functions as a base alignment. For this purpose, use the Start Alignment tab in the Load, create or change base alignment dialog box. It is only the CNC run that cannot be set in the start alignment.
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To activate the start alignment for the current measurement plan, you must tick the corresponding check box on the Start Alignment tab. For information on how to view, define or change the start alignment, please read How to create a new base / start alignment on page 4-51.
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Follow these steps: 1 In the list of prerequisites, click on the Base / Start Alignment button. The Load, create or change base alignment window will open. The Base Alignment tab is at the front.
2 To load a start alignment: Click on the Start Alignment tab. 3 Select the Load a saved Base Alignment or Load existing Start Alignment option. 4 Select the name of the part alignment that you wish to load from the list. 5 Click on OK to return to the prerequisites.
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In all cases, you must match the part alignment to the position of the workpiece. See How to adapt a base / start alignment on page 4-54. The Base / Start Alignment button will now be green. When loading the base/start alignment, only the workpiece position is changed, not, however, the definition of the features used. That is why the model in the CAD window does not change.
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To create a new base/start alignment: 1 In the list of prerequisites, click on the Base / Start Alignment button. The Load, create or change base alignment window will open. The Base Alignment tab is at the front.
2 To create a new start alignment: Click on the Start Alignment tab. 3 Select either Create new Base Alignment or Create new Start Alignment. 4 From the list, select the method you want to use for alignment (see Alternative alignment methods on page 4-76). 5 Click on OK. The Definition template (coordinate system) window is opened. This dialog box has five buttons and fields for defining the five references. Calypso automatically enters the information in the fields when you probe the workpiece to define the requisite features. You do not need to probe the workpiece if you have already measured the features required for the part alignment. 6 Make sure that the correct stylus is selected at the CMM control console.
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7 Define a feature for the reference. There are a number of possibilities: The feature already exists: Click on the appropriate button of the reference. The Selection dialog box appears on the screen. Select the feature of your choice from the selection list. Click on OK. Calypso transfers the feature to the appropriate field. The feature does not exist in the measurement plan as yet: If you are working on the CMM: You do not have to exit the Alignment dialog box. Probe point by point. Calypso's automatic feature recognition engine automatically registers the geometry of the feature. Click on OK when you have fully defined the feature as a reference. Calypso will automatically transfer the feature to the measurement plan. If you are working away from the machine: Click on the appropriate button of the reference in the Alignment dialog box. The Selection dialog box appears on the screen. Select the New option. Click on the appropriate button of the feature you want to define. Click on OK. In the CAD window, either probe the necessary number of points on the feature with the mouse. - or Click on one of the buttons Define a Space Point, Define Circle on a Cylinder, Define 2-D Line or Extract Features to import the entire feature right away. Calypso updates the feature definition at the left-hand side of the dialog box. Click on OK to close the definition template for the feature. 8 Define the features for the other references in the same way. 9 Click on OK when you have finished defining all the references. The part alignment is saved and the dialog box is closed. The Base / Start Alignment button will now be green.
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Once all of the references have been defined, Calypso will enter the corresponding features in the appropriate fields (see the example in the illustration below).
The default name for the measurement plan is derived from the name of the newly calculated base alignment. You can, however, highlight the name and overwrite it with a name of your choice. Click on the Comment button if you want to type in and save a comment containing additional information.
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3 Select either Change active Base Alignment or Change current Start Alignment. 4 Click on OK. The Definition template (coordinate system) window will open. You can see which features were used to define the part alignment. 5 Click on the Execute manual run now button. Calypso guides you through the procedure for computing alignment. The Manual CNC dialog box appears on the screen for this purpose.
The instructions in this dialog box tell you exactly which feature has to be probed and how often to ensure successful alignment. This dialog box is fully described in Manual CNC in the Calypso Online Help. 6 Using the joysticks, take the indicated number of probings on the indicated feature of the part. The information in the dialog box is updated after each probing. In this manner, you know how often you have to probe. When you take the final probing for a reference, the window displays the feature needed for the next reference (such as 2-D Line1). After the probing, Calypso takes a moment to update the part alignment and display the new image in the CAD window. Then you are returned to the Alignment window. 7 Click on OK to save this part alignment and return to the prerequisites.
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The Base / Start Alignment button will now be green. When adjusting the base/start alignment, only the workpiece position will be changed, not, however, the definition of the features used. That is why the model in the CAD window does not change.
The Automatic run check box has to be marked in the measurement plan in the definition template of the base alignment. 1 In the Load, Create Or Change Base Alignment dialog box, activate the radio button for the Change active Base Alignment option.
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3 Click on Add. 4 Enter in the End field, e.g., 5 as number of the loop cycles. 5 Point to the Break Condition field, right-click to open the context menu and select Formula.... 6 In the Formula... window, enter the following expression:
baseSystem().valueA<0.05
This Boolean expression is checked at the end of each loop and when it is satisfied (value of the expression = true), the loop is stopped. The value of the valueA variable is recalculated each time the loop is run. It stands for the approximation between the measured alignment and the alignment stored in memory. In the standard protocol, valueA is designated as Delta. 7 Close the Formula, Loop and Load, Create Or Change Base Alignment dialog boxes. 8 Start the measurement plan. Alignment terminates immediately if the workpiece has not been moved since the alignment was last computed. If a marginal change was made to the position of the workpiece, alignment is computed iteratively until the difference (delta) between two consecutive alignments is less than the value you specified (0.05). Refer to the default printout for information on the alignment procedure and the results, including the value for delta.
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!
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Important When making changes on the base alignment of an existing measurement plan, always do so with great care and deliberation especially when dealing with a complex measurement plan or when the measurement plan contains theoretical features, formulas or parameters. Check subsequently the nominal values of the features with regard to their correctness. To change a base/start alignment: 1 In the list of prerequisites, click on the Base / Start Alignment button. The Load, create or change base alignment window will open. The Base Alignment tab is at the front.
2 To change a start alignment: Click on the Start Alignment tab. 3 Select either Change active Base Alignment or Change current Start Alignment.
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4 Click on OK. The Definition template (coordinate system) dialog box appears on the screen. It shows which features were used to define the part alignment. 5 If you want to replace a feature for a particular reference with another feature which has already been defined: Click on the button for the reference in question to open the Selection (features) dialog box. In the list, click on the feature you want to use. Click on OK to confirm and close the Selection dialog box. The feature has now been replaced. Click on OK to return to the list of prerequisites. 6 If you want to assign a particular reference a feature that has yet to be defined: Click on the button for the reference in question. The Selection (features) window will open. Select New and choose the type of feature you want to define (e.g. plane or 2-D straight line). Confirm by clicking OK and use the CMM to probe the necessary points of the feature. Make sure that the correct stylus is selected at the CMM control console. As soon as you start probing, Calypso updates the feature definition at the left-hand side of the window. After probing, click on OK to close the feature's template. Click on OK to return to the list of prerequisites. After every change in the part alignment, the Base / Start Alignment button must be green. When a base/start alignment is changed, the nominal values of all of the features in the current measurement plan will be changed. The position of the base/start alignment relative to the workpiece will be changed. The position of the workpiece on the CMM will also be changed if only measured features are used.
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An offset also enables you to move the origin of the part alignment to a point that cannot be probed. You can define an offset in any and all of the three coordinate directions. Using the rotation function, it is possible to rotate a part alignment around a coordinate axis. There are two methods for entering the rotation angle: Rotate by an angle: The desired rotation angle is entered directly in degrees. Rotate by distances: The rotation angle is entered via vector coordinates. The rotation of the reference axis by secondary reference is described separately (see Rotate Distance on page 4-66).
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5 Click on the Offset button. The Offset entry and input fields for the coordinates are added to the Special Functions dialog box.
6 Enter the amount by which you want to offset the origin: To do so, click on the X, Y or Z field or fields, as appropriate. Enter the corresponding value or values. 7 Once you have entered the coordinates for the origin, click on OK. The offset is saved and the window is closed. The new position of the part alignment is displayed in the CAD window.
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5 Click on the Rotate by an angle button. The Around entry and input fields for the spatial axis and the rotation angle will appear in the Special Functions dialog box.
6 Enter the spatial axis around which you want the alignment to be rotated, and the angle: Click in the Around list and select the spatial axis of your choice. The list entry is not updated until after you have closed the window. Click in the Angle field and enter the angle of rotation (in degrees). 7 Repeat steps 6 and 5 if you want to define rotations about other spatial axes as well. 8 After you have entered all of the desired rotations, click on OK. The rotations are saved and the window is closed. The new position of the part alignment is displayed in the CAD window.
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3 Select Change active Base Alignment or Change current Start Alignment and click on OK. 4 Click on the Special button. The Special functions window will open. 5 Click on the Rotate by distances button. The Around entry, a selection field for the spatial axis and input fields for the respective complementary coordinates are added to the Special Functions window, along with a field for displaying the resulting rotation angle.
6 Enter the spatial axis around which you want the system rotated, and the vector for rotation: In the Around list, select the corresponding spatial axis. The coordinate input fields immediately change accordingly. The list entry, however, is not updated until you have closed the window. Specify the vector with its two coordinates in the coordinate system of the plane of rotation (the plane of rotation depends on the selected axis of rotation). The associated angle will appear immediately in the display field, calculated as the arc tangent of the quotient of coordinate 2 divided by coordinate 1. 7 Repeat steps 6 and 5 if you want to define rotations about other spatial axes as well. 8 Once you have entered the rotations, click on OK. The rotations are saved and the window is closed. The new position of the part alignment is displayed in the CAD window.
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Rotate to equal deviation Rotates the coordinate system about a given axis until a line between a point in the plane (the nominal coordinate) and the tertiary reference has a slope of 45. After this rotation, the delta-X and delta-Y of the nominal point and the tertiary reference are equal (delta-X (delta-Y) is the difference between the two X values (Y values)).
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Y act Y nom
Nominal coordinates X
The options only appear in the Special Functions dialog box if they would be reasonable to use and the base / start alignment satisfies certain preconditions.
Prerequisites
To be able to use the Rotate reference axis by secondary reference, the following preconditions must be met: The secondary reference of the base / start alignment was defined by either a circle, a slot, a rectangle, an ellipse or a point. For both coordinates of the plane in which the base alignment is rotated, the tertiary reference must be defined with the same feature, or with 2 planes, or with two 2D lines, or remain unchanged in both coordinates.
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Rotate Distance
Use the Rotate Distance function to define a value (distance) separating a defined coordinate of a given feature from the part alignment. In this case, Calypso rotates the part alignment until it is set to this distance.
Example
The example below illustrates the Rotate Distance function: The zero point of the part alignment is in the bore on the left. The center of the bore on the right is 50 mm away in the X axis. After activating the Rotate Distance function, this distance should maintain the nominal of 40 mm.
50
Calypso rotates the part alignment around the origin in the left bore until the distance you specified is achieved.
40
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This allows rotating the coordinate system such that a line going through the coordinate origin will go through the point that was used as the third reference when the base alignment was defined. When using the Rotate to origin line function, Calypso rotates the part alignment until the specified line touches the defined point. In the new coordinate system, the relationships between the X values and the Y values for both points (the one defined by the line and the point for the tertiary reference) are exactly equal. The Rotate to Origin Line is in a sense a Rotate to Equal Relationships.
Example
The example below illustrates the Rotate to origin line function: The zero point of the part alignment is in the bore on the left. The center of the bore on the right delivers the third reference for both the X and Y axes. With (20,30), a line is defined in the X-Y plane, which passes through the origin and the point at X = 20 mm, Y = 30 mm. After the Rotate to origin line function has been performed, the line should also pass through the center of the bore on the right. Calypso rotates the part alignment around the origin in the left bore until the line touches the center of the bore on the right.
The example below illustrates the Rotate to equal deviation function: The zero point of the part alignment is in the bore on the left. The center of the bore on the right delivers the third reference for both the X and Y axes. A line is defined with (20,30) in the X-Y plane of the coordinate system; it will pass with the slope 1 through the point at X = 20 mm, Y = 30 mm.
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After the Rotate to equal deviation function has been performed, the line should also pass through the center of the bore on the right. Calypso rotates the part alignment around the origin in the left bore until the line touches the center of the bore on the right.
Enter distance
6 Select the desired option: Rotate Distance Rotate to origin line Rotate to equal deviation 7 Rotate to distance: In the Rotate distance input field, enter the distance to be achieved by rotating (caution: pay attention to sign).
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8 In Rotate to origin line or equal deviation: In the input fields, enter the coordinates of the point through which the line should pass. 9 Click on OK to save the setting and close the dialog box. 10 Click on OK to close the Definition template (coordinate system) dialog box of the base / start alignment. You can observe the rotation of the base alignment directly in the CAD window.
This can be necessary in the following case, for example: During the alignment of a workpiece, the primary and the tertiary alignment is to be measured on the workpiece. The secondary alignment, however, is to be measured on a fixture that is no longer accessible after clamping down the workpiece. As a result, the feature for the secondary alignment can no longer be measured as soon as the workpiece is clamped onto the fixture. The base / start alignment can nonetheless be created. To do this, measure the secondary alignment in a separate measurement plan before the CNC run. You then define the base alignment / start alignment of the workpiece initially without secondary alignment, taking it instead from the existing base / start alignment of the separate measurement plan. To do this, apply the Load alignment for secondary reference function in the Special Functions dialog window for the base alignment / start alignment.
You can load the secondary reference for a base alignment/start alignment from another base alignment/start alignment under the following circumstances: The current base/start alignment is a standard coordinate system (no alternative alignment method such as 3D Best Fit, RPS Method, P6 Method). The primary alignment in the current base/start alignment has already been defined. The secondary alignment in the current base/start alignment has not yet been defined.
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NOTE
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Both the Load alignment for secondary reference and the Reference axis setting in secondary reference options thus cancel one another. Also in an already existing measurement plan it is possible to load the secondary reference of the base/start alignment from another base/start alignment. This, however, is only practical if the following conditions are met: The primary alignments of the current and stored base/start alignment are approximately the same. Otherwise, the nominal data is offset so much by the transformation after the loading of the secondary reference that no normal measurement is possible any longer.
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Important It is not admissible to enter just any base alignment as secondary alignment and then do the qualifying of the alignment thereafter. If the workpiece on the machine has been displaced and it thereby becomes necessary to requalify the base/start alignment, you must always qualify the base/start alignment first and load its secondary reference afterward. Not until afterward do you redefine the base/start alignment in which you want to load the secondary reference.
How the new axis is determined when loading the secondary reference
How does Calypso determine the new coordinate axis of the base/start alignment from the existing base/start alignment?
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The first coordinate axis of the new base/start alignment that has already been determined is compared with the six directions of the axes from the existing base/start alignment. Among these six axis directions, the axis is found that forms the smallest angle to the new primary alignment.
Z Y X
Origin in X and Y
The determined axis direction of the existing system forms, together with the primary alignment of the new base/start alignment, an angle smaller or equal to 45. For the secondary alignment, one of the two other axes of the existing base/start alignment is used: nearest direction of the existing system axis of existing system used for secondary reference X Y Y Z Z X X Z Y X Z Y
It is now important for the new coordinate system to know for which axis direction (in the new coordinate system) the axis of the existing system determined above is to be used. primary axis of the new system the existing axis becomes an axis in the new system X Y Y Z Z X
The primary direction (of the new alignment) is found in the first line, the secondary axis is below it.
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A base/start alignment exists whose secondary alignment is the same as the desired secondary alignment of the new base/start alignment. The secondary reference for the new base/start alignment has not yet been defined. To load the alignment for the secondary reference: 1 Determine the primary alignment of the new base/start alignment. 2 Determine the tertiary alignment of the new base/start alignment. 3 In the list of prerequisites, click on the Base / Start Alignment button. The Load, create or change base alignment window will open. The Base Alignment tab is at the front. 4 To load the secondary reference into a start alignment: Click on the Start Alignment tab. 5 Select Change active Base Alignment or Change current Start Alignment and click on OK. 6 Click on the Special button. The Special Functions dialog box appears on the screen. Once the prerequisites are met, additional input fields will appear in the upper part under Alignment for secondary reference.
7 Activate the Load alignment for secondary reference check box. 8 Select in the selection list the base alignment/start alignment whose secondary reference you want to accept for the current base alignment/start alignment.
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9 Click on OK to save the setting and close the dialog box. If the base alignment file cannot be loaded, a remark window appears on the screen. If Calypso is in CNC mode, the stop is switched over to red instead, and the CNC run is discontinued. A line is displayed in the status monitor with a corresponding error text. 10 Click on OK to close the Definition template (coordinate system) dialog box of the base / start alignment.
Other requirements
The following situation is presented as an example: There are two measurement plans one, to measure the plane rotation on a fixture, and a second, to measure the workpiece on the fixture. If the base alignment of the plane rotation was requalified (e.g., because the fixture was moved or turned about) and now it is switched over to the other measurement plan, a very difficult situation develops. The plane rotation was changed but the base alignment of the workpiece is still in the same position. This can be compared to the following: A workpiece was defined on the machine by probings (with complete base alignment). Now the workpiece is turned about and a new plane is measured. This plane is now replaced by the feature of the current plane rotation of the base alignment. The consequence is: When the base alignment window is opened and closed again, all nominal geometries are calculated again (shifting of the CAD model) due to the fact that the actual features of the primary and tertiary alignments were not likewise measured again.
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To compensate for this, the base alignment is calculated from the nominal geometries again when the base alignment window opens. If the stored alignment has not changed, the nominal base alignment has a zero vector and a universal matrix. If it has changed, however, the difference between the existing alignment and the new alignment in relation to the current alignment is added and saved. The calculation and saving of the base alignment when opening the window is only carried out in the case where the Load alignment for secondary reference function is activated.
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alignment back to the CAD origin and thereby maintain its alignment.
The names of the special functions calculated are listed. Besides OK and Cancel, all buttons and input fields are set to inactive.
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If you disactivate the Keep CAD Origin check box, the calculated special functions remain in the list. The buttons and input fields are active again. 5 Click on OK to change the base alignment as displayed and to close the dialog box. 6 Click on OK to close the Definition template (coordinate system) dialog box of the base / start alignment.
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Important If you delete a base alignment, you must define new part alignments. See How to adapt a base / start alignment on page 4-54. To delete a part alignment: 1 Choose Delete Base Alignment from the File menu. The Delete Base Alignment dialog box appears on the screen, with a list of all the base alignments defined in Calypso. 2 Select the name of the base alignment that you want to delete. 3 Click on OK.
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The base alignment is deleted from Calypso. Only the base alignment as such is deleted, not the references and features on which it is based.
The 3D Best Fit can be used to calculate the alignment for workpieces for which no clear references have been defined. This is a situation frequently encountered in freeform measurements. If you are using the Calypso Light version, you cannot use this function. The 3D best fit is a method that delivers the best possible fit between any number of points or geometric elements and their specified geometry. Number of points at least 1, no upper limit
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Description The errors between specified and actual points are squared and added up. The base alignment is changed until this value is minimized.
If you select the Best fit on CAD model option, the actual points are first aligned with the nominal points (according to Gauss) and the perpendicular base points of the actual points aligned in this way are then calculated on the CAD model. Finally, the actual points are aligned with the perpendicular base points (according to Gauss).
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RPS Method
The RPS Method is primarily used for measuring body panels for motor vehicles. Number of points at least 3, maximum 6
Description A coordinate (e.g. Z) is fixed 3 times A coordinate (e.g. Y) is fixed 2 times A coordinate (e.g. X) is fixed 1 time RPS alignment is usually an iterative process performed with the aid of a loop.
RPS is short for Reference Point System. RPS alignment is based on the 3-2-1 rule. Unlike other methods, RPS alignment is based on the points that are specified in the drawing of the workpiece. Alignment is therefore subject to rules and is not wholly userdefinable. One of the advantages is therefore that different results obtained with a given workpiece are comparable because they are all based on the same system of coordinates.
P6 Method
The P6 Method is particularly suitable for the alignment of pipes. Number of points exactly 3
Description The first point defines the origin in X, Y, and Z. The first and second points together define the primary axis. The third point defines rotation about this primary axis.
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and double-click on the symbol added to the list of features for a coordinate system. - or To create a new part alignment, click on Base / Start Alignment in the list of the prerequisites in the measurement plan area and then select the desired procedure from the list. The definition templates for all these methods are very similar in appearance. The illustration shows the 3D Best Fit, called from the prerequisites (base alignment).
The dialog box for RPS alignment has X, Y and Z check boxes that you must use to define which feature constrains which degrees of freedom.
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2 Click on Select Features to define the features you want to use for alignment. This opens the Selection (features) dialog box.
Here all of the features that have been defined will be displayed. 3 Press and hold down the Ctrl key and click on the features you need for alignment. The features you select in this way are listed in the definition template for alignment. 4 If you have to define reference features in addition to those already listed: In the first column, click to the left of the name of the feature for which you want to define a reference. An arrow appears, indicating the active line. Click on the Select References button. The selection dialog box opens. Here all of the features that have been defined will be displayed. Click on the feature you want to define as a reference. Click on OK to transfer the reference to the definition template. Repeat this step as often as necessary until all the references you need have been defined. 5 If you want to fit actual values to nominal positions as part of alignment: Click in the field you want to change.
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Define the position in the columns headed Nominal X, Nominal Y and Nominal Z. Repeat this step as often as necessary to define specified positions for other features. 6 The next step in RPS alignment is to define the fixation direction for each feature you selected: Click on the X, Y or Z check box, as appropriate, to select the fixation direction. Repeat this step for each feature in the list until all fixation directions have been defined. 7 If (during alignment with 3d Best Fit) you want to perform the best fit on the CAD model, activate the Best fit on CAD model check box. Qualification is then a three-step procedure: The actual points are fitted in the conjugated nominal points according to Gauss. The perpendicular base points of the fitted actual points on the CAD model are calculated. The actual points are fitted in the conjugated perpendicular base points according to Gauss. 8 Select the alignment method to be used in the CNC run (for more information, see Definition template (coordinate system) in the Calypso Online Help). 9 If you are ready to execute the alignment you just defined, click on the Execute manual run now button. Calypso will guide you through the alignment procedure and prompt you to take probings (see Basics about manual control on page 8-12). 10 Click on OK. The dialog box is closed and the coordinate system is saved. See also Loops for alignment to RPS on page 15-26.
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The rotary table is a fourth axis for the CMM and thus contributes to the expected measuring uncertainty. For an accuracy estimate in the case of features measured with the rotary table, the permitted fouraxis deviation of the CMM must always be used. In particular, the quality of the qualification of the rotary table axis has a strong influence on the accuracy that can be achieved. For this reason, you should proceed with great care (see Qualifying the rotary table axis).
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Exact mechanical alignment is not required, as minor angle errors can be compensated for in calculation. To enable Calypso to make measurements with the rotary table and to evaluate, the rotary table must be logged into Calypso and, besides this, a mobile rotary table must be connected to the control unit. To log in the rotary table: 1 Select Extras Workroom CMM and open in the CMM Configuration notebook the Rotary Table page.
2 Select the rotary table type. 3 Activate the Connect rotary table with control check box for a mobile rotary table. 4 Activate the Release rotary table functionalitycheck box. The rotary table illustration is no longer crossed off.
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5 Click on RT Reference Point. The rotary table rotates into the starting position and resets the reference point. 6 Click on Accept and then click on OK to confirm. The CMM Configuration notebook is closed. After the login and the enabling of the rotary table, two additional icons appear in the Calypso user desk: The Rotary Table icon in the prerequisites The RT travel commands symbol in the toolbar. You can now use the functionality of the rotary table.
3 Select the corresponding circle from the list and confirm with OK. Calypso now knows the rough position of the rotary table in the measuring range of the CMM. This is required for later automatic qualification of the rotary table axis.
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Setting the RT position is only necessary after mechanical movement of a mobile rotary table or first use of the rotary table with Calypso.
RT homing
In the same way as the three linear axes of the CMM (X, Y, Z), the rotary table also has a home position. This is automatically reached after every homing of the CMM. However, it can also be reached in measuring operation manually or automatically. In contrast to the linear axes, the rotary table has no mechanical limit stop. During homing, the zero marking on the scale is reached by the shortest path and the counter is set to zero. The maximum rotation angle on the rotary table is not restricted by a mechanical limit stop either; it is restricted by the memory of the counter. Depending on the type of rotary table, 10 to .... revolutions are possible. It therefore makes sense to run an automatic RT homing prior to each CNC run.
In Calypso, use the RT travel commands window. 1 Select Resources RT travel commands or click on the RT travel commands icon in the toolbar. The RT travel commands dialog box appears on the screen.
2 To move to a certain absolute position: In the Rotate to field, enter the desired angle position and click on the Rotate to button. 3 To execute a relative angle increment: In the Rotate by field, enter the desired angle increment and click on the Rotate by button.
Manual positioning
You can also use the joystick of the control console to move the rotary table. 1 To do so, hold down the button in the left joystick and move it to the left or right.
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2 To display the position you have reached, click on the Read button.
Entering patterns
Via File Current status of RT axis, you can also enter increments.
1 Enter the pattern number in the input field. Calypso uses this to calculate the required incremental angle and displays this in the field below. 2 Use the + and buttons to set which feature the pattern is to be positioned on. The required angle position is displayed in the Rotate to field. 3 Position the rotary table by clicking on Rotate to according to the displayed angle position.
Example
As an example, there is a cog with 25 teeth, and its 6th tooth is to be measured. 360/25 = 14.4 6x14.4= 86.4 Enter 25 as the pattern number, click six times on + and then on the Rotate to button. The rotary table positions itself to 86.4 and thus to the sixth tooth.
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When the rotary table rotates, all features, characteristics and coordinate systems are turned around the RT axis. Errors in qualifying the RT axis thus have an immediate effect on the measurement accuracy.
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Regularly, depending on accuracy requirements and ambient temperature: In general, for each stylus qualification, the rotary table axis should also be requalified. In the case of strong temperature fluctuations, it frequently makes sense to requalify the rotary table axis prior to every workpiece measurement.
2-sphere method
The RT axis is qualified over the entire height of the workpiece. This compensates for residual perpendicularity errors of the CMM and they have less of an effect on the measurement inaccuracy. Measurement can be run with master styli.
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Advantages
Disadvantages
Measurement cylinder required. The RT axis is qualified over the entire height of the cylinder. This Master stylus can not be used. compensates for residual perpendicularity errors of the CMM and they have less of an effect on the measuring uncertainty. Short measurement period Simple attachment; the cylinder is fastened to the rotary table in a way that can reproduced at any time. Very fast method. Measurement can be run with master styli. All measurements are carried out in the same Z height of the CMM. Residual perpendicularity errors of the CMM can lead to serious measurement errors in the case of measurements at other Z heights. Depending on the position of the rotary table in the measuring range, it might occur that the complete rotation range is not covered.
Self-centering method
Accordingly, these methods are suitable for different applications: Method 1-sphere method Application Standard method for relatively low accuracy requirements. Ideal for flat workpieces with large diameters (e.g. ring gears). The highest accuracy is achieved if the workpiece is located at approximately the same measurement height as the sphere was for determination of the axis. For tall workpieces. For tall workpieces. This method can also be used for the measurement of shafts with low deviations in shape. Instead of using a measurement cylinder, the rotary table axis is set directly on the workpiece prior to each run. Use in proximity to production The feature for qualifying the rotary table axis can be secured directly onto the workpiece palette. This makes it possible to requalify the rotary table axis prior to every workpiece measurement without wasting a great deal of time. These four methods are described below.
Self-centering method
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To qualify the rotary table axis with the 1-sphere method: 1 Secure the reference sphere onto the rotary table top, as far to the outside as possible. 2 Use the master stylus or another qualified stylus. 3 Open a new measurement plan.
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An RT axis measurement plan is supplied with Calypso that corresponds to the procedure described below.
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4 Select Resources Prepare rotary table or click on the Rotary Table button in the list of Prerequisites. The Rotary Table dialog box appears on the screen.
5 Tick the RT activated for this Meas. Plan check box. 6 Click on RT home position to move the rotary table to its home position. 7 Select Measure RT axis. This specifies that the RT axis is qualified with this measurement plan. 8 Click on OK to confirm. You receive the following message:
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9 Click OK to confirm the message. 10 Measure the reference sphere with 6 points. Make sure that the Base alignment does not rotate with RT entry is selected in the definition template of the sphere under Nominal Definition. 11 Use this sphere to form a base alignment. 12 Open the definition template for the sphere and use Nominal Definition Pattern Rotational pattern to place a loop over the sphere. 13 Enter 0/0/0 for the Center. The coordinates of the sphere are required here. As this sphere sets the base alignment, the coordinates are 0/0/0. 14 Under Angle increment, enter the desired value (e.g. 60) and under Real number the matching number of sphere measurements (e.g. 6). 15 Select Turn rotary table and confirm with OK. (This means the base alignment can no longer be run.) 16 In the toolbox or via Measure, select a circle and a plane. 17 Under Nominal Definition, select Recall at the two features. 18 For the circle and the plane, select all spheres in the loop. 19 Link the circle and the plane into a perpendicular. 20 Select Resources Prepare rotary table or click on the Rotary Table button in the list of prerequisites. The Rotary Table dialog box appears on the screen. 21 Click on the square Feature for RT axis button and select the perpendicular in the list. 22 Click on OK to confirm your input. A message appears on the screen. 23 Click on YES to confirm. 24 Define the clearance planes for the sphere. 25 Start the CNC run. You can either select all features and set the current selection as measurement scope, or you create features by, for example, specifying tolerances for the angles of the perpendicular. After the CNC run, the RT axis is qualified and saved on the computer (not in the measurement plan). This RT axis can now be used for workpiece measurements.
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CMM
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To qualify the rotary table axis with the 2-sphere method: 1 Secure the reference spheres onto the rotary table top at different heights, as far to the outside as possible. The different heights should approximately represent the size of the workpiece to be measured. 2 Use the master stylus or another qualified stylus. 3 Open a new measurement plan.
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4 Select Resources Prepare rotary table or click on the Rotary Table button in the list of Prerequisites. The Rotary Table dialog box appears on the screen.
5 Tick the RT activated for this Meas. Plan check box. 6 Click on RT home position to move the rotary table to its home position. 7 Select Measure RT axis. This specifies that the RT axis is qualified with this measurement plan. 8 Click on OK to close the screen. You receive the following message:
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9 Confirm with OK. 10 Measure the two spheres manually with 6 points each.
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Make sure that the Base alignment does not rotate with RT menu item is enabled in the definition template of the spheres under Nominal Definition. 11 Use the spheres to form a base alignment. In doing so, place the zero point in the upper sphere; use the lower sphere for the planar rotation. 12 Open the definition template for the upper sphere and use Nominal Definition Pattern Rotational pattern to place a loop over the sphere. 13 Enter 0/0/0 at Center. The coordinates of the sphere are required here. As this sphere sets the base alignment, the coordinates are 0/0/0. 14 Under Angle increment, enter the desired value (e.g. 60) and under Real number the matching number of sphere measurements (e.g. 6). 15 Select Turn rotary table and confirm with OK. 16 Repeat step 12 for the lower sphere. However, 0/0/0 must not be set under Center, rather the actual coordinates of the spheres in the base alignment. 17 In the toolbox or via Measure, select a cone. 18 Under Nominal Definition, select Recall. 19 Select all spheres in the loops. 20 Select Resources Prepare RT or click on the Rotary Table button in the list of prerequisites. The Rotary Table dialog box appears on the screen. 21 Click on the square Feature for RT axis button and select the cone in the list. 22 Click on OK to confirm your input. A message appears on the screen. 23 Click on YES to confirm. 24 Define the clearance planes for the upper sphere. 25 Start the CNC run. You can either select all the features and set the current selection as the measurement scope, or you create features by, for example, specifying tolerances for the angles of the cone.
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After the CNC run, the RT axis is qualified and saved on the computer (not in the measurement plan). This RT axis can now be used for workpiece measurements.
Qualifying the rotary table axis using the measurement cylinder method
In the measurement cylinder method, the rotary table axis is qualified using a measurement cylinder with an exact shape in two rotary table positions.
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To qualify the rotary table axis using the measurement cylinder method: 1 Secure the measurement cylinder onto the rotary table top using, for example, 3-jaw clamps). 2 Insert a qualified stylus that you can use to probe the cylinder as far towards the top and bottom as possible. 3 Open a new measurement plan.
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4 Select Resources Prepare rotary table or click on the Rotary Table button in the list of Prerequisites. The Rotary Table dialog box appears on the screen.
5 Tick the RT activated for this Meas. Plan check box. 6 Click on RT home position to move the rotary table to its home position. 7 Select Measure RT axis. This specifies that the RT axis is qualified with this measurement plan. 8 Click on OK to close the screen. You receive the following message:
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9 Confirm with OK. 10 Measure the cylinder manually in 2 sections that are as far apart as possible.
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In doing so, make sure that the Base alignment does not rotate with RT menu item is enabled in the definition template of the cylinder under Nominal Definition. 11 Open the definition template for the cylinder and use Nominal Definition Pattern Rotational pattern to place a loop over the cylinder. 12 Enter 0/0/0 at Center. 13 Under Angle increment, enter 180 and under Real number 2. -->translation follows! 14 Select Turn rotary table and confirm with OK. 15 Probe a point on the measurement cylinder from above. 16 Using the cylinder and the point, set the base alignment.
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Make sure that you only use the first cylinder in the loop (Cylinder1(1)) for the base alignment. 17 Link the two cylinders into a symmetry cylinder. 18 Select Resources Prepare RT or click on the Rotary Table button in the list of prerequisites. The Rotary Table dialog box appears on the screen. 19 Click on the square Element for RT axis button and select the symmetry cylinder in the list. 20 Enable the Rotationally symmetrical part near RT center and Retract to current side check boxes. 21 Click on OK to confirm your input. A message appears on the screen. 22 Click on YES to confirm. 23 Define the clearance planes for the cylinder. 24 Start the CNC run. You can either select all the features and set the current selection as measurement scope, or you create features by, for example, specifying tolerances for the angles of the symmetry cylinder. After the CNC run, the RT axis is qualified and saved on the computer (not in the measurement plan). This RT axis can now be used for workpiece measurements.
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If your CMM is equipped with a scanning probe, you should record the cylinder using scanning paths instead of discrete-point measurement (see Scanning). This leads to more stable results and thus more exact rotary table measurements.
How to qualify the rotary table axis using the selfcentering method
In the case of the self-centering method, the rotary table axis is qualified by means of self-centering probing of an entity (hole, cone, triple cone, etc.) in a number of rotary table positions (usually 6). To qualify the rotary table axis using the self-centering method: 1 Secure the entity to be measured onto the rotary table top as far to the outside as possible. 2 Use the master stylus or another qualified stylus. 3 Open a new measurement plan. 4 Select Resources Prepare rotary table or click on the Rotary Table button in the list of Prerequisites. The Rotary Table dialog box appears on the screen.
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6 Click on RT home position to move the rotary table to its home position. 7 Select Measure RT axis. This specifies that the RT axis is qualified with this measurement plan. 8 Click on OK to close the screen. You receive the following message:
9 Confirm with OK. 10 Select Resources Probe Self Centering. 11 Set the values shown above and confirm with OK. 12 Probe the entity from Z.
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In doing so, make sure that the Base alignment does not rotate with RT menu item is enabled in the definition template of the point under Nominal Definition. 13 Use this point to form a base alignment. 14 Open the definition template of the point and use Nominal Definition Pattern Rotational pattern to place a loop over the point. 15 Enter 0/0/0 at Center. The coordinates of the point are required here. As this point sets the base alignment, the coordinates are 0/0/0. 16 Under Angle increment, enter the desired value (e.g. 60) and under Real number the matching number of sphere measurements (e.g. 6). 17 Select Turn rotary table and confirm with OK. 18 In the toolbox or via Measure, select a circle and a plane. 19 Under Nominal Definition, select Recall at the two features. 20 For the circle and the plane, select all points in the loop. 21 Link the circle and the plane into a perpendicular.
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22 Select Resources Prepare rotary table or click on the Rotary Table button in the list of prerequisites. The Rotary Table dialog box appears on the screen. 23 Click on the square Feature for RT axis button and select the perpendicular in the list. 24 Click on OK to confirm your input. A message appears on the screen. 25 Click on YES to confirm. 26 Define the clearance planes. 27 Start the CNC run. You can either select all features and set the current selection as measurement scope, or you create features by, for example, specifying tolerances for the angles of the perpendicular. After the CNC run, the RT axis is qualified and saved on the computer (not in the measurement plan). This RT axis can now be used for workpiece measurements.
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measurement plan for qualifying the rotary table axis on page 4-101). The workpiece does not permit direct qualification of the rotary table axis, because it only contains features that are not suitable for setting the rotary table axis (prismatic parts, flat turned parts, shafts with major defects in shape). In this case, select the Load existing RT axis option in the Rotary Table window. A requirement here is that the RT axis has been qualified beforehand with a corresponding measurement plan (see Qualifying the rotary table axis on page 4-86).
How to import a measurement plan for qualifying the rotary table axis
If a workpiece permits direct qualification of the rotary table axis and you want to use an existing measurement plan to qualify the axis, you can import this measurement plan into the current measurement plan for the workpiece concerned.
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The imported measurement plan must have the same base alignment as the current measurement plan. To import a measurement plan to qualify the rotary table axis: 1 Click on the Rotary Table button in the list of prerequisites and click on the Import Measurement Plan button in the Rotary Table window. 2 Select the measurement plan that is suitable for the axis qualification. Groups with the features of the imported measurement plan are inserted in both the list of features as well as the list of characteristics.
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Mode: Current mode: measure workpiece or qualify RT axis. Date RT axis: Date and time of the last axis setting as well as position and orientation of the rotary table axis in the machine coordinate system. RT pos absolute: Current counter status of the rotary table. It is set to zero with RT home position, not with Set RT position to zero. Wobble angle and Eccentric specify the position of the current base alignment in relation to the rotary table axis. The Angle to main axis is the tilt of the base alignment in relation to the machine coordinate system. Presetting for new features: The mode used to record new features is displayed here.
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6 Click on Set RT position to zero. The current position of the rotary table is set to zero. All other RT positions in this measurement plan now refer to this home position.
The RT does not move to the home position immediately, only when the CNC starts. 3 To mechanically align the workpiece for the CNC run, enable the corresponding check box. In this case, after setting the base alignment, the rotary table is positioned in the CNC run in such a way that the axes of the base alignment run parallel to the CMM axes.
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With the aid of the drift correction, measuring errors caused by a drifting rotary table are avoided because the base alignment rotates along with the rotary table. Calypso does not use the nominal position of the rotary table for this, but the very precisely measured rotation angle of the rotary table.
When measuring a workpiece on a passive rotary table, the following prerequisites apply: The RT axis of the rotary table is qualified. The drift correction is switched on.
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If you use features later in the base alignment, reset the RT position of the rotary table to zero.
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Important When you reset the base alignment of the rotary table to zero, the relationship to previous results is lost for all further measurements. For this reason, set the base alignment of the rotary table to zero before beginning with measuring.
RT clearance planes
A few particularities are involved for the clearance planes when a rotary table is used in a measurement plan. As soon as the rotary table is active, additional new clearance planes and clearance groups are available for the features. The designations of these clearance planes are composed of RTSE or RTG and an axial direction. If you use the rotary table with rotationally symmetrical objects such that the workpiece is always measured from the same direction (direction of the CMM) as the rotary table is turned, it is recommended to use these RT clearance planes (RTSE...) or RT clearance groups (RTG...). If you use the usual clearance plane (SE), bear in mind that this clearance plane is linked to the base alignment. In other words, it rotates about the rotary table axis together with the workpiece (see illustration). The RT clearance planes or -groups do not rotate with the base alignment (and thus the workpiece) but are fixed instead. The position of the RT clearance planes is referred to the unrotated base alignment at a RT position of 0 degrees (see illustration).
RT position 0 degree RT position 45 degree
Y
0 Probing direction Probing direction SE +X
SE +X RTSE +X
RTSE +X
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In order to enter, check or change the RT position for the measurement of a feature, open the definition template of the feature, click on the Strategy button and double-click to open the Clearance Data.
The RT position input field is contained in the Clearance Data dialog box.
Base Alignment rotating / not rotating
Open the definition template of the feature to set Base Alignment rotating / not rotating. To switch off rotation of the base alignment, select the BA not rotating with RT entry under Nominal Definition. This setting is suitable for defining the RT axis. To switch on rotation of the base alignment, select the Nominal Input entry under Nominal Definition. This setting is suitable for measuring the workpiece.
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For this purpose, choose the RT position or Base alignment rotating with RT entry in the menu.
After you have marked the desired feature, enter any angle in the Set to box or select one of the default incremental angles. Select On or Off for base alignment rotating.
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Only the first RT position is displayed in the clearance data as well as in the Measurement Plan Editor Features.
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Center of symmetry
If you wish to measure one or several workpieces with rotational pattern, you can use the rotary table for this purpose. If this procedure is used, the rotary table always moves in several phases to a position in which the respective feature (or workpiece) is probed from the same direction.
Rotate rotary table as well
In order to use the rotary table for the rotational pattern, select the Rotate rotary table as well option in the Rotary pattern dialog box. An RT clearance plane that defines the direction for probing the workpiece is to be selected as the clearance plane.
Clearance planes
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A particularity arises from the different reference systems for angles on the workpiece and the angle specification for the RT position (see illustration).
270
90
180
0 270
Rotary table 90
Workpiece
270
90
180
180
0 270
Probing direction
Workpiece 90
Rotary table
If the rotary table (e.g. with a quadrant pattern) is to measure a part feature that is at an angle of 90 on the workpiece, the rotary table must rotate in the opposite direction, i.e. to the RT position 270.
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Clearance planes
Names of the clearance planes
The names of the clearance planes, of which the safety cube is composed, begin with the abbreviation SE, followed by the direction to be protected. For example, SE +X. The names of clearance planes that are additionally defined when a rotary table is used consist of the abbreviation RTSE and the direction to be protected. For example, RTSE +X. Do not make the clearance planes unnecessarily large, because in some cases this could lead to unfavorable routing or even collisions.
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Important Any time the part alignment is changed such that a new origin or axis alignment is defined, you must redefine the clearance planes. Failure to do so may result in collisions with the part. The preconditions that have to be satisfied before you can define the clearance planes are as follows: All styli of the current stylus system must be qualified. See How to qualify a stylus manually on page 4-29. The size of the probe must be defined in the system setup under Extras Workroom CMM (on the Probe page).
Prerequisites
Method
There are various methods for defining the clearance planes: You can define the Corners of the cube with the CMM. You can type in the X, Y and Z locations of the corners manually. If you do not have a CMM position (or I-POS) button on your CMM control console (which allows you to record the current position of the stylus), then you can use the CMM to probe the outside edges of the part itself as its clearance planes.
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If you use a CAD model, you can generate the clearance planes automatically. All you have to do is tell Calypso how far you want the clearance planes to be from the workpiece. These methods are described in the following sections.
Blocking edges
Blocking edges is a way of further restricting stylus travel without the need to change the size of the clearance planes. This can be useful, for example, if you have two or more workpieces positioned on the table or the design of the clamping device is such that it could cause a collision at an edge. The new route is calculated automatically. See How to block edges of the clearance plane on page 4-118.
(1)
(2)
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4 Press the position button on the right-hand joystick three times to save the current position. 5 Move the CMM to a position approximately 10 millimeters outside the opposing diagonal (bottom front left corner) of the workpiece (position 2): 6 Press the position button on the right-hand joystick three times to save the current position. 7 Click on OK to accept these values. The Update Clearance Plane Settings For Defined Features? message is displayed. 8 Click on YES if you want to update the clearance planes for all defined features, or on NO if you want to retain the original clearance planes. You will find more information on updating clearance planes in Clearance planes in the Calypso Online Help. The Clearance Planes button is now green.
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z y x
(2)
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Important The clearance planes generated by this strategy are very close to the workpiece. In order to avoid the risk of damaging a stylus, you should set a clearance distance of at least 10 mm (see How to move the approach position closer to the feature on page 7-40). To define the corners of the clearance planes: 1 In the list of Prerequisites, click on the Clearance Planes button. The Clearance Planes window is opened. 2 Under Alignment, select the reference alignment for the coordinates. The side areas of the safety cube are aligned according to this reference alignment. 3 Define the first corner (1). You do this by probing the workpiece in Z, X and Y, consecutively. Calypso automatically enters the values in each field in turn and highlights the next field so that you can determine the value by probing.
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If a corner is inaccessible, you can move to the corresponding position on the clearance plane, select the stylus, highlight the appropriate input field and use the intermediate position. 4 Define the second corner (2). The procedure is the same as in step 2, but you probe in the opposite direction. 5 Click on OK to accept these values. The Update Clearance Plane Settings For Defined Features? message is displayed.
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6 Click on YES if you want to update the clearance planes for all defined features, or on NO if you want to retain the original clearance planes. You will find more information on updating clearance planes in Clearance planes in the Calypso Online Help. The Clearance Planes button is now green.
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Important Check that you have defined all the clearance planes (depending on the geometry of the workpiece, the CMM might not be able to reach each plane directly). When you are ready to test drive to a clearance plane: 1 In the list of Prerequisites, click on the Clearance Planes button. The Clearance planes window will open. 2 Highlight the clearance plane of your choice (e.g. +Z) by clicking in the appropriate input field. 3 Click on Test Drive To The Selected Clearance Plane. The CMM moves to the clearance plane.
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Important The stylus will always first travel out in the direction of the +Z axis, before the CMM moves in the selected direction (e.g. +X). 4 If necessary redefine the value. 5 Select, if necessary, the Coordinate system again. The side areas of the safety cube are aligned according to this reference alignment. 6 Click on OK to accept these values. The Update Clearance Plane Settings For Defined Features? message is displayed. 7 Click on YES if you want to update the clearance planes for all defined features, or on NO if you want to retain the original clearance planes. You will find more information on updating clearance planes in Clearance planes in the Calypso Online Help.
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To block edges: 1 Select Plan Navigation Block Edges. The Blocking edges window will open.
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The bottom edges (the edges of the face on the table) are always blocked. The -Y or +Y edge is also blocked if the measuring machine is of the horizontal-arm type. You cannot revoke these settings. 2 Tick the check boxes for the edges you want to block. 3 Click on OK. The edges you selected are blocked with immediate effect.
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You can view and edit settings for the entire measurement plan or for individual features. You will find more information on the Features representation dialog box in the Calypso Online Help.
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2 To open the settings for a single feature: Mark the entry in the list of features and select Resources Feature representation. The Features representation window will open. It shows the default output settings for the available features (or for the feature you marked in the list, as applicable). Be sure to check all settings at the global radio buttons Position, Angle and Size. 3 If you want to change the setting for a feature, open the picklist of the feature in question in the Mode column and select Change. This activates the radio buttons on the right-hand side of the window. 4 Make all the necessary changes. 5 Repeat steps 3 and 4 until you have made all your changes. 6 Click on OK. The settings are saved and the window is closed. This dialog box is fully described in Features representation in the Calypso Online Help.
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Use this editor to check and, if necessary, change settings for features. The settings in question are primarily those relating to clearances in a CNC run. For more information, see Measurement plan editor features in the Calypso Online Help.
Use this editor to regulate how characteristics are output in the custom printout and define whether characteristics are to be executed in the CNC run. For more information, see Measurement plan editor characteristics in the Calypso Online Help.
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Temperature compensation
Temperature compensation
You can configure Calypso to consider the temperature-related expansion/contraction of the workpiece and the X, Y and Z scales of the CMM when taking the measurements. Additionally, you may establish temperature limits that trigger a warning when going above or below the limits at the start of the CNC run. The Temperature compensation is of great significance for precision of the measurements, since the nominal values are generally based on a workpiece and ambient temperature of 20 C, and the different materials expand/contract to different degrees as the temperature varies. Therefore, the expansion/contraction must be compensated in accordance with the respective material, if the workpiece cannot be brought to the reference temperature. Calypso receives the information about the temperature, depending on your CMM's equipment, from sensors on the scales or temperature sensors on the workpiece, through probing with a temperature probe or simply manually entering the temperature value. In any case, you must enter the coefficients of expansion for the workpiece materials directly. Most manuals on materials science give the coefficients of expansion. The following table shows the coefficients of expansion of certain usual materials: Material Aluminum (2024-T3) Aluminum (6061-T6) Aluminum (7079-T6) Cast iron Copper Magnesium (HK31A-H24) Nickel Steel (AISI C1020) Steel (AISI 304) Carbon steel Titanium (B 120VCA) Coefficient micrometers/C) 22.7 24.3 24.7 11.7 16.6 25.2 13.0 15.1 17.8 11.3 9.4
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Since the coefficient of expansion depends on the alloy, the values may vary slightly from one table to another. Differences in temperature above and below the granite plate of a CMM can cause a slight curvature of the plate. In high-precision CMMs, the thermal plate bending effect is also compensated. The compensation for thermal plate bending of the measuring table is automatically activated as soon as Calypso calculates the temperature compensation for the CMM scales. In this case, the plate will be simulated by a beam model.
If you use multiple materials to manufacture the same part, for example a cast-iron version and an aluminum version, you have two options: Create two measurement plans that are identical except for the coefficients of expansion for temperature compensation. Use the same measurement plan for both versions, but always remember to enter the coefficient of expansion for the respective material before starting a new series.
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2 To activate temperature compensation, tick the Temperature Compensation on/off check box. The Temperature probing on/off check box will now appear in the window. 3 Set under Workpiece temperature of sensor which temperature sensor should determine the workpiece temperature. 4 Under Workpiece, click in the Coefficient input field and enter the applicable coefficient of expansion for the workpiece. 5 Activate the Warning if workpiece temperature falls above ... or below ... check box if such a warning should be displayed at CNC Start, and enter the upper and lower limits for the temperature.
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6 Activate the Warning, if the difference between workpiece temperature and qualification temperature of the stylus used is greater than ... check box if such a warning should be displayed at CNC Start, and enter the maximum admissible difference. 7 Click on OK to confirm. Once you have activated temperature compensation, this means the following: If your CMM has automatic temperature sensors, the measured temperatures will be used automatically to correct the measurements. If your CMM does not have automatic temperature sensors, Calypso will automatically display the Temperature Compensation window before you run a measurement plan. You can then perform or configure a temperature probing or enter the measured temperatures yourself.
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Temperature compensation
5 Probe the workpiece with the temperature stylus. In a temperature measurement, the probe travels until it detects contact with the workpiece and then another 3 mm against the measuring force. After the first probing, an entry called Temperature probing will appear in the list of features. 6 Probe other points on the workpiece. After each probing, the temperature and the location of the point will be determined and displayed. The data regarding the location of the points will be stored in the technology list for the Temperature probing feature. This can be edited (How to configure automatic temperature probing (CNC) on page 4-127). The measured temperatures will be determined and displayed in the Temperature Compensation window. 7 Click on OK to confirm. Calypso calculates the average of all of the measured temperatures and enters this value in the Temperature Compensation window. This value will be used (instead of the temperature from any possibly present temperature sensor) for the temperature compensation for the workpiece. All of the measured temperatures and the calculated average will be included in the printed work listing.
If automatic temperature probing is enabled (How to activate temperature compensation on page 4-125), Calypso will begin probing the appropriate points on the workpiece with the temperature stylus at the start of the CNC run (in other words before the CNC alignment) and will thus determine the temperature of the workpiece to a high degree of precision. The simplest way to add a Temperature probing feature to the measurement plan is to perform a manual temperature probing (How to determine the temperatures by manual probing on page 4-126). A Temperature probing entry with the probed points will be automatically added to the list of features.
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The Temperature probing feature added to the measurement plan can be edited like any other feature; for example, you can change the point probed if necessary. You can also copy or delete it. In this manner, you can add several temperature probed points to a measurement plan.
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At the beginning of a CNC run, the system will only perform the Temperature probing feature that is entered under Feature in the Temperature Compensation window. How to configure the temperature probing in a measurement plan: 1 Click on the Temperature Compensation button. The Temperature Compensation dialog box appears on the screen. 2 Tick Temperature Compensation on/off, followed by the Temperature probing on/off check box as well (if the temperature stylus has already been selected, both check boxes are ticked automatically). The Probe with temperature sensor at one or several workpiece points! prompt will appear. 3 Cancel and click on the Switch to feature menu button next to Feature. The Selection window will open. In contrast to the usual window for selecting features, this one only lists the Temperature probing features for selection. (If the measurement plan does not yet contain any Temperature probing features, the New option will be preset and the Edit check box will be ticked.)
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4 To activate the desired Temperature probing feature, select it and confirm with OK. The selected feature will now be shown under Featurein the Temperature Compensation window. 5 To edit a specific Temperature probing feature, select it, tick the Edit check box and confirm with OK. The definition template for the Temperature probing feature will open and you can begin editing.
To define the probing strategy, click on the Strategy button and specify the probing method in the Strategy window. Here you can define a list of points, preset probing and intermediate points, define CMM steps with and without probing and insert programmed stops. Furthermore, you can edit the Clearance data. With OK, you will be returned to the definition template 6 Confirm the changes with OK. The selected and edited Temperature probing feature appears under Feature in the Temperature Compensation window.
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At the start of the CNC run, the temperature probing is conducted automatically in accordance with the selected feature. After the measurement, Calypso calculates the average of all of the measured temperatures and enters this value in the Temperature Compensation window. This value will then be used (instead of the temperature from any possibly present temperature sensor) for the temperature compensation for the workpiece. If you have enabled the issuing of a warning when the workpiece temperature limits have been exceeded, a warning will be issued accordingly before the run begins. You may decide either to cancel or to continue the run. If you have enabled the issuing of a warning when the difference between the qualification temperature and the current stylus temperature is exceeded, a warning will be issued accordingly before the run begins. You may decide either to cancel or to continue the run.
Printout
All of the measured temperatures and the calculated average will be included in the printed work listing.
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Important While the measurement plan is running, you cannot change the temperature values. If your CMM does not have automatic temperature sensors and you do not conduct a temperature probing, you must activate the temperature compensation before starting the measurement plan. At this point, it would be convenient to go ahead an enter the actual temperatures manually. To enter the temperatures manually:
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Temperature compensation
1 Click on the Temperature Compensation button. The Temperature Compensation dialog box appears on the screen.
2 Tick the Temperature Compensation on/off check box. 3 If the workpiece temperature is not exactly 20 C, click in the Temperature input field under Workpiece and enter the actual temperature (e.g. the temperature of the room in which the workpiece was stored). 4 If the workpiece is made of a material with a expansion coefficient different from the one specified, click in the Coefficient input field under Workpiece and enter the correct coefficient of expansion for the workpiece. 5 If the temperature in the room which contains the CMM is not exactly 20 C (68 F), click on the Scales fields and enter the temperatures from the X, Y and Z scales. (The coefficients of expansion for the scales are already known to Calypso.) The compensation values are calculated automatically and displayed. 6 Confirm the changes with OK.
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Chapter
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Defining features
Together with the prerequisites, the features and the characteristics form the framework of the measurement plan. There are three ways of defining features. You can probe the workpiece manually and determine the geometry via the automatic feature recognition. Alternatively, you can define the nominal values manually by taking the data from a technical drawing or the CAD model or importing it from a file. You can also use patterns for regularly arranged features. To define geometric objects that cannot be probed, you must interlink the features. The measurement strategy is defined together with the feature, in other words the sequence and the type of probings is defined.
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Defining features
Defining features
What is a feature?
A feature is a regular geometric element, or an element that is defined in a different manner, that is to be measured by the CMM. Features contain the nominal geometry, which is used for the purpose of evaluating the size, shape and position. The features are assigned to the associated characteristics. The various methods for defining features in general are listed below. Details on the individual features (e.g. how many probing points does a cone need?) can be found in Details on definition of the features on page 5-20. Features must be defined before Calypso can work with them. There are several ways to do this. The alternative that is selected will depend on the measuring job you wish to perform with Calypso. How to define features using automatic feature recognition on page 5-7. Use Calypso's automatic feature recognition and probe the feature with the CMM directly on the workpiece. Calypso will recognize the geometry of the probed feature and will fill the appropriate definition template. This procedure is recommended in most cases. If necessary, you can deactivate the automatic feature recognition for each feature type (How to define the automatic feature recognition on page 5-7). How to define a feature using definition templates on page 5-4. Enter a feature into the measurement plan first and then continue work with the definition template. This enables you to use the processing options for measured-value acquisition that are available in the definition tem-plate (e.g. scanning). This possibility is also quite useful if you have already devised a measurement plan or if programming is to be effected away from the machine. Importing features from CAD files on page 5-9. Import an existing CAD file and extract its features into your measurement plan. This possibility is also useful if you want to program away from the machine. In addition to the above-mentioned possibilities for defining the feature, you also have the option of defining a feature as a
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Defining features
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Defining features
construction as a constructed theoretical feature that cannot be probed by the CMM. A feature of this kind consists of features that have already been defined, e.g. an intersection of two features (see Linking features in constructions on page 5-50). Another way to define features is by DMIS import. If you have purchased this option, you can import runs programmed in DMIS to Calypso and thereby create a regular Calypso measurement plan with features (see Chapter 13 DMIS import (option) on page 13-1). You can use the Characteristic Input option to import features together with the characteristics from the ProE and UG CAD systems into Calypso if they are available in a given format (STEP file in the AP 203 or AP 214 format and ASCII data in the Q-DAS format, specification of WEPROM) (see Chapter 19 Characteristic input (option) on page 19-1).
Checking use
During your work, if you forget which features you assigned to which characteristic, you can check the usage of each feature with Calypso. Use the Check use of selected Features command which you can find in the context menu in the list of features. This opens a list of all characteristics associated with the feature in question. Details on the individual features (e.g. how many probing points does a cone need?) can be found in Details on definition of the features on page 5-20. In addition to the actual features, you can include special measurement plan elements in the list of features: Branch to GEAR PRO (Additional features Holos and Gear on page 5-43) HOLOS macros (Additional features Holos and Gear on page 5-43) XML files for Blade PRO (Turbine Blade additional feature on page 5-45) Macro measurement plans (Using macros in the measurement plan on page 7-18)
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Defining features
Change clearance groups. Change the mode for nominal value definition. Assign a different part alignment. Define characteristics and their tolerances. You will find more information under Definition template (feature) in the Calypso dialog reference in the Online Help. The appearance of the definition template in the Features window will depend on the features that have been selected. This illustration shows the definition template for the Plane feature as an example.
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To copy the feature into the measurement plan and then probe it: 1 Click on the Features button to view features in the measurement plan area. 2 Select the required feature in the Features submenu or under Features Additional features. The feature appears in the measurement plan. 3 Double-click on the feature to open its definition template. Calypso is ready to record measured values. 4 Probe the feature. The values that are determined by Calypso are automatically entered in the corresponding fields of the definition template. If you do not wish to probe a feature manually, Calypso can take care of this for you. See Path generation measuring features automatically on page 5-95.
Min. probings: 1 2 3 4 2 3 5 6 5 5 5
The automatic feature recognition is defined in the system setup. This is where you define the features for which automatic feature recognition is to be used (How to define the automatic feature recognition on page 5-7).
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This can be useful to exclude certain error codes or to define only certain features, for example, in optical measurements of bores where bores are just to be identified as circles.
Procedure
If you want to use the automatic feature recognition, simply probe the geometric element on your workpiece. Calypso enters the recognized feature in the list of features and opens the definition template (see How to define features using automatic feature recognition on page 5-7). The definition template offers you several options for working with the feature (see Definition template for features on page 5-3).
The automatic feature end is defined in the system setup. You can specify the number of probings. The default setting is as follows: Feature Point 2-D Line Plane Sphere Circle Cylinder Cone Ellipse Rectangle Slot Max. probings: 1 3 4 6 4 8 12 6 8 8
Procedure
When it probes, Calypso must know which feature you want to measure. Begin by adding the feature to the measurement plan, then open the definition template and take probings. The CMM will stop the measurements automatically when the specified number of measuring points for a particular feature have been taken.
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The notebook page for defining the automatic feature recognition is opened. Automatic feature recognition for all features is activated by default. 5 Deactivate the Allowed check box for each feature that you want to exclude from the automatic feature recognition. 6 Accept the settings with OK. Automatic feature recognition is thus configured for the entire measurement plan.
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Defining features
To define features using automatic feature recognition: 1 Click on the Features button to view features in the measurement plan area. (The features used for the definition of the base alignment should already be displayed.) 2 Select the stylus you want to use for probing, if the correct stylus is not already illuminated on the control console of the CMM. 3 Using the joysticks, move the stylus to the feature and probe the first point. Example: If the feature is a sloping plane on the side of a workpiece, move with the X/Y joystick over one corner of this plane and then probe in the Z axis. Once you have probed the point, Calypso will show the Point 1 feature in the template for the feature definition. (For detailed information on the features template, see How to define a feature using definition templates on page 5-4. 4 Probe the next point. Example: On a sloping plane, move over another corner of the plane and probe again in the Z axis. In the template, Calypso will update the feature to a 2-D line. 5 Probe the number of additional points required to define the feature in question (at least 3 points for a plane, for example; 5 points for a cylinder, and so on). Example: On a sloping plane, move to the remaining two corner points and probe each in the Z axis. Make sure that the points are not on the same line. (You should therefore move the stylus a little in the X and Y axes). Calypso recognizes the plane this way and displays it in the evaluation field. 6 If Calypso does not recognize the right feature, you can choose it manually from the features in the CAD Entities selection list.
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Important You cannot change the type of geometric element subsequently. 7 Click on OK to confirm your choice. You now have defined a feature to be measured on the workpiece (in addition to those already defined for the part alignment). To define additional features for this workpiece, repeat the same steps. When following this normal procedure, Calypso will automatically recognize which feature you wish to measure.
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Defining features
Calypso can convert CAD files with the following file name extensions: Extension .sat .exp .model .CATPart .prtxx, .prt .asm .igs .vda .dxf .stp .sldprt Creating program ACIS (standard) CATIA (optional) CATIA (optional) CATIA V (optional) Pro-E (optional) / Unigraphics (optional) Pro-E (optional) IGES (optional) VDAFS (optional) CAD systems such as AutoCAD and Caddy, etc. STEP (optional) Solid-Works
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When you load an .asm file, the individual parts must also be in the same directory. Calypso assembles the individual parts automatically to form a CAD model. Perform the following steps: Load a CAD file, define the parameters of the global measurement strategy (optional), and extract the features.
Procedure
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If you have loaded 2D data (e.g. from IGES, VDA or DXF format), you will have to define the third coordinate manually either by entering an offset in the Modify CAD Model dialog box or subsequently by changing the nominal geometry. (Only for Calypso older than version 3.8:) If you have a ProE or Unigraphics license, you are not permitted to change the hostname
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Defining features
and server code of the computer, as otherwise your license becomes invalid. If the license is lost, the interface no longer functions.
3 Select the CAD file of your choice and click on Open. The file will be loaded. If this is an .asm file of Pro-E, Calypso searches for the respective individual parts in the same file directory and combines these automatically to form a CAD model. If you are loading an IGES file, the progress of the data conversion will be shown in a window. The model will then be shown in the CAD window.
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When converting an IGES file, a log file with information on the converted features that are contained in the file will be created. Select CAD Logfile IGES to display this file. Once the model has appeared in the CAD window, you will be able to include the features in the measurement plan. You might want to edit the CAD file beforehand, refer to Working with the CAD window on page 3-1. You will find more information under Working with CAD data in the Online Help.
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2 Activate the check box of the feature for which you want to specify the parameters and then click on the Settings button. The appropriate strategy dialog box opens: 3 One after the other, double-click on each list entry for which you want to make strategy settings. Alternatively, you can select the entry and click on the magnifier . The appropriate definition dialog box opens. 4 Close each definition dialog box again by clicking on OK. 5 When you have finished defining the strategy, click OK.
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6 Repeat steps 2 to 5 for all other types of feature that you want to assign. As soon as you extract a solid geometry from the CAD model or extract a feature via the filter (using CAD Filter ...), Calypso assigns the strategies that you predefined to these features.
2 Select Edit Select All or highlight the individual features you want to insert into your measurement plan.
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Important Calypso assigns the stylus currently activated on the control console or via the CAD window to all features. 3 Click on Apply. The features are extracted and transferred to the measurement plan. This can take a few seconds to complete. 4 When transfer is completed, confirm by clicking on OK. You have now transferred the features defined in the CAD file to your measurement plan. You can edit the individual features in the usual way. Bear the following in mind: You must define the probing points if there are none defined in the strategy list of the feature. You can do this with the CMM or using only the CAD window (you will find more information in the Online Help under How to define a probing point in the CAD window). Calypso assigned all features to the same stylus. You will have to assign a more suitable stylus for some features, i.e. one with which the CMM can probe the features in question (see Editing a measurement plan on page 7-11).
How to import features from the CAD model to the measurement plan
You can import complete features from the CAD model displayed on the screen into the measurement plan. To do so, use the menu options from the Selection list on the CAD toolbar. 1 To import a plane, cylinder or cone into the measurement plan: Select Extract features from the menu. Click on the required feature in the CAD model The feature is highlighted and immediately added to the list of features. 2 To define a discrete point: Select Define a Space Point from the menu and click on the point of your choice on the surface of the CAD model. The point is now defined. 3 To define a line on a plane: Select Define Line on a Plane. Click on a point on the line you want to define.
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Use the mouse to drag the line. The line is shown on the screen. 4 To define two mutually opposite space points: Select Distance check. Click on a point on the model. The two space points and the connection between them are shown at the selected position on the screen. With the aid of these two points, you can check the wall thickness or the material deviation at the place in question, for example. 5 To define a circle on a cylinder: Select Define Circle on a Cylinder. Click on a point on the cylinder in question. The circle is shown at the corresponding level on the screen. 6 To define a probing point: Open the feature in question. Click on Strategy and select the appropriate stylus. Select Define Points. Click on the probing point of your choice on the surface of the CAD model. The probing point is now defined.
Patterns are not permitted for the following features: General curve General surface Curve 3D Curve All constructions
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Pattern procedure
Calypso supports regular and free pattern types. The available regular pattern types are linear and circular patterns: Circular patterns Polar Pattern Offset Rotational Pattern In the case of linear patterns, the feature is repeated at regular intervals along one or more axes. In the case of circular patterns, the feature is arranged with a certain angle offset around a centre. In the case of polar pattern offset, the local feature coordinate system keeps its orientation with respect to the workpiece coordinate system. In the case of a rotational pattern, the local feature coordinate system keeps its orientation with respect to the center of rotation. With free patterns, the additional positions of the feature can be freely defined. To do so, complete a position list in Calypso. Free patterns Pattern with position list
Pattern types
You can also work with pattern types. If you require a certain pattern type not only on one individual feature, define this pattern type with its parameters and save it under a new name. You can then use this pattern type for other features.
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Important If you edit a pattern type, all patterns that are based on this type will also be changed. If a pattern is defined, you can switch it on and off again via the context menu or via the Measurement Plan Editor Features.
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The pattern for a group can be defined and activated via the context menu or via the Measurement Plan Editor Features.
3 To use a new pattern, click on New, select the desired pattern type and click on OK. Enter the parameters in the corresponding dialog box. For more information, please see in the dialog reference in the Calypso Online Help under Polar pattern offset, 1-D Linear Pattern, 2-D Linear Pattern, Rotational pattern and Pattern with position list. By using a pattern, this will be entered automatically in the list of patterns with the name Patternx (x = , 1, 2, ...). You can rename the feature via the context menu. 4 To use an already existing pattern type, click on Selection of Pattern, select the desired pattern type and click on OK. For more information, please see in the dialog reference in the Calypso Online Help under Polar pattern offset, 1-D Linear Pattern, 2-D Linear Pattern, Rotational pattern and Pattern with position list.
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5 To edit an already existing pattern type, click on Selection of Pattern, select the desired pattern type and click on Edit and make your changes.
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2 Click on the Transfer format button in the upper toolbar. The Copy properties from <Feature_name> dialog box appears on the screen. All the check boxes are activated by default.
3 Deactivate the check boxes of the properties that you do not want to copy to other features. 4 Highlight the feature or features to which you want to copy the properties. Press and hold down the Shift or Ctrl key if you want to highlight more than one feature. 5 Click on OK. Copying is started.
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Defining features
When you define features, two basic rules apply to probing: Produce as large a measurement basis as possible. If, for example, you define the face of a cube as a plane, probe close to the corners of the workpiece. Probe as many points as possible (taking into account the time within which you want the CNC run to complete). This is particularly important when you record and evaluate shapes on a workpiece.
In most instances, Calypso can automatically identify the feature as an inside or outside feature from the probing direction. You also have the option of defining a feature as an inside or outside feature. However, always bear in mind that this affects the combination of the routes and the calculation of the tangential features. You define a feature as an inside or outside feature in its definition template by clicking on the Inside/Outside Feature button. The button indicates whether the inside feature or outside feature property is currently valid (illustration: inside feature on the left, outside feature on the right).
The measured value of a measurement sent to the CMM is always the center coordinates of the stylus tip. The coordinates of a measured value, therefore, always differ from those of the contact point the measured value you want at the time of measurement by the radius of the stylus tip.
probing direction
measured value
Calypso automatically corrects the measured value, so you always receive the coordinates of the actual contact point. There may be a residual error despite this correction, but you can usually prevent this.
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In the Tolerance For: group, you can immediately enter a tolerance for the corresponding nominal value if you activate a check box here. Calypso also automatically adds a characteristic to the measurement plan that checks the specified tolerance. If you activate the A (for angle) check box, you can freely select both the reference axis and the orientation for specification of the angle. One of eight possible angle symbols indicates which reference axis and orientation are currently valid. To change the set orientation of the angle, click on the button with the angle symbol and select the desired orientation in the Select angle format dialog box.
Point feature
Menu: Features Point Use the Point feature to determine the coordinates of individual points on the workpiece, in order to size the workpiece, for example.
Probing strategy
probing direction
To obtain the right correction for the stylus tip radius for normal vector directions which are non-parallel to the coordinate system, it is possible to switch to the space point procedure by clicking on Evaluation in the definition template. In case of an unknown normal vector direction, the correction will be automatically defined.
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Evaluation
Click on the Output button to open the Evaluation dialog box in which you can enter details relating to the conversion and correction of the measured values. Under Space Point Mode, you can now select the manner in which the point is to be calculated: Type of correction/conversion Radius correction in the direction of a coordinate system axis corresponding to the probing direction. Here, probing is effected in a coordinate axis direction; otherwise the radius correction will be effected in the direction of the coordinate axis which is closest to the probing direction. (default setting) Radius correction in normal vector direction. Radius correction in normal vector direction, followed by projection onto the normal of the nominal point. The radius (length of the tripod) used to measure the normal can be set using the Radius for space point normal measurement menu item in the Measurement Plan Editor Features. Radius correction in normal vector direction, followed by projection onto the coordinate system axis which corresponds to the reference axis of the nominal plane. No radius correction. This can be useful, for example, in the case of self-centering probing (see Alternative probing methods (self-centering probing) on page 5-88) between two teeth of a gear wheel in order to use this point for alignment (plane rotation).
Net Point
Midpoint
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The corrections that are made for the respective point type are shown in the diagram.
Probing direction
Nominal normal
Nominal contour
Actual normal
4 5 1 2 3
Actual conto
Nominal point 1 2 3 4 5 Touch Point Plane-Point Space Point Net Point Midpoint
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The contact point on the surface must always be entered as the nominal position for a point, regardless of the desired Space Point Mode.
Circle feature
Menu: Features Circle Using the Circle feature, you can probe bores, plugs and shafts with a circular cross section or workpiece parts with arcs. You can project the circle or arc onto any measured plane. Calypso uses the probed points to compute the circle or arc which best fits the probing points. The start angle and angle segment (for an arc) are specified in the definition template.
Probing strategy
The minimum number of points is 3. The probing points should be on a section perpendicular to the axis of the circle you want to measure. It is advisable to probe at least 4 points.
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Make sure that all the points you probe are at approximately the same height. If the height differences between the individual points are excessive, Calypso will compute a cylinder instead of a circle. If this happens, you can reconstruct a circle manually in the Geometry menu. The origin of the feature's local coordinate system is in the center of the measured circle (not in a projection plane of the coordinate system).
origin of LA
Gage correction qualification is a method by which you can determine the dynamic bending parameters for circles and cylinders occurring during measurement and correct them mathematically during further measurements. Gage correction qualification is only useful for scanning with a measuring probe.
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Plane feature
Menu: Features Plane Use the Plane feature to probe plane surfaces of the workpiece the position or inclination of which you want to determine. Calypso computes the plane from the points which you probe. In the definition template the computed length and width of the plane are displayed along with the coordinates of the probing points.
Probing strategy Automatic feature recognition
Probe at least 3 points. Take care to spread the points as evenly as possible over the plane. If the points are all in a line (an arc of minimal curvature), Calypso will compute a line instead of a plane. If this happens you can reconstruct a plane manually in the Geometry menu.
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Result output
This illustration shows the positions of the projected angles W1 and W2.
projection into the Z/X plane normal
spatial view Z
A1=0
plane
surface normal
example plane
A2
normal
plane Y
The origin of the feature's local coordinate system depends on the position of the plane relative to the axes of the coordinate system: Bottom left for a viewing position in +X, -Y and +Z. Bottom right for a viewing position in -X, +Y and -Z.
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The illustration below is an example showing how this applies to 5 planes of a cube.
Z Y X
The 2-D line can be defined and represented in two different ways: with X, Y and Z values for the start and end points of the line, with one point (X, Y, Z) of the line, the specified length and the projected angles W1 and W2. You can toggle between the two types of display in the Feature representation dialog box, which you can open from the prerequisites or via Resources Feature representation.
Probe at least two points (three are recommended, however). Make sure that all the probing points are roughly in line. Otherwise, Calypso will compute a plane instead of a line. If this happens, you can open the Geometry menu and regenerate the feature as a line.
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The origin of the feature's local coordinate system (FLCS) is at the first point on the line which defines the line fully when first registered in these examples points 1, 4 and point 3.
3
or
1
or
Result output
After measurement, the following results are output in the definition template and in the printout. Results X, Y, Z W1 (Z/X) Meaning Coordinates of the origin of the local coordinate system Projected angle 1. Projection in this case is in the X/Z plane; the reference axis is X. In the printout the projected angles are referenced to the position of the feature In the definition template the projected angles are referenced to the position of the feature's plane normal (the 2-D line corresponds to a reduced plane). W2 (Y/X) Projected angle 2. Projection in this case is in the X/Y plane, the reference axis is X. In the printout the projected angles are referenced to the position of the feature In the definition template the projected angles are referenced to the position of the feature's plane normal Sigma Min/Max Form Scatter referenced to the best-fit computed feature Minimum and maximum deviation, referenced to the best-fit computed feature Difference between minimum and maximum deviation, referenced to the best-fit feature.
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The illustration below shows the positions of projected angles W1 and W2 for a straight line on a cube. The reference axis is always the coordinate axis with which the projected angles are both less than 45 in this case the X axis.
projection into the X/Y plane
spatial view Z
A1 X
example line
A2
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Cylinder feature
Menu: Features Cylinder You can use the Cylinder feature to probe bores, plugs and shafts. As opposed to the circle, a cylinder yields information about height and depth as well.
Probing strategy
You must probe at least five points in order to identify a form as a cylinder: 1 Probe a circle first, i.e. at least the first three points on a section perpendicular to the cylinder axis. The axis of this section will be the provisional cylinder axis. 2 Probe at least two more points on another section perpendicular to the axis of the first section. Calypso computes the data of the cylinder from the circular sections at the different levels. The axis of the cylinder is computed perpendicularly through the centers of the two circular sections. If you probe nine or more points, there is no need for a probing strategy.
If geometrical error is excessive for a cylinder, Calypso computes a cone instead of a cylinder. This also happens if the two circular sections are too close together. If this happens, you can reconstruct a cylinder manually in the Geometry menu.
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Result output
This illustration shows the positions of the projected angles W1 and W2.
Z projection into the Z/X plane
spatial view Z X A1 Y
example cylinder
Y A2
The origin of the feature's local coordinate system is on the plane with the lowest probing point (not on a projection plane of the coordinate system).
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Gage correction qualification is a method by which you can determine the dynamic bending parameters for circles and cylinders occurring during measurement and correct them mathematically during further measurements. Gage correction qualification is only useful for scanning with a measuring probe.
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Cone feature
Menu: Features Cone Use the Cone feature to probe the location and position of insideand outside cones, the direction of the cone axis and the cone's taper angle.
Probing strategy
You must probe at least 6 points in order to identify a form as a cone. 1 Measure three points on a circular section parallel to the axis of the cone. 2 Move the CMM to another height. 3 Measure three points at this height. 4 Measure other sections, as in steps 2 and 3. Calypso computes the data of the cone from the circular sections at the different heights. The axis of the cylinder is computed perpendicularly through the centers of the circular sections. If you probe nine or more points, there is no need for a probing strategy.
If cone angle CA is very small, Calypso might compute a cylinder instead of a cone. The measuring uncertainty for the cone axis will be too high if the height difference between the circular sections is very small, and Calypso might compute a circle instead of a cone. If this happens you can reconstruct a cone manually in the Geometry menu.
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Result output
This illustration shows the positions of the projected angles W1 and W2. In this example, the reference axis is -Z.
Z projection into the Z/X plane
spatial view Z
X A1
example cone
Y A2
The origin of the feature's local coordinate system is in the center of the circle of smaller diameter. The direction of the axis is from the smaller toward the larger circle.
Sphere feature
Menu: Features Sphere Calypso uses the Sphere feature to compute the diameter and the center coordinates of a sphere, spherical cap or spherical zone.
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Probing strategy
Probe at least 4 points distributed as uniformly as possible over the surface of the sphere. If the stylus system and sphere position allow this, it is best to probe from different directions. The first two points should be probed near the sphere's pole and the remaining points along the equator of the sphere. If you fail to probe the points in the recommended manner, Calypso will not automatically recognize a sphere. If this happens you can reconstruct a sphere manually in the Geometry menu. There are no projected angles for a sphere. D represents the diameter of the sphere.
Result output
3D Curve feature
Menu: Features 3D Curve You can use the 3D Curve feature to measure freeform surfaces. This feature is extremely versatile and, consequently, it is described in a separate section (see Curve measurement (option) on page 16-1).
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If you are using the Calypso Light version, you cannot use this function. Bear in mind that this feature is not included in the normal Calypso scope of supply and must be obtained as an option.
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Ellipse feature
Menu: Features Additional features Ellipse You can use the Ellipse feature to probe bores, plugs and shafts having axes not parallel with an axis of the base alignment, as well as true ellipses. Bear in mind that automatic feature recognition is not available for ellipses. The ellipse can be defined in two different ways: by specifying the center (with X, Y and Z) and the two diameters D (major diameter) and D2 (minor diameter), by specifying the two focal points (with X1, Y1, Z1 and X2, Y2, Z2) and one of the two diameters (diameter D and note indicating whether this is the larger diameter). You can toggle between the two types of display in the Feature representation dialog box, which you can open from the prerequisites or via Resources Feature representation. In the definition template, the angles W1 and W2 indicate the position of the ellipse in relation to the respective plane (X in XY plane, Y in YZ plane and Z in ZX plane). If the defining specifications (second type of representation) do not produce an actual ellipse, the second diameter is set to 0 and the ellipse is no longer shown.
Probing strategy
Probe at least 5 points in a planar section. Distribute the points as uniformly as possible around the circumference of the section.
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Result output
The following illustrations show the definition of the minor diameter D2 and the major diameter D, as well as the location of the focal points.
D2
M (X, Y, Z)
D large
Dsmall
The origin of the feature's local coordinate system is in the center of the ellipse. It is not projected onto a plane of the coordinate system.
Slot feature
Menu: Features Additional Features Slot You can use the Slot feature to measure the length, width, depth and position of a slot. Projected onto a plane, a slot consists of two opposite semicircles and two opposite straight lines.
Probing strategies
You can use two different probing strategies to measure the slot. In both cases, you must probe at least five points (in any order). If there are several points on a segment, make sure that they are distributed as uniformly as possible.
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at least two points on one side of the slot, at least one point on the other side of the slot, at least one point on each of the semicircles. How to distribute the probing points according to the second strategy:
1 2 3 4 5
at least three points on one semicircle, at least two points on the other semicircle. You can distribute other probing points as you wish.
Feature's local coordinate system
The origin of the feature's local coordinate system is in the slots center of gravity, i.e. its center point.
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Rectangle feature
Menu: Features Additional Features Rectangle You can use the Rectangle feature to probe the length, width, depth and position of all elements of hollow rectangular geometry.
Probing strategy
Probe at least 6 points. Make sure that all points are spaced as uniformly as possible over the sides of the rectangle. Probe at least two points for each side of the rectangle. You must enter the value for the depth of the rectangular hollow manually in the Length field.
You must probe no more and no less than three points and then enter the offsets: 1 Probe the 3 points. 2 Click on the Output button. 3 In the Point Modification group, click on the Edit button. The Points offset dialog box appears on the screen.
4 Enter an offset for each point you want to modify. The points are offset along the probing direction. 5 Close the dialog box to accept the modified settings.
Automatic feature recognition
An offset plane is not recognized automatically by Calypso. Begin by adding the feature to the measurement plan and then take probings.
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You must probe no more and no less than two points in order to compute a symmetry point. 1 Open the definition template. 2 Probe the first point. 3 Probe the second point from the opposite direction. 4 Close the definition template.
Calypso automatically recognizes a symmetry point. Calypso computes the coordinates and the normal vector of the symmetry point and the distance between the original two probing points.
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The Radius Point feature is intended for probing cylindrical elements. The measured value is corrected in the measuring plane towards the connecting line between the center of the stylus tip and the specified center point.
Measuring plane R
Cylinder axis
Perform the following steps to measure a radius point: 1 Open the definition template. 2 Specify a point on the cylinder axis and the vector of the cylinder axis. 3 Probe a point. The actual radius and the coordinates of the probing point are read out in the definition template.
Automatic feature recognition
A radius point is not detected automatically by Calypso. First, insert the feature in the measurement plan, define a center point and then perform probing.
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1 Open the definition template. 2 Enter the coordinates for the sphere center point and the desired radius in the Center Point column. 3 Probe a point. The actual radius of the sphere, the vector from the sphere center point to the probing point and the coordinates of the probing point are read out in the definition template.
Example of application
Using the sphere point feature, you can define the radius of a sphere with a single probing and specification of the sphere center point.
Calypso cannot automatically detect a sphere point. First, insert the feature in the measurement plan, define the sphere center point and then perform probing.
To measure an angle point, you must specify a reference plane through the plane origin, a space axis and an angle and then probe exactly one point. The actual angle of the probed plane and the coordinates of the probing point are read out in the definition template. Perform the following steps to measure an angle point: 1 Open the definition template. 2 Enter the values for the for the location of the plane origin in the left column.
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3 Select how you want the reference plane to lie by specifying a space axis and an angle. 4 Probe a point on the plane that has to be measured.
Example of application
Using the angle point feature, you can compute the angle between two planes, for example, by probing. Specify one plane first. Calypso computes the second plane from a probing and the origin of the specified plane. Remember that automatic feature recognition is not available for the angle point.
A origin of planes
Calypso cannot automatically recognize an angle point. First, insert the feature in the measurement plan, define the plane origin and then perform the probing.
Each point of a general surface is therefore probed, measured and processed individually. Each point possesses its own strategy and resources. The entries in the strategy list are thus structured as trees in the Strategy dialog box. The associated clearance data and technology information can be found under each entry of a point. If no feature or technology is selected, clicking on the probing point icon will produce a new point here.
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The actual values of individual points are shown neither in the definition template nor in the point list; they appear only in the printouts and protocols (default printout, compact printout and custom printout). Nominal input and the definition as a theoretical feature are options for the nominal definition. A change in the nominal definition refers to all associated points of the general surface. You can add a nominal point to the general surface by clicking on the desired position of the CAD model in the CAD window (the definition template must be open when you do this). You can add a point to the general surface by probing with the CMM. Calypso cannot automatically recognize a general surface. Enter the feature in the measurement plan before probing.
Nominal definition
The General curve feature corresponds to the DMIS feature FEAT/GCURVE. No mathematically defined curve shape is computed from splines in the evaluation of a general curve to obtain the result of the nominal-actual comparison of two curved lines. The general curve feature is merely a container for a set of points belonging to a curve. Each point of a general curve is therefore probed, measured and processed individually. Each point possesses its own strategy and resources. The entries in the strategy list are thus structured as trees in the Strategy dialog box. The associated clearance data and technology information can be found under each entry of a point. If no feature or technology is selected, clicking on the probing point icon will produce a new point here. The points may be in any spatial location. The actual values result after projection of the data onto a plane specified in the definition template of the general curve (with X, Y, Z, NX, NY, NZ).
Strategy
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The actual values of individual points are shown neither in the definition template nor in the point list; they appear only in the printouts and protocols (default printout, compact printout and custom printout).
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Nominal definition
Nominal input and the definition as a theoretical feature are options for the nominal definition. A change in the nominal definition refers to all associated points of the general curve. You can add a nominal point to the general curve by clicking on the desired position of the CAD model in the CAD window (the definition template must be open when you do this). You can add a point to the general curve by probing. Calypso cannot automatically recognize a general curve. Enter the feature in the measurement plan before probing.
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Important Before starting a measurement, either HOLOS or GEAR must have been started, otherwise the CNC run will be canceled.
Enter the following in the definition template: the macro to be executed You can either enter the macro directly or by selecting it from a catalog. the coordinate system for the macro You can select a coordinate system in Calypso, which will be passed to HOLOS or GEAR. The manner in which the coordinate system will be used must be specified in HOLOS. a coordinate system from the macro You can receive a coordinate system from the macro and use it further in Calypso. To do so, enter the name under which the coordinate system should be used in Calypso.
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A free form surface is connected with a surface in the appropriate CAD model and is thus a theoretical element that does not possess any nominal value definitions. The Free Form Surface feature is limited by the CAD model and has no infinite expansion. The free form surface can be interrupted by bores. The free form surface feature does not posses an own coordinate system but uses the coordinate system of the appropriate CAD model. That is why you cannot assign a coordinate system to the free form surface feature. However, you can copy the coordinate system of the free form surface to another feature.
Coordinate system
The Turbine Blade feature is used to transfer nominal data and measured data for turbine blades to the Blade PRO program for evaluation. It creates several XML files that are processed in the Blade PRO program. The import of nominal data, the definition of the measuring technology as well as the measurement itself are carried out in Calypso. Use the curve feature for this. The Blade PRO program is used for evaluation only.
Together with the nominal data and the measuring results, all printout header variables belonging to the measurement plan are also transferred to Blade PRO. The variables of the SYS data group are assigned the type=static in the XML file, all other variables receive the type=dynamic. Example in an XML file: <Property operid="Master" type="static" />
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Entries
Enter the following in the definition template: Entries For additional information, please refer to the Blade PRO document. Activate the check box for the formats in which you want the output of the results. Shows all curves of the measurement plan. Select those curves that you want to evaluate with Blade PRO as turbine blades.
Prior to the CNC run, export the nominal data to Blade PRO if necessary. For this purpose, you open the definition temple for the corresponding turbine blade feature, mark the desired intersections and click on Export Nominals. The nominal data for each of the selected intersections is written in an XML file named Section_xxx_nominal.xml. The printout header variables are also transferred. The files are saved in the directory that is defined as BladeNomPath in the ...\calypso\home\om\curveParameter.txt file.
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After starting the CNC run, the following files are created and transferred to Blade PRO. Startup.xml: File with a referral to the blade specification file. The specification file is used by Blade PRO but must have been selected beforehand in Calypso. Section_xxx_actual.xml: Measured data files corresponding to Section_xxx_nominal.xml. After each measurement of a curve selected in the definition template, the corresponding data is written in the measured value file. The files are saved in the directory that is defined as BladeNomPath in the ...\calypso\home\om\curveParameter.txt file. The printout header variables are also transferred. Finish.xml: End code of the measurement Blade PRO will only start evaluation if this file is available. The data for the result output in Blade PRO is transferred to this file. Once the evaluation has been completed, this will will be deleted by Blade PRO. The Blade PRO program starts the calculation and evaluation once the Finish.xml file has been created. The results are created in the formats specified in the definition template. Once Blade PRO has deleted the Finish.xml file, Calypso continues the CNC run.
If you are using the Calypso Light version, you cannot use this function. For gage correction qualification, Calypso must first record the bending parameters of the stylus used. When a circle or arc or a cylinder is subsequently measured, you can instruct Calypso to correct the result by applying the bending parameters.
Prerequisites
The preconditions for recording and correcting bending parameters are as follows: A new measurement plan for the reference workpiece is open and you have defined the clearance planes. How to create a new measurement plan on page 4-4 Defining the clearance planes on page 4-113
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You know how to start a CNC run. Defining the scope of measurement on page 8-2 The circle or cylinder is measured on the same primary plane of the workpiece coordinate system as was used in recording the bending parameters.
If you are using the Calypso Light version, you cannot use this function. The bore or plug must be of known diameter.
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The bending parameters have no effect unless you have installed a measuring probe. The plug or bore is measured as an overlapping full circle in a separate measurement plan. To record the bending parameters: 1 Position the base alignment in the center of the reference bore or plug. 2 Select the Gage Correction Qualification utility by selecting Resources Utilities Gage Correction Qualification. Calypso adds the icon for gage correction qualification to the list of features. 3 Double-click to open the definition template. 4 Enter the qualified diameter of the bore or the plug in the D field. 5 Select the scanning method for the circle: Click on Strategy. Click on the Full circle button. In the list, double-click on Circle Auto Path. This opens the dialog box where you define the scanning speed. 6 Enter the scanning speed in the Speed field. 7 Click on OK to close all dialog boxes Click Yes at the prompt shown below.
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8 Perform a CNC run of the measurement plan so that Calypso can measure the bending parameters. Now that Calypso knows the bending parameters of the stylus, it will be possible to correct future measuring results of full circles and arcs accordingly (see the next section How to apply the bending parameters).
The prerequisite is that for the measurement the values for the diameter, measuring location, orientation and scanning speed are as close as possible to the values of the bending parameter definition. However, the height for the cylinder measurement is not decisive. To activate correction by application of the bending parameters: 1 Open the definition template of the circle or cylinder to which you want to apply the bending parameters. 2 Click on the Output button. The Evaluation (feature) window will open.
3 Activate the Gage Correction check box. 4 Click on OK to close the Evaluation dialog box. 5 Click on OK to save the settings and close the definition template. The next time you measure a circle or cylinder, the measuring results are corrected by the bending parameters.
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3 Use the Feature buttons to select the features for which the construction is required. When selecting a feature, you can specify that the nominal geometry is to be used for the evaluation. 4 Click on OK to confirm your choice. The features you selected are now interlinked in a construction.
Special aspects
Certain special aspects have to be borne in mind with the following constructions: Cone Addition (Cone Addition construction on page 5-78) Circle in contour best fit construction (Circle in contour best fit construction on page 5-80)
Let us suppose you have measured four circles. You would now like to learn the circle on which the center points of the measured circles are located. To this end, define a new circle from the recalled center points of the four measured circles.
circle 2
circle1
circle3
circle4
You can realize the following recall types with Calypso: Recall: Returns the reference point(s) (the origin of the feature's local coordinate system) of one or more features. Recall One Feature: Returns the entire feature.
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Recall Feature Points: Returns individual points, individual paths, specific areas (specified in coordinates) or all points of one or more features. Proceed very carefully when defining a feature by recalling. Theoretically, you could recall any number of features but this would not make any sense.
If a potential feature for the points recall has a pattern, this can be shown in the selection window in two ways: with loop: with brackets and start and end index, with index transfer: with brackets and asterisk. This representation determines the recall. To change between these representation types, use the menu items of the context menu: Add loop to all marked features: the marked features with pattern are shown with loop . Delete loops from all marked features: the marked features with pattern are shown with index transfer.
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Select loops individually: the window shows all marked features of the list with pattern and you can individually select each entry:
If the new feature does not yet possess any pattern, the following applies: If you select a feature with the with loop pattern, the reference points or the specified points of all pattern features of the feature are recalled. If you select a feature with the with index transfer pattern, you are prompted whether a pattern is to be assigned to the new feature. A pattern with the minimum actual number of all marked features with the with index transfer pattern is offered as default. By confirming this, the reference points or the specified points of the original feature of the patterns are recalled and the proposed pattern is assigned. If you reject this, a pattern with only one pattern feature is created. If you select one individual pattern feature, the reference points or the specified points of all pattern features of the selected pattern feature are recalled.
If a pattern has been assigned to the new feature beforehand, the following applies: If you select a feature with the with index transfer pattern, the reference points or the specified points of the original features are recalled and the pattern of the new feature is assigned. If you select a feature with the with loop pattern, the reference points of all pattern features of the feature or the specified points of all pattern features of the feature are recalled. If then the assigned pattern of the new feature contains more actual pattern features than the minimum of all actual numbers of patterns (of all marked features), you are prompted whether the
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pattern with the smallest actual number is to be used for the feature. By confirming this, the new feature will receive the corresponding pattern. By rejecting this, the previous pattern will be maintained.
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Important This leads to a stop of the CNC run. Since the number of pattern features of the newly defined feature is larger than the number of pattern features of the individual recalled features, some of the pattern features of the new feature are not defined. If you select one individual pattern feature, the reference points or the specified points of all pattern features of the selected pattern feature are recalled.
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2 Open the Nominal Definition list and select the Recall recall type. You then see the Selection dialog box with the features.
3 Activate Show all Features in Patterns or Loops to recall individual pattern features. Features with loop are shows with brackets and the specification of the index range, e.g. Circle1(1-4). Features with index transfer are shown with brackets and asterisk, e.g. Circle2<*>. 4 To adapt the features with pattern, mark the corresponding entries and use the context menu: Add loop to all marked features: All marked features with pattern are shown with loop and with the index range. Delete loop from all marked features: The loops of all marked features with pattern are shown with index transfer (with asterisk). Select loops individually: Opens a window with all marked features with pattern. Here, for each individual feature, you can select or deselect loop and index transfer.
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5 Select the feature or features you require press the Ctrl or shift key if necessary. You can define the evaluation method, filtering and outlier elimination for the required features. Filter and outlier elimination are valid equally for all selected features. 6 Click on OK to confirm. The reference point(s) is (are) are accepted.
The result is a theoretical feature that accesses the original feature with the getActual formula. To define a complete feature by a recall: 1 Open the definition template of the geometric element that you require to be created by a recall. 2 If the new feature should posses a certain pattern, select or define this via the Nominal Definition menu and the Pattern menu item.
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3 Open the Nominal Definition list and select the Recall One Feature recall type. You then see the Selection dialog box with the features.
Only those features are displayed that are of the same type as the feature to be defined. 4 Activate Show all Features in Patterns or Loops to recall individual pattern features. You can then access individual features of a pattern. 5 Select the corresponding feature and confirm with OK. The feature is accepted and determines the new feature.
Recall one feature and pattern
Once you have accepted a feature with a pattern, the new feature will also receive this pattern, regardless of whether you have assigned a pattern to this new feature beforehand or not. Once you have assigned a pattern to the new feature and you have accepted an individual pattern feature, this becomes the original feature of the assigned pattern.
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The Recall Points window with all available features is displayed. At the same time, two icons named Mark and Lasso function appear in the upper right corner of the toolbar. All the potential features for the points recall are listed in the Recall Points window.
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3 Activate Show all Features in Patterns or Loops to recall individual pattern features. Features with loop are shown with brackets and the specification of the index range, e.g. Circle1(1-4). Features with index transfer are shown with brackets and asterisk, e.g. Circle2<*>. 4 To adapt the features with pattern, mark the corresponding entries and use the context menu: Add loop to all marked features: All marked features with pattern are shown with loop and with the index range. Delete loop from all marked features: The loops of all marked features with pattern are shown with index transfer (with asterisk). Select loops individually: Opens a window with all marked features with pattern. Here, for each individual feature, you can select or deselect loop and index transfer. 5 To add the individual arcs of a cylinder to the list, click on the cylinder and select Open in the context menu. You have two options to recall points: You can recall all points of one or more features. You can recall certain points of one or more features. 6 To recall all points from one or several features into the new feature: Select the feature or features you require press the Ctrl or shift key if necessary and confirm with OK. 7 To recall certain points from a single feature into the new feature: In the list, select the feature with the points from which (or with some of the points from which) the new feature is to be produced. Click on the Mark symbol to represent the measured points of the feature with crosses in the CAD window. Click on the Lasso button and use the mouse to drag a rectangle (a cuboid is internally generated from the rectangle) around the desired points. In the list of features, the box (X,Y,Z,+X,+Y,+Z) entry appears behind the name of the feature in question. The coordinates of two diagonally opposite corner points of the cuboid are specified in the brackets.
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The sides of the cube are aligned with the base alignment. To change the corner points of the cuboid if necessary: Select Add limits in the context menu and overwrite the coordinates offered in the Range limits for point selection dialog box.
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To take over only a few points if necessary: Select Add limits in the context menu and specify the desired points in the Range limits for point selection dialog box. Examples of the specification of the range limits: Formula points(1,5) angles(10,90) Meaning Point 1 to point 5 The points in the angle range from 10 to 90 (only for circle segments) The points of the 2nd circle segment
Perpendicular construction
Menu: Construct Perpendicular Using the Perpendicular construction, you can have Calypso compute the shortest distance between two features.
Feature 1
With Feature 1 in the definition template, define the point from which the perpendicular will be struck. You can select any feature as Feature 1. The table below shows which coordinates are used by possible features: Feature 1 Point (probing) Circle Line Plane Use of the coordinates Coordinates of probing point Coordinates of center point Coordinates of the origin of the local coordinate system Coordinates of the origin of the local coordinate system
Feature 2
With Feature 2 in the definition template, set the direction of the perpendicular. The perpendicular is vertical on feature 2. Therefore, feature 2 must be a spatially defined element. The following is read out as the result of the computation: The straight line on which the perpendicular is located by the specification of two projection angles. You can modify the reference of the projected angles under Spatial axis.
Interpretation of results
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The length (distance) of the perpendicular. The calculated distance of the perpendicular is the distance of the point in Feature 1 to Feature 2.
Intersection construction
Menu: Construct Intersection With the Intersection construction, you can intersect straight lines, planes, free form surfaces, circles, cylinders, spheres and cones with each other and have tangents computed. To do this, you enter the two features and obtain one or more results. Depending on which feature you entered first, not all options are available to you for the second one.
Intersection with wall or axis?
If you select an axial element, such as a cylinder or cone, for the intersection, Calypso assumes that you want to intersect the axis of the element with a different element. If, however, you want to intersect the section surface of the element instead of the axis of the axial element, you must select the Wall check box in the definition template of the intersection. Free form surfaces can only be intersected with axes. Depending on the intersection, one to four results are shown in the Result Selection group of the definition template, and you select the intersection result you want to proceed with.
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Automatic correction
With this construction, Calypso supplies results even if the objects do not intersect geometrically but a meaningful, different interpretation (for example, tangent) is possible. When a cylinder or cone intersects a plane, Calypso performs automatic corrections under certain circumstances the plane is interpreted as vertical or parallel (refer to Intersection of a plane with a cylinder on page 5-68 and Intersection of a plane with a cone on page 5-69). When rotationally symmetrical, three-dimensional surfaces intersect, Calypso performs automatic corrections under certain circumstances the surfaces are interpreted as concentric or coaxial.
Interpretation of results
The following sections describe the different intersections and their results.
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Line 1
Intersection
Line 2
Calypso delivers four points as results. If you select the Spatial option in the definition template, you obtain as the intersection the center of the perpendicular between the two straight lines - the point closest to the two straight lines. If both straight lines are in one plane, this point coincides with the actual intersection of the two straight lines. If you select one of the other results in the definition template, you obtain in each case the intersection of the projections of the two straight lines to one of the three part coordinate system planes.
The result computed by Calypso is the spatially defined intersection line. The point of the computed intersection line that is closest to the origin is used as the origin of the feature's local coordinate system (reference point) of the intersection line.
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intersection 2
In the Result Selection group of the definition template, specify the intersection you require as the result: Result 1 for intersection 1 and Result 2 for intersection 2. If exactly one intersection is present because the circles are touching, two identical points are read out. There is no intersection between the circles.
center
Line
P2
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Calypso calculates as a result the intersections of the projected straight line with the circle. If the straight line only touches the circle and does not intersect it, two identical points are determined. Differentiation has to be made between the following two possibilities: Two intersections are present.
intersection 1
intersection 2
In the Result Selection group of the definition template, specify the intersection you require as the result: Result 1 for intersection 1 and Result 2 for intersection 2. There is no intersection between the (projected) straight line and the circle.
Perpendicular Lotfupunkt
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penetration point
Calypso computes as a result the piercing point of the straight line through the plane.
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If the check box Wall has been activated, Calypso will calculate: the piercing points of the line through the cylinder wall Otherwise: the intersection point of the line with the axis of the cylinder.
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Calypso computes as a result the intersections of the circular line with the plane. If computation is not possible, an error message is issued.
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K E
In the case of a wall intersection, Calypso will not create the exact mathematical ellipse as the intersection element but will automatically adjust this to form a circle if the plane does not deviate too greatly from the perpendicular position, i.e. if the angle between the normals of the plane and the axis of the cylinder is less than 45. In this case, the circle - the center point of which represents the intersection point of the cylinder axis with the section plane - which intersects the cylinder vertically will be calculated. No intersection is measured in all other cases.
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E E
Here, Calypso will not create the exact mathematical ellipse as the intersection element but will automatically adjust this to form a circle if the plane does not deviate too greatly from the regular position, i.e. if the angle between the normals of the plane and the axis of the cone is less than 45. In this case, the circle - the center point of which represents the intersection point of the cone axis with the section plane - which intersects the cone vertically will be calculated. No intersection is measured in all other cases.
If you are using the Calypso Light version, you cannot use this function. You can intersect a free form surface with an axis. You can use one of the following features to define the axis: cylinder, cone, torus, 3D line.
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The ACIS 3D Toolkit program must be open for the intersection calculation of a free form surface with one axis.
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When intersecting a free form usrface with an axis, Calypso supplies a 3D point. If several intersections are possible (since the free form surface has for example a wavy profile), only the first determined intersection point will be output.
The axes of the following features can be intersected with the free form surface: Cylinder (wall intersection not activated) Cone (wall intersection not activated) Torus 3D Line When defining the intersection, you can specify the free form surface as first or second characteristic.
The distance between the center point of the sphere and the cylinder axis must be less than half the cylinder radius.
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The distance between the sphere center point and the cone axis must be less than half the radius of the theoretical resulting circle. No intersection is determined in all other cases.
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onto the cylinder axis and the axis of which runs parallel to the cylinder axis. The angle between the (actual) cone axis and the cylinder axis must not be greater than 45. The distance between the intersection of the cone axis and the theoretical resulting circle must be less than half the radius of the theoretical resulting circle. No intersection is determined in all other cases. Otherwise: the intersection point of the two axes. The same conditions apply here as for the intersection of two lines.
S obtuse
h R K
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The two cones can lie parallel or antiparallel to each other. Calypso computes the intersection in both cases.
Symmetry construction
Menu: Construct Symmetry You can use the Symmetry construction to determine a symmetry feature between your selected Feature 1 and Feature 2. You can then use the symmetry feature obtained in this way freely in other constructions.
Feature 1 Feature 2 Interpretation of results
You can select any feature as Feature 1. You can select any feature as Feature 2. The computed symmetry feature is output in the form of coordinates common to the two features. The examples below will facilitate interpretation of the results: Symmetry point of two circles
symmetry point
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As the result, Calypso computes the position, length and width of the symmetry plane on which the symmetry point from the two start points of the two planes is located. Symmetry axis of two lines
line1
line2
symmetry axis
As the result, Calypso computes the coordinates of the symmetry axis on which the symmetry point from the two start points of the two lines is located.
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Feature 1
Point (generally a space point) is the only feature you can use as the first feature. The spatial axis of this first point defines the first plane on which the edge point will be situated. This plane must intersect with the plane of feature 2. Point (generally a space point) is the only feature you can select as the second feature. The spatial axis of this second point defines the second plane on which the edge point will be situated. This plane must intersect with the plane of feature 1. You can specify a plane or a point as feature 3. If you specify a point, this also defines a plane via the normal. The edge point is computed as the intersection of this plane with the intersection of plane 1 and plane 2. Calypso computes the coordinates of the edge point as the result. The example below illustrates how an edge point is computed for two planes in order to yield the coordinates of the imaginary corner. The third plane here is the drawing plane.
element 1 contour point
Feature 2
Feature 3
Interpretation of results
element 2
If the third plane is not defined, the edge point is defined centered between Feature 1 and Feature 2 (Feature 1 and Feature 2 usually differ at least slightly in height).
Projection construction
Menu: Construct Projection You can use the Projection construction to determine the position of a feature that was projected onto another feature (e.g. the position of a point projected onto a plane).
Feature 1 Feature 2 Interpretation of results
Define the feature you want to project as Feature 1. Specify as Feature 2 the feature onto which you want Feature 1 projected. Result output depends on the feature that results from the projection. The examples below will facilitate interpretation of the results:
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Projection of a circle onto a plane The projection of a circle onto a plane shifts the circle perpendicularly to the plane until it is on the plane. Calypso computes the coordinates of the center of the circle on the plane. Projection of a cylinder onto a plane Projection of a cylinder onto a plane produces a straight line formed by the two end points of the cylinder's axis on the plane. Calypso computes the two projected angles and the coordinates of the origin of the local coordinate system. A special case is a cylinder normal to the projection plane: in this case, projection produces a point on the plane. Calypso computes the coordinates of the point on the plane.
Click on the Feature 1 button to open the Selection dialog box, where you can select a regular geometric feature of your choice. As a result, Calypso calculates the coordinates of the point having the largest negative deviation.
Click on the Feature 1 button to open the Selection dialog box, where you can select a regular geometric feature of your choice. Calypso computes the coordinates of the point where positive deviation is at maximum.
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Click on the Feature Selection button to open the Selection dialog box, where you can select the features you want to have compared. From the selection list, select the characteristic (radius, angle etc.) of the selected features for which you want the minimum computed. The list contains all the main characteristics. Calypso computes the minimum for the characteristic you selected and displays the feature in question in the CAD window. For example, you can ascertain which cylinder in a group of three has the smallest diameter.
Interpretation of results
Click on the Feature Selection button to open the Selection dialog box, where you can select the features you want to have compared. From the selection list, select the characteristic (radius, angle etc.) of the selected features for which you want the maximum computed. The list contains all the main characteristics. Calypso computes the maximum for the characteristic you selected and displays the feature in question in the CAD window. For example, you can ascertain which cylinder in a group of three has the largest diameter.
Interpretation of results
Average-Feature construction
Menu: Construct Average-Feature Using the Average-Feature construction, you can have Calypso calculate the average value of several measurement results. The features from which the results originate must all be of the same kind (e.g. only cylinders).
Feature selection
Click on the feature selection button to select the features for whose measured values you want to compute the average.
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Selection list
In the selection list, define the characteristic (radius, angle, etc.) for which you want the average computed. The list contains all the main characteristics.
If you are using the Calypso Light version, you cannot use this function. The only feature you can select is a cone, because cone additions are computed exclusively for cones. If you have selected the Diameter Definition option, you can either enter the height directly or determine this indirectly using another feature. Calypso will require that you make the following entries: At L: Enter height L, the height at which the diameter should be calculated, and enter the reference point of the height entered under Referenced To: Height L can be referenced to the Cone Origin.
Height L will be measured from the cone origin (the intersection point of the cone axis with the surface area closest to the cone center).
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Here, the coordinate axis which lies closest to the cone axis will be computed first. The diameter will be output on the point of the cone axis for which the coordinate on this axis is equal to L. Or at: If you do not wish to enter the height directly, you can use this button to determine a feature that (if necessary, via the intersection point with the cone axis) defines the height of the required diameter. Only the Point, 2D Line and Plane features are suitable here.
Position definition
If you have selected the Position Definition option, you can either enter the appropriate diameter or determine the required height indirectly using another feature. Calypso will require that you make the following entries: At D: Directly enter the diameter for which the appropriate height should be calculated. Or at: If you do not enter a diameter, you can use this button to determine a feature to indirectly determine the height at which the position will be defined (the height above the cone origin). Only the Circle, Circle on Cone, Cylinder, Cone and Ellipse features are suitable here.
Interpretation of results
Calypso will either calculate a specific diameter or a specific height on the cone depending on what you have selected.
Planes are the only feature you can select. The plane you select here is the origin or reference plane for computing the plane with offset. In the Offset input field enter the value by which the offset plane should be offset compared to the plane selected in Feature 1.
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Interpretation of results
Calypso computes the coordinates of the plane with offset as the result. Please note that the offset plane is usually a plane which does not really exist and, consequently, no probing points can be taken.
The Circle in contour best fit construction is available only if the Curve Measurement option is enabled. Menu: Construct Circle in contour best fit With the Circle in contour best fit construction, you receive (according to your selection) a circle or a space point that is determined through the best fit of a circle in a plane profile of gothic or elliptical shape. You can use this construction in practice to determine how a sphere of a given diameter behaves in a path with a certain profile, for example. You define the contour, the circle and the desired result in the definition template for the Circle in contour best fit.
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Feature
You select a curve or a 3d curve as the feature. The curve must be gothic or elliptical in shape, otherwise best fit of a circle cannot be calculated.
Elliptical shape Sphere Angle Angle Gothic shape Sphere
Calypso internally calculates a compensating plane for the curve and projects the curve points into this plane. Best fit is then performed with the planar contour.
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You cannot change the filter, outlier and evaluation settings in the selection window for the curve. You can change filters and outliers only in the feature itself. You enter the diameter of the circle for the best fit process under Diameter.
Diameter
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You can also have Calypso calculate the diameter with a formula. For a better fit, you can enter a wave separation length (WTL) for filtering the profile (no filtering if you enter 0). Filtering can avoid excessive deviations between the determined and actual contact points. Consideration of the wave separation length differs from the filtering of measured values otherwise used in Calypso. It is a special method for the circle in contour best fit.
You can also specify a Minimum contact angle. This can exclude ambiguities during the best fit process (in case of real, distorted data records). Contact points that are no further apart than by this angle are regarded as a single contact point. If one of the following error messages appears at the bottom of the window, you can attempt to achieve an unambiguous result by increasing the minimum contact angle. No two-point contact with contact point greater than minimum angle
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The minimum contact angle is not taken into consideration if the curve contains points from measurements performed with different stylus tip radii. You select the desired result type by clicking on the appropriate symbol under Result Selection. You can choose from four different result types and receive a circle or a space point depending on your selection: Icon Output (features highlighted) Space point X, Y, Z (the left circle-curve contact point positioned closest to the start point of the curve) Circle with center (X, Y, Z), diameter and normal (of the compensating plane) Gap (the radial distance between circle and curve at the position of the bisecting line of the angle between the two contact points) Start angle (angle of the right contact point on the circle) Angle range (angle between the right and left contact points) Space point X, Y, Z (the right circle-curve contact point positioned closest to the end point of the curve) Space point X, Y, Z (the curve point with the maximum radial distance to the circle) Gap (the maximum radial distance between circle and curve) When you click on OK, Calypso performs the best fit and calculates the results. If the initial data is insufficient for the best fit or is conflicting, an error message will appear at the bottom edge of the window.
Result selection
Prior to the best fit process, Calypso uses the points of the specified curve to calculate a compensating plane and then projects the curve onto this plane. The greater the form deviation, the less precise the result of the best fit will be. So that you can estimate the accuracy of the best fit, the following results from the calculation of the compensating plane are displayed on the right side of the dialog box:
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Form deviation (distance between minimum and maximum deviations) Number of points Minimum deviation (largest negative deviation) Number of the point with the largest negative deviation Maximum deviation (largest positive deviation) Number of the point with the largest positive deviation These results are also output in the default printout and compact printout.
Characteristics from the definition template
You can automatically add characteristics to the measurement plan by activating the corresponding check boxes. Gap The special Gap characteristic is used for evaluating the gap width between the circle and profile. Depending on the result selection, the gap width at the angle bisecting line or the maximum gap width can be evaluated using this characteristic. Start Angle The Start Angle characteristic checks the angle between the first contact point and the reference axis. Angle Range The Angle Range characteristic checks the angle between contact points. Only circles can be used as the features in this case. End angle The End angle characteristic checks the angle between the second contact point and the reference axis. You can also subsequently edit the definition templates of these characteristics. However, the results will make sense only in combination with the Circle in Contour Best Fit.
Two types of error can occur with the circle in contour best fit: Primary errors are errors that prevent results from being calculated. Examples of these errors include contours with fewer than three points or an incompletely defined nominal geometry. Secondary errors occur if it was not possible to reach a result during calculation of the best fit due to insufficient input parameters. Secondary errors are displayed in the error line at the bottom edge of the window (below the geometry). This error message is preceded by an indication of whether the error occurred in the calculation of the nominal geometry or the actual geometry. If both geometries are faulty, only the error text
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for the actual geometry is output and printed in the protocol/printout. If Calypso is able to calculate the actual geometry but not the nominal geometry, 0 will be entered for Vector, Diameter/Radius, Normal, Gap and Start Angle and 360 will be entered for the angle range for a circle.
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Not infrequently, however, other decisions have to be made because of special considerations relating to measurement or the material, for example, or on account of other, specific requirements. The term measurement strategy describes all the additional definitions you make so that Calypso and the CMM can return an optimum measuring result. The measurement strategy derives from the measuring task as such: A measurement strategy refers only to the corresponding feature, not to an entire measurement plan.
Tasks
The tasks that defining a measurement strategy can involve are as follows: Selecting Utilities and inserting them in the strategy list (Stop, Position CMM without Probing, Stylus System Change, Clearance Data, etc.) Using technology macros (discrete-point mode) Selecting a path generation method (See Path generation measuring features automatically on page 5-95). Editing the Point List (See Point list on page 5-87). Editing the Travel (See Editing the travel paths on page 7-29). Checking and editing Clearance Data (See Checking the travel paths on page 7-32). You can take care of all these tasks in the Strategy dialog box that you open from within the definition template of the feature in question.
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The diagram shows an example of the Strategy window with a Circle feature.
Path generation Point list Discrete points (single points) / scanning (paths) Technology macro Utilities Edit technology
Strategy list
You will find more information on this window under Strategy in the Calypso dialog reference in the Online Help.
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Point list
The point list contains the coordinates for all the points together with the normal vectors that have been collected for the feature. You can edit these coordinates and, for example, define optimum probing points. Additionally, the styli to be used are included in the list of points. The illustration below shows an example of the Point List window with a plane measured at 4 points.
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Important Be careful when changing the list, because the CMM goes to each point in the list as soon as you run the measurement plan. To display or change a point list of a feature: 1 Double-click on the feature to open its definition template, and click on the Strategy button. The dialog box appears on the screen. 2 Click on the button with the icon for the point list.
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3 To change a coordinate, click in the corresponding entry field, and overwrite the old value. 4 Click on OK. The settings are accepted.
Z Y locking mechanism X
In this example, self-centering probing of the V-groove necessitates cancellation of the lock in the X axis in order to avoid faulty probing.
probing direction
Z Y locking mechanism X
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Self-centering probing is an option only for measuring probes. To activate probe self centering: 1 If you want to activate this function for a particular feature: Highlight the feature in the measurement plan. Select Resources Probe Self Centering. The Self Center Probing dialog box is opened. Skip to step 4. 2 If you want to activate this function only for individual probing points of the feature: Open the definition template of the feature. Click on the Strategy button. Highlight the probing point in the strategy list. Click on the Self Center Probing button. The Self Center Probing dialog box is opened. Skip to step 4. 3 If you want to activate this function for all features of a measurement plan: Check that no features are highlighted in the measuring plan. Select Resources Probe Self Centering. The Self Center Probing dialog box is opened.
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5 Set the parameters for self-centering probing. Define the axes that you want to lock. Select the type of measuring force activation and enter the values in mN. For a circle path, also select the angle between the force direction and the rotational axis. 6 Click OK to save the settings. The next time it probes, Calypso will use the settings you just activated.
There is a difficulty involved if geometric elements with rotational pattern are to be measured on a CMM without rotary table and without RDS-CAA: The identical features of the pattern cannot be measured with one and the same stylus because the probing direction is different for each feature.
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Example: 8 bores
Eight bores are to be measured on a rotationally symmetrical part; these bores are defined in Calypso as cylinders with rotationally symmetrical pattern. This pattern cannot be measured at first without a rotary table and without RDS-CAA, as it is unclear which styli are to be used for the individual positions. If you have activated the automatic stylus search and a stylus is available for each required direction, Calypso can measure the cylinder without difficulty.
This is how the automatic stylus search works: Calypso searches through all qualified positions of a stylus system and compares the shaft direction of each stylus with the planned probing direction. For a cylindrical or circular feature, Calypso uses the axis of the feature. In the case of a planar feature, Calypso uses its normal.
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Calypso uses the stylus with the smallest angle between stylus shaft and axis or normal to perform the measurement. In order to make the result unambiguous, you have to specify how this angle is to be measured i.e. whether the axis or normal is to be oriented nearly in the direction of the shaft or in the opposite direction of the shaft.
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The shaft direction is defined as the direction from the fastening point to the tip of the stylus. Calypso minimizes either the angle between the stylus shaft and the axis or normal, or the angle in the opposite direction of the axis or normal. The direction you have to choose depends on the geometry of your workpiece.
Maximum angle
To reduce the danger of shaft probing (e.g. in the case of cylinder measurements), you can restrict the permitted angle between the shaft and normal or axis.
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If there is no stylus in the permitted angle range, Calypso is unable to probe. The CNC run is halted, and you receive a corresponding message.
A requirement for the automatic stylus search is that all the required styli or stylus positions must be qualified. The shaft direction must also be specified for qualification. (A query appears asking for the probing angle if probing has not been in the direction of the main axis of the CMM.) To activate the automatic stylus search: 1 In the definition template of the relevant feature, open the strategy dialog box by clicking on Strategy. 2 Double-click to open the relevant technology window for the probing, e.g. Probing point. 3 Under Stylus, select one of the two Auto entries: Auto1: Shaft away from normal: The stylus whose angle between shaft direction and opposite direction to the normal or axis of the feature is the smallest is set. Auto2: Shaft along normal: The stylus whose angle between shaft direction and normal or axis of the feature is the smallest is set.
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The shaft direction is defined as the direction from the fastening point to the tip of the stylus. 4 Click on OK to confirm. In the CNC run, the corresponding styli are dynamically selected and assigned.
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You can also make the Auto1 and Auto2 entries via the Measurement Plan Editor Features.
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An error message appears if the restriction of the angle range means that no suitable stylus is found in the CNC run. The CNC run is cancelled.
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You must have qualified your stylus with the Tensor setting in order to use path generation for scanning (see Installing and qualifying stylus systems on page 4-17). The measurement strategy depends on a number of parameters, from the group of the characteristic (shape, position, size) through tolerance up to the stylus used. Calypso uses these parameters to calculate starting parameters of the CMM that lead to the best possible compliance with the tolerance you demand. You only have to enter the minimum data. With path generation you can continuously record measuring points and generate paths from discrete points, if you have a CMM with measuring probe. Or you can just generate a path from discrete points, if you have a CMM with trigger probe (pseudo scanning). Path generation is a macro that automatically measures a feature with set parameters, for example a certain number of surface lines or screws on a cylinder or cone. With this you can reach a high point density and thus adequate information about the workpiece surface. High point densities are the prerequisite for standardized, extremely accurate evaluation of your features. To use a path generation method, follow these steps: Set the global settings for evaluation of the characteristics groups in the System Set Up (you will find more information in the Online Help under How to change the measurement parameters of the CMM). Enter the feature in the measurement plan and probe its geometry. Alternatively, you can load a feature from a CAD file. See Defining features on page 5-2. Assign a path generation method. Check and/or change the settings of the path generation method. Assigning the path generation method is split into three steps: Adding the path generation method to the strategy list.
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Making general settings. These settings are common to all path generation methods. Setting values for the path generation method. These settings are described separately because they depend on the chosen path generation method.
Strategy list
3 Choose the path mode. To change the setting, click on the displayed button. (You have chosen path generation if the points are displayed connected.) 4 Click on the button for the path generation method you want.
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The path generation method is entered in the strategy list. At the same time, Calypso immediately generates the path from the discrete points if you choose this in step 3.
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Rectangle Cylinder Sphere Cone Curve For the curve, the Unknown Contour method is activated in the technology window: For all other given features, you can insert a path in the strategy list using the Unknown Contour icon.
Enter the start point and end point of the travel path in the technology window for the unknown contour. Calypso executes the measurement between the start and end points using the shortest path while, of course, observing the feature and keeping in contact with the workpiece.
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You can extract the data for path generation straight from the CAD model. When you use this method, the system returns a series of either start and end angles or start and end points. Open cylinders and cones are taken into account: Each new path is checked directly against the CAD model in order to identify material flaws, if any, and eliminate them from the path. The path can thus be generated with restrictions, or you may be able to generate different paths. (At this time, the function is implemented only for the circle and arc.) If you make subsequent, manual changes to the path data, Calypso does not recheck the information. This means that you have a great deal of latitude in defining paths.
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If the workpiece does not allow scanning the circle path with a single stylus (e.g. in the case of a full circle on a camshaft), you can split the circle path into arcs to scan each arc individually with an appropriate stylus. The individual arcs can be combined in a circle path by means of the Group Circle Sections function. After the measurement, the circle path is assembled from the selected arcs and evaluated.
The entries for path generation can be parameterized. To do so, click on the corresponding fields with the right mouse button and then select Formula in the context menu. In the Formula dialog box, you can use the variables that are defined in the measurement plan to make formulas and enter PCM commands. The following entries can be parameterized. Scanning speed Step distance Start angle (input in decimal degrees!) Angle range (input in decimal degrees!) Stylus System Stylus
Single probing points and intermediate positions can also be parameterized. Here, it will be necessary to define the basis system for the purpose of clarity. To do so, click on the PCM-Reference button in the Point List dialog box.
In the Reference system for PCM variables dialog box, you can define which of the three relevant coordinate systems should be used a basis for the conversion of parameters to numerical values. This coordinate system will apply to all parameters of the feature that is currently open. All technological parameters of this feature will always be calculated on the basis of this coordinate system irrespective of the view that has been selected.
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Measuring range
The meanings of the term measuring height and the resulting measuring range are explained by the illustration below:
Ursprung lokales ElementeKoordinatensystem X
minimale Mehhe
Mebereich
maximale Mehhe
The parameters of the features to be measured are known. To scan a circle path using several styli, you must define which arc is to be scanned with which stylus. Keep in mind: An arc may not contain any discrete points. The direction of rotation of the first arc must correspond to the direction of rotation of the assembled circle path. The other arcs can have any direction of rotation.
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The assembled circle path begins after the largest gap between adjacent circle paths
To group arcs, select these in the strategy window using the mouse and click on Group Circle Sections. The selected arcs are assigned to a group. The grouped arcs are treated and evaluated the same way as a circle path scanned with a stylus. If one of the selected arcs is already included in a group, this will be removed from the group and added to the new group. Under certain circumstances, the old group might thus be deleted.
Removing a group
To remove a group, choose Select Group in the context menu. Click on Group Circle Sections. To remove individual arcs from a group, highlight the desired arcs and mark Remove From Group.
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Coordinate list
Marking frame
Make sure that you have entered a value for the rounding-off of corners in the system setup. Check this value by pressing on the Basic Settings button and then on the SCAN Limits tab.
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2 You always need three points if you want to create a circle segment or full circle from the collected points (start point, direction point and end point). The corresponding three points have to be displayed in the coordinates list. Use the arrow buttons next to the Number field to do so. 3 Click on the circle segment icon or full circle icon, depending how you want to connect the points. The green border now encloses the three points from which the circle segment or full circle was calculated. You see the new connection in the CAD window. 4 Continue in this way with all following points. The order does not matter for this: You can probe new points at any time and/or choose/edit connection types between any points.
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There are four ways to define the circle path: Accept the default setting: The center of the circle is in the center of the plane; the minimum of the length and width of the plane as set as the diameter, corrected by 1.5 times the stylus tip radius. Enter the values for the circle center and diameter. Click on 3 points on the plane on the CAD model. Click on a cylinder or a cone on the CAD model. This generates a circle path around the cylinder. You can modify the circle path in the CAD window by moving the circle center with the mouse or by changing the diameter by grasping the circle line with the mouse.
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The curve on the plane can be scanned with the rotary table. The check box Scan circle section with rotary table must be activated for this purpose. The preconditions for this are that the rotary table is activated for the current measurement plan and the spatial axis of the plane is in the direction of the rotary table axis.
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2 Click on the Basic Settings button if you want to enter required point densities. You switch to the corresponding page in the system setup (you will find more information on this in the Online Help under How to change the measurement parameters of the CMM). 3 If you have not defined a tolerance yet, enter it in the Expected Tolerance field for the feature. 4 Click on the Calculate button. Calypso runs a new calculation with the parameters of the Settings group. The scanning speed proposed by the system depends on the required accuracy. 5 Enter the number of the stylus with which the CMM is to perform the path generation method in the Stylus field. 6 Enter the values for the path generation method. See Path generation measuring features automatically on page 5-95. 7 Click on OK to save the settings and close the dialog box. You are returned to the Strategy window. 8 If you do not want to set any more path generation methods for this feature, click OK. Otherwise repeat the steps from Features you can measure with path generation on page 5-108. The path generation method has now been fully defined and will be executed once a CNC run is initiated.
Line
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Feature Plane
Icon
Path generation method/discrete-point measurement Grid measurement The plane is acquired in a grid of user-definable pitch. Polyline measurement A polyline is measured on the plane. Circle path on plane A circle path is measured on the plane. Polyline paths Polylines at a distance from the edge
Four-Point Circle Macro This measurement is semiautomatic. To execute this measurement, move the stylus to the center of the circle (cylinder, cone) that is to be measured. Calypso takes 4 probings and calculates the values for the circle from them. Grouping circle sections Combines the selected arcs in a group and undoes the existing grouping. A group is evaluated the same way as a circle path scanned with a stylus. Support function for special applications, e.g. if a circle is to be measured with several styli.
Circle
Circle Auto Path Definition (Circle Auto Path Measurement). The start angle and angle range can be set. Helical path (screw line measurement) Suitable for special applications (threads). Gradient, number of turns, start angle and rotation direction can be set.
Cylinder
2 Circle Auto Paths. Two circles are measured the first at the top of the cylinder and the second at the bottom of the cylinder. The measuring heights can be set individually. 1 Circle Auto Path. This intersection is measured at the center of the cylinder. The measuring height can be set. Form lines. The number of surface lines is editable. Helix Path (helical path/screw line measurement). Gradient, number of turns, start angle and rotation direction can be set. Helix Path Variable (screw line measurement with VAST Navigator). Gradient, number of turns, start angle and rotation direction as well as the number of additional circles can be set.
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Feature Sphere
Icon
Path generation method/discrete-point measurement Define Sphere Position. Calypso probes the sphere and in so doing defines the position of the sphere. The probing locations cannot be influenced. In CNC runs, you will also be requested to take manual probings. Sphere Macro. You can enter the taper angle for the area in which these probings are to be taken.
Cone
2 Circle Auto Paths. Two circles will be measured the first at the top of the cone and the second at the bottom of the cone. The measuring heights can be set individually. 1 Circle Auto Path. One or more intersections will be measured between the base surface and top surface of the cone. The number of intersections and their measuring heights can be set.
Curve
Curve segment measurement: Only for the Curve option (see Curve measurement (option) on page 16-1). The segment to be measured is defined by three or more points: If you define three points, they represent start point, end point and direction of curvature (direction around circumference) of the curve segment, in that order. If you define more than three points, they represent a full circle; the first point defines the start point and the direction around circumference is clockwise (from the top or outside).
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Chapter
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Defining characteristics
The characteristics enable you to check the tolerance limits that your workpiece and its features should meet. You integrate the required characteristics in the measurement plan and link them with the measured features. If those features are already defined, will be defined or maybe are to be imported from a CAD file later on, it makes no difference. Calypso supports any given order in which you define the features or characteristics of your measurement plan. You should be familiar with the basic concepts of Calypso before you proceed with this chapter. If you are not, you should read Calypso user desk on page 1-5 and Measurement plan-oriented measuring with Calypso on page 1-14.
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The optimum best-fit methods are the default settings for the respective characteristic groups. This section shows and explains the advantages and disadvantages of the mathematical best-fit methods. This means that for each measuring requirement that arises within the framework of a measuring strategy you can now select the best-fit method which is best suited to your individual requirements.
Best-fit methods
Calypso uses the following best-fit methods: Gauss Tschebyscheff (minimum criterion) Calculation as circumscribed or inscribed feature Calculation as tangential element (outside/inside).
Specifying the best-fit method
In Calypso, you can specify which best-fit method to use for which feature at two places: in the Evaluation dialog box, which you can access from the definition template for the respective feature using the Settings button.
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in the Evaluation dialog box, which you can access from the feature selection for the characteristic using the Settings button. The selected method will be used to calculate the characteristic when the data is evaluated. If you select Default, the best-fit method defined in the feature will be used. Not all best-fit methods are available, only those suitable for the selected feature (see Using the best-fit methods on page 6-6). You can view and change the parameters for the best-fit method in the system set-up by selecting Extras Workroom Measurement. The current settings are on the Point Density tab.
Example
The following diagram shows the actual shape of a scanned circle with the ideal geometric shapes. Those shapes result from the different best-fit methods.
outlier
Gauss fitting-in Minimum fitting-in (Tschebyscheff) Hull Element Fitting-in element X Actual outline
As can be seen from the illustration, depending on the best-fit method used, results can differ when dimensions (e.g. diameter), form deviations and position (e.g. center) are checked.
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Feature 2D Line 3D Line Plane Circle Sphere Cylinder Cone Ellipse Rectangle Slot Point
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Defining characteristics
To go from merely obtaining measurements to their evaluation, it is necessary to define the characteristics. This is performed as following: You integrate the characteristics into the measurement plan, a procedure for which you have three options: You can choose characteristics from the menu bar of the user desk. You can choose characteristics from a toolbox of Calypso. You can define characteristics implicitly in the definition template of a feature. Refer to the section entitled Definition template for features on page 5-3 for a description of the check boxes of the Tolerance For: group. You can assign the features to the characteristics, please see Connecting a characteristic to a feature on page 6-16. You can find more detailed information regarding the different characteristics in List of characteristics on page 6-43.
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The content of the characteristic definition template varies with the selected characteristic. There are three ways of opening a definition template: Select the characteristic and click on the Change View button. Right-click on the characteristic to open the context menu and then select Open. Double click on the icon of the characteristic. The template of this characteristic will open. Here, the fields for tolerance and actual value are shown. The buttons for the required references of this characteristic will still be shown as empty. Example: After you select and double-click on the True Position characteristic, the following dialog box will appear on the screen:
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Utilities
In the Utilities group in the toolbox and under Resources Utilities in the menu, you can find some special elements that, strictly speaking, are not characteristics but are required for the measurement plan in certain circumstances: Alignment 3D Best Fit (not in Calypso Light) RPS Method P6 Method Stylus qualification Gage Correction Qualification (not in Calypso Light, see Greater accuracy by gage correction qualification on page 5-47). Erosion Module (option) Textelement Save Alignment Load Alignment Delete Alignment Zero Base Alignment (see How to set a base alignment to zero on page 4-76) The utilities are described with the runs, characteristics and features for which they are needed. Only the following utilities are described here. Alignment, 3D Best Fit, RPS Method, P6 Method Stylus System Qualification Erosion Module Textelement Save Alignment Load Alignment Delete Alignment
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You can use this utility to define the qualification settings for any (already defined) stylus or stylus system. Calypso automatically performs qualification during the CNC run of the measurement plan. If you use a stylus system changer, Calypso automatically uses the correct stylus system. Otherwise, you will be prompted to insert the stylus system.
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The erosion module is an option you can purchase and have enabled. You can add the Erosion Module utility to the measurement plan by selecting Resources Utilities Erosion Module or via the toolbox on the Utilities page.
The erosion module provides a file with translation and rotation values for two related alignments which is suitable for erosion machines. It will be necessary to enter the type of erosion machine that is being used along with the name and directory of the file that will be created.
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The directory path must be available. It is not created automatically. These alignments refer to the clamping device on the one hand and to the erosion electrode on the other. Here, the alignment of the workpiece or tool (erosion electrode) (Xe, Ye, Ze) will be determined on the basis of the alignment of the clamping device (X, Y, Z).
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Here you cannot select alignments with index that are based on references with pattern. Important If you specify the alignments in an order that is the wrong way around, you receive other compensation values. During the CNC run, i.e. when measuring the feature, the alignments will be formed - if this has not already been executed - and the parameter file of the erosion module will be saved on the hard disk or a floppy disk.
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Procedure
First, your inputs and the manufacturer-specific entries in the Conf.dat configuration file are used to create an Erodier.Edm initialization file as an ASCII file. By editing the entries in the Conf.dat configuration file, you can control the output of the file for the erosion machine. Once the erosion module has been executed, an ASCII file will be available in a format that can be used with the erosion machine.
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Result
The file contains the names of the erosion machines and a special code for the coordinate transformation in each case. For each erosion machine type, there are two lines in the following form:
;MachName<serial number> = <machine name> <machine-specific switch>
The details for the coordinate transformation are in the machinespecific switches, an 8-digit binary number. Example:
;MachName01 = Erode de luxe 11110000
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The 8 digits of the switch (counted from the left) have the following functions: Digit 1 2 3 4 5 6 7 8 Function 1 changes sign of X 1 changes sign of Y 1 changes sign of Z 1 changes sign of C 1 changes the reference system Manufacturer-dependent Not used Code electrode/tool; e.g.: 0 = ELEKEle,X-38.611,Y34.783,Z50.202,C-7.023 1 = WKSEle,X-38.611,Y34.783,Z50.202,C-7.023 A 1 in the 5th digit thus has the same effect as swapping the alignments of the clamping device and the erosion electrode.
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Textelement utility
With Resources Utilities Textelement or by using the toolbox on the Utilities page, you can enter the Textelement utility on the current page in the measurement plan. The Textelement utility appears with its symbol in the list of characteristics. Double click to open a window which will allow you to enter a text.
Text output
In the case of a CNC run of the measurement plan, the text will be output in the printouts and protocols (the default printout, the compact printout and the custom printout). Only the text itself is output in the default printout and compact printout. The custom printout also includes the name of the characteristic (e.g. Textelement7). The text will only be written in the printouts and during CNC run and not when opening or closing the definition template (as is usual in the case of characteristics).
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Saving alignments
Calypso can save, load and delete alignments again during a CNC run. In the definition template for the Save Alignment utility, enter the file name and select the alignment to be saved. If the alignment has a pattern, you must determine the desired index. When the utility is executed in the CNC run, the actual alignment (calculated from the actual values) is saved on the hard disk in the ...\Calypso\home\om\workaera\basesystems directory. A subdirectory is created with the name that was entered in the definition template. If you entered backslashes \ here, further subdirectories will be created under this directory. If there is no actual alignment of the set alignment, this will be calculated during the CNC run and, if necessary, measured. If the alignment cannot be measured and calculated, the symbol for the utility will turn red in the measurement plan.
Loading alignments
Calypso can save, load and delete alignments again during a CNC run. In the definition template for the Load Alignment utility, enter the file name for the alignment to be loaded. If the alignment has a pattern, you must determine the desired index. When the Load Alignment utility is executed in the CNC run (e.g. because a feature refers to this alignment), the alignment is loaded from the hard disk. The directory for alignments is ...\Calypso\home\om\workarea\basesystems. If the file name contains backslashes \, the program will branch to the appropriate subdirectories. If a Load Alignment utility is contained in the measurement plan, it is treated as a normal alignment. Its name (not identical to the file name) appears in the geometry reference system lists and the lists for linked alignments, for example. No distinction is made between nominal values and actual values when loading. Nominal values and actual values are equal in this case. In the case of a DMIS run, the loaded alignment is used as the current alignment.
Special aspects
The name of the alignment to be loaded need not necessarily be the file name.
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An error message will be issued if an alignment cannot be loaded (because the file is not present). In addition, a message stating this will appear in the status window, and the CNC run will be interrupted if necessary. The base alignment is returned for critical calls, such as the nominal alignment for the nominal geometry.
Deleting alignments
Calypso can save, load and delete alignments again during a CNC run. In the definition template for the Delete Alignment utility, enter the file name for the alignment to be deleted. All alignments are listed in the
...\Calypso\home\om\workarea\basesystems directory.
If the file name contains backslashes \, the program will branch to the appropriate subdirectory. The file you specified in the definition template is deleted during the CNC run. If the file is not present, the run will continue without a message. The symbol for the utility in the measurement plan will turn red. If the file is write-protected, an error message will appear stating that the file cannot be deleted. The CNC run is resumed.
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in the Online Help under How to select features in the CAD model). The first feature you click on will be adopted as the Feature, the second as Primary Datum, the third as Secondary Datum etc. corresponding to the sequence of the buttons. You use the Automatic Feature Predefinition function. To do this, you must have activated the Automatic Feature Predefinition check box on the Features notebook page under Extras Workroom Measurement. If this check box is ticked, when a new characteristic is opened, the last feature that was open will be entered automatically. Example: You create a Circle1 and close the window. You then add diameter, roundness, X value and Y value, etc., to the measurement plan in the list of characteristics. When you open these characteristics one after the other, Circle1 is already entered for the first feature of each characteristic. Use the displayed button in the template window. In this way you can connect new features or features that have already been defined to the characteristic. You establish the connection to the characteristic in the Selection dialog box.
Input field
Overview
If the measurement plan is large, you might find it useful to have an overview of how a feature is used in the various characteristics. You can obtain an overview of this nature by opening the list of features, highlighting a feature and selecting the Check use of selected features command in the context menu. This opens a list of all characteristics in which the feature you selected is used.
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You can assign indexes to characteristics. Thus, you define with one definition template several characteristics of the same type. For details, please refer to Characteristics with indexes on page 6-22.
You can limit the scope of the model of the features by, for example, clicking on the appropriate buttons. 4 If you want to filter the measured values: activate the Filter check box and if necessary, click on the Settings button to define the filter. You will find more information on filters and filtering in the section entitled How to set and activate a filter on page 6-36. 5 If you want to eliminate outliers: activate the Outlier Elimination check box and if necessary, click on the Parameters button to define parameters for eliminating outliers. You will find more information on outliers in the section entitled How to eliminate outliers on page 6-38. 6 If you want to use a best-fit method other than the default, click on the Parameters button and select the method you want in the dialog box. Note that all best-fit methods are not necessarily available for all features. 7 Click OK to assign the values in accordance with your settings. This takes you back to the definition template. If the characteristic requires more than one feature, you can define the rest of them by repeating the steps described above. You will find more information on the Selection dialog box under Selection (features) in the Calypso Online Help.
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How to assign a feature that has not yet been defined via selection
When you entered the characteristic in the measurement plan, maybe you did not define the feature. Or maybe you noticed that you need more features. It does not take much effort to create a new feature within the definition template of the characteristic and directly assign it. 1 Open the definition template by double-clicking the characteristic of your choice. The definition template is opened. 2 Click on the Feature (or Feature1) button. The Selection (features) window will open. 3 Select the New option. A list of all the types of feature possible for the characteristic in question is displayed. 4 Select the feature type and click OK to confirm your choice. This opens the definition template of the feature. 5 Define the feature. The procedure is exactly as described in How to define a feature using definition templates on page 5-4. 6 When you have probed all the points, click OK. This closes both the definition template and the Selection window, so you return to the definition template of the characteristic. If the characteristic requires more than one feature, you can define the rest of them by repeating the steps described above. You will find more information on the Selection dialog box under Selection (features) in the Calypso Online Help.
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3 Activate the Select existing Features radio button, if it is not already activated. 4 Click on the feature you want in the list.
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You can limit the scope of the model of the features by, for example, clicking on the appropriate buttons. 5 Activate the Edit check box. 6 Click on OK. This opens the definition template of the assigned feature. 7 Make the necessary alterations to the feature (see Definition template for features on page 5-3). 8 Click on OK. The changes you made to the feature are saved and the definition template for the characteristic reappears on the screen. If the characteristic requires more than one feature, you can define the rest of them by repeating the steps described above. You will find more information on the Selection dialog box under Selection (features) in the Calypso Online Help.
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3 Click on the Transfer format button in the upper toolbar. The Characteristics assign to Features dialog box appears on the screen.
The dialog box contains a second page on which you can copy the properties of characteristics. To open the second page, click on the symbol for the characteristics at the bottom left of the dialog box or on the user desk. 4 Set a radio button in the Naming block to specify whether the characteristics will be entered with standard names or whether you will define the names in a dialog. If you do not want to be prompted to enter names, Calypso will assign each new characteristic a standard name. 5 Set a radio button in the Existing characteristics block to specify whether or not existing characteristics will be overwritten. 6 In the list of features, highlight the feature or features to which you want the characteristics assigned. Press and hold down the Shift or Ctrl key if you want to highlight more than one feature. 7 Click on OK to start the assignment. If you activated the Request all names radio button, the number of boxes suggesting names will be equal to the number of characteristics you selected times the number of features. If a characteristic already exists, the default is the current name, whereas a standard name (see above) is suggested for new characteristics. 8 Overwrite the names suggested by the system, if applicable.
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Defining characteristics
The new characteristics are added to the list of characteristics. If this list already contains the same characteristic for a feature the original characteristic will be overwritten or not, depending on which radio button you activated in the Existing characteristics block.
This characteristic represents a series of characteristics that differ only in the value of the corresponding loop variable (in this case LOOP1). The LOOP1 loop variable must, of course, have been used for the definition of the characteristic to make sure that these characteristics differ from each other. Example: You use the LOOP1 loop variable in the name of the feature to which the characteristic refers. This gives a 1:1 relation between several features (of the same type) and several characteristics (of the same type).
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Example: You defined the (1,8,1)Roundness1 characteristic. You want the following representation of the characteristic on the feature: Characteristic Roundness1(1) Roundness1(2) Roundness1(3) Roundness1(4) Roundness1(5) Roundness1(6) Roundness1(7) Roundness1(8) Feature Circle1(4) Circle1(6) Circle1(8) Circle1(4) Circle1(2) Circle1(8) Circle1(6) Circle1(4)
You define for the Circle1 feature an index exchange with three groups: Start index 4 4 8 End index 8 2 4 Step width 2 -2 -2
The example shows that the relation between the characteristic and the feature may not be clear after the index exchange: The Circle1(4) feature is not only measured in the Roundness1(1) characteristic but also in the Roundness1(4) characteristic. Only the first use found is recorded in the compact printout.
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2 Select the feature with pattern to be measured and select Index exchange in the context menu. The Loop window will appear on the screen.
3 Enter the definitions for the index exchange in the list of loop values and confirm with OK. 4 Click on OK to close the Selection (feature) window. A loop or construction is automatically assigned to the characteristic and the defined index exchange is entered.
NOTE
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By selecting Delete Index Exchange in the context menu, you delete the index and the index exchange as well as the loop placed over the characteristic.
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An index exchange is carried out between the current loop index of the characteristic and the Circle2(*) characteristic. Open the Selection (feature) window in the definition template of the Distance characteristic. In the context menu of the Circle2(*) feature, select Index exchange... and enter the parameters for start, end and step in the Loop window: Start = 2, End = 8, Step = 1. Now, the distance is calculated as shown above.
The tolerances determine the calculation of the scanning speed for the measuring strategy. See Path generation measuring features automatically on page 5-95. To enter tolerances and nominal values: 1 Open the definition template by double-clicking the characteristic. The Definition template (characteristic) 2 is opened (taper angle of a cone is shown here by way of example).
2 Enter the required nominal value (or several for locations) in the Nominal (or Nominal Position) field.
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3 Now enter the tolerance values: You can choose the tolerance group from the selection list (below the name of the characteristic). Once you have made your selection, the corresponding values appear in the Upper Tolerance and Lower Tolerance boxes. Or you can type the tolerance values directly into the Upper Tolerance and Lower Tolerance if you need your own tolerance values. 4 Activate the None check box if you do not want tolerances taken into account in measurement evaluation. 5 Select Last input from the menu if you again need the most recently selected tolerance. 6 Click on OK to close the definition template of the characteristic. You have now defined all the characteristic parameters Calypso needs for the evaluation of measuring results. The elements in this dialog box are fully described in Definition template (characteristic) 1 in the Calypso Online Help. Keep in mind that the icon of the characteristic is now displayed with either a green or red background, depending on whether it is inside or outside of the tolerance. If the feature has not been measured yet, the icon has a dark gray background (indicating that it is completely defined).
Thickness measures DIN 1683 Thickness measures GHTB 20 to GTB 16.5 GTB 17/5 moulding/not moulding DIN 1684 GTB 17/5 m. linear measures / not m. linear measures DIN 1684 GTB 17/5 m. thickness measures / not m. thickness measures
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Tolerance type GTB 17 moulding/not moulding GTB 16/5 moulding/not moulding GTB 16 moulding/not moulding
Tolerances DIN 1684 GTB 17 m. linear measures / not m. linear measures DIN 1684 GTB 17 m. thickness measures / not m. thickness measures DIN 1684 GTB 16/5 m. linear measures / not m. linear measures DIN 1684 GTB 16/5 m. thickness measures / not m. thickness measures DIN 1684 GTB 16 m. linear measures / not m. linear measures DIN 1684 GTB 16 m. thickness measures / not m. thickness measures
DIN 1685 Rough Linear measures / DIN 1685 Linear measures GTB 20 to GTB 15 castings of cast iron thickness measures DIN 1685 Thickness measures GTB 20 to GTB 15 with spheroidal graphite DIN 1686 Rough castings of cast iron with foliated graphite DIN 1687 Rough castings of heavy metal alloys Linear measures / DIN 1686 Linear measures GTB 20 to GTB 15 thickness measures DIN 1686 Thickness measures GTB 20 to GTB 15 Sand rough DIN 1687 GS GTB 20 to GTB 16 m. / not m.
Pressure die casting DIN 1687 GD L GTB 14 m. / not m. Linear measures / thickness measures for high-melting and low-melting alloys DIN 1688 Rough castings of light metal alloys Sand rough DIN 1688 GS GTB 20 to GTB 16 m. / not m.
Pressure die casting DIN 16901 Plastic tolerances General tolerances DIN 16901 Gen. 160 A / 160 B DIN16901 Gen. 160 B / 160 B
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Tolerance type
Tolerances Tolerances for DIN 16901 with directly entered A. 160 A / 160 B values with directly entered deviations DIN 169091 with directly entered A. Precision Techn. A/B Select General tolerances (fine, medium, coarse, very coarse) or special, material-specific tolerances (cast blanks, plastic parts) with the appropriate DIN standard (for information on how to add tolerance tables of your own to this menu, see Defining custom tolerance tables on page 6-30).
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2 If you have not assigned features, click on the Feature button and select the feature whose position you want to check. This illustration shows the template for the True Position characteristic for checking a cylinder.
Selection list
3 From the RFS (= Regardless Feature Size) selection list, select the entry: MMC to apply the most-material condition, or LMC to apply the least-material condition. The Nominals button now appears beside the selection list. 4 If Diameter has not been defined as a characteristic for the feature, click on the Nominals button. Calypso adds Diameter as a characteristic for the feature to the measurement plan and opens the definition template: Enter the nominal value for the diameter. Click on OK to close the definition template for the diameter. 5 Define reference features, if necessary. You can apply MMC or LMC to the reference features as well. To do this, click on the button of the reference and proceed as described above, starting at step 3. 6 Click on OK. The settings are saved and the definition template is closed.
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<?xml version="1.0" ?> <!DOCTYPE tolerancesDefinitionFile SYSTEM "tolerancesDefinitionFile.dtd"> <tolerancesDefinitionFile> <userNorm name = "Feinmessraum" group = "3" description = "Feinmessraum1"> <range stop= "18"> <value name = "UT" value = "+4.5"/> <value name = "LT" value = "-4.5"/> </range> <range start = "18" stop="30"> <value name = "UT" value = "+7.5"/> <value name = "LT" value = "-7.5"/> </range> <range start = "30" stop="50"> <value name = "UT" value = "+8"/> <value name = "LT" value = "-8"/> </range> <range start = "50" stop="80"> <value name = "UT" value = "+8.5"/> <value name = "LT" value = "-8.5"/> </range> <range start = "80" stop="120"> <value name = "UT" value = "+9.01"/> <value name = "LT" value = "-9.01"/> </range> <range start = "120" stop="180"> <value name = "UT" value = "+10"/> <value name = "LT" value = "-10"/> </range> <range start = "180" stop="250"> <value name = "UT" value = "+11"/> <value name = "LT" value = "-11"/> </range> <range start = "250" stop="315"> <value name = "UT" value = "+11"/> <value name = "LT" value = "-11"/> </range> <range start = "315" stop="400"> <value name = "UT" value = "+12"/> <value name = "LT" value = "-12"/> </range> <range start = "400" stop="10000"> <value name = "UT" value = "+13"/> <value name = "LT" value = "-13"/> </range> </userNorm> </tolerancesDefinitionFile>
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When you copy this file into the calypso\opt\om\data\toldat directory, the tolerances menu will have another item called Feinmessraum1, and this item, in turn, will offer you a total of 10 tolerances.
Meanings of the entries
The following entries in the file are customizable: group=3 The standard entry is group=1. If there are two or more userdefined tolerance tables, this number defines the position at which the submenu will appear when the User defined tolerance pulldown menu is opened. description=Feinmessraum1 The text displayed in the pulldown menu. range stop=18 Nominal range from 0 mm to 18 mm, inclusive. value name = UT value = +4.5 Upper tolerance of nominal range 0 to 18 (+4.5mm). value name = UT value = -4.5 Lower tolerance of nominal range 0 to 18 (-4.5mm). range start = 18 stop=30 Nominal range from 18 mm to 30 mm, inclusive.
The use of filters is recommended only for a large number of points, i.e. only for scanned features.
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The current standard calls for at least seven points (earlier standards: five points) as the prerequisite for using filters. This value is set as the default value for measurement plans in version 3.8 and higher. You can toggle the minimum number of points between 7 and 5 for the current measurement plan in Measurement plan editor characteristics.
!
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Important Once the minimum number of points has been changed to 7, filtering might no longer be possible for certain features in measurement plans created with older versions of Calypso. The No result message appears.
Filtering a profile with a low-pass filter (low frequencies pass the filter, high frequencies do not) yields an average line in which waviness and other long-wave profile components are present, while the effects of surface roughness are largely eliminated. The average line is produced by analyzing measuring points within equal sections (double the wave length): The measuring points are analyzed with weighting within each section. The profile obtained in this way is compensated and serves as the basis for calculating parameters of waviness.
High-pass
Filtering with a high-pass filter (high frequencies pass the filter, low frequencies do not) yields an average line in which waviness is suppressed, while the effects of the surface roughness are still present. A band-pass filter results from the combined use of a low-pass and a high-pass filter. This suppresses both the long-wave (waviness) and short-wave (surface roughness) profile components that exceed the respectively specified limit.
Band-pass
Eliminating outliers
Outliers are geometric points that differ significantly from the geometric form yielded by the other measured points and as such, they can produce a large error when the computed feature is calculated. An error of this nature would easily propagate through the actual-value determination of the corresponding characteristic.
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Prior to the actual outlier recognition, the measured points are filtered through a band-pass that is composed of low-pass and high-pass filters. Thus, measured values that are otherwise not detectable as outliers can likewise be eliminated. You define yourself the characteristic of the band-pass (How to eliminate outliers on page 6-38).
Blockage 1 Low-pass Band-pass High-pass Passage Blockage
1/2
0 UPR
s/100 100
s/2 2
A measured (prefiltered) point is tagged as an outlier if it is further than a defined threshold (threshold = factor * standard delta) from the computed Gaussian element. You also predefine the factor.
The setting for the characteristic always takes priority. If filtration/outlier elimination is not activated for the characteristic, the setting for the feature applies. If filtration/outlier elimination is not activated for the feature, Calypso refers to the default settings for the characteristic groups. Bear in mind that filtration requires a minimum number of points to be probed. If the number of probings is less than this minimum number, the filter is not activated and a message to this effect is issued. A feature obtained by recall from a feature filtered beforehand is automatically not filtered subsequently, even if filtration is activated.
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2 Click on the appropriate Settings button. 3 Set the parameters as necessary in the Filter or Outlier mode dialog box and activate your settings, if applicable. The current setting is displayed beneath the corresponding check box. 4 Click on OK. The dialog box is closed and the settings are accepted. The filter or outlier elimination activated in this way applies with its parameters to all the features required for the characteristic, unless a setting to the contrary is made in a given feature's definition template.
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3 Click Settings to define the settings for the filter. The Filter window will open.
4 Select Filter Method and Filter Type, then enter the limit values for the selected filter. You can specify the filter parameters via Undulations Per Revolution or via Wavelength Lc. You must enter a value range if you have entered the Band-pass filter type everything exceeding this range will be filtered out. 5 Activate the Filter on check box if you would like for it to be possible to activate the filter from the Reference (feature for characteristic) dialog box. 6 Click on OK to save the settings and close the dialog box. This returns you to the Characteristics window, which is still open. If you activated a filter, the filter method and the filtration parameters now appear below the Filter check box (e.g. Gaussian 150).
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At the bottom right you can see whether or not outlier elimination is activated. If it is active, its parameters are shown. 2 Activate the Outlier Elimination check box to activate elimination, or deactivate the check box to deactivate elimination.
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3 Click Parameters to define the parameters for outlier elimination. The Outlier mode dialog box appears on the screen.
4 Enter the Factor for Outlier inside and outside the workpiece with two decimal places. 5 Select the range of data reduction: Only Outlier: Only the real outliers are eliminated. Include Adjacent Points: The number of adjacent points to be eliminated in addition to the outliers can be determined in tests for manual measurement. To Computed Feature: For CNC operation, it has been shown to be effective to eliminate adjacent features until the first probing point again lies beyond the computed feature.
Include Adjacent Points Include Adjacent Points
Outliers
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6 Enter the prefilter: For circles, cylinders, cones and spheres, you enter the lower and upper value for the Undulations Per Revolution. For all other features, you enter the lower and upper value for the Wavelength Lc. For more information about the function of the prefilter, see Filtration and outliers on page 6-32. 7 Click on OK to save the settings and close the dialog box. This returns you to the Characteristics window, which is still open. If you activated outlier elimination, the words Outlier Elimination now appear below the No Outlier check box.
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2 Click on the characteristics icon at the bottom of the dialog box. The Copy Properties from <characteristic name> dialog box appears on the screen.
3 Activate the check boxes of the properties of the selected characteristic that you want to copy to other characteristics. 4 Highlight the characteristic or characteristics to which you want to copy the properties. Press and hold down the Shift or Ctrl key if you want to highlight more than one characteristic. 5 Click on OK. Copying is started.
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List of characteristics
The table below lists the items of information you need to define the characteristics for size, form and location: Menu Location in command toolbox Size Standards
Characteristic X value
Description
Size Determines the position of a given feature in X. Characteristics The location of each feature is stated in coordinates for X, Y and Z. The position of a circle, for example, is defined by its center. The values are referenced to the part alignment. Size Determines the position of a given feature in Y. Characteristics The location of each feature is stated in coordinates for X, Y and Z. The position of a circle, for example, is defined by its center. The values are referenced to the part alignment. Size Determines the position of a given feature in Z. Characteristics The location of each feature is stated in coordinates for X, Y and Z. The position of a circle, for example, is defined by its center. The values are referenced to the part alignment. Size Determines the diameter of a round feature Characteristics such as a circle, cylinder, cone, or sphere. Size Determines the radius (= half the diameter) of Characteristics a round feature such as a circle, cylinder, cone, or sphere. Size Determines for a feature the radius and the Characteristics angle (specified in the feature's local coordinate system) of each individual probing point. This corresponds to presentation of the probing points in the polar coordinates. In this way the results for a small arc segment can be enhanced. Note: The angles are only output, if Additional Position Result is activated in the Measurement Plan Editor Characteristics. Size Determines the length of the axis of a Characteristics rotationally symmetrical body.
Y value
Size Standards
Z value
Size Standards
Diameter
Radius
Radius measurement
Length of Axis
Size Standards
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Description
Size Determines the position of a given feature with Characteristics the Radius polar coordinate. The location of each feature can be defined in terms of the polar coordinates (Radius, Angle, Height). The position of a circle, for example, is defined by its center. The values are referenced to the part alignment. Size Determines the position of a given feature with Characteristics the Angle polar coordinate. The location of each feature can be defined in terms of the polar coordinates (Radius, Angle, Height). The position of a circle, for example, is defined by its center. The values are referenced to the part alignment. Size Determines the position of a given feature with Characteristics the Height polar coordinate. The location of each feature can be defined in terms of the polar coordinates (Radius, Angle, Height). The position of a circle, for example, is defined by its center. The values are referenced to the part alignment. Size Determines the first projected angle of a Characteristics certain feature based on the part alignment. In a spatial system of coordinates, the axial direction can be defined by two projected angles. A projected angle is an angle on a workpiece plane viewed from the third axis. Projected angle no. 1 is based on the reference axis (the axis common to the two planes of projection) of the feature. Feature axis X Y Z Angle 1 Y/X Z/Y X/Z
Polarposition Angle
Size Standards
Polarposition Height
Size Standards
Size Angle
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Description
Size Determines the second projected angle of a Characteristics certain feature based on the part alignment. In a spatial system of coordinates, the axial direction can be defined by two projected angles. A projected angle is an angle on a workpiece plane viewed from the third axis. Projected angle no. 2 is based on the reference axis (the axis common to the two planes of projection) of the feature. Feature axis X Y Z Angle 2 Z/X X/Y Y/Z
Cone Angle
Size Angle Size Angle Size Angle Size Angle Size Angle
Size Determines the angle of aperture of a cone. Characteristics Size Determines the half angle of aperture of a Characteristics cone (the angle between the axis of the cone and the cone's lateral surface). Size Determines a features angle of inclination Characteristics from the Z axis of the part alignment. Size Determines a feature's angle of rotation about Characteristics the Z axis, referenced to the X axis of the part alignment. Size Calculates the angle that the axis of rotation of Characteristics a feature assumes with the part alignment. Determines the two-dimensional distance between the midpoints of two features. This characteristic is used to determine the distance between the projections of two twodimensional features on a datum plane. Determines the direct three-dimensional distance between the midpoints of two features. This characteristic is generally used for two points defined in all three dimensions (e.g. the centers of spheres).
Polar 2d
Location Size Characteristics Distance and Form and Location Distance Size Location Distance Characteristics and Form and Location Distance
Polar 3d
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Defining characteristics
Characteristic Cartesian
Description
Size Location Determines the distance between two features Distance Characteristics in Cartesian coordinates (along the X, Y and Z axes). and Form and Location Distance Size Size Determines the distance between the two Distance Characteristics reference features of a symmetry point. and Form and Location Distance Size Size Determines the distance of a space point or Distance Characteristics net point referenced to its nominal value. and Form and Location Distance Size Size Distance Characteristics and Form and Location Distance Determines the distance of a point feature from the origin of a coordinate system or the distances of two point features from each other. The distances output are those along the Cartesian axes, along with the point-to-point distance (radius) and the vector angle. The reference point for a circle, ellipse, sphere, rectangle or slot is always the midpoint.
Simple Distance
Diameter Two
Size More Size More Size More Size More Size More
Size Determines the second diameter of an ellipse. Characteristics The first diameter of the ellipse is measured with the Diameter command. Size Determines the height difference between two Characteristics given points of the curve. Size Determines the axial and radial deviations of a Characteristics lift curve. Size Determines the distance between two curves. Characteristics Size Determines the expansion of a curve in a Characteristics predefined direction.
Curve Slope
Curve Stroke
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Characteristic Radius 2
Description
Size Determines the second radius of an ellipse Characteristics feature. The first radius of the ellipse is measured by the Radius characteristic. Size Determines the length of a slot or a rectangle. Characteristics Size Determines the width of a slot or rectangle. Characteristics Size Determines the average of multiple length Characteristics measurements. Form Determines the roundness or circularity of a Characteristics given circular feature. The circle can be on a cylinder, a sphere, or a cone. The definition template includes a button labeled Graphic for form plots (see How to display variations in form and location graphically on page 9-33). Form Determines the flatness of a flat feature. The Characteristics definition template includes a button labeled Graphic for form plots (see How to display variations in form and location graphically on page 9-33). Form Defines for a flat feature the flatness within Characteristics given rectangular zones. The definition template includes a button labeled Graphic for form plots (see How to display variations in form and location graphically on page 9-33). Form Determines the straightness of a line. Characteristics The normal tolerance direction reflects straightness in the probing direction; the parallel tolerance direction reflects straightness parallel to the surface of the workpiece. The definition template includes a button labeled Graphic for form plots (see How to display variations in form and location graphically on page 9-33).
Slot Length
Slot Width
Average
Flatness In A Zone
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Defining characteristics
Description
Form Determines the cylinder form of a cylindrical Characteristics feature. The definition template includes a button labeled Graphic for form plots (see How to display variations in form and location graphically on page 9-33). Form From the extreme values of features, Characteristics determines form deviation as the difference between the maximum and minimum measured values normal to the feature (e.g. cone form or sphere form). Form This characteristic is optional. It defines the Characteristics deviation of a defined curve (see Curve measurement (option) on page 16-1). Form Defines the deviation of a plane from its Characteristics nominal geometry. Its value depends on the selected shape of zone (see DIN ISO 1101 Profile on page 6-50). Location Determines the position of a given feature in Characteristics relation to a datum reference frame. You have the choice of defining the reference features, the base alignment, or one of the systems of coordinates. Each defined part alignment can be used as the datum reference frame. When you define the position tolerance, you can click on the Special button to apply the Offset and Rotate functions with reference to the base alignment (see Moving or rotating the base / start alignment on page 4-60). Alternatively, you can use the best fit of bore pattern function (see How to use best fit of bore pattern on page 6-54). Location Determines the concentricity of a given feature Characteristics (e.g. of a circle) relative to one or two reference features. Location Determines the coaxiality of a given feature Characteristics (e.g. of a cylinder) relative to another feature. Location Determines the perpendicularity of a planar, Characteristics cylindrical, conical or a straight-line feature relative to one or two reference features. Location Determines the parallelism of a planar, Characteristics cylindrical, conical or a straight-line feature relative to one or two reference features.
Form
Curve Form
GDT Profile
DIN ISO 1101 Concentricity DIN ISO 1101 Coaxiality DIN ISO 1101 Perpendiculari ty DIN ISO 1101 Parallelism
Form and Location Form and Location Form and Location Form and Location
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Menu Location in command toolbox Form and Location Form and Location
Description
Location Determines the symmetry of a feature relative Characteristics to two reference features. Location Determines the deviation of a feature from a Characteristics reference feature and a defined angle.
Form and Location Determines the deviation of a feature (circle, Location Characteristics circle on cone, cylinder, cone) normal to the Runout reference axis in the radial direction. If the reference feature has no axis (point or 3D point), Calypso uses, as the reference axis, the axis of the characteristic that is moved to the position of the reference feature. A measured point is only useful as reference feature, if it is acquired by self-centering probing. Form and Location Determines the deviation of a feature in the Location Characteristics direction of the reference axis. Runout Form and Location Location Determines the angle between two features. Characteristics You have a choice of results: acute angle, this angle's supplement to 180 and the supplementary angles of both to 360. Determines the gap between the profile and circle for the Circle in Contour Best Fit (Circle in contour best fit construction on page 5-80). Determines the start angle for the Circle in Contour Best Fit (Circle in contour best fit construction on page 5-80). Determines the angle range between the contact points for the Circle in Contour Best Fit (Circle in contour best fit construction on page 5-80). Determines the end angle for the Circle in Contour Best Fit (Circle in contour best fit construction on page 5-80).
Feature Angle
(from the Circle in Contour Best Fit construction) (from the Circle in Contour Best Fit construction)
Angle Range
End angle
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The profile can be determined for the following characteristics: Plane Cylinder Cone Sphere Point General surface
NOTE
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The DIN ISO 1101 Profile corresponds to the TOL/PROFS defined in DMIS. When defining the DIN ISO 1101 Profile, you can choose from four shapes of zone: The following are observed: The deviation from the nominal surface to the inside and outside (with the same values) The deviation from the nominal surface to the inside The deviation from the nominal surface to the outside The deviation from the nominal surface to the inside and outside (with unequal values) For the bilateral tolerance with unequal distribution, a further input field is activated for the Tolerance (one side), in which you additionally specify the side to which the tolerance applies with the Inside / Outside Switch button.
Shapes of zone
Shape of zone Bilateral One-sided (inside) One-sided (outside) Bilateral (unequal distribution)
Result of profile
The result of the profile depends on the shape of zone. The following are output: The largest deviation (inside and outside) times 2P Example
One-sided (inside)
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The following are output: The largest deviation outside the workpiece
Example
The largest deviation (inside and outside) from a calculated center line times 2
The General Surface feature contains only a set of points and not a mathematical description of the surface. Therefore, the points can be evaluated only individually: Each actual point is compared with its associated nominal point. The stylus touch point is calculated based on the stylus tip center, stylus tip radius and the normal vector of the nominal point. The deviation D of the point is formed from the nominal point and actual point along the normal vector of the nominal point. The deviation perpendicular to the normal vector of the nominal point is ignored. This corresponds to the procedure for the space point. The greatest absolute deviation of all point comparisons is then used as a measure for the profile.
Restrictions
The following restrictions apply to the profile: No restrictions may be set for the best fit. Negative tolerances are not permitted.
The following particularities apply to the profile of a general surface: No filters or outlier elimination. Only the Gauss evaluation method is possible.
As in general, the following applies to profile with reference features: Either no reference feature or all three reference features are defined. Otherwise, no result will be output.
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The measured values received from the flatness check of the rectangles can be evaluated in different ways: Flatness relative to a part plane For each rectangle, the difference between the maximum and minimum distance of the actual points of the rectangle to the fitted part plane of the rectangle is specified. Flatness relative to the overall plane For each rectangle, the difference between the maximum and minimum distance of the actual points of the rectangle to the fitted overall plane is specified. This provides you with a measure for the flatness of each rectangle. For output, you can specify which of these single results is to be displayed: all flatnesses all flatnesses that exceed the given tolerance the maximum flatness. A flatness plot is possible in the same way as with the conventional DIN ISO 1101 flatness. Minimum and maximum of the rectangle with the greatest flatness are shown in the plot with *.
DIN ISO 1101 True Position with Best Fit of Bore Pattern
The True Position characteristic offers options for best fit of bore pattern.
Initial values
The nominal points and the appropriate actual points can lie in one or more parallel planes. For the best fit, the nominal points are moved by means of plane coordinate transformation so that the selected best-fit condition is fulfilled. As the result of this operation, Calypso computes the rotation and offset of the bore pattern. Additionally, the best fit data is used to generate another coordinate system. You can access the origin of this coordinate system using PCM functions. The following best-fit methods are available for the best fit of bore pattern: Gauss Best Fit. With this method, outliers have only a minimal influence. Limitations due to reference features are not taken into consideration. Optimum setting parameters can be derived from this for the machine tools. Minimum Best Fit (Tschebyscheff). Outliers have a significant effect on the result when this method is used. Limitations due to
Results
Best-fit methods
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reference features are not taken into consideration. Optimum setting parameters can be derived from this for the machine tools. Tolerance Best Fit. Iterative attempts are made to bring all values into tolerance. Possible movement and rotation ranges are limited due to the reference features. This corresponds to a good/bad evaluation of a mechanical gauge with an additional evaluation of the single deviations. L1 Best Fit. Outliers have less effect with this method than is the case with the Gauss method. Limitations due to reference features are not taken into consideration. Optimum setting parameters can be derived from this for the machine tools.
Evaluation mode
The evaluation method for the features used to calculate the best fit of bore pattern can be changed in the multiple selection dialog box for features. The Outer Tangential Element evaluation method is set by default. Some results may not be reproducible, because this method is very susceptible to outliers. Better reproducibility can be achieved using the Gauss feature evaluation method.
In addition to the evaluation method, you can select filtration and outlier elimination for the selected features.
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If there are no references for the True Position, the result of the best fit of bore pattern (rotation angle, Y translation and Z translation) is added to the nominal reference system of the best fit of bore pattern.
Returns: Origin in x of the coordinate system (calculated from the bore pattern) Origin in y of the coordinate system (calculated from the bore pattern) Origin in z of the coordinate system (calculated from the bore pattern) These functions can also be used for any other coordinate system. You can thus access the x, y and z origin of the best fit of bore pattern in the definition template of any feature by entering a formula. This also allows you to use constructions (e.g. recall) on the bore pattern
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3 Activate the Best Fit of Bore Pattern radio button. This automatically generates the coordinate system with the name of the best fit of bore pattern it is initially identical to the base alignment. 4 Enter the tolerance. Use the buttons labeled Primary Datum, Secondary Datum and Tertiary Datum to specify the reference features so that the bore pattern can be computed later. This automatically defines the coordinate system with the name of the best fit of bore pattern. If you do not enter a reference, the base alignment is used by default. 5 Click on the Bore Pattern button to define the settings for evaluating the bore pattern. This is the dialog box in which you define the settings.
6 Click on the Select Features button to select the features you need for best fit of bore pattern. - and/or Use the Select Bore Pattern selection list to include bore patterns (i.e. feature groups) defined beforehand.
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Defining characteristics
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In the multiple selection window for features, you can change the evaluation method for the features (default: Outer Tangential Element) and set the filtration and outlier elimination. All the features you select are listed in the Features List. The coordinates as shown here are referenced to the constraints selected beforehand. The values are editable and can be shown in Cartesian or polar form. 7 Select a best-fit method from the Best-Fit Methods group: Select the best-fit method of your choice from the selection list. Select Translation and/or Rotation for the means of fitting. 8 Start computation by clicking on the Execute button. When computation is completed, the result is displayed in the Result of Fit group.
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The coordinate system with the name of the best fit of bore pattern is automatically corrected by the result of fit. To see a graphic representation of the best fit bore pattern, mark the Graphic check box (see How to display variations in form and location graphically on page 9-33). 9 Click on OK. The settings are saved and the window is closed.
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Defining characteristics
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Chapter
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You must define characteristics and features, but there are also a number of things you can do which, although not absolutely essential, will streamline the work of measurement and make your job easier. You must already have created a measurement plan and defined features and/or characteristics in order to proceed with this chapter.
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Enter a new name and press Enter to confirm. The original measurement plan is retained, and the new measurement plan is also saved to hard disk.
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2 Overwrite the name in the File name field with the desired new measurement plan name. 3 Click on OK to confirm. You have now created a new measurement plan under another name; the original (old) measurement plan still exists. You may have to delete the old plan.
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1 Select File Open. The administration dialog for the measurement plans will open. A subfolder is created in this folder for each Calypso measurement plan. 2 Select the measurement plan that should be deleted, right-click and, in the context menu that appears, select Delete. The selected measurement plan will be deleted. You can also use the Windows Explorer to delete measurement plans.
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Remember to save the measurement plan after you make changes to it (select item File Save). All of the following sections assume that you have a measurement plan open on the Calypso user desk.
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2 To highlight several features or characteristics that are not listed one after the other, press and hold down the Ctrl key and click on each feature or characteristic in turn. You deselect by clicking on a highlighted feature or characteristic. To undo the entire selection, release the Ctrl key and click on any point outside the highlight. 3 To highlight a block of several features or characteristics listed one after the other: Click on the first feature or characteristic you want to highlight. Press and hold down the shift key and click on the last feature or characteristic you want to highlight. When you highlight a feature or characteristic, the button and text are highlighted by a dark gray background. When you select a characteristic, its features in the CAD window turn a different color. 4 Double-click with the left mouse button on the icon in the measurement plan area. The feature or characteristic definition template appears on the screen.
A copy does not contain the measured data of the original feature only the properties, nominal data and tolerances. To copy features or characteristics: 1 Highlight the feature you wish to copy, or hold down the Ctrl key to highlight several features. 2 Press Ctrl+C or click on the Copy button. 3 Click on the new position in the list and then click on the Paste button. The features or characteristics will be pasted into the list at the position you selected. To insert the copy or copies multiple times, press Ctrl+V or click on the Paste button a corresponding number of times. 4 You can also copy the features or characteristics into a different measurement plan. To do this, open the desired measurement plan
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and insert the features or characteristics at the desired position with Ctrl+V or the Paste button.
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To delete a feature or characteristic for good: 1 Click on the feature or characteristic you want to delete forever. 2 In the context menu, select Delete. The feature or characteristic will be deleted.
If you are using the Calypso Light version, you cannot use this function. If you want to evaluate only certain characteristics, you can define a characteristic group, known as a mini-plan, within the measurement plan. This allows you to check, edit and run this mini-plan, but leaves the other characteristics unchanged in the measurement plan area. You can read about how to create these groups and ungroup them in Defining the scope of measurement on page 8-2.
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You should name features before you define them (probe them, in other words). When you subsequently rename a feature, you have to redefine a characteristic associated with it. To rename a feature, characteristic or feature group listed in the measurement plan area: 1 Click on the button of the feature or characteristic. 2 Double click on the icon. This opens the definition template of the element. - or Right-click and select Rename from the context menu. The Name/Comment window is displayed. 3 Overwrite the name of the element in the Name field. You can also use the Comment field to enter a comment, which will appear on any measurement plan report that contains this characteristic. 4 Click on OK to confirm. The button now has the name you just entered.
The Undo command in the Edit menu is used exclusively for deleting individual probing points within a feature. However, you can revert to the last saved version of your measurement plan.
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Important All changes made since the last time the measurement plan was saved will be lost. 1 Save the measurement plan without saving it beforehand. 2 Reopen the measurement plan.
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The contents of the measurement plan are now as they were when last saved.
Calypso always checks in the currently displayed list, i.e. either in the list of characteristics or list of features. To look for an item in a measurement plan: 1 Click on the Search button. The Search dialog box will appear.
2 Enter the name of the desired item in the Find what field. If you want to differentiate between cases, activate the Match case check box. If you want to look for complete words only, activate the Match whole word only check box. 3 Click on the Find Next button. Calypso looks through the list from top to bottom. When a matching item is found, it is marked in the list. 4 If Calypso did not find the item you were looking for, click on Find Next until the item is found. Calypso always starts the search from the last highlight in the list going downwards. 5 If you want to start from the beginning, click on the Start at top button. The items found in the search are displayed in a selection list.
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7-11
Example: Checking and changing the operating mode in the Settings Editor
This example demonstrates how to check and change the operating mode: 1 Select Resources Measurement Plan Editor Features to open the features editor.
List of settings
List of defaults
Feature type
2 Go to the list of settings at the top left and select the section for which you want to view or change the settings. The currently valid settings appear in the column on the right. 3 To change the current settings, select the feature to which you want the change to apply: For the higher-order measurement plan setting: Activate the Apply to all defaults of this plan check box. For selected features: Click on the feature of your choice in the column on the left. You can select a block of features (e.g. Feature 1 to Feature 5) by holding down Shift and highlighting them with the mouse, or you can mark several individual features by holding down
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Ctrl and highlighting them with the mouse (e.g. Feature 1, Feature 3, Feature 5). 4 Select the value for the new setting from the Set To list. The highlighted features are immediately updated in the list of currently valid settings. 5 Restart the procedure at step 2 if you want to view or change settings for other sections as well. 6 Click on OK. The changed settings are accepted and the Measurement Plan Editor Features is closed.
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If you are using the Calypso Light version, you cannot use this function. Mirroring a measurement plan along a coordinate axis means that all features with their strategies (e.g. probing points) are mirrored on the plane formed by the other two coordinate axes.
About mirroring
Bear the following in mind: No actual values are mirrored. The actual values are deleted prior to mirroring. After mirroring, the nominal values of the characteristics that mirroring can change (these include distances and X values, for example) are updated. You have to assign styli to the mirrored measurement plan manually.
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The coordinate systems are not mirrored, because the mirrored direction of rotation would be counterclockwise. The coordinate systems are transformed: only the coordinate origin (zero point) is mirrored; the directions of the axes remain unchanged, relative to the base alignment.
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The base alignment is unaffected by this transformation. Important Parameters and patterns are not mirrored. If your measurement plan contained parameters or patterns, they have to be reentered after the measurement plan has been mirrored.
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If you are using the Calypso Light version, you cannot use this function. To mirror a measurement plan: 1 Open the measurement plan you want to mirror. 2 Select Plan Advanced Mirror Measurement Plan. The Mirror Measurement Plan dialog box appears on the screen.
3 Under Mirror in Plane, select the coordinate axis perpendicular to the mirror axis.
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4 Go to Change Stylus Data and select a different stylus, if applicable. The data applicable to your selection is listed in the display area. 5 Click OK to confirm your selection. The measurement plan is mirrored. The image in the CAD window is refreshed; the new view shows you the workpiece after mirroring. 6 Save the mirrored measurement plan by selecting File Save or by selecting File Save As if you want to keep the original, unmirrored measurement plan as well.
If you want to combine the measurement plans of a horizontal-arm CMM with two measuring columns, you should, if possible, use the same features for alignment (definition of the base alignment). In order to combine measurement plans you must create a master measurement plan on a CMM designated for the purpose, and import the measurement plans from other CMMs into this master.
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feature or characteristic is preceded by the name of the original measurement plan, with a period as separator. Example: Two features of the same name, Cylinder1, from the measurement plans Testblock1" and Base are named Testblock1.Cylinder1 and Base.Cylinder1 in the master measurement plan. 3 Edit the measurement plan: Delete superfluous characteristics and add constructions of features across individual measurement plans. 4 Save the master measurement plan.
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When saved, the $ will be removed from the name. To make it easier to distinguish the master measurement plans from regular ones, you should save them in a separate directory.
No further measurements take place in this CNC run. Instead, the process is used for calculations only, and the results are printed out or generated as result files. If the Clear Existing Results check box was marked, the latest results of the individual measurement plans will be imported. If this option was not selected, the results are recalculated from the individual measurement plans' results already available on the computer.
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Advantages of macros
What benefits arise from including macros in a measurement plan? Macros make it easier for you to create and handle recurring measuring tasks: You can measure several identical components in assemblies (e.g. valve seats in an engine block). You can measure multiple features, i.e. features with recurring but varying fundamental quantities (e.g. stepped cylinders, stepped pyramids, rows of holes with increasing radius). You can program measuring tasks that are repeated on different workpieces. This also facilitates distributed preparation of measurement plans by several employees.
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Separate parameters
The transfer parameters and PCM parameters of the macro are logically separated from the parameters of the measurement plan. This permits parameters with the same name to exist in both the measurement plan and in the macro without this leading to misinterpretations. Calypso treats them as two different parameters: Parameter a of the macro named Test is known as Test.a parameter in the measurement plan. This allows Calypso to access the PCM parameters of the macro by reading them from the measurement plan.
If the measurement plan contains variable values, these must be listed for the macro and assigned initial values. To create a macro: 1 Open the measurement plan you wish to use as a macro.
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2 Select File Macro Define Macro Parameters. The Parameter definition window will open.
You can edit the list of macro parameters in this dialog box. 3 To create the Parameter column of the parameter list automatically: click on the Automatic button. Calypso searches for all parameterized values in the measurement plan and enters them in the Parameter column. Every variable in the measurement plan that you wish to use as a macro must be contained in the parameter list and must have been assigned an initial value. 4 Enter a default value for each macro parameter. 5 You can also enter a comment for each parameter. You can save the measurement plan as soon as it contains all necessary entries. 6 Select Edit Save Measurement Plan as Macro. The measurement plan is saved together with the transfer parameters as a macro with the name of the original measurement plan. - or Select Edit Save Measurement Plan as Macro as.... You can rename the macro in the Save Measurement Plan As... dialog box.
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The macro is not integrated as a reference. Instead, it is permanently integrated as a copy of the selected macro. This means that changes in the original macro measurement plan are not automatically made in the integrated macro. Follow these steps to add a macro to a measurement plan: 1 Open the measurement plan into which you want to integrate the macro. 2 Open the list of characteristics or the list of features. 3 Highlight the element behind which you want to add the macro in the list. 4 Select File Macro Integrate macro. You can see the Load Measurement Plan window with the list of directories under ...\Calypso\home\om\workarea\macros, in which the macros are contained as files named inspection.
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5 Open the subdirectory containing the desired macro and doubleclick on the inspection file. Calypso first permanently adds all features and characteristics of the selected macro into the current measurement plan and then opens the definition template for the macro.
6 Enter the currently valid value for each of the transfer parameters, if necessary, or select menu item Formula in the context menu and then write the appropriate formula in the Formula dialog box.
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As with the content of the comment field, you can no longer change the names of the transfer parameters here.
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7 Click on OK to confirm. A symbol for the macro is displayed both in the list of characteristics and in the list of features.
Furthermore, the elements of the macros are shown in the CAD window.
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During integration into the measurement plan, only the features, the characteristics and the parameters are taken over from the macro. The settings (e.g. clearance planes, stylus system, printout/protocol definitions and CAD data, etc.) of the measurement plan apply. You can access the individual macro elements via the measurement plan editor and, for example, define the clearance plane or stylus.
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4 Select Edit Save Measurement Plan as Macro. The macro measurement plan is saved together with the transfer parameters as a macro under its current name. - or Select Edit Save Measurement Plan as Macro as.... You can rename the macro in the Save Measurement Plan As... dialog box.
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Important A macro integrated in a measurement plan is not automatically updated when the original macro measurement plan is changed. If you have made changes to a macro and want these changes to work in a measurement plan in which the macro has already been integrated, you will therefore have to update the macro.
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To update an individual macro in a measurement plan: 1 Right-click on the macro entry in the list of characteristics or list of features and select Update in the context menu. To update all macros of a measurement plan: 1 Select File Macro Update all macros.
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Toolboxes
With toolboxes, you can easily insert features and characteristics into your measurement plan. Toolboxes contain the respective symbols. You can use the drag&drop functionality to create custom toolboxes that contain only the items that you most frequently use. The master toolbox includes all features, characteristics and utilities. It is embedded in the Tool Box Builder dialog box. The Toolbox Builder also allows you to create custom toolboxes.
Here are the details on working with toolboxes: The available element groups are listed in the column on the left. When you select an element group, its contents are listed in the middle column. To move an item from the toolbox to your measurement plan, you simply click and hold the left mouse button on the symbol and drag it over to the measurement plan. The right column of the Toolbox Builder is where you set up custom toolboxes. Just like any other dialog box in Windows, you can close a toolbox by clicking on the Close button in the title bar.
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Toolboxes
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Once you have saved a custom toolbox and then exited the Toolbox Builder, there is no way to edit the custom toolbox (other than deleting it and starting again from scratch). To create a custom toolbox, follow these steps: 1 Click on the Open Selected Toolbox(es) button. The Tool box selector window will open.
If you have not defined any custom toolboxes, only the Master Toolbox is listed here. 2 Highlight Master Toolbox and click on Open. 3 Name your new toolbox: Delete the unnamed label and type a name for the toolbox. 4 Now you can assemble your elements: Click and hold the left mouse button on the desired toolbox button and drag it over to the right column. Keep in mind: Custom toolboxes do not have groups. All buttons are in the same list. You cannot change the order of items in the custom toolbox. To delete an item, click on the item to highlight it and select File Delete from the menu bar of the dialog box. 5 Select Toolbox Builder File Save. The toolbox configuration you put together is saved.
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1 Click on the Open Selected Toolbox(es) button. The Tool box selector window will open. 2 Highlight your toolbox and click on Open. The Tool box builder window will open. 3 To move the items you need from the toolbox to your measurement plan, click an item, hold down the left mouse button and drag the item to the measurement plan area. Release the mouse button. 4 As soon as you click anywhere else on the user desk, the toolbox is hidden. To display it again, click on the Select Toolboxes button.
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Calypso generates the routes automatically provided clearance planes have been defined around the workpiece (see Defining the clearance planes on page 4-113). To avoid collisions with other objects on the table, you can generate outer clearance planes in addition.
You may be able to optimize the routes, depending on the geometry of the workpiece and the resulting positions of the features. You also have the option of changing the coordinates for a route to a feature. This is useful, for example, if you want to ensure that the probing points for a cylinder are uniformly spaced. You have the following options for checking and optimizing travel paths: Checking the travel paths on page 7-32 Editing travel paths between features on page 7-33 Editing travel paths within a feature on page 7-40.
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Outer clearance planes (dimensions), Other stylus-specific data, position of a stylus system changer rack, etc.).
Automatic navigation check
When the navigation check is switched on, the end positions, the outer clearance planes and the rack with the stylus systems are taken into the calculation of the travel paths between the features, each according to the settings.
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corresponding to the directions of the coordinate axes (positive or negative), referenced to the base alignment of the workpiece.
Clearance group SG+Z1 Clearance plane SE+Z
A clearance group is akin to a local clearance space in which two or more features can be combined. This is a way of avoiding unnecessary retractions of the probe to the clearance plane. A clearance group, hierarchically speaking, is below a clearance plane (parent group) from which the features of the clearance group in question are reached.
Retract planes
The illustration below shows what a retract plane signifies:
SE+Z
Retract plane
SG+Z2
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It is not necessary to define a retract plane if the approach and departure positions of all features in a clearance group are such that they can be reached without collision when the head moves from one to the other. This means that features on different sides of a common interior space can be assigned to the same clearance plane.
Loop clearance groups
Generally, a feature has only one clearance plane/group. Activate the CNC Loops-Safety Group check box if the feature is measured in a loop and you want to use the same movements as for a new clearance group (retract to parent group). This makes sence if the feature is in a feature group with pattern. Afterward, the travel paths are optimized.
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Important There is no guarantee that the run will be collision-free if you fail to check the defaults. The most practical procedure for checking the defaults is described below: When you program the feature, check the clearance plane, the clearance distance and the retract distance. Change the default settings if necessary. (For more information, see Clearance data in the Calypso Online Help). The criterion for the correct clearance plane is the position of the probe relative to the clearance planes (on the approach to the first intermediate position of the feature in question). When you finish programming the measurement plan, select Resources Clearance Planes and click on the Test Drive To The Selected Clearance Plane button to perform a test move (see How to test the clearance planes on page 4-117). This is your opportunity to recheck the assignment of features to clearance planes in the displayed CAD model.
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Important Other travel paths might be generated, depending on the characteristics selected or if the run takes place without a result reset.
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Perform the first CNC run at reduced speed. If routing turns out to be poor, click on the Help button in the Start Measurement dialog box and proceed in accordance with the instructions.
Consider edge blocking: It could be either a hindrance or a help, depending on the circumstances (see How to block edges of the clearance plane on page 4-118). The activities which influence the paths between features are as follows: How to define clearance groups on page 7-33 How to delete a clearance group on page 7-34 Assigning clearance planes and clearance groups on page 7-35 How to define the retract plane in a clearance group on page 7-36 How to activate the navigation check on page 7-38 How to define the outer clearance planes on page 7-39
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1 Select Plan Navigation Sub Clearance from the menu bar. The Define sub clearance window will open.
2 Click on New and enter a name for the new clearance group in the input box. After you confirm with OK, a list with the clearance planes will open.
3 Select the appropriate clearance plane under Parent Group and then click on OK. 4 Confirm the Define Clearance Groups dialog box with OK. The window will be closed.
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1 Select Plan Navigation Sub Clearance from the menu bar. The Define sub clearance window will open.
2 In the Clearance Group list, select the group you want to delete. 3 Click on Delete. 4 Click on OK. The clearance group is deleted.
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3 In the strategy list, double-click on Clearance Data. The Clearance Data dialog box appears on the screen.
The elements that make up this dialog box are described in Clearance data in the Calypso Online Help. 4 To reassign the clearance plane or clearance group, click on the arrow beside the Clearance Group selection list. 5 Hold down the mouse button and select the clearance plane (CP) or clearance group (SCP) of your choice by highlighting it and then releasing the mouse button. The new clearance plane or clearance group is now assigned to the feature and is taken into account in the next automatic CNC run.
Editing several features
Use the Features Settings Editor if you want to assign clearance planes or clearance groups to several features at a time (see How to edit measurement plan settings on page 4-120).
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1 Select Plan Navigation Sub Clearance from the menu bar. The Define sub clearance window will open.
2 Activate the Retract To Inner Plane check box. The field labeled Clearance Distance Probe Part Or Enter Data is now active. 3 Type in the height of the retract plane relative to the datum of the base alignment (perpendicular to the higher-order clearance plane). 4 Click on OK. The retract plane is defined and the dialog box closes.
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the end positions of the CMM (measuring range limits) The values are takes from the system settings. the outer clearance planes You can determine the outer clearance planes by entering 6 coordinates. the stylus changer rack The stylus changer rack and the stylus system in the rack are considered automatically. The stylus of each rack projecting the farthest into the measuring range specifies the plane on which the travel path is checked. Each of these three criteria can be switched on or off individually.
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2 Activate the desired checks: CMM End Positions Outer Clearance Planes Rack with stylus systems The CAD window shows the measuring range and outer clearance planes as a wire frame model. A transparent volume cube represents the clearance planes. The foremost styli of the stylus system changer rack are shown as points. 3 Click on OK to confirm. During the CNC run, Calypso checks the specified path with regard to lack of collisions and changes the path if necessary.
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2 Select the coordinate system. The selected coordinate system determines the inclination of the boundary planes of the outer clearance planes with respect to the workpiece and its clearance planes. 3 Enter the 6 required coordinates. 4 Click on OK to confirm.
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3 In the strategy list, click on Clearance Data. The Clearance Data dialog box appears on the screen.
The elements that make up this dialog box are described in Clearance data in the Calypso Online Help. 4 Check that the correct clearance group is selected. 5 Click on the Clearance Distance check box to deactivate the default. 6 Type the new clearance distance into the input field. 7 Click on OK to close the window. The approach position should now be close enough to the feature to improve the travel paths.
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2 Click on Strategy. The Strategy window will open. 3 In the strategy list, click on Clearance Data. The Clearance Data dialog box appears on the screen.
The elements that make up this dialog box are described in Clearance data in the Calypso Online Help. 4 Under Move to ..., select the with each probing setting. 5 Click on OK to close the window. The stylus now moves forward and, after each probing, it moves to an additional intermediate position at the height of the clearance distance.
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Calypso must know that there is a stylus system changer. Additionally, the appropriate stylus system must be in the stylus system changer.
Procedure
To configure the stylus system changer: Specify the stylus system changer in the system setup (once-only operation) Determine the length of the master stylus (once-only operation), (not applicable to RDS, MCR20 and SCR200) RDS only: determine the RDS geometry In the Stylus System Change dialog box, insert an icon for each holder (MCR20 and SCR200: for one holder only, all others are automatically created when the rack is qualified) Set the approach parameters Determine the position of each holder (MCR20 and SCR200: qualify the rack) Assign the stylus systems to the holders These points are described in detail in the following sections. Once these steps have been performed, they do not have to be repeated as long as the stylus system changer is not changed in any way, for example by being moved. When the automatic stylus system changer is properly configured, you can execute an automatic change of stylus systems.
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Important Always comply with the instructions in the user guide supplied with the MCR20. The Renishaw user guide states that the MCR20 has to be aligned with a machine coordinate axis. Deviation of up to 0.25 mm from the machine axis over the width of the rack (200 mm) is tolerated. If the MCR20 stylus system changer is selected, only MCR20 holders are displayed. Holders of other types for this machine configuration are deleted.
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Special aspects
On account of the special design of the MCR20, you must bear the following in mind: After the Store Stylus operation, the probe moves only to the transfer point, because without a measuring module movement is restricted to the zone of magnetic force movement without a measuring module outside the MCR20s zone of magnetic force causes the controller to issue collision messages. No machine operations are triggered by a manual stylus system change with the MCR20. If the RDS is used with TP20, you cannot change the RDS plate manually. In the pickup process, the stylus system change solenoids of an index head, if fitted, are not actuated.
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Important Never change the stylus system without calling up the manual or automatic stylus system change (e.g. by selecting another stylus system in the qualification dialog and changing the stylus system manually). Strong solenoids affect the TP20 probe. If probing fails, switch off the solenoids if necessary or consult the user guide supplied with the TP20/Renishaw. Whenever possible, always use the manual or automatic stylus system change function to change stylus systems with the TP20 and MCR20, because this is the only way that Calypso can monitor the status of the probe (stylus system in probe or stylus system not in probe).
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Important Always comply with the instructions in the user guide supplied with the SCR200. On account of the special design of the SCR200, you must bear the following in mind: The SCR200 has a photoelectric barrier that is interrupted when a stylus system change takes place. Movements between individual holders take place inside the space delimited by the photoelectric barrier. The stylus system does not move out of this space until the change has been completed.
Special aspects
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Important If the photoelectric barrier is interrupted during a CNC run, the controller switches permanently to closed contact with probe. If this happens, the probe no longer recognizes probings and collision is inevitable. Movement without a measuring module outside the zone delimited by the photoelectric barrier is possible, but there is no protection against collision. Consequently, it is best not to perform movements with the machine if you change stylus systems manually.
Use of a PH10
If the machine is equipped with an articulated probe from Renishaw (PH10), you must also bear the following in mind: If you have qualified stylus positions that could cause a collision with the stylus system changer rack when stylus systems are subsequently changed, you must use Approach Parameters to change the parameters for the holders in question. The travel path above or in front of the holder must be parameterized in such a way that the probe can rotate before and after the stylus system change without any risk of collision.
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Important Never change the stylus system without calling up the manual or automatic stylus system change (e.g. by selecting another stylus
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system in the qualification dialog and changing the stylus system manually). Whenever possible, always use the manual or automatic stylus system change function to change stylus systems with the TP200 and SCR200, because this is the only way that Calypso can monitor the status of the probe (stylus system in probe or stylus system not in probe).
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Important Always comply with the instructions in the user guide Installation and User's guide H-1000-5787-01-A ACR3 autochange rack system! The described instructions for the definition of holders and change operations apply. If the ACR3 stylus system changer is selected, only ACR3 holders are displayed. Holders of other types for this machine configuration are deleted.
The ACR3 can only be operated horizontally. Maximum two systems may be interconnected with each other (max. 8 positions). When using extensions, only the changer located directly at the head of the PH10M may be used. Otherwise, the resulting force at the PH10M becomes too high. Reliable operation of the stylus changer is only garanteed if the tolerances for probe alignment are met. These are 0.2 in pitch, roll and yaw. If this is not possible, you must use the AM1 module of Renishaw. When using the AM1, measuring range is sacrificed and you have to take an amount of kinematic uncertainty into account.
Meeting tolerances
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The movement strategy to a holder is set up so that the stylus system changer is outside of the measuring range. Please be aware that a minimum distance of 150 mm (6 in.) between the holders is necessary. An empty area of 120 mm (4 in.) below the holder is necessary. Without the empty area, it is not possible to mount a lateral stylus in the RST stylus system.
To define the geometry: Compute the offset from the virtual axis intersection of the RDS axes. Qualify the four preset angular positions for the RDS. Calypso uses this information to compute the intersection of the axes.
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The illustration below shows an overview of the definition of the slot distance X. The probe is shown from above, e.g. from +Z.
2
X
Reference edge
Calypso helps you when defining the slot distance with a dialog. If you know the value of the slot distance (offset), you can enter this directly in the Slot Distance field. To define the RDS slot distance: 1 Find an appropriate vertical reference edge in the measuring range. An appropriate reference edge must be parallel to the machine coordinates. 2 Position the RDS stylus system so that the outer slot wall is in a plane with the reference plane. In the above illustration, this is position 1. 3 Click on Read Position. Calypso saves the current stylus position. 4 Turn the RDS 180 around its A axis. In the illustration, this is position 2. 5 Position the RDS stylus system so that the outer slot wall is in a plane with the reference plane. 6 Click on Read Position. Calypso saves the current stylus position.
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7 Check the results in the Slot Distance field. Typical values are around 38 mm (1 in.).
How to define the axis intersection
The position of a holder is always based on the axis intersection of the two rotational axes of the RDS. Calypso must therefore first calculate the intersection of these axes. Before Calypso can do this, you must qualify the four additional stylus positions of the CZ master stylus (refPos1 to refPos4) (styli 2 to 5): A/B = 0/90 A/B = 0/90 A/B = 90/0 A/B = 90/0
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The CMM now also has the information it needs about stylus system changes.
Racks for RDS stylus systems can be measured with any qualified stylus. You cannot use the automatic stylus system change functionality for RDS with an MCR20; only the TP20 stylus modules can be changed. Follow these steps to define the length of the master stylus: 1 Insert the master stylus (see How to install a stylus system on page 4-18). 2 Select Resources Automatic Stylus System Change. The Automatic stylus system change window will open.
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3 Click on Length of Master Stylus. 4 A prompt appears, asking you whether the master stylus has been inserted. Check the control console to make sure that stylus 1 is selected and click on OK.
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5 At the prompt to probe on the adapter plate, use the joysticks to touch the adapter plate to the surface of a holder. You should probe the area in which the adapter plate would normally contact the holder. 6 At the prompt to probe with the stylus, use the joysticks to probe the same place on the holder, using the stylus tip this time. The length of the master stylus is shown in a separate box. 7 Click on OK to close the window. Calypso now knows the length of the master stylus. The locations of the holders can now be defined.
You can use only one MCR20 or SCR200 with 6 holders in conjunction with the CMM. You do not need to add a holder in the case of the MCR20 or SCR200 Calypso automatically adds six new holders in the Automatic Stylus System Change dialog box. To add a holder: 1 Select Resources Automatic Stylus System Change. The Automatic Stylus System Change window opens. 2 Click on the arrow for the Edit list and select Add Holder. You are prompted to enter a name for the holder.
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3 Click in the input field, enter a new name and click OK to confirm your entry and proceed. If you defined AN RDS with SP600 as probe under Extras Workroom CMM, you are prompted to enter the type of the new holder: RDS or SCP600. An icon for this holder, accompanied by the name you assigned, appears in the Automatic Stylus System Change window.
4 Add more holders as necessary, until the configuration of your stylus system changer in the system matches that at the CMM. When you create a new holder, a default is defined for the intermediate position before and after stylus system change: this is a safety precaution. You can change the default if a lower value is preferable (see How to check or change approach parameters on page 7-54). Before you can set the positions of the new holders in the machine coordinate system, you first have to determine the approach parameters.
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These distances are defined from each given position (e.g. before entry into the rack) to the midpoint of the probe. The Position Over Holder distance is from the stylus system adapter plate (on the bottom of the probe) to the top of the rack. The default value is 0 mm. You can change the settings for each holder. If you need to change these distances because of part or stylus clearance problems, please be aware of how close the movements are around the probe holders and the rack.
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Important An articulating probe rotates the stylus to the intermediate position. The values for Position Before Holder, Position After Holder and Position Over Holder must be set such as to ensure collision-free rotation for every stylus used.
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Caution: risk of destruction! Unsuitable inputs in this window can lead to collisions and thus to destruction. 5 Enter the applicable values for the position before, over and after the holder. 6 Select the Approach In direction. If you have an MCR20 or an SCR200, the Approach In direction is set to a default that you cannot change here. 7 (only for the master user): Under Distance to stylus system rack during empty running, enter the distance to the holder during the run after storing the stylus system until picking up a new one. This input is necessary to avoid collisions for certain stylus system changers with stylus system that project a great distance.
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8 (only for the master user): If necessary, move the position in the holder by a certain amount under Offset. This allows subsequent compensation for slight shifts compared to the initially measured reference position.
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After indirect qualification, you can also use Offset to add and assign approach parameters to holders with probing points that are so far out that they cannot be directly approached. 9 Click on OK. The settings are saved and the window is closed.
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Important The approach direction has to be set before you define the position of a holder (see Approach parameters for the stylus system changer on page 7-52). Risk of collision if this procedure is not adopted. To define the position of a holder: 1 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen. 2 Click on the icon of the holder whose position you want to define. The icon turns green. 3 In the Changer list, select Define Holder Location. 4 When you see the prompt asking whether you want to overwrite the existing position, click on OK. You are prompted to select the name of the stylus system for this holder. 5 If no stylus system has been qualified yet and you merely want to define the position of the holder, click on Cancel. If you already know which stylus system you want to assign to the holder, select the name of the stylus and click on OK to confirm.
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Do not click on OK as long as you have not completed the following step. In addition, ensure that the dust cover is open.
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6 Calypso reacts differently, depending on which type of probe is installed: With a trigger probe you are asked to move the stylus to the center of the circle. Ensure that you measure the holder location in the area between the hexagon screw head and the surface. With a measuring probe, a cone on the side of the holder is located by self-centering probing. With Renishaw probes (TP20 and TP200), you are prompted to probe points on the MCR20 or SCR200. With an RDS probe, the back and side reference surfaces are automatically probed after probing the upper reference surface. When the measurement is finished, you will see a symbol for the stylus system in the holder symbol. The name is below the symbol. 7 Repeat these steps for every holder which has not yet been defined.
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Important Always use Reduced Speed (potentiometer) for movement, as otherwise there is a risk of collision. If no SP600 is loaded in the RDS, the following prompt appears: Please use an SP600 for the qualification. 5 In this case, insert an SP600 in the RDS. If this stylus has not yet been used for qualifying an SCP600 rack, you must determine its length. Proceed in the same way as for determining the master stylus length (Defining the master stylus length on page 7-50). 6 Open the cover of the SP600 as prompted, lock it by means of the retention pin and confirm with OK. Calypso checks the current angular position of the RDS. The nominal angles of both axes depend on the approach direction set beforehand. If the angles do not correspond, an error message appears. After confirmation of this message, Calypso stops the qualification operation. 7 If the angles correspond: Probe a point in the approach direction as prompted. Calypso takes care of everything else automatically. 8 Remove the retention pin and close the cover. The covers have to be closed so that the solenoids mounted in them can function correctly and keep the switching contact closed during stylus system changes. 9 Click on OK. The window will be closed.
With the ACR3, it is only possible to create four holders. Use the Delete Group function to delete holders. To define the holder positions of the ACR3: 1 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen. 2 Click on a holder icon in the Automatic Stylus System Change window. 3 In the Changer list, select Define Holder Location.
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4 When you see the prompt asking whether you want to overwrite the existing holders, click on OK. If the ACR3 stylus system changer is selected, only ACR3 holders are displayed. Holders of other types for this machine configuration are deleted.
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Important Always use Reduced Speed (potentiometer) for movement, as otherwise there is a risk of collision. A query Is the rack in the locked position? (On the right of the swivel range) appears. 5 Set the rack to the locked position (as shown in the dialog) and confirm with OK. 6 Lock the covers with the tool and insert the autojoint gage in holder 1. 7 Remove the stylus from the probe as prompted. 8 Approach the position using the joystick. With Accept point you record the current position and close the window. 9 Remove the gage as prompted and insert the probe again. By confirming, the creation of probing points is activated again. The position of the next measured point is shown. 10 Probe a point at the left corner of holder 1 in the Z axis. Calypso takes care of everything else automatically. When the measurement is finished, you will see all holders of the ACR3 in the stylus system change window. 11 Remove the retention pin and close the cover. 12 Click on OK. The window will be closed.
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Important Before you define the holder positions of the MCR20, the covers must be opened and the approach direction set (see Approach parameters for the stylus system changer on page 7-52). Risk of collision if this procedure is not adopted. To define the holder positions of the MCR20: 1 Open the covers of the MCR20.
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2 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen. 3 Click on a holder icon in the Automatic Stylus System Change window. 4 In the Changer list, select Define Holder Location.
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Important Always use the PS2R stylus system without extension (2 mm head, 20 mm shank) for the qualification procedure. The deviation between P1 and P2 in the Y coordinate (for approach direction in Y) must not be more than 0.2 mm (see the user guide for the MCR20). You are prompted to enter the name of the stylus system for this holder. 5 If no stylus system has been qualified yet and you merely want to define the position of the holder, click on Cancel. If you already know which stylus system you want to assign to the holder, select the name of the stylus and click on OK to confirm. The information about the stylus system refers only to the holder active at the start of the qualification procedure. 6 Click OK when you see the prompt asking you whether you want to overwrite the existing holders and add undefined holders. If the MCR20 stylus system changer is selected, only MCR20 holders are displayed. Holders of other types for this machine configuration are deleted.
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Important Always use Reduced Speed (potentiometer) for movement, as otherwise there is a risk of collision.
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P1
P6 P7
Z+ Y+ P2 X+
Calypso takes care of everything else automatically. When the qualification is completed, all six holder positions of the MCR20 are labeled from 1 to 6. 8 Close the covers when prompted. The covers have to be closed so that the magnets mounted in them can function correctly and keep the switching contact closed during stylus system changes. 9 Click on OK. The window will be closed.
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Important Before you define the holder positions of the SCR200, the covers must be opened and the approach direction set. The cable between SCR200 and SI200 (controller for TP200) must be disconnected for the qualification process, in order to interrupt the signal from the photoelectric barrier (see Approach parameters for the stylus system changer on page 7-52). Risk of collision if this procedure is not adopted.
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To define the holder positions of the SCR200: 1 Open the covers of the SCR200. 2 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen. 3 Click on a holder icon in the Automatic Stylus System Change window. 4 In the Changer list, select Define Holder Location.
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Important Always use the PS2R stylus system without extension (2 mm head, 20 mm shank) for the qualification procedure. The deviation between P1 and P2 in the Y coordinate (for approach direction in Y) must not be more than 0.25 mm (see the user guide for the SCR200). You are prompted to enter the name of the stylus system for this holder. 5 If no stylus system has been qualified yet and you merely want to define the position of the holder, click on Cancel. If you already know which stylus system you want to assign to the holder, select the name of the stylus and click on OK to confirm. The information about the stylus system refers only to the holder active at the start of the qualification procedure. 6 Click OK when you see the prompt asking you whether you want to overwrite the existing holders and add undefined holders. If the SCR200 stylus system changer is selected, only SCR200 holders are displayed. Holders of other types for this machine configuration are deleted.
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Important Always use Reduced Speed (potentiometer) for movement, as otherwise there is a risk of collision.
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Calypso takes care of everything else automatically. When the qualification is completed, all six holder positions of the SCR200 are labeled from 1 to 6. 8 Close the covers when prompted and reconnect the cable between the SCR200 and the SI200 to reactivate the photoelectric barrier. 9 Click on OK. The window will be closed.
A stylus system has to be qualified before you can assign it to a holder. Qualify the stylus system in accordance with the instructions in How to qualify a stylus manually on page 4-29. To assign a qualified stylus system to a holder: 1 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen.
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2 Select the holder to which you want to assign the stylus system by clicking its icon. The icon turns green. 3 In the Changer list, select Set stylus system to holder. A list of all qualified stylus systems is displayed. 4 Select the name of the stylus system you want to assign to the holder, and click on OK to confirm your choice. The stylus system is assigned, and by way of confirmation the stylus system name appears below the icon for the holder. 5 Repeat the above steps for the holders to which no stylus system has been assigned as yet.
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Important When storing or getting a stylus system for the first time, you should be prepared to cancel the procedure quickly. If the approach parameters are incorrect, you can avoid a possible collision by canceling. To automatically change between stylus systems that are both stored in the changer rack, follow these steps: 1 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen. 2 Click on the holder icon that contains the stylus system you would like to install. 3 Click on the Changer drop-down list and select the Change Stylus System entry. The CMM first stores the stylus system that is currently installed, then picks up the stylus system you selected.
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Important When storing or getting a stylus system for the first time, you should be prepared to cancel the procedure quickly. If the approach parameters are incorrect, you can avoid a possible collision by canceling.
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To automatically store an installed stylus system and then manually install a different stylus system, follow these steps: 1 Select Resources Automatic Stylus System Change. The Automatic stylus system change dialog box appears on the screen. 2 Click on the stylus system holder icon where the currently installed stylus system should be stored (the icon for an empty holder on the rack). 3 Click on the Changer drop-down list and select the Remove Stylus System entry. The CMM places the stylus system in the selected holder. There is then no longer a stylus system installed in the probe. 4 Click on OK to close the Automatic Stylus System Change dialog box. 5 Proceed with the steps for manually changing a stylus system, as described in How to install a stylus system on page 4-18.
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If you have the appropriate utilities installed on your computer, you can view files of the following formats: *.txt, *.rtf, *.doc, *. bmp, *.avi, *.flc, *. pdf and *.gra. The information is saved in a file, whereby each measurement plan can be assigned its own file for user information. You can also use the same file for different measurement plans. You can create video files on any PC with a video grabber board and a video camera.
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Files created using Microsoft Word (*.doc) should be saved in Word in the Rich Text Format (RTF), and subsequently this file (*.rtf) should be used. This has the advantage that the document is opened as write-protected with the CZViewer. You can view the added information in the Start Measurement dialog box by clicking on User Information.
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Only one user information file can be selected for each measurement plan. You can change which file is selected simply by following the same directions for selecting a file the first time.
An icon is displayed at the top left corner for each measurement plan, if the folder of the current measurement plan (.../workarea, inspections) includes a file called icon.bmp which contains the icon. 3 Click on User Information. A window pops up that shows the selected user information. If the file contains a drawing, a picture or a photograph, you can return to the Start Measurement dialog box by clicking on Apply. If it is a video, the Windows Media Player appears. You can change the playback speed, fast forward or rewind, and perform other
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functions. Refer to your Windows documentation for instructions on using the Media Player.
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Chapter
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The preconditions listed below must be satisfied before you can run a measurement plan: The CMM must be initialized (you will find more information in the Online Help under How to initialize the CMM). The scope of measurement must be defined. A measurement plan defines what is to be measured, whether or not a custom printout will be generated, and how the CMM will perform the measurement. Calypso automatically measures all the features you defined and calculates the characteristics in the order you specified. Before you run a measurement plan, you should always make sure that the CMM is clear for automatic movement around the part and fixture. Use the joysticks to move the stylus above the part and fixture. If you want to combine two or more measurement plans (and evaluate them together), you do so by starting a master measurement plan.
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If you want to test characteristics only once or twice, you can mark the characteristics in question and start the measurement plan. Calypso runs only your selection. If you want to measure a large number of characteristics repeatedly, you can highlight the characteristics in question and combine them in a measurement plan group. This group behaves like a single characteristic. It is represented by a button of its own in the measurement plan and can be assigned a name.
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If you are using the Calypso Light version, you cannot use this function. If you test certain characteristics frequently, independently of the overall measurement plan, but you prefer not to combine the characteristics in a measurement plan group, you can highlight the characteristics in question, combine them in a characteristic group, save and run this group. If you are using the Calypso Light version, you cannot use this function. If you want certain characteristics repeatedly omitted from measurement, you can mask the characteristics in question. Masked features are highlighted light gray in the measurement plan list. You will find more information in Measurement plan editor characteristics in the Calypso Online Help.
Feature group
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Masked
Features
If you do not want to run the entire measurement plan, you can measure without characteristics in order to obtain initial information on the features.
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Press and hold down Ctrl key and click on the characteristics you want to select. In the Start Measurement dialog box you can activate this selection by clicking on Current Selection under List Of Characteristics (see Starting a measurement on page 8-9).
If you are using the Calypso Light version, you cannot use this function. You can run a group of this nature separately, i.e. without the other characteristics in the measurement plan.
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The grouped characteristics no longer appear individually in the measurement plan. You have to open the grouping if you want to see the individual characteristics again. To create a measurement plan group: 1 Press and hold down the Ctrl key and click on each characteristic you want to have in the group. 2 Open the Edit menu and select Group. The characteristics you selected are grouped and the group is represented by a button in the measurement plan. 3 Click on the group in the measurement plan and then click on the right mouse button to open the context menu. 4 In the context menu, click on Rename and type in the new name. It is always a good idea to assign meaningful names to the groups. 5 Press OK to confirm the new name. In the Start Measurement dialog box you can activate this selection by clicking on Current Selection under List Of Characteristics (see Starting a measurement on page 8-9).
If you are using the Calypso Light version, you cannot use this function. To ungroup a measurement plan group: 1 Highlight the group in the measurement plan. The line is grayed.
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2 Open the Edit menu and select Ungroup. The characteristics are again listed individually in the measurement plan.
If you are using the Calypso Light version, you cannot use this function. If you prefer not to create a measurement plan group (for example because you do not want a group named in the work printout), but you want to repeat certain characteristics, you can create a feature group.
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A feature group has a name, but this name does not appear in the measurement plan. To create a feature group: 1 Press and hold down the Ctrl key and click on each characteristic you want to have in the group. 2 Select Plan Mini-Plan Define. Calypso prompts you to assign a name to the group. 3 Assign the group a name and click on OK. The feature group is now defined. In the Start Measurement dialog box you can activate this selection by clicking on the feature group under List Of Characteristics (see Starting a measurement on page 8-9).
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To enter global printout header data: 1 Select Resources Report Header Parameters. The Input parameter window will open.
2 Click on the field you want to complete and enter the appropriate values or plain text. 3 If you want the system to prompt for the local printout header data at the start of the CNC run, activate the Force Input at Start check box. 4 Click on OK. The entries are saved and the window is closed. The data you entered is included in the custom printout when the measurement is completed.
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3 Click on the Data Input button. The Input parameter window will open.
4 Click on the field you want to complete and enter the appropriate values or plain text. 5 Click on OK. The entries are saved and the window is closed. The data you entered is included in the custom printout when the measurement is completed.
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Starting a measurement
Starting a measurement
As regards measurement, a distinction is drawn between two process modes: CNC run The CMM is under the fully automatic control of Calypso. The prerequisite is that the CMM must have CNC capability. Manual run In a manual run Calypso administers only the measurement plan and tells you which feature you must probe next, and how many probings to take. As well as probing the features, you also control the CMM. Both modes of measurement are started from the Start Measurement dialog box. This where you set the options for the measurement plan run, and where you start measurement. It contains the parameters you use to define the scope of measurement, set the parameters for the printout, and define the settings for the CMM.
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2 Set the parameters as necessary for measurement. You will find more information on setting these parameters in Start measurement / measurement plan definition in the Calypso Online Help. 3 Click on OK to start the measurement plan. Calypso commences probing. 4 When measurement is completed, you can click on the Show Default Printout button. The results of measurement are displayed. 5 Once you have checked the results, click anywhere in the open part of the User Desk to hide the listing.
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Starting a measurement
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7 When measurement is completed, you can click on the Default Printout button. The results of measurement are displayed. 8 Once you have checked the results, click anywhere in the open part of the User Desk to hide the listing.
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Never close the Stoplight window, because if you do Calypso will lose contact with the CMM. However, you can always minimize the window or put it behind another window. You can display the Stoplight window permanently in the foreground. In addition to controlling the process, the Stoplight window also enables you to activate various views that show additional information while the measurement run is in progress. They are: Base Alignment, Move in Part Alignment System, Stylus Information, Display Position Probing On/Off Task bar Status Monitor You can also display the Stoplight window in the Always on top mode.
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To cancel a run: Click on red in the Stoplight window or press the Esc key on the control console (not in case of Dynalog P!). The CMM immediately cancels measurement. You have to click on green before you can start a measurement plan again.
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Important for SP600 If you use an SP600, you must clear the stylus before you set the stoplight to green. Otherwise, the weight of the stylus itself would be determined incorrectly. To clear the CMM: 1 In the Stoplight window, click on the green light. This reestablishes the connection between controller and CMM. 2 Using the joysticks, carefully move the stylus away from the workpiece until it reaches a safe position. You can now resume your work. To be on the safe side, check the stylus system and make sure that the stylus is not twisted or damaged.
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Important for SP600 If you use an SP600, you must clear the stylus before you set the stoplight to green. Otherwise, the weight of the stylus itself would be determined incorrectly. To restart an interrupted run: 1 Set the stoplight to green. 2 Click on the Start Measurement button. The Start measurement / measurement plan definition window will open. 3 Deactivate the Clear Existing Results option. 4 Click on OK to restart the run. Calypso reruns the measurement plan. This time around, however, it measures only the features for which no measured values were recorded.
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Chapter
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9-1
Result printouts
The printouts are logs that are generated while the measurement plan is running. Calypso offers logs of three different kinds, known as the default printout, the compact printout, and the custom printout. Additionally, the measuring results can also be output to MS Excel. The Default Printout is a detailed log of all results obtained in measurement. You cannot change the way in which this information is presented. If you want to output the deviations in the Amount mode, the column has the heading Dev. <->.
The Compact Printout is shorter than the default printout. It lists the characteristics together with the measured features for speedy
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Result printouts
assessment. The contents and representation of the compact printout can be configured.
The results of the characteristics are color-coded: green means within tolerance, red means out of tolerance, brown means warning limits violated (color can be deactivated). If the deviation is output in the Amount mode, the column has the heading Dev. <->. The compact printout is saved in the measurement plan directory as an ASCII file (without color-coding information) called cprotocol.txt. The Custom Printout allows you to decide which elements you want to include and to arrange the sequence in which they are
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presented, along with the mode of presentation. Furthermore, you can influence the layout of parts of the custom printout.
By default, Calypso creates a default printout after each evaluation and displays it on the screen. You can also move it to the background. If you want another printout to be created, make the necessary setting in the Start Measurement dialog box that opens by selecting Plan CNC-Start CNC-Start.
Combined evaluations
You can also combine two or more measurement plans and so create combined assessments (see Combining several measurement plans on page 7-16). The measurement plans you combine in this way need not necessarily be on the CMM they can be created and run on CMMs at different points in the network. If you have installed Excel 2000, you will also be able to output the measuring results in the form of an Excel report. Three predefined reports are available in the ...\calypso\home\om\excel-report directory.
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Result printouts
The type of report required can be selected in the Format Custom Printout window (see How to define the output of the printout on page 9-5). You must then activate the output to MS Excel in the Start Measurement window. After execution of the CNC run, the results will be output in an Excel document in the ...Calypso\home\om\workarea\results directory. The name of the document is a combination of the measurement plan name and the part number.
Defining printout
The contents and form of printout can be selected in the Format Custom Printout window. You specify what (e.g. characteristics) the custom printout is to contain and how (e.g. in what order) it is to appear. Enter the warning limits for the features and characteristics. Define the desired printout type for output to Excel. For the result output in DMIS format (Saving measuring results to files on page 9-45), you can select a dmi file for the DMIS head.
If you want to output measurement plan groups in the custom printout, you must set the Group in Custom Printout setting to On in the Measurement Plan Editor Characteristics. 3 To define the DMIS header for result output in DMIS format (Results to file) related to the specific measurement plan: Click on the Select DMIS header button to select the desired file. Otherwise, a default printout header will be used.
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4 To allow the measuring results to be output to an Excel file: click on the Select EXCEL Report button and select the required report type. Three predefined reports are located in the ...\calypso\home\om\excel-report directory: Characteristic.xls for output of the characteristic data Feature.xls for output of the feature data FeatChar.xls for output of characteristic and feature data
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You can only use this function if you have installed Excel 2000 on your system. Prerequisite: The ReportINI.xls file must be available in the same directory as the reports.
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Important The file names of the measurement plans used must not contain any special characters (based on DOS conventions) or blanks. Experienced Excel users can modify the existing report files or to create their own. 5 Click on OK to confirm. The settings will be accepted and the window will close. You can determine which report is to be output in the Start Measurement window before you start your measurement plan. For more information, see Format custom printout in the Calypso Online Help.
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Result printouts
To display the measuring results in the default printout: Click on the Show Default Printout button. The default printout is displayed.
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You can also click on this button to display the results even if you have closed the Default Printout window.
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The printout is output on the printer that has been defined as the standard printer in the Windows settings.
Examples of printouts
In the following you will see some examples of printouts.
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Result printouts
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Result printouts
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Example of an Excel report of the Feature.xls type for the output of feature data:
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Result printouts
Example of an Excel report of the FeatChar.xls type for the output of characteristic and feature data:
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The custom printout is your way of presenting measuring results, for example, to a customer or client. You can generate your own custom printouts tailored to your needs and preferences or to those of your client, and present the results of measurement in detail. Custom printouts are ideal for attractive graphical presentations. Consequently, they consist of various graphics files. You can edit these graphics files as necessary.
Compact printout
The compact printout offers less possibilities for layout. The output format of the compact printout is automatically predefined by selecting the output format for the custom printout. You can customize the header of the compact printout via the Header Editor. For using and modifying custom printouts and compact printouts, the following steps are necessary: How to define the output of the printout on page 9-5 Designing printouts with the Header Editor on page 9-17
If you are using the Calypso Light version, you cannot use these functions.
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The data for each section is saved in separate files in the directory called calypso\opt\om\protform\default\.... These sections are listed in the table below, alongside brief descriptions of their contents. Section Printout header Contents Automatic fields with information on: workpiece measurement data etc. Header line Specifications for presentation of the results. The printout area contains the characteristics and the measuring results as well as coordinate systems, etc. Resources Result Presentation Header Line Editor File name: header.gra Edit under Resources Result Presentation Printout Header File name: vphead.gra
Printout area
Characteristics
Contains the icons, the Resources Result Presentation names and the results of the Characteristic Editor characteristics. File name: cffra.gra Contains the icons, the Resources Result Presentation names and the results of the Feature Editor features. File name: me.gra Resources Result Presentation Characteristic Group Editor File name: grpcf.gra Contains the icons, the Resources Result Presentation names and the references of Characteristic Editor the coordinate system. File name: cfpos.gra any Resources Result Presentation User Defined Header Resources Result Presentation Printout Header Compact Printout File name: cphead.gra
Features
Characteristic groups
Coordinate systems
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global dummies. You enter these dummies once for each measurement plan (such as the part number, for instance), while others (e.g. time, measurement plan name) are filled in automatically by Calypso. local dummies. These dummies are filled in by you or by Calypso before each start of the measurement plan; they include the order number and remarks, for example. For more information, see Preparing header data on page 9-21.
Icon of characteristic
Name of characteristic
Histogram
Along with the actual value and nominal value and upper and lower tolerances, the printout contains further information, indicated by the arrows in this illustration. This information includes: Icon of the characteristic: The icon of the characteristic can assume one of several colors: red: Characteristic is out of tolerance yellow: Characteristic is in the defined warning range (if defined) green: Characteristic is within tolerance. Histogram: The vertical line in the histogram represents the middle of the tolerance range. The dashes represent the tolerance limits.
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Each dash represents 25% of the tolerance limit. The illustration below, for example, represents 50% of the upper tolerance limit.
If the value is out of tolerance, the numerical value of the deviation is displayed instead of the histogram.
If you are using the Calypso Light version, you cannot use this function. This illustration shows the Header Editor for features.
Graphic toolbox
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You can change the following structural aspects: Printout header (also for the compact printout) Header line, Characteristics, Features, Characteristic groups, Coordinate systems and Additional, user-defined pages. For this purpose, use the individual editors under Resources Result Presentation.
NOTE
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You need some experience with drawing programs in order to use the editor.
Header Editor
The functions of the Header Editor are not described in detail in the following as they do not differ greatly from those of conventional drawing programs.
NOTE
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If you are using the Calypso Light version, you cannot use this function. The drawing area is where you lay out the custom printout. The special toolbox provides a number of variables or fields that you can insert into the custom printout; the choice varies, depending on the editor. These are filled either automatically by Calypso while the measurement is in progress, or manually by the operator. The graphic toolbox contains icons representing the usual graphics tools for drawing simple graphical elements, and for inserting complete graphic files (such as a company logo, for example) into the custom printout. The info bar contains information on size of image, working directory and current scaling. The toolbar contains a selection of commands for controlling the Header Editor:
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The commands available in the menu bar are as follows: Menu File Menu Item New Save Save As Open Format Function Creates a new custom printout Saves the current custom printout. Saves the current printout under a new name. Opens an existing printout. Opens the Page layout dialog box. This dialog box is fully described in Page layout in the Calypso Online Help. Prints the current printout. Closes the dialog box Copies the selected element to the Clipboard. Copies the selected element to the Clipboard and removes it from the drawing area Pastes the contents of the Clipboard back into the printout. Selects all elements in the drawing area. Duplicates the selected element. Not yet available
Print Close Edit Copy Cut Paste Select All Duplicate Make Polygon
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Menu Draw
Menu Item New Number Field Text Field Output Field Data Output Field Table Output Field Graphic Fill Color Border Color Line Width Properties
Function Inserts a number field for numerical inputs. Inserts a text field for alphanumerical inputs. Inserts an output field. Inserts a data output field. Inserts a table output field. Inserts a graphic (file, OMView or form and location plot) Defines the fill color for an object Defines the color for an object's border Defines the line width for an object's frame Opens the Properties (Header editor) dialog box. This dialog box is fully described in Properties (Header editor) in the Calypso Online Help. Defines the width of an object Defines the height of an object Defines the name for the object Prompts whether you want to create a new view of the object Brings an object into the foreground Brings an object one layer forward Sends an object to the background Sends an object one layer back Creates a group for symbols Creates a group for statistics Creates a group for comments Creates a group for references Groups the selected objects Ungroups a group Aligns selected objects vertically and/or horizontally
Width... Height... Object Name... Object Visibility... Bring To Front Forward Send To Back Backward Group For Symbols For Statistics For Comments For References Grouping Ungrouping Align...
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Menu View
Menu Item Refresh Zoom In Zoom Out Grid Off Define Grid Scale feature Reset Page Select Objects
Function Not yet available Zooms in the view Zooms out the view Switches the grid on and off Defines the size of the grid Scales an object by the defined scaling factor Not yet available Lists all objects that occur in the printout template
If you are using the Calypso Light version, you cannot use this function. There are two types of printout header data: Local data: You have to enter this data each time you start a measurement plan Global data: You enter this data once only for each measurement plan. Calypso also provides other information for the printout header data (such as tester, date, etc.), which cannot be modified. In addition to the fields provided by Calypso, you can define your own printout header fields and, if necessary, their input mode and value selection (Defining your own printout header data on page 9-22). To define which data is incorporated into the printout header, select Resources Result Presentation Printout Header and Resources Result Presentation Printout Header Compact Printout.
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The available printout header data is listed in a column reserved for this purpose.
Within the column, the printout header data is arranged in groups, as follows: Data group SYS EDIT START Type local/global global local Subsequently entered automatically by Calypso once only per measurement plan under Resources Printout Header Parameters. for each measurement plan start in the Start Measurement dialog box, see How to enter local printout header data on page 8-7. automatically by Calypso
OTHER
local/global
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If a userfields.ini file exists, Calypso then refers to this file to determine which data is queried in the Input Parameter dialog box and which values can be acquired for the individual printout header parameters. You can also activate and edit this file yourself. For convenient and reliable input of the printout header data, you can define selection lists with a given, limited scope, for example (INI File for Printout Header Data on page 9-24).
NOTE
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If a variable defined in the userfields.ini file was already defined in the userfields.txt file, the definitions in the userfields.ini file will overwrite those from the userfields.txt file.
If you are using the Calypso Light version, you cannot use this function. The additional input fields will have to be defined in the userfields.txt ASCII file. You can obtain this file by renaming the xxx_userfields.txt file you received in the ...\Calypso\opt\om\protform directory to userfields.txt. If a file called userfields.ini is present in addition to theuserfields.txt file, its settings will overwrite those of the userfields.txt file. To define the additional input fields, add one further line with the following elements, separated by commas, for each required input field: Element ID Designation Display control Meaning will be used in the result file, must begin with u_ will be displayed in dialogs E = appears in the dialog when editing, R = appears in the dialog at CNC start, RE = appears in both dialogs
Activating file
NOTE
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Supplementing file
You can, for example, append the following three lines in the userfields.txt file:
u_field1,FELD 1,RE u_field2,FELD 2,R u_field3,FELD 3,E
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Once you have called the Report Header File Editor using Resources Result Presentation Printout Header you will notice that the newly defined fields have been added to the left selection column of the printout header fields. These fields can now be added to the printout header in the same manner as standard fields in Calypso. The values for the added fields are entered in two dialogs: for the fields in the Input Parameter dialog that are highlighted with R (during CNC run, after clicking on the Printout Header Data button, or mandatory at the start), for the fields in the dialog under Resources Printout Header Parameter that are highlighted with E, for the fields in both dialogs highlighted with RE. The entered values will appear in the printout header of the custom printout and the compact printout. The identifications (e.g. u_field1) and the appropriate values will be output in the result header file (*_hdr.txt).
The settings in this file will overwrite the settings of any existing file named userfields.txt. If no INI file is active (default state), any parameter can be entered for the printout header data.
The INI file must first be activated and edited as a text file in the ...\Calypso\opt\om\protform directory. Calypso comes with the zzz_userfields.ini file (it contains an example of self-defined printout header fields). You can activate the supplied zzz_userfields.ini file by renaming it to userfields.ini. The format of the userfields.ini file largely corresponds to that of a normal Windows INI file: The file consists of individual sections, each of which is introduced by a line with the section name in square brackets. Each section consists of lines in the form <option>=<value>. The names of the options are firmly assigned. A number of values for one option are entered with separating commas. If a value itself contains one or more commas, this value must be placed in quotes ("). Example:
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All characters that follow a semicolon are regarded as comments and ignored. Exception: The semicolon is located between two quotes (";"). A line that starts with REM is regarded as a comment and ignored.
Structure of the userfields.ini file
For the userfields.ini file, the following has been agreed for the section and option names: The [Fieldnames] section contains the names of the other sections defined in this file that can represent an input field, a value list or a combo box. Deviating from the usual format, this section consist of lines of the form <option>. For each of the options defined in the Fieldnames section, there is a separate section with this name. Each section that represents an input field, a selection list or a combo box contains lines with the following options:
<option>
<value>
The name of the input field (is displayed in the Input Parameters dialog box to the left of the input field or list) When you are editing the measurement plan and a value for the field is to be entered (menu item Resources Report Header Parameters) Otherwise When a value for the field is to be queried on CNC start Otherwise For input via combo box or selection list Otherwise The name of the section with the entries of the combo box or selection list Combo box Selection list The value to be displayed before a selection is made. Important: If the default value is to be an entry from a list (combo box or selection list), it is not the actual entry that should be here, but its option name.
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Each combo box and each selection list is assigned as a value of the selectiveListValues option the name of the section in which the individual entries of the list appear line by line. Each of these lines has the form <option>=<value>. The options are entered in the protheadpara file; the assigned values, on the other hand, are displayed in the relevant list.
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This enables, for example, the entry of numerical values as UserIDs in the protheadpara file for further processing, whereas the user names are displayed in the Input Parameters dialog box. What follows is an example of a userfields.ini file.
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[u_field3] name=Weekday editMode=true runMode=true selectiveList=true selectiveListValues=u_field3_valueList editable=false defaultValue=3 [u_field4] name=Amount editMode=true runMode=false selectiveList=false defaultValue=0.0 [u_field5] name=Currency editMode=true runMode=true selectiveList=true selectiveListValues=u_field5_valueList editable=true ; the user can type in values using the keyboard (and not only ; selecting the values from the given list) defaultValue=Euro REM Now defining the valuelist for the userfield with the name "Month" [u_field1_valueList] 1=January ; this is also the default value - see option defaultValue ; at definition for u_field_1 2=February 3=March 4=April 5=May 6=June 7=July 8=August 9=September 10=October 11=November 12=December
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[u_field3_valueList] REM this is the valuelist for the userfield named "Weekday" 1=Monday 2=Tuesday 3=Wednesday 4=Thursday 5=Friday 6=Saturday 7=Sunday REM the following value list doesn't need special keys for the values. So the keys are the REM same as the values. [u_field5_valueList] Euro=Euro Dollar=Dollar Yen=Yen Franc=Franc DM=DM
If you are using the Calypso Light version, you cannot use this function. To work with a custom printout template: 1 Open the editor for the section you want to edit by selecting Resources Result Presentation. 2 Open the template sketch by selecting File Open and then clicking on OK. The template is displayed as a sketch. 3 You can edit the sketch in accordance with your needs and preferences to create the template for your own custom printout: Highlight the object you want to use in the graphic toolbox or the special toolbox. In the drawing area, click on the position where you want to insert the object. 4 Save the template: Select File Format to define the format. Select File Save As.
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!
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Important Do not, under any circumstances, change the name of the file, because Calypso always uses the same name. Change the name of the directory called default if you want to create two or more versions of the printout. Overwrite the default name with the name of a directory you have created for this purpose with Windows NT Explorer. Click on OK. Your template is now saved.
If you are using the Calypso Light version, you cannot use this function. In this example, we want to have Calypso prompt for the pallet number when the measurement plan is started and include the number entered by the user in the custom printout. 1 Select Resources Result Presentation Printout Header. The file now shown under Sketch should now be vphead.gra.
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2 Select File Open. The printout header is now displayed on the user desk.
3 In the list of fields on the left, go to the START section, mark the Tool field and click in the printout header at the point where you want to position the field. Delete the word Tool from the label and type Pallet number instead. 4 Close and save the printout header you edited. 5 Open the list of characteristics. 6 Make sure that no characteristic is highlighted, right-click to open the shortcut menu, and select Parameter. The Settings dialog box appears on the screen. 7 Under Presettings, enter the following:
PALETTE=inquire(Enter the pallet number: ") setRecordHead("tooldf",PALETTE)
Explanation: What is found in the tooldf variable is output into the palett number printout head field. The effect of the first line is that a prompt box opens and the user is prompted to enter the pallet number. The effect of the second line is that the number entered in this way is assigned to the tooldf variable and is thus subsequently printed in the printout under pallet number. Commands entered in PCM apply to the entire measurement plan, which means they are executed when the measurement plan starts.
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Name of field Start Comment Comment: Name Test ID Lot ID Subject Number Name: Process Plan Order Version: Audit-No.: Tool Signature:
ID startcomment vda_remark procid lotid partnbLong vda_subjno vda_name mfgdev order vda_version vda_auditno tooldf vda_signature changeoper creationswi changedate produceoper creationdate creationdme
OTHER
Changed By (operator) Creation Of Software Rev. Revision Date Created By (operator) Creation Date Creation Of CMM Type
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Form plots are available for the following characteristics: Straightness Flatness There is also a Fourier analysis plot for this. Roundness There is also a Fourier analysis plot for this. Cylindricity Best Fit of Bore Pattern Curve Form (curve measurement is an option of Calypso). Curve Slope (curve measurement is an option of Calypso). You can either select an existing format file or a format file that you have created yourself (*.gra) to display the deviations in graphical form.
Location plots are available for the following characteristics: Parallelism, Perpendicularity, Inclination Line - Line Line - Plane Plane - Axis Plane - Plane Runout Radial runout of circles Total radial runout of cylinders Axial runout or total axial runout of planes You can either select an existing format file or a format file that you have created yourself (*.gra) to display the deviations in graphical form.
You can also freeze the representation in the CAD window and output it as a drawing with spatial effect in a plot (Outputting the CAD view as a plot on page 9-38).
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Selection list for the type of plot Format file selection list Selection list for characteristics
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2 Select the type of plot you require for the characteristic from the upper selection list. 3 From the selection list below that, select the format file which should be used to display the form or location plot. Default refers to the standard Zeiss format file. CAD View means output of the CAD window as a plot. All characteristics for which the type of form or location plot can be used are listed in the Characteristics selection list. You can select two or more in the case of some characteristics. 4 Select the characteristic. The Form Plot window opens with the type of plot you selected. The editing options in the Form Plot window are described in detail in Working with the form and location plot Window on page 9-41. 5 Click on OK when you are ready. You can always bring the form or location plot window back to the foreground again if you need it.
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the form or location plot is called. The illustration shows the window using the Roundness characteristic as an example:
Selection list for the type of plot Format file selection list Selection list for characteristics
4 Select the type of plot you require for the feature from the upper selection list. 5 From the selection list below that, select the format file which should be used to display the form or location plot. Default refers to the standard Zeiss format file. CAD View means output of the CAD window as a plot. All characteristics for which the type of form or location plot can be used are listed in the Characteristics selection list. You can select two or more in the case of some characteristics. 6 Select the characteristic. The Form Plot window opens with the type of plot you selected. The editing options in the Form Plot window are described in detail in Working with the form and location plot Window on page 9-41. 7 Click again on the selection window for form or location plots if you want to view other form or location plots. This moves the Form Plot window to the background. You can now display the form or location plots of other characteristics together with the current form or location plot. Repeat step 6 for this. 8 Click on OK when you are ready.
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You can always bring the form or location plot window back to the foreground again if you need it.
A condition for output of a certain CAD model is that you have previously created the desired CAD model with its parameters (zoom factor, scope of model, rotation angle, offset, magnifying factor etc.) in the CAD window and saved it under a certain name using CAD View Save View. You activate the output of the CAD window as a plot in exactly the same way as the form or location plot using the Graphic button in the definition template of the characteristic. Then select CAD View as the format, acisView as the subdirectory and acis_3d.gra as the format file. A selection of possible CAD views appears. The current view has the name model. Other previously saved views appear with their file names.
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If you create your own format files, you must, for this reason, store them in the subdirectory with the corresponding name (see list). If the subdirectory does not yet exist, create it. Plot type Roundness Multiroundness Multiple roundness transposed Multiroundness with diameter Fourier analysis Flatness 3D Flatness View Flatness of Circle Segments Flatness of Line Segments Multi-Flatness of Circle segments Multi-Flatness of Line segments Fourier analysis Straightness Straightness Multistraightness Cylindricity Cylinder form of Circle segments in 3D Cylinder form of Line segments Cylinder form of several circle segments Cylinder form of single circle segments Curve Form Curve form linear Curve form 2D Curve form 3D Multi-Curve form 2D Multi-Curve form linear Curve Slope Slope Type 1 Slope Type 2 CurveformSlope CurveformSlope2 cz_cu_sl_Type1_ls.gra cz_cu_sl_Type1_p.gra cz_cu_sl_Type2_ls.gra cz_cu_sl_Type2_p.gra curveformline curveform2d curveform3d multicurveform2d multicurveformline cz_cu_li.gra cz_cu_2d.gra cz_cu_3d.gra cz_mcu_2d.gra cz_mcu_li.gra Cylinderformcircular3d Cylinderformline Cumradialrunoutmulticircle cz_cf_3dc.gra cz_cf_l.gra cz_crro_mc.gra straightness multistraightness cz_sn.gra cz_msn.gra flatness3d circlemulti linemulti multiflatnesscircular multiflatnesscircular fourieranalyse cz_fn3d.gra cz_fn_mc.gra cz_fn_ml.gra cz_mfn_c.gra cz_mfn_c.gra cz_fo.gra multiroundness multiroundness multiroundness fourieranalysis cz_mr.gra cz_mr_t.gra cz_mr_dia.gra cz_fo.gra Subdirectory File name
Cumradialrunoutsinglecircle cz_crro_sc.gra
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Plot type Slope Type 3 Position Bore Pattern Perpendicularity Perpendicularity Perpendicularity 3D Multi perpendicularity on circle segments Parallelism Parallelism Parallelism 3D Multi parallelism on circle segments Angularity Angularity Angularity 3D Angularity of circle segments Runout Axial runout 3D Cumulative axial runout 3D Cylinder form using many circle segments Multi axial runout line Multi cumulative axial runout line Multi radial runout Multiple radial runout circle CAD window (for all form and location plots) CAD View
Subdirectory CurveformSlope3
multiPerpendicularityOnCircl cz_pe_mc.gra e parallelism parallelism3d multiParallelismOnCircle angularity angularity3d multiAngularityOnCircle axialRunout3d cumAxialRunout3d Cumradialrunoutmulticircle multiAxialRunoutLine multiCumAxialRunoutLine multiRadialRunout radialRunoutOnCircle cz_pa.gra cz_pa3d.gra cz_pa_mc.gra cz_an.gra cz_an3d.gra cz_an_mc.gra cz_ar3d.gra cz_car3d.gra cz_crro_mc.gra cz_ar_ml.gra cz_car_ml.gra cz_rro.gra cz_rro_sc.gra
AcisView
acis_3d.gra
Designing Your own format files for form and location plots
In addition to the format files provided by Calypso for displaying form and location plots, you also have the option of creating your own format files. To do so, use the Header Editor which can be called using Resources Result Presentation Characteristics Editor.
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You can customize the printout header of the plots via the Header Editor. Call up the editor via Resources Result Presentation Report Header and then open the mbhead.gra file in the directory ...\Calypso\opt\om\pictures\formplott\calypso.
NOTE
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If you are using the Calypso Light version, you cannot use this function. Details on how to work with the Header Editor can be found under Header Editor on page 9-18.
In the case of the Fourier representation for flatness and roundness, the amplitudes for the different harmonics as well as a table with the largest amplitudes and the associated harmonics are displayed. The amplitudes are shown in radial direction in the Fourier analysis of roundness and the amplitudes are shown in normal direction with respect to the plane in the Fourier analysis of flatness.
NOTE
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The precondition for Fourier analysis of flatness is that the plane was measured with a circular path. You can enter the number of harmonics to be shown. The maximum number of harmonics that can be shown is equal to half of the measured points. The graphic automatically fits into the intended space. The scale of the X axis is logarithmic and starts at 1 = fundamental wave.
Presentation format
Calculation process
To determine the values to be shown, all measured points are filtered first, if necessary, and outliers are eliminated. Then, to calculate the various amplitudes, a Fourier analysis is carried out, taking into account unequal distances between the measured points. In the Fourier analysis of roundness, the valid deviation is the deviation in the direction of the normal with respect to the plane.
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The illustration below shows the Form Plot window for a roundness plot for a circle.
In this window, you can edit the representation of the form and location plot and print the current representation. The window consists of three areas: The form plot header, containing the data from the printout header. The form plot area. It shows the validated specified form along with the actual contour as derived from the measured points. The two red lines represent the upper tolerance limit and the lower tolerance limit. You can see at a glance where a measured point deviates from specification, and in which direction. A data table with the name of the characteristic, the actual value, the tolerance, the number of points, and the data for the filter, if used.
Marking extreme points
You can mark the extreme points. To do so, select Edit Plot Type in the form plot window and enable the Extreme Points check box. You then have a choice of different marking symbols.
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1 In the Form Plot window, select the command File Print. The Windows Print dialog appears on the screen.
2 Make the desired settings on the respective pages. 3 Click on OK to accept the modified presettings only for the current plot. The Form Plot window reappears on the screen.
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3 In the Form Plot window, select Edit Modify Chart Settings. This opens a notebook laid out like the notebooks containing the system settings.
4 Set the parameters as necessary. 5 Click on OK to accept the modified presettings for all further runs. The Form Plot window reappears on the screen. 6 Click on OK to close all sub-windows along with the definition template for the characteristic.
NOTE
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This dialog box is fully described in Form plot properties in the Calypso Online Help.
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If you are using the Calypso Light version, you cannot use this function. The table below describes the file types supported at this time with the standard file names and paths used by Calypso. Contents, form, standard path and name The measuring results are saved in a text file in table format. The results are therefore available for use in other programs, especially spreadsheet programs. Files of this type are saved under ...\calypso\home\om\workarea\results under the name of the measurement plan which corresponds to the measuring results, including part number indices. When you save the measured values in a merge file, the measured values of different CNC runs are saved sequentially in a common file. Before you can save the measured values in a merge file you have to initialize them. Merge files always have table format. They are saved in C:\calypso\home\om\workarea\results under the name merge. The measuring results are saved in a file in DMIS format and are suitable for the CMM accept processes. Files of this type are saved in C:\calypso\home\om\workarea\dmisout under the name of the measurement plan that belongs to the measuring results. Note: DMIS recognizes only one single tolerance mode. The deviations are therefore output as in the Number String mode, even if the Amount mode is set. The measuring results are saved in a file in QDAS format and are suitable for QDAS statistics programs (e.g. qs-STAT, procella). The system only saves the results of those characteristics that correspond to the characteristic set in the measurement plan editor (Characteristic to Statistic on). Files of this type are saved in the C:\calypso\home\om\workarea\qdas directory under the name of the measurement plan that belongs to the measuring results.
Merge file
DMIS
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Contents, form, standard path and name The measuring results are saved as a PDF file (Portable Document Format) in the ...\calypso\home\om\workarea\results directory. Note: You can limit the number of stored PDF files. The custom printout is saved together with all created form and location plots and/or the compact printout. The file names consist of the name of the measurement plan, the part number and a fixed extension: *_gra.pdf for custom printouts with plots *_txt.pdf for compact printouts Note: This option can only be used if one of the following programs is installed on the Calypso computer: Adobe Acrobat Writer Ghostscript FinePrint / pdfFactory The measuring results are saved as a PostScript file (*.ps) in the ...\calypso\home\om\workarea\results directory. The measuring results for curves are output as an ASCII file under C:\calypso\home\ASCII\measurement plan name\element name.txt. You can select which data should be written to the ASCII file: Nominal values or actual values with or without normals and deviation. You can also select an export in VDA format: The curve points corrected by the stylus tip radius are written in a file as MDI (pointvector sequence). You can define individual paths and names for the following data types: Printout (default and compact printout) Table file (characteristics, features, printout header) PDF file (graphic and text) DMIS file Q-DAS file
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For an individual measurement plan, you can then select either the default name or the generally defined individual names or the separately defined individual names for each type of output files.
NOTE
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You must have the right Define Paths. To define paths and names of output files: 1 Select Resources Name for output files for this measurement plan if you want to define individual names only for the active measurement plan. The Name definitions for output files for this measurement plan window opens. 2 Select Resources Name for output files for all activated measurement plans if you want to define individual names as default for all measurement plans. The Name definitions for output files for all activated measurement plans window opens. 3 In the Output File selection list, select the file type whose name you want to define. 4 Activate Name of output file variable. 5 Only in the Name definitions for output files for this measurement plan window: To ensure that the set assignments are active for all measurement plans, you must activate Name from setting for all measurement plans. You can only make the individual settings for the active measurement plan if you do not activate this check box. 6 Enter the name of the output file with the appropriate extension in the Name definition of output file in PCM Syntax (with or without path) input field and confirm you entry by pressing the Return key.
NOTE
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If you do not enter any path, the path of the current measurement plan is used. The name is entered in the Current Name output field. If the name contains parameters (e.g. part number) to which no values have been assigned, these parameters are not displayed. All file types, for which you defined an individual name, as well as the names themselves, are shown in the All name definitions deviating from default output field. 7 Select another file type if you want to define additional names for output files or close the window with OK. The defined names will be used for the selected output files.
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If a file already exists under a name used for the output files, the file will be overwritten with the new output file. The default printout is created in addition under a default name (protocol) irrespective of the name definition.
If you are using the Calypso Light version, you cannot use this function. To define which file type the results will be saved under: 1 Select Resources Results to File. The Results to File dialog box appears on the screen:
2 Use the radio buttons to set saving on or off for each file type. Activate the appropriate radio buttons or initialize the merge file.
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Important Initialization deletes existing entries in the merge file. Activate the Select at CNC Start radio button if you want Calypso to prompt for confirmation before saving to this type of file. 3 If necessary, set an upper limit for the number of PDF files saved. Calypso will then automatically delete the oldest PDF file in the directory before the upper limit is exceeded. 4 Click on OK to accept the settings and close the dialog box.
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The measuring results will be saved after the CNC run in accordance with the settings that have been made.
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The custom printout with all form and location plots and/or the compact printout are only displayed as a PDF if the corresponding check boxes have been enabled in the Start Measurement dialog box. In a QDAS file, only the results for which the selection point of the characteristic Characteristic to Statistic is set to On or Default in the Measurement Plan Editor Characteristics are stored. This dialog box is fully described in Results to file in the Calypso Online Help.
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3 Activate the Adobe PDF settings tab and deactivate the Show Adobe PDF results and Input prompt for Adobe PDF file name check boxes. Deactivation of the check boxes inhibits the prompting for the directory in which the PDF output is to be saved. Adobe saves the output in the directory in which the last PDF output of Calypso was saved. To define the directory for the PDF output, proceed as follows: 1 Select Settings Printer in the Windows Start menu. The Windows printer dialog is opened. 2 Click on Adobe PDF and select Properties from the context menu. The Adobe PDF Properties dialog box is opened. 3 Activate the Connections tab and add a connection of the Adobe PDF Port type if necessary or configure an already available connection of this type. 4 Select the desired target directory for the PDF output in the Browse for Folder dialog. Now, Calypso saves the PDF files in the selected target directory.
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Opening and closing of the communication interface, as well as launching of the external process, are performed by means of PCM commands. You therefore must possess the PCM option in order to access the measured results. The external process may be programmed in one of the following languages: VisualBasic VBA (VisualBasic for Applications) VisualBasicScript (WSH) [WSH = Windows Scripting Host] Calypso provides a DLL with the name CalypsoInterface.dll as the interface. Using this interface, a CalypsoInterface object can be produced with the corresponding access methods. This CalypsoInterface ActiveX component does not have an interface of its own. It is installed on any computer and waits for its application. The CalypsoInterface with its properties and functions (Syntax of the CalypsoInterface on page 9-54) is used in the external process to access the measuring results and data of the measurement plan.
Access procedure
If all preconditions have been met, access to the measured values takes place in three steps: Calypso opens a communication channel (socket) to the outside world. Calypso starts the accessing external process and waits until it is complete. Calypso closes the communication channel (socket) again. Calypso adds three commands to the measurement plan for this purpose (Permitting access to measuring results on page 9-52).
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Before you can access the measured results of the current measurement plan in Calypso from the outside, the following preconditions must be met: The PCM option has been enabled for Calypso. You have installed and registered the CalypsoInterface (How to install and uninstall CalypsoInterface on page 9-52). You have programmed a process that can access the desired measured results using the functions of the interface (Syntax of the CalypsoInterface on page 9-54).
The external process will then run as soon as it is called by Calypso. For this purpose, three PCM commands must be entered in the measurement plan settings, for example (it makes sense to enter them in the postsettings).
openSocket() systemCallForResultAccess("<executable program>") closeSocket()
The content in <executable program> depends on the programming language you used.
Example
If you wrote a Visual Basic script with the name getValuesFromCalypso.vbs, the three lines would look like this :
openSocket() systemCallForResultAccess("Wscript C:\getValuesFromCalypso.vbs") closeSocket()
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If you no longer need the communication interface of Calypso, you can uninstall it in order to free up space on your computer. How to uninstall CalypsoInterface: 1 Open the MS-DOS input prompt or select Run in the Windows Start menu. 2 Using cd\, change to the directory containing the CalypsoInterface.dll file. 3 Enter the following:
regsvr32 /u CalypsoInterface.dll
4 Select the directory of your destination computer into which you copied the CalypsoInterface.dll file and delete this file.
You can program a process in one of the following languages in order to access the measured values via the communication interface of Calypso: VisualBasic VBA (VisualBasic for Applications) VisualBasicScript (WSH) [WSH = Windows Scripting Host] CalypsoInterface must have been installed on the destination computer on which you program the process and must be registered (How to install and uninstall CalypsoInterface on page 9-52).
Your program should have the following structure: Construction of the CalypsoInterface object Define a host name if necessary Define the timeout Setup of the connection to Calypso Accept measured values; generate messages if necessary Cleardown of the connection to Calypso End of the program
Example Syntax
You can find an example of a VBScript with a similar structure under Example: VBScript Application (WSH) on page 9-61. The necessary properties and functions are listed in the following sections .
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The examples for using the syntax refer to programming with VisualBasicScript.
Construction of CalypsoInterface
The syntax for constructing the CalypsoInterface object is as follows:
CreateObject("CalypsoInterface.Calypso")
It makes sense to create only a single instance of the Calypso object data exchange can take place through only one port of the server.
Set MyCalypso = CreateObject("CalypsoInterface.Calypso")
Example
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Properties of CalypsoInterface
The CalypsoInterface object has the properties listed in the table below. Property HostName Example:
MyCalypso.HostName = "160.4.11.146"
Function Specifies the host name of the server on which Calypso is running. Default: "localhost" If the client (VBS, VB or VBA program) is located on a different computer than that of Calypso, this property must be assigned the computer name or the IP address of the server before the connection is established. Specifies the latest time after which a connection setup attempt with Calypso will be aborted. Default: 10. [seconds] Specifies the amount of time after which a timeout is to take place when waiting for a reply from Calypso. Default: 5 [seconds] Port number of the socket via which Calypso awaits contact. Default: 9998 Contains an error code. Meaning: 0 No error -1 Error when calling the implemented object functions Returned value of the respective function: 0 for numerical values False for Boolean values Empty character string for string values If data exchange was successful but the requested element is not present, "nil" is returned in the case of string values. 11 CalDataSent Data sent, but no response -9 CalNoDataSent No data sent -10 TimeOut. No response from Calypso -11 No connection to Calypso -12 Timeout during communication setup -13 TimerError 7 Value immediately after connection setup (see State) ???? Windows system errors and their numbers
TimeOutConnect Example:
MyCalypso.TimeOutConnect = 10
TimeOut Example: MyCalypso.TimeOut = 10 Port Example: MyCalypso.Port = 9998 ErrNo (Read access only)
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Function Calypso.ErrName is assigned the "Description" parameter of a system error. Specific errors of the Calypso object (-9 to -13, 11) currently contain no designation of the error. Permits a message to be issued: If the property Calypso.ErrMessage = True, a message window (MsgBox) with the error code will be displayed as soon as the condition Calypso.ErrNo < 0 is met. Default: False Important! The use of a MsgBox in ActiveX components can cause problems: A MsgBox interrupts program execution and must be acknowledged by the user. Defines whether to wait for a response for the data exchange functions. The waiting duration then depends on the property Calypso.TimeOut. Default: True Returns a numerical value for the status of the socket connection. Meaning: 0 1 2 3 4 5 6 7 8 9 SckClose SckOpen SckListening SckConnectionPending SckResolvingHost SckHostResolved SckConnecting SckConnected SckClosing SckError
ErrMessage Example:
MyCalypso.ErrMessage = False
WaitResponse Example:
MyCalypso.WaitResponse = True
State
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Sets up the connection to Calypso. Successful execution is a precondition for all access functions. The return value is the State property (type: long). The ErrNo Example: e = MyCalypso.ConnectCalypso property is possibly assigned an error number. State = 7 means: connection has been set up If e <> 7 Then err = MyCalypso.ErrNo Any other return value indicates an error. See property State above.
errTxt = MyCalypso.ErrName MsgBox( err & " " & errTxt) End If
CloseCalypso
Ends a connection between the client VB/VBA program and the Calypso server. The return value is the State property (type: long; see property State above). The ErrNo property is possibly assigned an error number.
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Used for Determining whether the feature is present. Position Reading X, Y, Z nominal value
GetGeometry.ActualXYZ("Identifier")
Position Reading X, Y, Z measured value Normal Vector Reading NX, NY and NZ nominal value In the case of the 2D line, this is the normal of the plane on which the line is located.
Vector
GetGeometry.NormalVector("Identifier") Example:
Set MyCalypso.Vector = MyCalypso.GetGeometry.NormalVector("Cone1") NX = MyCalypso.Vector.X NY = MyCalypso.Vector.Y NZ = MyCalypso.Vector.Z
ErrNo = -1 if invalid
GetGeometry.ActualNormalVector("Identifier")
Normal Vector Reading NX, NY and NZ measured value Nominal value Inside/outside identifier
Vector
GetGeometry.IoSign("Identifier")
GetMeasElements.Geometry.Radius("Identifier")
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Function
Used for
Returned
GetMeasElements.Geometry.ActualRadius("Identif Reading radius measured value Double ier") ErrNo = -1 if invalid GetLineDirection("Identifier") Nominal direction of line Vector ErrNo = -1 if invalid Vector Double ErrNo = -1 if invalid Double ErrNo = -1 if invalid Double Angle in radian measure ErrNo = -1 if invalid Double Angle in radian measure Double ErrNo = -1 if invalid Double Double ErrNo = -1 if invalid Double ErrNo = -1 if invalid Double
GetActualLineDirection("Identifier") GetEllipseDiameter2("Identifier")
Actual direction of line Reading D2 nominal value Ellipse Reading D2 measured value Ellipse Reading AC nominal value
GetActualEllipseDiameter2("Identifier")
GetConeAngle("Identifier")
GetActualConeAngle("Identifier ")
GetLength("Identifier")
GetActualLength("Identifier") GetWidth("Identifier")
GetActualWidth("Identifier") GetHight("Identifier")
GetActualHight("Identifier")
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GetCFType("Identifier")
String
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" & X)
X = MyCalypso.GetGeometry.ActualRadius("CylFroCe") If MyCalypso.ErrNo <> 0 Then MsgBox("Error: GetGeometry.ActualRadius") Else MsgBox ( "Actual Radius of CylFroCe : " & X) End If If MyCalypso.CloseCalypso = 0 Then MsgBox( "Connection closed") Else MsgBox ( "Could not close the connection to Calypso") End If WScript.Quit[1]
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If you are using the Calypso Light version, you cannot use this function. Calypso supports the catalog structure of qs-STAT.
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CNC run of CALYP S O measurement plan with activated QDAS output QDASCONV.CON Configuration file
CNC-E nd
If conversion to QDAS has been activated, the QDASCONV.EXE conversion program converts this results file into a QDAS description file and a QDAS values file. The conversion program uses the file structures defined in the configuration file QDASCONV.CON.
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In a QDAS file, only the results for which the selection point of the characteristic Characteristic to Statistic is set to On or Default in the Measurement Plan Editor Characteristics are stored.
The description data in the DFD file starts with a 4-character key that indicates the data type in the file. 0 ... 999 1000 ... 1999 2000 ... 2999 3000 ... 3999 Description of the value formats Part data Characteristic data Measurement plan data
Example: K1001 Engine block Where: K = Key 1001 = Part number Engine block = Information content
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During the first run, all characteristics should be sent to qs-STAT, so that a complete data model can be created in qs-STAT. If only certain selected elements are sent to qs-STAT later, the data model is updated; all elements which are not measured stay at counter status 1.
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If only part of the measurement plan is sent to qs-STAT during the first run, but all characteristics are then sent as a later run, the data model created earlier is not updated. Additional data, such as batch number, operator, and machine number can be added to any run in additional data records as necessary. The sequence of the characteristics in a file is determined by the measurement sequence. If characteristics are missing due to focusing of the CNC run, the measurement value is set to zero and the dimension is labeled as invalid.
In a QDAS file, only the results for which the selection point of the characteristic Characteristic to Statistic is set to On or Default in the Measurement Plan Editor Characteristics are stored.
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After execution of a CNC run, the measuring results will be saved as the description file (*.dfd) and the value file (*.dfx) in the directory ...\calypso\home\om\workarea\qdas and under the name of the corresponding measurement plan.
Every relevant line of the configuration file has the following line format:
KXXXX LLL T H:<Name>
XXXX: 4-character key for indication of type of contents 1 ... 255 A = Alphanumeric I = Number F = Floating point number D = Date P = Key word from the header file, Example: P:planid W = directly from this file; Example: W:Prismo7
H:<Name>
Spaces and tabs are used as separators. Spaces at the beginning are not allowed. Comments begin with #.
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Sections B, C and D contain the keys (including definition) to be requested from the customer which are necessary for the description file and the value file, as well as a description of how the data fields are to be filled. The values defined here are valid for all workpieces. You can, however, individually adapt the QDAS information part in the custom printout for every workpiece. Section E defines the extra data fields to be created in the values file.
Section B: Parts data to be created
In this section of the configuration file, all part information which is to be requested from the customer is specified here with key, length and type and, in some cases, contents. Frequently used keys and their labels for parts data:
K1001 K1002 K1003 K1004 K1005 K1007 K1040 K1041 K1042 K1043 K1900
Part number Part label Part short label Part modification status Product Part number short label Drawing catalog Drawing number text Drawing change Drawing index Remarks
You do not necessarily need to use the keys listed here. You can add new keys at any time.
Section C: Constant feature data to be created
Some of the specifications needed to describe features are not known by the user or machine, and are not contained in the measurement protocol. Some of this data has the same values for all features. This data is therefore defined as constant feature data in this section of the configuration file.
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Frequently used keys and their labels for constant feature data:
K2004 K2005 K2007 K2211 K2212 K2213 K2214 K2215 K2220 K2221 K2303 K2305 K2306 K2307 K2342 K2343 K2344 K2401 K2402 K2404 K2405 K2406 K2407 K2408 K2409 K2410
Type of feature Feature class Type of control Type of distribution Normal number text: Comparison normal Normal label Normal temperature Normal number Number of tester Number of measurements Section/Bookkeeping Machine number Area in plant PTM number Measurement plan name Measurement plan creation date Measurement plan creator Test equipment number text Test equipment label Test equipment resolution Test equipment number Test equipment manufacturer SPC device number SPC device label SPC device type Test location
You do not necessarily have to insert values for these keys in the configuration file, because you can enter them in the data module of the qs-STAT statistics program.
Section D: Variable feature data to be created NOTE
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Some of the feature data can be taken directly from the measurement protocol. Values for this data do not have to be entered in this section of the configuration file. Do not change data in section D.
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Frequently used keys and their labels for variable feature data:
K2001 K2002 K2003 K2100 K2101 K2110 K2111 K2112 K2113 K2120 K2121 K2142 K2151
Feature number Feature label (additional text from configuration file) Label short text (Calypso feature type) Nominal value/Target value Nominal value Lower limit Upper limit Lower deviation Upper deviation Type of lower limit Type of upper limit Unit label Tolerance as text (tolerance width)
For every measurement, additional data can be saved in the value file. This data is valid only for the corresponding measuring run. Keys and their labels for additional data fields
K0005 K0006 K0007 K0008 K0009 K0010
Events Lot number/Identification number Nest number/Spindle number Tester (number from catalog) Text Machine number (number from catalog)
These values can change with each measuring run. It is therefore useful to use the columns from the printout. The keys in this section affect only the first measuring run. They should be evaluated only if they are valid for all measurements, for example if all workpieces come from a certain machine. To save all corresponding data with the measurement run, these keys can also be listed in the QDAS information section of the measurement protocol.
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############################################################################## # File: QDASCONV.CON # Configuration file for QDASCONV.EXE ############################################################################## $B---------------------------------------------------------------------------############################################################################## # Section B: Parts data to be created (K1000 - K1099) # (see also QDAS data formats) # All customer-required data must be specified here # CALYPSO: The data is taken from the header file #----------------------------------------------------------------------------K1001 30 A P:planid K1002 80 A P:partcomment K1004 20 A P:partrv K1007 20 A P:partsn K1041 30 A P:drawingno K1053 20 A P:order K1081 20 A P:mfgdev K1086 20 A P:tooldf K1101 40 A P:vda_departm K1201 20 A P:dmesn K1202 40 A P:dmeid K1900 255 A P:startcomment $C---------------------------------------------------------------------------############################################################################## # Section C: Feature data to be created that is the same for all features # (see also QDAS data formats) # All customer-required data must be specified here, the format is # the same as in section $B # CAUTION: Values from the characteristic file are not allowed here. #----------------------------------------------------------------------------K2004 1 I W:0 K2005 1 I W:3 K2007 1 I K2011 4 I K2013 22 F W:0.0001 K2022 1 I W:4 K2142 40 A W:mm K2301 20 A P:mfgdev K2302 40 A P:mfgdev K2303 40 A P:vda_departm K2306 40 A P:vda_departm K2342 40 A P:planid K2343 20 D P:creationdate K2344 20 A P:produceoper K2401 40 A P:dmesn K2402 80 A P:dmeid K2406 40 A W:Carl Zeiss Oberkochen K8500 5 I W:3
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$D---------------------------------------------------------------------------############################################################################## # Section D: Feature data to be created that is specific for all features # (see also QDAS data formats) # All customer-required data must be specified here, the format is # the same as in section $B # No value identifications are defined, the values are taken from the # characteristic file. # If no source is given, the values will be calculated. ############################################################################## K2001 20 A C: K2002 80 A C:id K2003 20 A C:type K2100 22 F K2101 22 F C:nominal K2110 22 F C:lowertol K2111 22 F C:uppertol K2112 22 F C:lowertol K2113 22 F C:uppertol K2120 1 I K2121 1 I K2130 22 F K2131 22 F K2141 5 I K2151 20 A K2213 22 F C:actual $E---------------------------------------------------------------------------############################################################################## # Section E: Additional data fields to be created in the values file # All customer-required data must be specified here, the format is # the same as in section $B ############################################################################## #K0001 22 F C:actual #K0006 14 A P:lotid #K0007 5 I P:tooldf #K0008 5 I P:operid #K0009 40 A P:startcomment
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Chapter
10
.................................................................................................................................
Duplex mode
Very large workpieces can be measured using CMMs with two measuring columns (duplex CMMs) to obtain almost twice the usable measuring volume offered by a CMM with only one column. Each of the two columns measures, but computations and evaluations take place on only one of the two computers. Calypso enables you to prepare, perform and evaluate duplex measurements of this nature. Note that to do so, you must have Calypso running on both computers. The sections included in this chapter explain the basics of working with duplex CMMs, and step you through the procedures involved.
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Duplex mode
Calypso enables you to prepare, perform and evaluate duplex mode. Note that to do so, you must have Calypso running on both computers.
Run mode
There are two different types of duplex mode run control: Synchronous mode The measurement plan runs on the master. The master controls both measuring columns, with only one moving at any time. The client is only a conveyor of commands and results. Asynchronous mode The measurement plan runs on both computers. The measuring columns move relatively independently of each other, controlled by the relevant computer. However, if data from the other measuring column is required for calculating a specific feature, the measuring column will wait until this data has been provided by the other measuring column.
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The sections included in this chapter explain the basics of working in duplex mode, and step you through the procedures involved: You have to prepare duplex mode in order to take measurements with two measuring columns. In particular, Calypso must know how the two measuring ranges, originally independent, relate to each other (see Preparing for duplex mode on page 10-4). Important when measuring in any given run: log on, measure, log off (see Measuring with a duplex CMM on page 10-15).
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In the same way as in duplex mode, you can also control more than two measuring columns in multiplex mode. In this way, you can increase the measuring range again and you can save additional measuring time in asynchronous mode. The procedure is principally the same as in duplex mode; you have a master and several clients.
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Duplex mode
Examples of entries in the services" file: qmaster czcol1 czoemint acis counter holos ZVICONTROL col0 col1 col2 col3 oscssd 10012/udp 9996/tcp 9999/tcp 9998/tcp 9888/tcp 4959/tcp 8888/tcp 9800/tcp 9801/tcp 9802/tcp 9803/tcp 5019/tcp
# CADLINK-UX # CALYPSO # Double Column MAN # Column1 # Column2 # Column3 # VERSANT connect service
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hosts file
Entries in the hosts file (example): #################################################### # # SubNet 192.4.1 Testroom # # 192.4.1.65 cnc1 CNC1 # Master 192.4.1.66 cnc2 CNC2 # Client # 192.4.1.55 dynalog1 # computer1 -> Master 192.4.1.56 dynalog2 # computer2 -> Client # 192.4.1.200 cmm_1 CMM_1 # controller1 -> Master 192.4.1.201 cmm_2 CMM_2 # controller2 -> Client 192.4.1.202 cmm_3 CMM_3 # controller3 192.4.1.203 cmm_4 CMM_4 # controller4 # #################################################### In this example cnc1 CNC1 is the name of the master PC. dynalog1 is the name of the control console connected to the master CMM. cmm_1 CMM_1 is the name of the master CMM's controller.
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Duplex mode
Coupling methods
There are two possible methods: Translational coupling A reference sphere is positioned in the center of the common zone. Translational coupling involves computing the offset of the two device zero points. Translational and rotational coupling Three reference spheres are arranged to form a triangle in space. They should delimit the common zone of the measuring space vertically and horizontally. Translational and rotational coupling involves computing the residual angle of the two device coordinate systems relative to each other remaining despite alignment. Calypso has a measurement plan for each method with which you can proceed with coupling.
Stylus
Install the appropriate master stylus in each column for coupling. This ensures maximum precision. You have the option of using some other, qualified styli if less precision is sufficient. Once the two measuring ranges have been coupled for the first time, the relevant data is stored in Calypso and is evaluated for measurements in duplex mode. The coupling has to be readjusted under the following circumstances: Method Translational + rotational Translational + rotational Translational Translational
Subsequent coupling
Reason for coupling Always after a mechanical alteration From time to time in operation (e.g. once a week if use is frequent) Every time the system is restarted Every time a measuring column homes
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3 Enter the requisite information for coupling the systems: Under Columns: enter the number of columns (in duplex mode usually 2). The port number is taken from the services file in the ..\winnt\system32\drivers\etc directory. The measuring columns are correlated to the computers on the basis of the computer names in the hosts file, in this case, for example, cnc1. You can overwrite the defaults, listed here by way of illustration: Master Arm 1 = Column1 Controller 1 = CMM_1 Client Arm 2 = Column2 Controller 2 = CMM_2
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Duplex mode
5 Enter the requisite information for coupling the systems on this computer: The port number is taken from the services file in the ..\winnt\system32\drivers\etc directory. Correlation is on the basis of the computer names in the hosts file, in this case, for example, cnc2. It is advisable to check the connection before coupling the measuring ranges.
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6 On the client, click on the Interface button. The Interface page appears on screen. The page shown here is the Interface page on the master:
7 Check the settings for the connection: Address for controller on client: cmm_2,4712 Address for control console on client: cmm_2,4712 Note the comma after the digits. IP address of controller on client: IP address found: 192.4.1.201
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Duplex mode
8 If you wish to control the columns in asynchronous operation: On the client computer, select Extras Workroom Environment and open the notebook to the Dual Arm page.
9 In the first line, enter the path for the measurement plans on the master PC and in the second line the path for the base alignments on the master PC. Enter the locally valid path designation under Directory path and, under Mounted as... , enter the valid network designation under which the client system can access the path. 10 Click on OK. The notebook is closed and the settings are accepted.
1 Close Calypso, but do not close the taskbar and the Stoplight window. The connection is set up in the Stoplight window only. Always proceed exactly as described below, otherwise the connection will not be successful.
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2 In the Stoplight window on the client computer, select View Multi Arm and click on the Initialize... button.
3 In the Stoplight window on the master computer, select View Multi Arm. 4 Tick the Connected with Clients check box to establish the connection to the client computer. The prompt shown here is displayed:
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Duplex mode
5 Do not click OK to confirm until the client reports that its status is Wait for Master...:
When the connection is successfully established, the following dialog box appears on the screen:
Important: Make sure that the Column1 entry is labeled in black (not gray).
You can now proceed to redefine the connection or, if this has already been done, you can start measuring.
How to check the measurement plans before coupling the measuring ranges
Once you have set up the connection, the next step is to couple the two measuring ranges. Calypso provides two measurement plans for this purpose: The col2_trans" plan for exclusively translational coupling, The col2_rotate" plan for rotational and translational coupling. It is best to check the measurement plan before using it, if you are unsure whether all the settings are correct. The procedure is as follows: 1 Select File Open and select the measurement plan for the coupling you are going to use.
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2 Select Resources Measurement Plan Editor Features. 3 Make sure that the setting for Stylus is MasterStylus (or the qualified stylus you are going to use) for all features. 4 Make sure that the setting for Man CNC Mode is MAN for all features. 5 Make sure that the entry under Columns is column 2 for all features that will be measured with column 2. 6 In the list of characteristics, open the 3-D Best Fit1 characteristic. The Definition template (alternative alignment methods) window will open.
7 Make certain that the Column2 (arm ID slave) entry is set under Receiver. 8 Select File Save to save the measurement plan.
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Duplex mode
2 In the Stoplight window, click on the Define Coupling button and select Translate or Translate and Rotate. 3 In response to the prompt, manually probe six points in succession on a sphere using measuring column 1 (the master). The number of the point to be probed appears in the dialog box under Next Probing Point. 4 In response to the prompt, manually probe six points in succession on the same sphere, this time using measuring column 2 (the client). If you selected translational and rotational coupling, you must repeat this procedure at two more positions on the measuring plate. 5 In response to the prompts, probe sphere 2 and sphere 3 in succession, first with measuring column 1 (master) and then with measuring column 2 (client). When measurement is completed, the master sends its computed coupling matrix to the client. The client uses the coupling matrix to convert its measured points into the coordinate system of the master before sending this information back to the master. As soon as this process is completed, you can start measuring in duplex mode. Alternatively, you can clear down the connection between the two computers and set it up again later when measurements are to be made.
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We recommend the following general procedure for measuring in asynchronous operation: Set up the measurement plan for asynchronous operation. First test the measurement plan in synchronous mode (Measurement Plan Editor Features: set Duplex run mode to Synchronous). Only then test the measurement plan in asynchronous mode (Measurement Plan Editor Features: Duplex run mode set to asynchronous).
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Duplex mode
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Important risk of collision Do not forget the intermediate positions, as otherwise there would be a risk of collision. Important If you are preparing a measurement plan for asynchronous operation, you must make absolutely sure that the measuring columns cannot collide under any circumstances. That is to say, the areas in which the measuring columns move must never overlap. As long as the areas of movement overlap, the possibility of a collision cannot be excluded, because the measuring columns move independently of each other in asynchronous mode. Please check the following functions and settings in particular using the Measurement Plan Editor Features: Columns Stylus System Stylus Clearance Group RDS angles
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If you are measuring in asynchronous mode, you have to save the measurement plan after every alteration. Otherwise the client will not be able to read the current alterations.
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Duplex mode
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Chapter
11
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Managing Calypso
This chapter is intended primarily for system administrators (e.g. the Master user) or experienced users, who are authorized to change the Calypso system settings. This chapter explains how to check and, if necessary, change system settings. This includes, for example, defining users or initialization of the CMM.
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Installing Calypso
Calypso is automatically installed on your computer when you receive the system. However, the installation instructions are included here in case you need to reinstall the software for any reason. The installation requires: the Calypso software CD the CMM floppy disk
System requirements
To guarantee the error-free running of Calypso, your system must at least fulfill the following requirements:
Hardware requirements
Windows-compatible Siemens, Compaq, Hewlett-Packard or DELL PC with 2.5-GB hard drive CD-ROM drive 17 SVGA monitor 3.5" floppy drive LAN card Mouse Keyboard
Performance parameters
Minimum requirements: Pentium IV processor with 1.7 GHz clock frequency 256 MB RAM 32 MB OPEN-GL-compatible display board Recommended configuration: Pentium IV processor with 2.4 GHz clock frequency 512 MB RAM 64 MB OPEN-GL-compatible display board Recommended configuration for CAD applications: Pentium IV processor with 3.0 GHz clock frequency 1 GB RAM 128 MB OPEN-GL-compatible display board
Software requirements
The PC must run one of the following operating systems: Windows NT 4.0 Windows 2000
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Installing Calypso
Windows XP
System settings
If your system was configured by Zeiss service personnel, you will not have to modify the settings. If this was not the case, click on Start Settings Control Panel and select Display and set True Color under Colors on the Settings tab.
Before you can install or uninstall Calypso, you must have administrator rights. If you already have an older version of Calypso installed on your computer, run the uninstall program before you install a new version. Existing data such as measurement plans, stylus data, base alignments or other CMM-specific data will not be deleted during the uninstallation process. It is, however, recommended, that a backup copy of the existing Calypso directory be made using Windows Explorer. Follow these steps to uninstall Calypso: 1 Turn your computer on. Windows will start automatically. 2 Select Start Settings Control Panel in the Windows Start menu and click on Software. 3 Select the Calypso program on the Install/Uninstall tab, click on Add/Remove and follow the instructions on the screen. 4 In the Program Administration dialog box, select the Remove Program option and click on Continue. 5 In the next window, click on Remove. Uninstallation will be effected automatically. The current status will be displayed. 6 Confirm completion of uninstallation with Finish. 7 Confirm the computer restart message with Yes. Your computer will be restarted. Calypso has now been uninstalled.
Once you have removed an existing version of Calypso, you will be able to install the current version. Follow these steps to install the software: 1 Turn your computer on. Windows will start automatically. 2 Insert the CMM System Disk into the floppy disk drive.
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The write protect on the floppy must be off. You can also copy the CMM floppy disk to a directory on the hard disk and specify this directory later. 3 Place the Calypso software CD in the CD-ROM disk drive. If the CD starts automatically, the Calypso installation window will appear immediately. Skip to step 7. 4 If this is not the case, select the Windows command Start Run. At the prompt for a file name to run. 5 Click on Browse, select the CD drive and, on this CD, the Calypso.exe file. 6 Click on Open and then click on OK. After a few moments, the Calypso installation window will appear. 7 Select the language for the installation and click on Continue. 8 Click on the Install button and then on Calypso. The installation program checks if there is enough space on the hard drive of your computer and prompts you to insert the CMM floppy disk. 9 Click on Yes if the floppy disk is inserted. Otherwise, select the path for the CMM floppy disk in the next window and click on OK. A Welcome screen appears. 10 Click on Proceed to accept the copyright agreement and continue. The User Information window will open. 11 Enter the user information and click on Proceed. The Setup Type window will appear on the screen. 12 Select Standard if you do not wish to alter any of the presettings and then click Proceed. - or Select Changed and click on Proceed if you wish to change the following settings in the windows that follow: Drives and target directories for installation Features to be installed
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The settings as you define them in this step are subsequently proposed as the defaults for the next Standard installation. After a short time the system indicates that it is Ready to install the program.
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Installing Calypso
13 Click on Install. Calypso will now be installed automatically. The current status will be displayed. Afterwards, the message InstallShield Wizard completed will be displayed. 14 Click on Finish. 15 Confirm the restart message with Yes and remove the floppy disk from the drive. Your computer will now be restarted. Calypso has now been correctly installed.
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1. Drive A: :
The default folder is C:\TEMP. 6 Click on Unzip. The files are unzipped. A message appears on the screen when all files have been unzipped. 7 Click on OK to acknowledge this message and click on the Close button in the WinZip Self-Extractor dialog box. The program files are now in the C:\TEMP directory on your hard disk, waiting to be installed (see How to install the program files contained in the Service Pack on page 11-8).
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Managing Calypso
4 Click on OK to close the message box. Calypso's system files will be updated the first time the program is called after installation of the Service Pack. This may take some time. You will then be asked to close and restart Calypso.
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Managing Calypso
The last error report is opened. 2 In the Comment field, please enter as precisely as possible the circumstances which led to the error.
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You must type in a comment before you can print or save the error report. 3 In the Address area, select the appropriate address from the Selection list. 4 Enter your name, address, phone and fax numbers, and your email address. 5 If you wish to forward the error report to Carl Zeiss by fax: Select File Print and fax the error report to the number stated under Address.
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6 If you wish to forward your error report to Carl Zeiss by e-mail and also wish to forward the measurement plan: Select File Save. You will be asked if you also wish to save the measurement plan as some errors can only be analyzed with the help of the measurement plan. 7 Confirm with Yes if customer support at Zeiss has requested that you forward the measurement plan. The error report will be compressed and saved (if necessary, with all the data from the current measurement plan directory and from the actual values directory) on your hard disk as a file called hotl in the ..\calypso\var\opt\om\hotline directory. 8 Send this file by e-mail to the address stipulated under Address.
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The other menu items under File are used for special service purposes: Open can be used by Zeiss employees to unzip the forwarded measurement plan. The Record geometric calculation menu item should only be used when instructed to do so as this triggers resource-intensive processes.
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Managing Calypso
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The instructions (column headed See) are in the corresponding sections in the Online Help system. Setting Retract Distance Menu item Measurement Tab Travel See How to change the measurement parameters of the CMM How to change the CMM configuration
Beeping upon probing Users logged in Decimal precision Expansion coefficients of the scales Automatic login at start
Probe
Administration How to view or enter a user description Language Temperature How to change your environment How to change the CMM configuration
Administration How to activate automatic login Features How to change the measurement parameters of the CMM How to change the measurement parameters of the CMM How to change your environment How to change the measurement parameters of the CMM How to change the CMM configuration
Measurement
Features
Environment
Start
Measurement
Methods
Control console type Add user Delete user Rename user User Copyright of Calypso
Panel
Administration How to add new users Administration How to delete a user Administration Renaming a user Administration Basics about users Copyright How to view general information about the program version How to change the CMM configuration How to change the CMM configuration
CMM CMM
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See How to change your environment How to change the measurement parameters of the CMM How to change your environment
Window colors Device administration Speed of CMM for positioning and scanning Hardware and drivers
Colors
Administration How to change the CMM configuration Speed How to change the measurement parameters of the CMM How to change the CMM configuration How to check the home directory How to initialize the CMM How to view general information about the program version How to change the CMM configuration How to change the CMM configuration How to change the CMM configuration How to change your environment How to change your environment How to change the CMM configuration How to change the measurement parameters of the CMM How to change the CMM configuration
CMM
Home directory (for storing user- User specific settings) Initialization of the CMM Internal parameters of the software installation Coefficients (expansion) for scales Machine type (CMM type) Master in duplex operation Measure unit of length (mm or Inch) (user interface) Measure unit of length (mm or Inch) (printouts) Maximum diameter of probe Measured points (for automatic feature recognition) Measuring range of CMM Nominal mode CMM Miscellaneous
CMM Measurement
Machine
Nominal value How to change the measurement parameters of the CMM Internals
Reread (internals)
Miscellaneous
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See How to change the CMM configuration How to change your environment How to change your environment How to change your environment How to change the CMM configuration How to assign general user privileges How to change the CMM configuration
Path (directory) for actual values Environment Path (directory) for measurement plans Path (directory) for table files Computer allocation in duplex operation Assigning privileges Master stylus in sensor system Rounding measure for preset nominal value Scanning speed Environment Environment CMM User CMM Measurement
Nominal value How to change the measurement parameters of the CMM Speed How to change the measurement parameters of the CMM How to change the CMM configuration How to change your environment How to change the CMM configuration How to change the measurement parameters of the CMM How to change the CMM configuration How to change the measurement parameters of the CMM How to change your environment How to change your environment How to change your environment
Measurement
Interface type and address Font CMM serial number Clearance distance
Client in duplex operation Rounding to nominal value (rounding dimension) Language (user interface) Language (printouts) Start conditions
CMM Measurement
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Setting Start procedure (automatic login) Status log for system Control type (hardware and drivers) Stylus system holders Stylus system changer Probe configuration Diameter of probe Temperature unit (Celsius or Fahrenheit) (user interface) Temperature unit (Celsius or Fahrenheit) (printouts) Positioning speed
Menu item User Status monitor CMM CMM CMM CMM CMM Environment Environment Measurement
Tab
See
Administration How to activate automatic login Control Stylus system change Stylus system change Probe Probe Language Language Speed How to view the system status monitor How to change the CMM configuration How to change the CMM configuration How to change the CMM configuration How to change the CMM configuration How to change the CMM configuration How to change your environment How to change your environment How to change the measurement parameters of the CMM How to change your environment How to change your environment How to change your environment
Assigning file with default name Environment Angle unit (measure unit) (user interface) Angle unit (measure unit) (printout) Environment Environment
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Chapter
12
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Auto-Run interface
As system administrator, you can use the Auto-Run function to create and edit Auto-Run interfaces. In an Auto-Run interface, you no longer work in a measurement plan but rather with measurement plans as objects. You combine the prepared measurement plans created with Calypso and thus map typical measuring configurations and sequences. An Auto-Run interface prepared in this way allows measurement plans to be run automatically without the measurement plans themselves having to be edited. Thus, even users who do not have specialist knowledge of how to work with Calypso can run measurement plans.
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Auto-Run interface
On an Auto-Run interface, you no longer work with features and characteristics but with complete measurement plans instead. You thus map the desired measuring configurations and sequences. For this purpose, you edit the Auto-Run interface you create desks, place your icons for measurement plans and icons on the desk and determine the scope and sequence of measurement. The CNC start parameters are determined for each measurement plan. Finally and this is the purpose of Auto-Run you can have the measurement plans in the Auto-Run interface executed in a CNC run.
A certain number of new terms are encountered in the context of Auto-Run interfaces. These terms are important for understanding the functions of Auto-Run. Auto-Run interface In an Auto-Run interface, you no longer work in a measurement plan but rather with measurement plans as objects. The measurement plans are represented by measurement plan icons (see Layout of the Auto-Run interface on page 12-3). Desks An Auto-Run interface can contain one or more hierarchically linked desks. A desk can contain measurement plan icons and pallets (see Basics about desks on page 12-3). Measurement plan icon A measurement plan icon is a symbol that represents a measurement plan (see Basics about measurement plan icons on page 12-4). Pallet You can space several workpieces over a defined grid on a pallet and then measure them all at once (see Basics about pallets on page 12-5). Branch A branch is a direct link between desks (see Basics about branches on page 12-6). The hierarchical structure of the desks is mapped by branches. Keyword Each icon (measurement plan or pallet) can have its own unique keyword. Keywords allow a desired icon to be found quickly.
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Desks
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You can structure your Auto-Run interface with the aid of desks. A desk contains measurement plans and pallets that belong together. By means of branches, you can change to different desks along a tree structure.
Measurement plan icon Pallet Branch
You can thus recreate the following structure, for example: Machine processing stage type workpiece. On every level, you then create as many branches as there are levels below it. By selecting the appropriate branch, you can quickly follow a path to the desk with the measurement plan for the desired workpiece.
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On the Auto-Run interface, however, you see only an icon a symbol labeled with the name of the measurement plan instead of the entire measurement plan as such. You can set the size of the icon yourself. Several icons from the same measurement plan can be contained in one desktop, distinguished, for example, by different start parameters. Calypso then assigns a serial number in brackets to the name of the measurement plan (e.g. test block1 (2)). When you select a run in the CNC start parameters, the name of the run is appended with a hyphen to the measurement plan name (e.g. test block1 - test run).
lines (Y-division) Y
X palette alignment
You can define how the pallet is divided so you can map each pallet in full.
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This makes sense, for example, if you want to map the workpieces in a tree structure. You can thus recreate the following structure, for example: Machine processing stage type workpiece. For this purpose, you create as many branches on each level as there are levels below it. By selecting the appropriate branch, you can quickly follow a path to the desk with the measurement plan for the desired workpiece.
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It appears when you have attempted to execute a command for which you do not possess access privileges. Consult your system administrator if the command in question is one you urgently require.
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Prerequisites
The preconditions that have to be satisfied before you can start a measurement are as follows: Your Auto-Run interface must be loaded (see How to load an Auto-Run interface on page 12-9). The correct desk must be selected (see How to select a measuring configuration on page 12-10). The correct measurement plan must have been found and marked beforehand. The scope of measurement must be defined (see How to define scope and sequence in Auto-Run on page 12-10). These preconditions must be satisfied before measurement can be started.
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3 If the name of the currently open interface is noname.arn, click on Open. 4 If a name other than noname.arn appears in the status bar: Click on Save and Open. Save the original interface. Consult your system administrator if you encounter difficulties with saving. The original interface is saved and the File Open dialog box appears on the screen. 5 Highlight the name of the desired interface and click on Open. The selected Auto-Run interface is loaded.
If you possess the necessary equipment, you can also scan the required keyword using a barcode reader. To find an icon via a keyword: 1 Make sure that your Auto-Run interface is loaded. 2 Check whether the workpiece to be measured is at the correct position on the CMM.
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Auto-Run interface
3 Select Tools Looking for icons. The Looking for icons dialog box appears on the screen.
4 Enter the keyword for the desired icon - or If you have the appropriate equipment: scan the keyword with a barcode reader. 5 Confirm with the Enter key or by clicking on Search. The icon with the keyword is searched in all desks. If the icon is found, the desk is changed if necessary and the icon is highlighted. The name of the highlighted icon is displayed behind the text Selected icons: in the search window. If no icon is found with the entered keyword, the text (Nothing) will be displayed in red.
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You have to define which workpieces of a desk will be measured in a CNC run. To select workpieces for measurement: 1 Make sure that you have selected the correct desk. 2 While holding down the Ctrl key, click on the icon of each measurement plan (or each pallet) to be run. A narrow black border appears around each icon you select. The Start button is activated. After the start of the CNC run, the marked icons will be executed in the order in which you marked them. To check or change the order: 1 Select Measurement Sequence or click on the Define Sequence icon in the toolbar. The Define Sequence dialog box with the currently valid sequence of processing appears. 2 Mark the line to be moved and click on the arrow buttons to move the line to the desired position. 3 As soon as you are satisfied with the changed sequence, confirm with OK. See How to start a measurement in Auto-Run on page 12-11 for instructions on starting a CNC run.
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Auto-Run interface
If you run several measurement plans one after the other, you can enter the printout header parameters for all started measurement plans for which the forced input upon CNC start was activated. This saves you from entering the parameters at the end of one and prior to the start of the next measurement plan. Use the Continue> and < Back buttons to page in the Input Parameter window through the input pages for all concerned measurement plans and make your settings. On the last page, the description changes to OK, and you can start processing of the marked icons.
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After clicking on Cancel and confirmation of a query, the CNC run for all marked icons is started. All entries confirmed with Continue > will be accepted. For all other measurement plans, the available printout header parameters will be used.
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Important If, in your measurement plan, the Forced Input of Printout Header Parameters at CNC Start has been used for a forced stop of the CMM (to insert new components, for example), you can no longer use these measurement plans in version 4.0 and higher. However, the stopping of the CMM can be defined in the preparameters of a measurement plan.
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Auto-Run interface
To do so, you must have the privilege Show Custom Printout or Show Default Printout. You must first select the measurement plan or pallet icon whose last default printout or custom printout you want to open by clicking with the mouse. Under Edit <Type of Icon> and in the coantext menu of the icon you will find the Printout of Last Run <Printout Type> menu item. If you selected Custom Printout, the measurement plan will be loaded before the custom printout is displayed. This can take a few seconds. The custom printout of the last run that was started by Auto-Run is loaded. The Default Printout is usually displayed immediately regardless of whether the run was started by Calypso or Auto-Run. The contents of the protocol file in the measurement plan directory is shown. If this file is empty (size = 0 KB), an empty printout window appears.
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The contents of the protocol file in the measurement plan directory is shown. If this file is empty (size = 0 KB), an empty printout window appears. The printout header data of an Auto-Run icon may differ from those of the original measurement plan. The printout header data of the Auto-Run icon is shown. The assignment of pallet location and saved actual values of the last CNC run is not possible with pallets, since the pallet location is not saved or defined. Thats why the printout header data of the original measurement plan is used with the exception of the part number, whose count is incremented by Auto-Run.
Custom printout
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Auto-Run interface
Configuring Auto-Run
With the aid of Auto-Run interfaces, Calypso processes are defined and mapped so that even inexperienced users will have no trouble running them. Before you start mapping desks, the first thing to do is assign privileges to the future users. You also have to check the parameters set in the system settings for measurement and for the CMM and make any changes that might prove necessary.
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NOTE
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Only the Master user may set up new users. To assign privileges: 1 Select Configuration Users Privileges. The User rights window will open.
The names of all defined Calypso users are listed on the left. 2 Highlight the name of the user for whom you want to define privileges. All privileges available for the Auto-Run interface are now listed on the right.
3 To assign a privilege, activate its check box in the Status column. A tick means that the user in question can execute the action specified under Privileges.
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4 Once you have defined the privileges for this user, click on OK. The settings are saved and are active for this user with immediate effect.
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For purposes of documentation, you can output the list of privileges of the selected user on the set printer. To do this, click on the printer symbol in the upper left corner of the window. If you do not mark an individual user, the privileges of all users will be printed.
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Right Defining parameters for the measurement plan in a pallet Defining pallet parameters Defining measurement sequences in a pallet Inserting a measurement plan in a pallet Creating a new branch Defining sequence Starting/aborting measurement Defining keywords Opening a search window Blocking the workspace when a Search dialog is open
Creation of new elements of the Auto-Run interface. Privileges for the measurement sequence. Privileges for keywords. If you assign this privilege, mouse actions will be disabled in the workspace when theLooking for icons window is open. This is intended to prevent an unintentional focus change (and thus unintentional runs) when barcodes are being scanned. Menu items under Tools. Privileges for additional functions in the Stoplight window. Cancel, Continue and Reconnect are also possible without these privileges. Access to the parameters Speed, Results, Base Alignment, List of Characteristics, Printout Header Data, information on the measuring run and Parameter File in the Start Measurement window, irrespective of which privileges are set for the individual parameters. Access to the speed parameters and to information on the measuring run in the Start Measurement window, even if the privilege for Defining CNC parameters is not set. Access to the results parameters and to information on the measuring run in the Start Measurement window, even if the privilege for Defining CNC parameters is not set. Access to the base alignment parameters and to information on the measuring run in the Start Measurement window, even if the privilege for Defining CNC parameters is not set.
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Auto-Run interface
Special aspects Access to the List of Characteristics parameters and to information on the measuring run in the Start Measurement window, even if the privilege for Defining CNC parameters is not set.
Defining the Parameter File CNC Access to the Parameter File in the Start Measurement parameter window, even if the privilege for Defining CNC parameters is not set. Defining printout header data Access to the printout header data parameters and to information on the measurement run in the Start Measurement window. Note: The forced input of printout header data upon CNC start as set in the measurement plan is not affected by the blocking of this privilege. Privileges for printouts
Defining printout Opening last custom printout Opening last default printout Configuring CMM Configuring measurement Configuring environment Changing styli Qualifying styli
On the Machine page of the CMM Configuration notebook, make sure that the measuring range is defined completely and correctly. 2 Select Configuration Measurement to check the parameters for the measurement method. There is an explanation in the Online Help under How to change the CMM configuration.
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3 Select Configuration Environment to check the parameters for the environment of the users. There is an explanation in the Online Help under How to change your environment.
To load a background image: 1 Make sure that no icons are marked. 2 Select Edit Background image... Create New Background Image... or click on the Enter new background image icon in the toolbar. The standard Windows dialog box for file selection opens. 3 Select the desired background image in the file selection dialog. All common Windows-compatible image formats are permitted. 4 Click on Open to confirm. The image is placed on the workspace of the Auto-Run interface below any icons present there. The image is initially fitted in without distortions or cropping so that it completely fills the workspace in at least one direction.
To change the size of a background image: 1 Select Edit Background image... Change Size of Background Image. The Defining Icon Size dialog box opens. 2 Enter the new height and width values and confirm with OK. The background image with its new dimensions is placed under the workspace.
Deleting a background
To remove a background image: 1 Select Edit Background image... Remove Background Image. The background image is removed after a confirmation prompt.
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Auto-Run interface
The tasks involved in mapping the measuring configuration are as follows: Defining desks Adding a measurement plan Positioning a measurement plan icon Setting the size of an icon Placing a graphic on the measurement plan icon
Enter a new name for the desk. Click on OK. The desk now has a new name. 2 If you have already created a desk: Select Desk New.
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Click on OK. The name of the new desk appears in a selection list in the toolbar. You have now defined a desk, in other words a two-dimensional map of the empty CMM measuring range.
Make sure that no measurement plan is open in Calypso, because it would be overwritten in an Auto-Run process. To add a measurement plan: 1 Click on the Measurement Plan symbol. 2 Select the desired measurement plan in the Windows file selection dialog. 3 Click on OK to load the measurement plan and close the dialog box. Calypso creates an icon for the measurement plan and initially places it in the top left corner of the desk. All you have to do is position the icons and check the CNC parameters.
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To place a bitmap image on a measurement plan or run icon: 1 Highlight the icon. 2 Select Edit <Type of Icon> Load Icon Image... 3 Select the desired image file in the file selection dialog. The image is then placed on the measurement plan icon or on the run icon. With the menu item Edit <Type of Icon> Remove Icon Image, you can display the icon again with the standard bitmap.
3 Enter the height and width you want the icon to have on the desk. 4 Click OK to save your entries. The dialog box closes and the icon is resized to your specifications. All subsequently created measurement plan icons automatically receive the same size.
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You can also use the mouse to define the size of the icon: if you move the mouse pointer to the edge of the icon, the mouse pointer changes into a double arrow and, with the left mouse button pressed, you can then drag the border of the icon in the displayed arrow direction.
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Mapping a pallet
Multiple workpieces of similar type are mounted on a pallet. Calypso determines the position of the pallet on the table by computing the pallet's base alignment. The position of the workpieces is derived from the alignment of the measurement plan and the column and rows of the pallet.
Input fields for number and pitch of grid lines in X and Y axes
2 Select the base alignment for the pallet from the Pallet System selection list. 3 In the Pallet Name input field, enter a name for the pallet. 4 Define the grid for the pallet:
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Auto-Run interface
In the Group Columns column, enter the Distance and the Number of columns. In the Group Rows column, enter the Distance and the Number of rows. 5 Click on OK. The icon is created and appears in the top left corner of the desk. You still have the option of defining the size of the icon (How to define the size of an icon on page 12-24).
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3 Enter the loop parameters: Select the Add command from the context menu if there are no input lines in the dialog box. Click in the From: input field and enter the start value for the loop. Click in the To: input field and enter the end value for the loop.
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Auto-Run interface
Click in the Step: input field and enter the step width of the loop. 4 If you want to define another section for the loop: Select the Add command from the shortcut menu. A new line is inserted. Repeat the definition of the loop in step 4 for the new line. 5 Click on OK to save the settings and close the dialog box. 6 Activate the Loops radio button to prepare the pallet for the CNC run.
At this point, you should define the CNC parameters (see Preparing a measurement on page 12-31), so that the pallet can be measured.
At this point, you should define the CNC parameters (see Preparing a measurement on page 12-31), so that the pallet can be measured.
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To take full advantage of this function, you must have the PCM option. After a pallet run, a pickup position should be approached to replace the measured workpiece with the next workpiece. However, the pickup position should not be approached after every pallet location run as this would be very time consuming. The pickup position should only be approached after the run of the last pallet location has been completed. This can be accomplished with the aid of PCM commands. In the case of a single pallet, the current pallet location number and the number of the last pallet location are additionally included in the printout header data. Add a query to the post-parameters of the measurement plan. This query is used to check whether the current pallet location number corresponds to the last pallet location number. When the numbers correspond to each other, the CMM should move to a defined position. Example:
if (getRecordHead("palletlocationnumber") == getRecordHead("lastpalletlocationnumber")) then positionCMM(100,-100,-50) endif
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The query functions in any case, regardless of whether the pallet was started via a loop or via selected pallet locations.
The assignment of keywords also permits automated selection of the correct measurement plan for the workpiece or pallet of workpieces in question. Precondition: You possess the required barcode readers.
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Auto-Run interface
The barcode of the measurement plan icon or of the pallet icon with which the workpiece is to be measured is affixed to each workpiece or pallet.
The line with the previously marked icon is selected. 2 To generate the keywords automatically for all icons: Click on the Default button. A keyword formed from the name of the icon is automatically generated for each icon. If there are icons of the same name, Calypso assigns a serial number in brackets, starting with the second icon. 3 To enter or change a keyword: click on the corresponding line in the table and enter the keyword.
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Preparing a measurement
Only after you have defined desks with measurement plans or pallets can you prepare for measurement. You can perform all preparations for measurement or only some that depends on the privileges you have assigned to the user who is going to perform measurement. You have the following options for evaluating results: Displaying the position of the probe Defining CNC parameters Defining the scope of measurement Defining the input of printout header data Defining stylus settings Changing the sequences in desks Defining printout
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Auto-Run interface
To view the position of the probe: 1 Click on the Display Alignment symbol or select Tools Display Alignment. The current machine coordinates for the position of the probe are displayed in the Stop Light Name - Position dialog box.
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You will find more information on CNC runs and on this dialog box in How to start a CNC run on page 8-10 and in Start measurement / measurement plan definition in the Calypso Online Help. 3 Open the Base Alignment selection list and select the base alignment in which the measurement plan will run. 4 Define the scope (see Defining the scope of measurement on page 8-2). 5 With a variable measurement plan, select under Parameter File the appropriate parameter file if necessary. In the case of a single pallet, it is only possible to assign the same parameter file to all pallet locations. For detailed information about the parameter files, please refer to Variable measurement plans in PCM on page 15-4. 6 Define the other parameters in the Result and CMM groups. 7 Click on OK when you have made all the settings. The window will be closed. The parameters are saved along with the measurement plan and the desk.
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Auto-Run interface
To define the scope of m easurement for a measurement: 1 Highlight the icon of the measurement plan or the pallet that you want to run. 2 Open the Measurement Plan Definition window (How to define CNC parameters on page 12-32). 3 Define the scope of measurement in the left group Selection. To add all characteristics to the scope of measurement, select All Characteristics. To add only a certain number of characteristics to the measurement scope, select Current Selection and click on the Feature selection from measurement plan icon. The Feature selection from measurement plan window opens with a tree structure of all characteristics of the current measurement plan.
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If the Feature selection from measurement plan window has already been opened for the current measurement plan, the characteristics selected during the last call are preset. Select the characteristics to be added to the scope of measurement and confirm with OK. You can unfold and fold groups of characteristics by doubleclicking or by clicking on the symbol in the upper right corner. To add only a certain group of characteristics to the measurement scope, select the option under Current Selection and select the desired group of characteristics in the list box located next to it on the right-hand side. This determines the scope of measurement.
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3 Enter the global printout header parameters if necessary. 4 If you want the user to enter certain (local) printout header parameters only directly before the measurement, activate Force Input at Start. 5 Click on OK to confirm. In the CNC start parameters, the system administrator or the user can enter additional printout header parameters, overwrite default parameters or accept the data of the original measurement plan after clicking on Data Input in the Input Parameter window.
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Auto-Run interface
As soon as the user carries out the CNC start for one or more icons, the Input Parameter window opens for all measurement plans that were activated by Force Input at Start, one page for each icon involved. In this way, the user can determine the printout header data for all following measurements upon CNC start.
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Important If in your measurement plan the Forced Input of Printout Header Parameters at CNC Start has been used for a forced stop of the CMM (to insert new components, for example), you can no longer use these measurement plans in version 4.0 and higher. However, the stopping of the CMM can be defined in the preparameters of a measurement plan.
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To define the sequence: 1 Highlight the measurement plans to be performed in a CNC run. If you want to highlight multiple measurement plans, press and hold down the Ctrl key and click on the respective icons. 2 Click on the Define Sequence symbol. 3 The Define Sequence dialog box is opened. All the measurement plans you highlighted are listed in this box.
The measurement plans are listed in the sequence in which they are run. 4 To change the sequence: Highlight the name of a measurement plan in the list. Click on the Up / Down button until the measurement plan is in the desired position in the sequence. Repeat the process for the other measurement plans, until the sequence is correct. 5 Click on Undo if you decide you want to restore the original sequence. 6 Click on OK to accept the sequence as it is. The window will be closed. As soon as you start measuring, the measurement plans are run in your custom sequence. Calypso retains this sequence until such time as you define another.
The user privileg for defining the printout is called Define Printout.
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Auto-Run interface
The printout output via Auto-Run is icon-related. Settings which are changed in a measurement plan icon are only valid for this specific icon even if the same measurement plan applies to another icon. If you want to change the printout for several icons of the same measurement plan, edit the original measurement plan and load the settings of the measurement plan for the individual icons. These settings are also active when the last custom printout is opened subsequently. Thus it is possible to open for one measurement several custom printouts with different formats and settings one after the other. To define the printout for an icon: 1 Highlight exactly one measurement plan or pallet icon. 2 Select Edit <Icon Type> Define Printout... or Define Printout... in the context menu. The Format Custom Printout dialog box appears on the screen.
The name of the selected measurement plan or pallet is shown on top of the window. The three tabs Compact Printout, Custom Printout and Warning Limit are displayed below. 3 Make the desired settings for the printout on the three tabs. The settings correspond to those in the Format Custom Printout window for the original measurement plan. The settings fort he default printout, the selection of the Excel and DMIS report and the printout reset are not included.
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4 To transfer the settings for these icons from the original measurement plan to Auto-Run, click on the Load settings from measurement plan button. 5 Activate the Apply settings for next run check box if you would like that the settings made should only apply to the next CNC run. The settings made here will be reset after the next CNC run of this icon. The check box is activated by default. 6 To accept your changes, confirm with OK.
Administrating Auto-Run
One of your functions as system administrator is to set up the AutoRun interface and make sure it remains up to date. The tasks involved are summarized in this section.
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Auto-Run interface
To adapt the paths for the measurement plans: 1 Select Edit Replace paths for measurement plans. The Replace paths for measurement plans window will open.
This window shows a list of all desks, measurement plans and icons of the Auto-Run interface and the actual paths. The Valid column shows whether the path exists.
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The setting Yes under Valid means that the path exists. This must not necessarily be the path which contains the object displayed, however. The setting No under Valid means, in contrast, that this path is not the correct path for the displayed object. The list shows all desks in the same way in succession. The first line is a subheading with the name of the desk. The second name contains the path for the background image if available. The following lines contain the desk, pallet and measurement plan icons included in this desk as well as the paths of the pallet and measurement plan icons. Additionally with regard to pallets, if no measurement plan has been inserted in a pallet, the path cannot be entered and the column with the validity always indicates No. If an icon is linked to an image, a line with the text (Image) and the path of the image file appears after the line with the icon name. If the icon contains the absolute path for a parameter file (see Loading parameter file in the CNC run), an additional line with the text (Parameter File) and the path of the parameter file appears after the line for the image. 2 Modify the paths entered in the table by overwriting them. - or -
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Select those lines that you want to edit in one go (if applicable by using multiple selection). To do so, use the context menu with its menu items. Use the Find what and Replace with fields to replace the incorrect character strings in the paths with the new character strings in the selected (or, if applicable, all) lines. to complete the Replace with field, you can use the Reset and Looking for directory buttons. Start replacement by clicking on Replace or with OK. The replacement process is executed. When activating the Request Each Replacement check box, you have the option to confirm or to retract each individual replacement or to cancel the entire process. Otherwise, a message about the number of replacements made appears upon completion of the replacement.
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The names of the image files and measurement plans are not changed by the replacement. Calypso ensures that these names remain unchanged. This prevents, for example, a measurement plan change. Thus, it is not possible to transfer CNC start parameters or printout header data accidentally from one measurement plan to another measurement plan. If a measurement plan is to be replaced, you must assign the corresponding icon again. The same applies to images.
3 Enter a new name for the desk. 4 Click on OK. The desk is renamed.
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Auto-Run interface
3 Click on Yes to delete the desk. 4 Click on OK. The desk is deleted from the Auto-Run interface.
2 Click on Yes to delete the icon. 3 Click on OK. The icon is deleted from the current desk.
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Chapter
13
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Calypso can import DMIS files and convert them into measurement plans. To achieve this, a DMIS post processor runs and processes the DMIS commands. The DMIS import is an option of Calypso. You can license this functionality and have it enabled in your system if it would be of use to you. Contact your Carl Zeiss Service for more information. The sections included in this chapter explain the basics of importing DMIS measurement plans, and step you through the procedures involved.
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What is DMIS?
DMIS stands for Dimensional Measuring Interface Standard. DMIS is a programming language used for programming mechanical, optical, laser and video measuring systems. DMIS is designed to be a programming language for all or at least many measuring machines. The vocabulary of DMIS is very large and resembles that of a genuine programming language: there are language elements for declarations and definitions of variables, loops, conditional jumps, mathematical functions, coordinate transformations and of course commands for measuring machine control such as positional movements, probing, geometric elements, measurements, stylus system changes, temperature compensation, etc. DMIS-compatible measuring machines read the DMIS commands from an ASCII file and then perform the measuring run.
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The DMIS post processor integrated into Calypso can translate DMIS commands of Version 3.0, with certain restrictions. If the DMIS measuring program has been created taking this requirement into account, there should not be any implementation problems.
Characterization file
The characterization file for Calypso is located on your system at the path ..\Calypso\home\om and has the CHARACTERISATIONFILE file name.
In particular, all features are listed here which can be converted by the post processor into Calypso features.
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No clearance planes
DMIS does not recognize any clearance planes used to define implicitly the clearance moves in Calypso. In DMIS, all movements are specified explicitly.
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Therefore, when carrying out a CNC start of a measurement plan generated from DMIS under Navigate-Feature to Feature, you must never run the start with the Automatic setting. In this case, select the Use Position Points Only setting.
The stated measurement plan features are intended specially for the translation of DMIS programs. However, if adequate care is taken, they can also be used in other Calypso measurement plans. Important risk of collision Extreme care is needed when adding such features to measurement plans imported from DMIS, because the coordinate systems were defined in the features at the time of import and should only be changed there.
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This tab is only intended for special circumstances. For standard installations, you do not need to do anything here; the settings are correct.
On this tab, the paths for the language library and the Calypso messages are displayed on the left-hand side, while the settings for the import are displayed on the right-hand side. You can make the following settings: Language library (DLL) After clicking on Browse..., you can assign a directory if necessary. Calypso host name or IP address This is the name or the Internet protocol address of the computer on which Calypso is running and for which the import function is waiting. Port Displays the port of the DMIS post processor. Directory of Calypso messages If necessary, you can overwrite the directory in this box directly.
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Take GOTOs which are outside of MEAS-ENDMES blocks This check box is activated by default. If you deactivate it, no clearance commands will be accepted during the translation into the Calypso measurement plan (the movement commands within the features will be retained). The clearance paths must then be generated by Calypso during the CNC run itself. The advantage is: if a DMIS measurement run is designed from the outset to be used only for Calypso, you can omit the clearance paths when setting up the run. At the CNC start of a measurement plan generated from DMIS, you must select the Automatic setting under Navigate-Feature To Feature. Dont ask for error confirmation. Just go on. Activate this check box if you do not want the DMIS post processor to ask you whether to continue the process if it discovers errors or inaccuracies in the DMIS program during the translation process. You can also check up on the errors in the reports after the import process. Update the graphic in Calypso with every feature This check box is activated by default. Deactivate the check box if the CAD window of Calypso is not to be updated constantly during the translation process. This will save up to 20% of the reading time.
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After the import, you should save the measurement plan immediately, because at first it is only stored in the main memory of the computer. During the import, the post processor creates reports, which you can read and save, if required. You can start the measurement plan immediately after the import, or edit the measurement plan and run it later.
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In order to import a DMIS program: 1 Select File Import DMIS. The Import of DMIS-Inspection-Files to Calypso dialog box appears.
2 Click on the Selection of DMIS File... button. The standard Windows dialog box for opening files appears on the screen. 3 Select the desired DMIS file (file name extension .dmi) and click on Open. The import starts running; you can follow its progress and the creation of the Calypso measurement plan. A message confirming the end of the import appears.
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If Calypso is not connected to the CMM, you will be given a message and can decide whether you want to continue with the import or not. 4 If printouts have been created during the import, you can view them and save them. 5 After a successful import, click on End. Calypso is displayed on the screen; the measurement plan that has just been imported is opened. 6 Select File Save to save the measurement plan. 7 In the Prerequisites phase, click on the Qualification icon and qualify the styli. 8 Select Resources Select Stylus for this Measurement Plan..., click on the For Measurement Plan option in the Measurement Plan Editor Features and choose from the list the stylus that has just been imported.
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9 Start the CNC run by clicking Plan CNC-Start CNC-Start. The Start Measurement window is displayed.
10 Under Navigate-Feature To Feature, select the relevant entry: Use Position Points Only: in this way, the automatic consideration of the clearance planes by Calypso is switched off. The reason for this is that there are no clearance planes in a DMIS program: all clearance paths are programmed and entered directly. Automatic: the movement paths are generated by Calypso. Only select this entry if you have configured the DMIS import so that no GOTOs are adopted in the measurement plan by the post processor.
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Important If you do not switch off automatic movement path generation in spite of the translated movement commands, the movement commands will be incorrect and there will be a risk of collision. 11 Click on OK to confirm. The imported measurement plan is processed.
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All problems that occur during the translation are logged. Two different reports are generated: Syntax report The DMIS File Report on Syntax Check printout is produced before the actual translation. Any syntax errors in the DMIS file are logged here. If the syntax errors are too serious, the DMIS import will abort. This printout can be useful for the creator of the DMIS measurement program for evaluation purposes. Import printout The Calypso Import Printout contains all messages about special features relating to the measurement plan which have been noted during the import by the post processor, e.g. the inability to assign a stylus because there is no connection to the CMM. The printouts are displayed on the Printout tab.
Saving printouts
If you would like to evaluate the printouts at a later stage, you can save them as a text file (.txt). To do so, click on the Save printouts button and select a directory. The file name is preset, but can be overwritten.
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Chapter
14
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Calypso can export measurement plans and convert them into DMIS files of the format DMIS 3.0. To do so, an integrated DMIS preprocessor runs to create and correctly compile the DMIS commands. The DMIS export is an option of Calypso. You can license this functionality and have it enabled in your system if you want to use it. Contact your Carl Zeiss Service for more information. The sections that follow explain the basic principles and the procedure for exporting measurement plans to DMIS.
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What is DMIS?
DMIS stands for Dimensional Measuring Interface Standard. DMIS is a programming language used for programming mechanical, optical, laser and video measuring systems. DMIS is designed to be a programming language for a large number of measuring machines. The vocabulary of DMIS is very large and resembles that of a genuine programming language: there are language elements for declarations and definitions of variables, loops, conditional jumps, mathematical functions, and coordinate transformations. There are also commands for measuring machine control such as positional movements, probing, geometric elements, measurements, stylus system changes, temperature compensation, etc. DMIS-compatible measuring machines read the DMIS commands from an ASCII file and then perform the measuring run.
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The preprocessor first internally converts the Calypso measurement plan into a sequential procedure and then translates it into DMIS format. The file created as a result can be used in any measuring machine with DMIS capability.
DMIS regognizes only one tolerance mode (Number String in Calypso). The setting for Amount will therefore not be exported.
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The DMIS file is a text file that you can view and edit, e.g. with WordPad. 3 Click on Save. The Designator assignment: Calypso -> DMIS dialog box is opened. You see the names of the features in the Calypso measurement plan and the corresponding automatically generated DMIS labels (maximum 10 characters).
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Unlike Calypso, DMIS does not recognize any stylus systems. It only recognizes styli. Stylus names are furthermore automatically shortened to 10 characters, and their reference to the respective stylus system can thus be lost. 4 If required, change the DMIS labels according to your wishes. For example, you can specifically change the stylus name so as to restore the reference to the respective stylus system. 5 Click on OK to confirm. The export runs; in the Progress... Translating PCM to DMIS window, you can follow the creation of the DMIS program. A message confirming the end of the export appears. 6 After the export, click on End. 7 Click on OK to confirm.
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Chapter
15
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15-1
Introduction to PCM
Calypso uses the PCM programming language for variable control of measuring runs. Of course you can use Calypso without PCM, but PCM offers you a powerful toolset for simplification and automation, along with part-variant programming and parameter-supported and interactive control of measuring runs.
What is PCM?
PCM is a programming language for parameterizing measuring runs. PCM is short for parameter-coded measurement". PCM enables you to simplify and rationalize measuring runs in Calypso: You can program measurement plans in such a way that you can measure various workpiece variants, and you can set parameters to influence the automatic run of a measurement plan. PCM has functions for calculating values, for controlling the CMM, and for interactive input/output dialogs. You can vary the way in which a measurement plan runs by programming loops and conditions. In certain situations you can have Calypso generate special messages.
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A yellow input box in Calypso always contains a parameter or formula. In Calypso, you use PCM when you enter a Formula in an input box for a feature. By so doing, you automatically define a variable and assign it parameters. The color of the input fields changes, in this case to yellow. By the same token, when you set a condition in Calypso or define a loop, you automatically create PCM code. Once you have familiarized yourself with the syntax, you can employ the PCM code to enter conditions and loops or other commands directly or generate files for import into Calypso.
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In this way one and the same measurement plan can be used to measure and test different workpieces: for example, a plate with either one or two holes even if the radii are different. Different geometries, differences in the number of certain features, the presence or absence of features all these can be parameterized.
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Example
The two workpieces in the illustration above are different, but similar: they have some identifying characteristics in common, while others are unique to each. The first workpiece in the illustration has a central hole with a radius of 20, while the hole in the second workpiece, while of the same depth, has a radius of 10 and is offcenter. This workpiece, moreover, has a second hole. The variables that could be used here are as follows: positions of the holes (hole1_center, hole2_center), their radii (hole1_radius, hole2_radius) and the number of holes (number_holes). These variables have to be assigned values for each workpiece, so that a measurement plan can be run: Variables Number_holes hole1_center hole2_center hole1_radius hole2_radius Parameters for workpiece No. 1 1 any 20 any Parameters for workpiece No. 2 2 point(-60.30,40,0,0,1) 10 10
point(-40,30,40,0,0,1) point(-20.30,40,0,0,1)
Set up in this way with only five different parameters, the measurement plan is able to measure two different workpieces.
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You do this by defining a variable for the characteristic in question and assigning it the corresponding value.
*.para
Workpiece1.para
Measurement Plan
*.para
Workpiece2.para
*.para
Workpiece3.para
The parameter files can be created in two ways: You save the entered parameters of a measurement plan.
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You create the parameter file directly with an ASCII editor. To do so, you need experience with measurement plans and reliable knowledge of the PCM syntax PCM uses, a functional syntax similar to the programming languages Basic, C, Fortran etc. (see PCM syntax on page 15-51). When you create a parameter file it is important to remember that the file name extension has to be .para, so that Calypso can recognize it as a parameter file.
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characteristic. Once the characteristic has been determined, its output parameters are evaluated. 3 Before a feature defined for a characteristic is measured, its input parameters are evaluated. The features output parameters are evaluated when measurement completes. 4 If input or output parameters are set for a condition or loop, the input parameters are evaluated before the condition is checked or the loop is run. The output parameters are evaluated after the element referenced by the condition or loop. If the condition results in a stop, the output parameters are not evaluated. You might find it useful to visualize the input and output parameters as parentheses bracketing the objects in question.
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PCM recognizes four types of variable: number, point, vector and string. Each variable has a name consisting of alphanumeric characters (without blanks; first character is no number), and different variables have different names. Examples: radius_1, set-down point, message_354 You are not allowed to use reserved names, in other words strings that are required in the PCM syntax: X, Y, Z, the names of functions and commands, and so on.
Arrays
Groups of variables are called arrays. The only difference in the names of variables in an array is the array index. Example: radius[1], radius[2], radius[3], radius[4] In this case, radius is an array with four variables.
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You can enter the value using one of the following formats: Variable type number vector point string
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The last three components of a variable of the point type represent the coordinates of a normalized vector. This means that the root of the sum of the three squares (= the length of the vector) must always be 1.
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Return values
The return value is an important function of a variable: the individual parts of a parameter have to be addressed so that you can work with them. The return values of variables of the point type are defined as follows: Function variable_name.x variable_name.y variable_name.z variable_name.nx variable_name.ny variable_name.nz Return value x value of the point variable y value of the point variable z value of the point variable x value of the normal vector of the point variable y value of the normal vector of the point variable z value of the normal vector of the point variable
You can access variables of the vector type as follows: Function variable_name.x variable_name.y variable_name.z Return value x value of the vector variable y value of the vector variable z value of the vector variable
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There are also a number of functions for input and output, for run control and for working with files, plus measurement-specific and CMM-specific commands, system commands and CMM movement commands (see PCM quick reference on page 15-51).
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Simple condition
The syntax of the simple condition is as follows:
if CONDITION then DEFINITION endif
Meaning: If CONDITION is satisfied, DEFINITION is processed. If CONDITION is not satisfied, DEFINITION is not processed. The DEFINITION can be formulas, value assignments, functions or other conditions or loops of your choice, always with line breaks as separators.
Meaning: If CONDITION is satisfied, DEFINITION1 is processed. If CONDITION is not satisfied, DEFINITION2 is processed. DEFINITION1 and DEFINITION2 can be formulas, value assignments, functions or other conditions or loops of your choice, always with line breaks as separators.
Example
In the example below, the result variable is assigned the diameter of circle circle_1. A message corresponding to this quantity is then output on the screen:
Result=getActual("Circle_1").diameter if result>10 then message(Diameter circle_1 is greater than 10) else if result<10 then message("Diameter circle_1 is less than 10") endif endif
Defined loop
In the case of the defined loop, the number of loops is defined unequivocally. The syntax of the defined loop is as follows:
for index=start to end [step] DEFINITION next index
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The following must be inserted: for index the name of the loop variables (random), for start, end and step whole numbers, for DEFINITION random formulas, value assignments, functions or other conditions or loops of your choice, always with line breaks as separators. Meaning: the functions or commands under DEFINITION are processed (end - start + 1)/step times, whereby step is set to 1 if no other specification is made. At the same time, the specific value for index is always entered in DEFINITION: at first start, then start+step, start+2*step etc. up to end. With next i, the loop index is incremented by step each time.
Example for i=1 to 4 message(i,". step: ",step[i]) next i
Conditional loop
In the case of the conditional loop, the number of runs depends on the fulfillment of a condition, whereby the condition is only tested after the first run. Therefore a conditional loop must run at least once. The syntax of the conditional loop is as follows:
repeat DEFINITION until CONDITION
Meaning: DEFINITION is processed. Then CONDITION is tested. If CONDITION is fulfilled, the loop is ended. If CONDITION is not satisfied, DEFINITION is processed again and CONDITION is tested again. The CONDITION can be set up as a logical combination of several subconditions. The DEFINITION can be formulas, value assignments, functions or other conditions or loops of your choice, always with line breaks as separators.
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Important Please note that infinite repetitions are possible with the conditional loop if the condition is never fulfilled.
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In PCM and in the formula, the decimal separator is always a period (.; example: 3.5 + 4.8, and not: 3,5 + 4,8). The comma is used as the separator within value assignments (example: Location = point(3.5, 4.5, 1.5, 0, 0, 1)).
If you are using the Calypso Light version, you cannot use this function.
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To enter parameters for a measurement plan directly: 1 Select Plan Advanced Parameter. The Parameter Input dialog box opens.
2 Click in the (white) input box and start defining the parameter: Start with the variable name, followed by =. Proceed with the definition. Please observe the syntax described in Arithmetic operators and functions on page 15-11 as well as the parameter syntax (see Example for PCM: ASCII parameter file on page 15-50). 3 Click on OK. The window will be closed. The parameter is now included in the list of all available parameters (this dialog box is fully described in Formula in the Calypso Online Help).
If you are using the Calypso Light version, you cannot use this function. To save the measurement plan parameters in a file: 1 Select Plan Advanced Parameter. The Parameter Input dialog box opens. 2 If necessary, edit the parameters, value assignments and formulas shown.
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3 Click on the diskette icon. The Save: Select Parameter File dialog box opens. 4 Enter the name of the file (do not omit the .para extension), select a directory and click on Save. The variables and parameters you selected are saved in the file.
If you are using the Calypso Light version, you cannot use this function. To open a *.para file: 1 Check that the Parameter Input dialog box is open (Plan Advanced Parameter). 2 Click on the Open icon. The Open: Select Parameter File dialog box opens. 3 Select the appropriate file and click Open. The parameters in the file are listed in the input window and are available for your current measurement plan.
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2 Right-click in the input box whose value you want to calculate with the formula, hold down the mouse button and select the Formula command from the context menu. The dialog box shown below is opened:
3 In the box labeled Formula, enter the formula, making sure your entry complies with the PCM syntax rules (see Arithmetic operators and functions on page 15-11). 4 Click on the Function button to open the hierarchically ordered list of all operators, functions and commands.
Open the corresponding branch and double-click on the element of your choice to copy it to the formula input box.
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5 To insert a parameter into the formula: click on the Settings button. Double-click on the parameter of your choice in the Parameter List to insert it into the formula. 6 To insert a loop variable into the formula, click on the Loop button. LOOP1 appears in the input box. 7 Click on Compute if you want to test your settings by computing the formula's return value. 8 Click OK to confirm your settings and terminate formula input. The value returned by the formula is displayed in the input box from which you called formula input. Note that the color of this field has changed to yellow.
Setting conditions
You can link computation of characteristics to conditions that enable Calypso to execute jumps in the CNC run in accordance with the measuring results.
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A basic knowledge of programming structures will help you understand the following. You can choose whether to have the condition queried before or after the characteristic is computed. Calypso ascertains whether the condition is true or false. You also have the option of linking the entire measurement plan to a condition.
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In addition to the conditions for characteristics or the measurement plan, PCM also enables you to enter simple conditions or conditions with alternative directly in the input/output parameters (see Programming conditions and loops on page 15-12). If the condition is queried before calculation, Calypso either computes the characteristic and continues or executes the instruction linked to compliance with the condition. This instruction can be either of the two stated below: cancel the automatic measurement run do not compute the characteristic and continue. If the condition is queried after calculation, the only alternatives are: cancel the automatic measuring run continue.
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If a loop has been defined around the characteristic, processing depends on what was defined first.
4 Set the condition first: Right-click in the yellow input box to open the context menu. Select Formula. The Formula dialog box appears on the screen. Enter the condition in the Formula dialog box and click on OK to confirm your entry (see How to enter formulas on page 15-17).
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The only possible return values for the condition are true and false. Use the comparison operators (see Arithmetic and comparative operators in PCM on page 15-53) for this purpose. You can test the return values of comparison operators by clicking on Compute in the Formula dialog box. The condition is displayed in the input box. 5 If you wish to make the presettings or postsettings, click on the Settings button and enter the settings. 6 If you do not want the condition to be queried until after the characteristic has been computed, click on the box labeled Post
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condition. The characteristic box is now right at the top of the window.
7 If you want the automatic run canceled or measurement of the feature to be omitted if the condition is true (satisfied): make sure that the Yes button is beside the End program box. If it is not, you can move it there by clicking the Yes button. 8 If you want the automatic run canceled or measurement of the feature to be omitted if the condition is false (not satisfied): make sure that the No button is beside the End program box. If it is not, you can move it there by clicking the No button. 9 Click OK to confirm and terminate definition of the condition. The condition will be checked and evaluated in the next automatic measuring run.
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NOTE
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The only possible return values for the condition are true and false. Use the comparison operators (see Arithmetic and comparative operators in PCM on page 15-53) for this purpose. The condition is displayed in the input box. 4 If you want to set input or output parameters, click on the Settings button and enter the parameters. 5 If you do not want the condition to be queried until after the characteristic has been computed, click on the box labeled Post condition. The characteristic box is now right at the top of the window. 6 If you want the measurement plan run canceled if the condition is true (satisfied): make sure that the Yes button is beside the End program box. If it is not, click on the Yes button. If you want the measurement plan run canceled if the condition is false (not satisfied): make sure that the No button is beside the End program box. If it is not, you can move it there by clicking the No button. 7 Click OK to confirm and terminate definition of the condition. The condition will be checked and evaluated in the next automatic measuring run.
Inserting loops
NOTE
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This section is intended for advanced users who are familiar with the basics of programming structures. Loops are used primarily in measurement plans in which identical or similar features are arranged in regular patterns (as is the case, for example, with a perforated plate). You can also use loops when you configure the base alignment. If you place a loop around a feature, characteristic or the entire measurement plan, the feature, characteristic or measurement plan is processed several times in succession.
NOTE
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Note that you cannot enter loops directly in the input/output parameters with PCM. You have several options for defining a loop:
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Direct loop definition Select in the context menu of the corresponding element the Loop menu item and enter the desired values in the Loop dialog box. A loop is defined by a start index, an end index, and an increment. The loop variable starts the first run with the start index. Prior to each run, it is increased by the increment and compared with the end index. As soon as the loop variable has exceeded the end index (with positive increment: greater than the end index; with negative increment: smaller than the end index), the loop will not be repeated any more. Indirect loop definition You define a pattern for a feature or a group of features. Similar to the loop, a run is repeated several times, each time with a modified index. Additionally, another abortion condition is defined with Actual Number: As soon as the number of runs has reached the value of the actual number, the computation is terminated. You can define one or multiple cycle levels in a loop (nested loops), so you can process repetitions in the second, third or fourth level. In each of these levels, a dedicated loop counter variable, the loop index, is incremented in steps.
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6 If necessary, repeat steps 4 and 5 to insert another loop level. Under Nest Level, select a different type of bracket for each level to nest the loops. There are four types of bracket available. 7 Click on the Settings button to set input and output parameters for the loop. The Settings dialog box appears on the screen. 8 Perform the steps described in Entering parameters and formulas on page 15-15 and click on OK to confirm and terminate your entry. This returns you to the Loop Interface window.
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You can define only one abortion condition per loop. 9 If necessary, enter a abortion condition in the box provided for this purpose.
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10 Click OK to save the loop and close the window. You have now defined the loop. It will be executed in the next CNC run. To ensure that something happens each time the loop is run, you have to use the LOOPi (i = 1,...,4) loop variables in the characteristic and/or in the features to vary the measurement run. For example, you could multiply the loop variable with a constant offset in order to increase an X value step by step.
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4 Activate the New radio button and check the Edit check box. 5 Select the way in which you want to specify the pattern (Polar Pattern Offset, 1-D Linear Pattern, 2-D Linear Pattern, Rotational Pattern, Pattern with position list). 6 Click OK to confirm your choice. The dialog box for defining the pattern of your choice (example: 1D Linear Pattern) appears on the screen.
7 Enter the values for the pattern. Make sure that the value for Actual Number corresponds to the number of loop runs resulting from the loop placed around the characteristic. 8 Click OK to confirm and close the window. 9 Click OK to close the feature template. The loop is executed as soon as you start an automatic measuring run (see Running a measurement plan on page 8-1).
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The baseSystem().valueA<0.1 abortion condition (for syntax, see baseSystem on page 15-62) means that once measuring has commenced, the measuring process will continue until the valueA best-fit value is less than 0.1.
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Example
If, for example, coordinate system A uses the feature called 3D Line1 and coordinate system B also uses a feature of this name, 3D Line1 is not measured again when coordinate system B is measured if you used the same type of brackets when you defined the two iterations in the Loop window. Calypso assumes that the line has already been measured and that it does not have to be measured again. You have to use brackets of a different type to ensure that the 3D Line1 is measured again when coordinate system B is aligned. You could do this, for example, by selecting round brackets ( and ) for loop 1 and angle brackets < and > for loop 2.
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You can define input and output parameters for the following objects in Calypso: an entire measurement plan, a macro, a characteristic, a feature, a condition, a loop. The entire PCM syntax is at your disposal for defining input and output parameters. You will find more information on the Settings dialog box in in the Calypso Online Help.
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An object, in turn, can consist of several other objects or be superior to these lower-order objects, so this means that under certain circumstances the input parameters and then the output parameters of the lower-order objects might be evaluated first. If the object in question is a condition and the condition leads to omission of the characteristic or cancellation of the CNC run, the output parameters of the condition are not evaluated.
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Prerequisite: A line containing the following command is contained in the respective settings:
inquireParameterList("parameter_name1","comment1",...)
All variables that are to be entered using the list must be listed in the brackets. To enter the input and output parameters using a list: 1 Select the line with the inquireParameterList(...) command. 2 In the context menu, select Calculate. The Parameter Input dialog box appears on the screen with a list of the parameters that are contained in the brackets of the inquireParameterList command.
3 Enter the currently required values for the parameters or overwrite the default values.
NOTE
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During the measuring run, you can overwrite only the entries in the Value column. 4 Click on OK to confirm. The dialog box is closed and the parameter values are accepted.
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You will find more information on this dialog box in Point generator in the Calypso Online Help. You can use the point generator to define a curve if the mathematical description of the curve is known. You can use the point generator to load parameter values into a curve. In this process, another point on the curve is defined in each successive step.
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3 Enter the start index, the end index and the step (increment). Each input box also accepts a formula. If you want to enter a formula, right-click in the box, select Formula from the context menu and use the Formula Interface window to enter the formula. 4 Enter the point to be defined in the step in the Point box. If the mathematical description of the curve is known, you can enter it here in the form of a formula. If the points are stored in a file, you can enter the name of the file here and import the points. Right-click in the box, select Formula from the context menu and use the Formula Interface window to enter the formula or the statement. 5 You can also enter an optional comment indicating the nature of the curve. This comment appears only in Calypsos table file. You can activate output to the table file by selecting Resources Results to File in the Results to file dialog box.
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If you are using the Calypso Light version, you cannot use this function. 6 Click OK to close the Point Generator window. You have now defined the nominals of the curve.
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!
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Important Note that movement commands are executed by the CMM and that collisions could result. Move the CMM slowly and stop in good time if necessary. 2 Highlight the PCM expression in question and right-click. 3 Select Compute from the context menu. The highlighted expression is computed or executed on the basis of the currently valid values of the variables. If an error is encountered or parameters for variables have not been defined, messages to this effect are issued.
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Enter the desired character string in the Find PCM Text dialog box and click on Search. Calypso searches all PCM printouts of the measurement plan and shows the character strings found.
The Use Of <pcmtext> dialog box shows all character strings found in a hierarchically ordered tree structure. The buttons for extending and compressing all or selected branches make it possible to customize the tree structure to suit your requirements and to enable fast access to the points of interest.
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Double-click on the icon of the characteristic or feature in this dialog box to select the corresponding feature in the measurement plan.
If you are using the Calypso Light version, you cannot use this function. The procedure for testing PCM commands is as follows: 1 Select Plan Advanced PCM-Test settings. The PCM test functions window will open.
2 Select PCM Test Printout to log the execution of each formula. Each time a value is assigned or a variable calculated, the new value is output in the default printout. Bear in mind that PCM Test Printout makes the program run more slowly. 3 Select Activate print command to activate the print commands in your PCM inputs. The print command is not executed unless this check box is activated. In this way you can print the current values of the variables at any point in your measurement plan. 4 Click on OK. The window will be closed. The settings are used the next time the measurement plan is run.
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You will be able to use Calypso's speed to best effect if you bear the following in mind: Activate the print command only for test purposes. Activate the PCM text printout only for test purposes.
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point_1.nx
=>
return value is 1
Examples for calculations with variables: Pnew = P1 *2. The return value is 20 Pnew = (vector_1.xpoint_1.z)/2. The return value is 10.01 r=type051_n0.x/2 zdelta=(r1-r)/tanphi norm=(nx4*nx4)+(ny4*ny4) Examples for output in the default printout:
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The Print command is not executed unless you have activated the Test printout check box in Plan Advanced PCM-Test settings. If you are using the Calypso Light version, you cannot use this function. print("Radius_1 has the value: ",radius_1) Calypso outputs the following string (example): Radius_1 has the value: 26.2655 print("r1 = ",r1,", r = ",r,",tanphi = ",tanphi) Calypso outputs the following string (example): r1= 23.5, r = 46, tanphi = 0.7874
NOTE
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Meaning: If CONDITION is satisfied, DEFINITION1 is processed; if not satisfied, DEFINITION2 is processed. DEFINITION1 and DEFINITION2 can be formulas, value assignments, functions or other conditions of your choice, always with line breaks as separators. The example below shows how this syntax is used:
message("Test if with PCM") P1 = 1 message("Value ist:" ,P1) //----------------------------------------------------------
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if P1 == 1 then message("is equal. Value was:" ,P1) endif if P1 < 1 then message("is less than 1: Value was:" ,P1) else if P1 > 1 then if P1 > 5 then message("is greater than 5: Value was:" ,P1) endif message("is greater than 1: Value was:" ,P1) endif endif //--------------------------------------------------------test = point(1,2,3,0,0,1) message("X" ,test.x, "Y",test.y, "Z",test.z, "nx",test.nx, "ny" ,test.ny, "nz" ,test.nz) if test.x == 1 then message("X value is:" ,test.x) endif
If you are using the Calypso Light version, you cannot use this function. The example below illustrates the principle of parameterization: 1 You begin by compiling an ordinary measurement plan: Take a perforated plate, define the base alignment at the top left front and take two probings in -Z. For the two probing points point_A and point_B, define the two corresponding features Z-value_A and Z-value_B. 2 Define the variables so that the positions of the probing points can be parameterized: Select Plan Advanced Parameter, and enter the following:
X_value_point_A Y_value_point_A Z_value_point_A X_value_point_B Y_value_point_B Z_value_point_B = = = = = = 10 25 0 30 40 0
Click on OK to terminate input. The positions of probing points point_A and point_B can now be parameterized.
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3 You do this by substituting variables for the fixed X, Y and Z coordinates: Open probing point point_A, click in the input field for the X value and select Formula from the context menu. Click on Settings in the formula window. The variables you defined beforehand are listed. Click on X_value_point_A. Instead of X the measurement plan now contains a variable with 10 as its parameter value. Repeat the entire procedure for the Y and Z values of A. Parameters have now been substituted for the fixed X, Y and Z values of probing point point_A. Proceed in precisely the same way to substitute parameters for the fixed X, Y and Z values of probing point point_B. 4 Run the measurement plan. The CMM moves to the coordinates. If you now assign other parameters to the variables
X_value_point_A Y_value_point_A Z_value_point_A X_value_point_B Y_value_point_B Z_value_point_B = = = = = = 18 37 0 44 23 5
and restart the measurement plan, the CMM will move to the new coordinates.
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These lines define the 12 points from which the curve will be generated. If you want to include a comment for each curve point, add the following lines to the parameter file:
name103[1] = "type103_n1_p1" name103[2] = "type103_n2_p2" name103[3] = "type103_n3_p3" name103[4] = "type103_n4_p4" name103[5] = "type103_n5_p5" name103[6] = "type103_n6_p6" name103[7] = "type103_n7_p7" name103[8] = "type103_n8_p8" name103[9] = "type103_n9_p9" name103[10] = "type103_n10_p10" name103[11] = "type103_n11_p11" name103[12] = "type103_n12_p12"
You must also open the Point Generator dialog box (see below) and define the name103[index] variable in the Comment box. 2 Open the definition template of the curve. 3 Go to Nominal Definition and select Parameter Data. The Point Generator dialog box is opened. 4 Enter the following values in the Point Generator dialog box: Start Index = 1 End Index = 12 Increment = 1
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5 Click on the Point input field and use the context menu to open the Formula dialog box. 6 Enter the following variable name:
type103[index]
You have now entered a changeable variable name. The point generator replaces [index] with the current value of the loop counter in each step, starting with the start index. 7 Close the Formula Interface window.
This formula defines a series of 50 points with changing X and Y values, all situated on the plane Z=0 and having the same vector (0,0,1). point(x,y,z,nx,ny,nz) defines a point variable. Use the index loop counter of the point generator as the argument in the cosine function. In each of the points the x value is index*10, the y value is 50*cos(index*10), and the z value is 0. 4 Close the Formula Interface window.
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The characteristic in this example is the roundness of a hole. If the characteristic goes out of tolerance, you want to remove foreign matter from the hole and repeat the measurement. To accomplish this using PCM functions: 1 Place a loop with 6 repetitions around the characteristic. 2 Point to the Break Condition field, open the context menu and select Formula... The Formula dialog box appears on the screen. 3 In the Boolean Expression (Yes / No Test) field, define status_5==1 as the abortion condition and click on OK. 4 Write the following program code into the field for the output parameters of the characteristic:
//************************************************************************************************ // Measure Circle hole_5 , check roundness; if out of tolerance, interrupt CNC and request next // task: repeat feature or measure next feature or terminate CNC run. //************************************************************************************************ // Defining starting conditions status_5 = 2 hole_5 = getActual("DIN Round_hole_5").actual // If out of tolerance, open a window and inquire CNC End, Continue or Repeat if hole_5 > 0.01 then message("DIN Roundness of hole_5 is:" ,hole_5) status_5 = inquire("1=CNC End, 2=Continue, 3=Repeat. Enter a number") message(status_5,"Is your entry correct?", "DIN Roundness of hole_5 is", hole_5) if status_5 == 2 then message("CNC run will be continued") status_5 = 2 endif endif
if status_5 == 1 then message("The CNC run will be terminated due to excess tolerance in Circle hole_5.") cncBreak() endif
if status_5 == 3 then message("The measurement of the circle will be repeated.") if LOOP1 == 5 then message("CNC run will be terminated due to too many loop runs in feature hole_5.") cncBreak() endif endif print("Status ist",status_5, "DIN Roundness of hole_5 is", hole_5)
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In radian measure 180 corresponds to the number = 3.14159265359. The result of the formula depends on the variable PartRotationActive: When PartRotationActive=0 is set, the formulas return value is 3.14159265359 * 0 = 0. The base alignment is not rotated. When PartRotationActive=1 is set, the formulas return value is 3.14159265359 * 1 = 180. The base alignment is rotated 180.
If you are using the Calypso Light version, you cannot use this function. If you are using character string functions and polls, you can ask for the required file name in the dialog.
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With the following lines, you can implement a poll for the desired parameter file and the loading of the relevant file:
// Select file PCM_PARA=inquireText("Which file do you want?",cr(),"File1=1",cr(),"File2=2",cr(),"File3=3") // Compose file name PCM_Filename="Parameterset_"+PCM_PARA // Specify path for files path=C:/calypso/home/om/PCMFILES // Load PCM file readPCMFile (PCM_filename)
If you are using the Calypso Light version, you cannot use this function. To define the loop with linear offset: 1 Select Plan Advanced Parameter and enter the following values:
Circle_position = point(20.5,15.5,-5,0,0,1) OffsetX = 10 Circle_diameter = 50
2 Parameterize the circle: Define the base alignment. Define the circle with measurement strategy. Open the feature definition template for a circle and enter parameters in the Formula Interface window. Input box X: circle_position.x Input box Y: circle_position.y Input box Z: circle_position.z Input box D: circle diameter 3 Define the Diameter characteristic and place a loop over it. If more than one characteristic is needed, e.g. X value, Y value and diameter, you have to parameterize the nominals for all
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characteristics. Then combine the characteristics in a group and place the loop around the group. 4 Parameterize the nominal. 5 Place a loop over the characteristic: Start = 1. End = 5 Increment = 1. The next step is to update the feature with loop counter and offset parameter. 6 In the Circle definition template, select Formula from the context menu opened by right-clicking in the X Nominal field. The field for the X value contains the circle_position.x variable. You want to increment this value by the offsetX value each time the loop is run. Enter the following in the formula:
circle_position.x + ((LOOP1 1) * offsetX)
LOOP1 is the loop variable of the 1st loop; you can transfer it into the formula by clicking on Loop. The start index for LOOP1 is the value from the Start input box for the loop. 7 Run the measurement plan. The loop is run. The expression for the X value assumes the following values one after the other: 20.5, 30.5, 40.5, 50.5, 60.5.
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The ASCII parameter file can be generated using the Notepad in Windows NT. 2 Save this file as perplate_A.para. 3 Create a measurement plan with base alignment and a circle. The elements of the base alignment can also be parameterized. They are omitted here for the sake of clarity. 4 Define a circle with measurement strategy. 5 Define each of the variables contained in the parameter file described above as an array (with square brackets and the LOOP1 loop variable) and read in the perplate_A.para parameter file. The parameters from the file are assigned to the variables. 6 Open the feature definition template for the circle. In the X Nominal input field, enter CirclePos[LOOP1].x. In the Y Nominal input field, enter CirclePos[LOOP1].y. In the Z Nominal input field, enter CirclePos[LOOP1].z. In the D Nominal input field, enter Circlediameter[LOOP1]. Open the commentary field with Formula in the Name/Comment window and enter the textCircle[LOOP1] text parameter. 7 Define the characteristics X value, Y value and diameter. The nominal values are parameterized using Formula. 8 Combine the characteristics in a group. 9 Place a loop over the group: Start = 1. End = NumberCircles
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You can import the NumberCircles variable into the End field using the Formula Interface window. Increment = 1. 10 Start the measurement plan. Depending on the content of the parameter file, you can use this measurement plan to measure different numbers of circles with different positions and diameters.
If you are using the Calypso Light version, you cannot use this function. Let us assume, for example, that a workpiece has two variants, A and B. Variant B has three extra holes with a diameter of 10 mm. 1 Generate a complete measurement plan, complete with the three holes. 2 Combine all characteristics of the three holes in the group called Additional hole pattern variant B". Selection of the variant is controlled by means of a PCM parameter as a switch. 3 Select Plan Advanced Parameter and enter the following:
// Measure additional hole pattern variant B when parameter is 1 MeasureAdditionalHolePatternActive = 1
4 Highlight the Additional hole pattern variant B" group and set a condition: Select Condition from the context menu. Click in the input box for the condition to open the context menu and open the Formula Interface window. In the Formula Interface window, click on Settings. Confirm the MeasureAdditionalHolePatternActive variable. Insert == 1" as an additional entry. The condition is now defined: the Additional hole pattern variant B" group is measured only when the MeasureAdditionalHolePatternActive" variable is equal to 1. 5 Run the measurement plan. The Additional hole pattern variant B" group is measured.
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7 Run the measurement plan again. The Additional hole pattern variant B" group is not measured in this run.
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PCM syntax
Like the programming languages Basic, C, Fortran and so on, PCM uses a functional syntax with the following rules: Definitions and value assignments as follows: variable_name=value
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Blanks are not permitted in names and formulas; the syntax is case-sensitive, so it distinguishes between uppercase and lowercase letters. Multiplication and division precede addition and subtraction when formulas are resolved. The decimal separator is the period (example 3.85). In functions, the function parameters (the arguments) are in parentheses and separated by commas. In commands (procedure calls), the function parameters (the arguments) can be omitted. Example: getActual(). Comments can be entered in each line: everything following the //" string is ignored.
Variables in PCM
There are four types of variable in PCM. The type of variable is defined implicitly by the value assignment: Variable type number Examples of value assignments e = 2.71828 Variable2 = 2.0 P1 = 80 Axis=vector(10,12,0) CylinderB = point(-10,12.5,0,0,0,1) Text_1 = "Circle" Text_2 = Enter the number:
Arrays
Arrays can also be defined with variables using special value assignments with square brackets. Example:
array[1] = point(-10,12.5,0,0,0,1) array[2] = point(-12.12.5,0,0,0,1) array[3] = point(-14,12.5,0,0,0,1) array[4] = point(-16.12.5,0,0,0,1) In this case, array is an array consisting of 4 variables of the point type.
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The array index in square brackets can also be specified by a variable (of type number, as an integer). You can therefore define an array of any length in a single loop instruction. Example: for I = 1 to numberTeeth type[I] = inquireNumber("Which tooth type is in position number ",I) next I You can gain direct access to a specific element in an array by specifying the array index. Example: Length = output values[4]
You can use the following comparative operators for conditions in PCM: Operator < > <> == >= <= Result Truth value of a<b Truth value of a>b Truth value of a not equal to b Truth value of a=b Truth value of a greater than or equal to b Truth value of a less than or equal to b
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Trigonometric Functions
PCM supports the following trigonometric functions: Function sin (angular degree) sinRad (radiant angle) cos (angular degree) cosRad (radiant angle) tan (angular degree) tanRad (radiant angle) arcsin (value) radArcsin (value) arccos (value) radArccos (value) arctan (value) radArctan (value) arctan2 (value1,value2) radArctan2 (value1,value2) Result Sine value Sine value Cosine value Cosine value Tangent value Tangent value Arc-sine in degrees Arc-sine in rad Arc-cosine in degrees Arc-cosine in rad Arc-tangent in degrees Arc-tangent in rad Arc tangent from the quotient value1/value2 in degrees Arc tangent from the quotient value1/value2 in rad
Other functions
Other mathematical functions are available: Operator squared(value) sqrt(value) Result Value squared Square root of value
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Result evalue Natural logarithm of value Common logarithm of value Value1 modulo value2 Integral proportion of value |Value| (=absolute value of the value) Value, rounded to the given number of places; if specification of number of places omitted: 0 places Sign of value2 times value1 (default of value1 = 1): Value1, if value2<0 + Value1, if value2 0 Sign of value2 times value1 (default of value1 = 1): Value1, if value2<0 0, if value2 = 0 + value1, if value2>0 Maximum of the indicated values Minimum of the indicated values 1 for true 0 for false Examples: squared(3) = 9 sqrt(225) = 15 exp(0) = 1 ln(1) = 0 log(10000) = 4 mod(22,8) = 6 int(34.5674) = 34 abs(-35.335value) = 35.335 round(35.335,2) = 35,34 sign(-12,-34) = 12 sign(-12) = -1 max(1,2,5,8,3) = 8
signWithZero([value1,]value2)
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Examples: asc("8") = 56 chr(111) = "o" format(3278,45) = "3278,45" val("3278,45") = 3278,45 len("This is a character string") = 26 inStr(3,"Position","o") = 7 inStr("Position","o") = 2 mid("PCM functions",1,3) = "PCM" strElement(4,",","hello,here,we,are,again") = "are" strElement(4,"e","here,we,are,again") = "ar" subStr("This is a test",4,9) = "s is a"
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display
Displays the Display window on the screen in which a character string is shown. The CNC run is not interrupted. The syntax is:
display("message")
inquire
Corresponds to the inquireNumber command, but is supported by PCM only for the sake of upwards compatibility. The syntax is:
variablename = inquire("Dialog text for poll")
inquireNumber
The inquireNumber command can be used to create a dialog for querying a numeric value. The syntax is:
variablename = inquireNumber("poll text for workpiece number")
or
variablename = inquireNumber("line1"[,cr()],"line2"[,cr()],...,"lines")
Here the optional elements "cr() each cause a line break on the screen. Example 1:
P1 = inquireNumber("Enter 1 to continue measuring") if P1 == 1 then message("You entered 1, so I will continue measuring") else if P1 <> 1 then message("You do not want to continue measuring.") endif endif
Example 2:
number = 10 P1 = inquireNumber("Last word was: ",number,cr(), "Enter new number:") message("You have entered the number:",P1)
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Example 3:
type = inquireNumber("Cone tooth = 1", cr(), "Cylinder form tooth = 2", cr(), "Long cylinder tooth = 3", cr(), "Spherical form tooth = 4", cr(), "Please enter number")
inquireList
The inquireList command can be used to create a menu for querying a character string. The syntax is:
variablename = inquireList("Menu title","Menu item1","Menu item2",...,"Menu itemn")
The command causes the appearance of a menu with the given title line on the screen. As a value, the variable is assigned the character string of the menu item which has been selected with a mouse click or the arrow keys and confirmed with OK. Examples:
NameForPrintoutheader = inquireList("Name for printout header","Test printout","Default printout",)
inquireParameterList
If the inquireParameterList command is contained in the presettings or postsettings, the user can open a dialog box and enter the parameters in it using a list. The syntax is:
inquireParameterList("p1","k1",...,"pn","kn")
All variables (p1 to pn) that are to be entered via the list must be contained in the brackets together with comments k1 to kn. To open the dialog box, the user must highlight the line containing the command and select Calculate in the context menu.
inquirePasswordText
Opens the dialog box for entering a text. The entered text is masked (in the form of asterisks). The function supplies the return value of the entered text. The syntax is:
inquirePasswordText("dialog title")
The character string entered for dialog title is written in the title bar of the dialog box. Example:
enteredText = inquirePasswordText("password:")
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inquireText
The inquireText command can be used to create a dialog for querying a character string. The syntax is:
variablename = inquireText("text line")
or
variablename = inquireText("text line1"[,cr()],"text line2"[,cr()],...,"text lines")
Here the cr() optional elements each cause a line break on the screen. Examples:
string1 = inquireText("Enter the name")
message
Outputs the current values of one or more variables. The syntax is:
message(variable,variable,variable,...)
Inserting cr() instead of a variable causes a line break on the screen. Example:
message("The value of variable P1 is: ", P1, cr(), "The value of variable P2 is: ", P2)
print
Prints the current values of one or more variables in the printout.
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If you are using the Calypso Light version, you cannot use this function. The syntax is:
print(variable;variable;variable;...)
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The print command will not be active unless you have activated the Activate print command check box after selecting Plan Advanced PCM-Test Settings in the PCM-TestFunctions window. This means you can use the command for test purposes. Examples:
print("Print this dialog text in the printout") print("Print the value of variable P1 in the printout"; P1)
redrawCAD
Recalculates all features and updates the CAD window. The syntax is:
redrawCAD()
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Whenever the file name is used without path name, this function will access the directory of the current measurement plan. If the name of the drive is missing, the current directory will be used. Example: addToFile(wd+"\info.txt","line",1) Here wd is a variable that contains a path specification.
copyFile
Copies a file, i.e. saves a copy of the file under a name to be specified. The syntax is:
copyFile("file name1","file name2")
Whenever the file name is used without path name, this function will access the directory of the current measurement plan. If the name of the drive is missing, the current directory will be used.
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If a file with the name file name2 already exists, this will be overwritten. Example: copyFile("test.txt","test2.txt") creates a copy of test.txt in the current measurement plan directory and saves it under the name test2.txt.
deleteFile
Deletes the specified file. The syntax is:
deleteFile(file name)
Whenever the file name is used without path name, this function will access the directory of the current measurement plan. If the name of the drive is missing, the current directory will be used.
getActualInspectionDir
Returns the directory of the current measurement plan. The syntax is:
getActualInspectionDir()
getWD
Returns the current directory. The syntax is:
getWD()
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Example: wd = getWD()
readPCMFile
Reads in a PCM file. The syntax is:
readPCMFile (file name)
Whenever the file name is used without path name, this function will access the directory of the current measurement plan. If the name of the drive is missing, the current directory will be used. The new parameters which are read in will, in each case, overwrite the current parameters of the same name.
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The parameters which were available before the CNC run will only be temporarily overwritten. The original start setting will be used for the next CNC run. The file name can also be entered in the form of several parameters. The parameters will, depending on the type, be put together to form a string. Example1:
readPCMFile("testparameter.para ")
Example2:
P1 = "c:" P2= "\calypso\home\om\ "+"test.para " readPCMFile(P1,P2)
Example3:
readPCMFile("c: ", "\calypso\home\om ", "test.para ")
renameFile
Renames a file. The syntax is:
renameFile("file name old","file name new")
Whenever the file name is used without path name, this function will access the directory of the current measurement plan. If the name of the drive is missing, the current directory will be used. Example: renameFile("test.txt","Test2.txt") renames the test.txt file test2.txt.
writeActualsToVDA
Saves filtered actual values in VDA format in the specified file.
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NOTE
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The actual values refer to the base alignment and do not contain any radius correction. The syntax is:
writeActualsToVDA(["characteristic name"],"file name")
The characteristic name is optional. If no characteristic name is indicated, the current characteristic will be used. The function supplies true as soon as saving is completed, otherwise the function supplies false.
Coordinate values returned by getActual, getNominal and measure always refer to the base alignment of the current feature.
baseSystem
Returns characteristics of the base alignment. The syntax is:
baseSystem().characteristic
Possible values of characteristic are: x, y, z, valueA, euler1, euler2 and euler3: Function baseSystem().x baseSystem().y baseSystem().z baseSystem().valueA baseSystem().euler1 baseSystem().euler2 baseSystem().euler3 Return value X value of base alignment Y value of base alignment Z value of base alignment valueA value of base alignment euler1 of base alignment in rads (angle of inclination) euler2 of base alignment in rads (angle of inclination) euler3 of base alignment in rads (angle of inclination )
The formula for calculating the plane angle of the base alignment is:
plane angle = (euler1 euler3) * 180 / p
Example: result=baseSystem().x The X value of the base alignment is written into the result variable.
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getActual
In conjunction with an argument, it returns a certain current value of a feature, coordinate system or bore pattern. The syntax is:
getActual("feature_name").characteristic
The feature name can be indexed directly or with a variable (for example, a loop variable):
getActual("Cone",3).x
or
getActual("Cone",LOOP3).x
characteristic is a dummy for the following: Function x Return value X value of the reference point x value of the origin for coordinate systems and bore patterns Y value of the reference point Y value of the origin for coordinate systems and bore patterns Z value of the reference point Z value of the origin for coordinate systems and bore patterns Angle 1 Angle 2 Angle of Inclination Angle of Rotation Diameter Radius Two Radius Angle Length Deviation in the set tolerance mode Deviation Form error Polar coordinate, radius Polar coordinate, angle Polar coordinate, height
a1 a2 inclinationAngle rotationAngle diameter radiusD2 radius angle len deviation sigma form coordPolRadius coordPolAngle coordPolHeight
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Used without an argument, it returns the current value of the characteristic. The syntax is:
getActual()
getNominal
Returns a certain nominal of a feature. The syntax is:
getNominal("feature_name").characteristic
measure
In conjunction with an argument, it returns a certain current value of a feature, coordinate system or bore pattern. The syntax is:
measure("feature_name"[,loop index]).characteristic
The feature name can be indexed directly or with a variable (for example, a loop variable):
measure("Cone",3).x
or
measure("Cone",LOOP3).x
See the table above for the possible values of characteristic. Used without an argument, it returns the current value of the characteristic. The syntax is:
measure()
The CNC run is broken off, the stop light changes to red.
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displayPositionCMM
Opens the Position dialog box, in which the current coordinates of the probe are displayed in the machine coordinate system in the same way as with a dial gage. The syntax is:
displayPositionCMM()
This dialog allows the user to set each coordinate or all coordinates to 0. In terms of calculation, this means that the local vector of the position at which zeroing took place is subtracted from the respectively current position in the displays in the further course of the process. After closing with OK, the dialog returns the most recently displayed coordinate as the result. Example: starting_point=displayPositionCMM() assigns the variable starting_point the value 0.005443d@20.345677d@200.311123d.
getCNCMode
Supplies the travel mode of the CMM: "manual" or "cnc". The syntax is:
getCNCMode()
getPositionCMM
Supplies the current position of the probe in machine coordinates as the result. The syntax is:
getPositionCMM()
getStylus
Returns characteristics of the stylus. The syntax is:
getStylus("stylus_name","plate_name").characteristic
Stylus name and plate name must be strings enclosed in straight quotes ("). The possible values of characteristic are: radius, diameter or angle The current stylus name can be omitted. Examples: Command/assignment getStylus().radius getStylus("stylus_+Y").radius Return value/effect The current stylus tip radius is returned. The stylus tip radius of stylus_+Y is returned.
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Return value/effect The radius of stylus_+Y is returned from plate_A. The StylusDiameter variable receives the radius of stylus_+Y from plate_A.
getTemperatureCorrection
Returns characteristics of the temperature correction object. The syntax is:
getTemperatureCorrection().characteristic
See the table for the possible values of characteristic: Function getTemperatureCorrection().temperatureCorrection getTemperatureCorrection().coefficientPart getTemperatureCorrection().temperaturePart1 getTemperatureCorrection().temperaturePart2 getTemperatureCorrection().temperatureStylus getTemperatureCorrection().temperatureTableFrontBottom getTemperatureCorrection().temperatureTableFrontTop getTemperatureCorrection().temperatureTableRearBottom getTemperatureCorrection().temperatureTableRearTop getTemperatureCorrection().temperatureX1 getTemperatureCorrection().temperatureX2 getTemperatureCorrection().temperatureX getTemperatureCorrection().temperatureY getTemperatureCorrection().temperatureZ Return value Boolean value: temperature correction is active or not active Thermal expansion coefficient of the component Temperature of workpiece sensor 1 Temperature of workpiece sensor 2 Temperature of the temperature stylus Sensor temperature at the bottom front of the table Sensor temperature at the top front of the table Sensor temperature at the bottom rear of the table Sensor temperature at the top rear of the table Temperture of sensor 1 on the X scale Temperture of sensor 2 on the X scale Temperature of the scale in the X axis Temperature of the scale in the Y axis Temperature of the scale in Z axis
positionCMM
Moves the probe to the specified position (in machine coordinates). If no axis sequence is specified, the CMM moves in Z first, then Y, and finally X.
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Important This is a direct movement command addressing the CMM. Risk of collision. The probe moves directly to the position; the clearance planes are ignored. The syntax is:
positionCMM(x,y,z,["axis1","axis2","axis3"])
The parameters 4 to 6 define the sequence in which the coordinates are executed. Use: For example, you can define movements to pickup positions in the output parameters of the measurement plan. Example: positionCMM(500,-100,-200) The CMM moves first in Z to -200 mm, then in Y to -100 mm and then in X to +500 mm in the machines system of coordinates. Example: positionCMM(200,-200,-10,"Y","Z","X") The CMM moves first in Y to -200 mm, then in Z to -10 mm and then in X to 200 mm.
positionRS
Moves the probe to the specified coordinates in the specified coordinate system with the specified stylus. (Standard: Base alignment). The syntax is:
positionRS(X,Y,Z,[coordinate system,stylus])
searchDistance
Sets the search distance. The syntax is:
searchDistance(distance)
In this case distance is the distance traveled by the probe before nominal probing. This value must be entered in 0.1 mm. It applies until it is overwritten or canceled by a reset (stop light goes from green to red and then back to green). Examples:
searchDistance(10.000) => Search distance before nominal probing is
1 mm
searchDistance(60,000) => Search distance before nominal probing is
6 mm
setCNCMode
Sets the travel mode of the CMM. The syntax is:
setCNCMode(mode)
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stepRS
Moves the probe along X, Y, Z relative to the current position in the specified coordinate system (standard: base alignment). The syntax is:
stepRS(X,Y,Z,[coordinate system])
It is used together with the systemCallForResultAccess command. It serves to close the CalypsoInterface, with which measured data is taken over from Calypso. For information on using the PCM commands and programming the application that accesses measured data from Calypso, see Programmed access to measuring results on page 9-51.
date
Returns the current date in the respective country language. The syntax is:
date()
dateAndTime
Returns system date and time. The syntax is:
dateAndTime()
Example: date=dateAndTime(). Date and time are written into the date variable (of type string) in the format defined by the system.
dateInNumbers
Returns the current date as numerical values. The syntax is:
dateInNumbers()
openSocket
Opens a communication channel between Calypso and an external application. The syntax is:
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openSocket()
It is used together with the systemCallForResultAccess command. It serves to open the CalypsoInterface, with which measured data is taken over from Calypso. For information on using the PCM commands and programming the application that accesses measured data from Calypso, see Programmed access to measuring results on page 9-51.
systemCall
Calls system commands. The syntax is:
systemCall("filename")
The filename file is called and executed. filename must be an executable file, e.g. a batch file or a program. You can use this function to copy results to another computer, for example. Example: systemCall("D:\home\om\philips\main\help.bat") The statements in the help.bat file are executed.
NOTE
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Calypso is not stopped during execution of the system command. Any CNC run will continue.
systemCallForResultAccess
Calls system commands and waits for them to be processed. The syntax is:
systemCallForResultAccess("executable command that starts an *.exe")
Starts an application. This application can access Calypso data while the measurement plan is not being processed further. By contrast, systemCallWithWait does not permit access to Calypso data and systemCall does not stop the CNC run. This command must be used together with the openSocket and closeSocket commands. In the example below, commands are sent to Calypso by the SimpleBasicTest Visual Basic Script via the Weprom interface:
openSocket() systemCallForResultAccess("WScript c:\temp\SimpleBasicTest.vbs") closeSocket()
For information on using the PCM commands and programming the application that accesses measured data from Calypso, see Programmed access to measuring results on page 9-51.
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systemCallWithWait
Calls system commands and waits for them to be processed. The syntax is:
systemCallWithWait("filename")
The filename file is called and executed. Calypso will wait until the file "filename" has been processed. filename must be an executable file, e.g. a batch file or a program. Example: systemCallWithWait("D:\home\om\philips\main\help.bat") The statements in the help.bat file are executed. Calypso will wait until the batch file has been processed.
NOTE
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It is not possible to access the measured data of the current measurement plan with this command.
time
Supplies the current time. The syntax is:
time()
timeInSeconds
Supplies the current time in seconds. The syntax is:
timeInSeconds()
wait(nSeconds)
Interrupts the measurement plan run for nSeconds seconds The syntax is:
wait(nSeconds)
Example:
wait(10)
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You will find a complete list of all printout header variables in Printout header data (reference) on page 9-31.
presentationOff
Switches off a custom printout. The syntax is:
presentationOff()
Example: You want a graphic to appear only when certain characteristics are measured. To accomplish this, you define a custom printout with a graphic. You switch off the custom printout by default in the start parameters of the measurement plan. You then request the custom printout for the characteristics in question by opening the Settings window and specifying presentationOn() in the input parameters.
presentationOn
Switches on a custom printout. The syntax is:
presentationOn()
setProtocolSetting
Defines the settings for the custom printout. The syntax is:
setProtocolSetting("setting","value")
The following can be set for setting and value: setting outputFormat userDefinedPages value Name of the desired output format Name of the file custom defined page to be attached to the custom printout. Prerequisite: User Defined Pages in the Format Custom Printout dialog box is activated. Examples: setProtocolSetting("outputFormat","default") defines the default format as the output format. setProtocolSetting("userDefinedPages","userProtocol1.gra") attaches the userProtocol1.gra page to the existing printout.
setRecordHead
Sets the value of a printout header variable. The syntax is:
setRecordHead("printout header variable","value")
You will find a complete list of all printout header variables in Printout header data (reference) on page 9-31.
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Meaning: If CONDITION is satisfied, DEFINITION is processed. If CONDITION is not satisfied, DEFINITION is not processed. A DEFINITION can be formulas, value assignments, functions, conditions or loops of your choice, always with line breaks as separators.
Meaning: If CONDITION is satisfied, DEFINITION1 is processed. If CONDITION is not satisfied, DEFINITION2 is processed. DEFINITION1 and DEFINITION2 can be formulas, value assignments, functions, conditions or loops of your choice, always with line breaks as separators.
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message("Test if with PCM") P1 = 1 message("Value is :",P1) //---------------------------------------------------------if P1 == 1 then message("is equal. Value was:" ,P1) endif if P1 < 1 then message("is less than 1: Value was:" ,P1) else if P1 > 1 then if P1 > 5 then message("is greater than 5: Value was:" ,P1) endif message("is greater than 1: Value was:" ,P1) endif endif //---------------------------------------------------------test = point(1,2,3,0,0,1) message("X" ,test.x, "Y",test.y, "Z" ,test.z, "nx" ,test.nx, "ny" ,test.ny, "nz" ,test.nz)
The following must be inserted: for index the name of the loop variables (random), for start, end and step whole numbers, for DEFINITION random formulas, value assignments, functions or other conditions or loops of your choice, always with line breaks as separators. Meaning: the functions or commands under DEFINITION are processed (end - start + 1)/step times, whereby "step" is set to 1 if no other specification is made. At the same time, the specific value for index is always entered in DEFINITION: at first start, then start+step, start+2*step etc. up to end. With next i, the loop index is incremented by step each time.
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Conditional loop
The conditional loop has the following syntax:
repeat DEFINITION until CONDITION
Meaning: 1.) DEFINITION is processed. Then CONDITION is tested. 2.) If CONDITION is fulfilled, the loop is ended. 3.) If CONDITION is not satisfied, DEFINITION is processed again and CONDITION is tested again. Continues with 2.). The CONDITION can be set up as a logical combination of several subconditions. The DEFINITION can be formulas, value assignments, functions or other conditions or loops of your choice, always with line breaks as separators. As the condition is only tested after the first run, a conditional loop must run at least once.
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Important Please note that infinite repetitions are possible with the conditional loop if the condition is never fulfilled.
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Chapter
16
.................................................................................................................................
Geometric elements such as circle, line, plane etc. can easily be measured with the basic version of Calypso. To measure freely formed part surfaces, special measuring techniques are required. The Curve and 3D curve features and the Curve form characteristic are for measuring and evaluating known and unknown open and closed 2D and 3D curves. Curve measurement is one of Calypso's optional features. You can license this functionality and have it enabled in your system if it would be of use to you. Contact your Carl Zeiss Service for more information. This chapter assumes that you are familiar with the procedures for defining features and characteristics (see Defining features on page 5-2 and Defining characteristics on page 6-7).
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Z Y
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Spatial curve (3D curve) Spatial curves (3D curves) have three degrees of freedom: theoretically, they are not constrained in any direction. You can measure and test 3D curves with Calypso.
Lift curve (face curve) Lift curves, also known as face curves, are special threedimensional curves that run across cylinder sections. Every point in a lift curve can be described by means of two values: namely by the angle of rotation on the surface of the cylinder and the deviation of the curve from the circular line in a given direction (e.g. radial or axial). Therefore, the lift curve is a special 3D curve and like the 2D curve has only two degrees of freedom.
Z
The illustration shows an axial lift curve with deviations in the direction of the Z axis.
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You will find more information on this definition template under Definition template (curve) in the Calypso dialog reference in the Online Help.
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In the CAD window, curves are displayed as continuous lines; they are calculated as approximations with the aid of splines. You have the option of mapping a tape coupled to the curve, in order to highlight the spatial component of a 3D curve. You can set the width of this tape by clicking on Evaluation in the Evaluation dialog box at Tape width. 0 means: no tape.
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In the Change nominal values window, select the In vector direction option, deactivate the Lift curve check box and enter 0 explicitly for the Length and Cylinder radius. Or: In the Evaluation window at 3d curve, deactivate the Lift curve check box.
You can use neither automatic feature recognition nor the technology macros for this purpose. To define the nominal data, you can: Import an existing file. The file format can be one of the following: VDA (Cons, Curve, MDI, PSET, POINT, CIRCLE), ASCII, PAB, or DXF. For ASCII files, the values are read in the following sequence: x-nominal, y-nominal, z-nominal, u-nominal, v-nominal, wnominal, x, y, z, u, v, w. For ASCII files with axial lift data, the values of each line are read as angles and appropriate heights. Use the point generator to define the curve points: either to define the curve points mathematically or to import external files with a different format. Digitize a curve. You generate the nominal values of an unknown outline by probing. Enter the curve's nominal data, e.g. taken from a technical drawing, by means of the keyboard. Extract the nominal data from the CAD model: using the CAD Modification menu and clicking with the mouse. Once the nominal points have been defined by one of these methods, you can proceed with processing them and thus changing the position and the shape of the curve.
!
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Risk of collision! Always check the nominal vectors after defining the curve points, and make sure that the vectors do not point into the material (risk of collision).
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3 Select the desired format. The Scanware converter must be installed on your system if you want to import a DXF file created by a ScanWare DXF converter. This option is not available for 3D curves. 4 Select the desired file: Enter the complete path in the input field. If you do not know the path, click on the small arrow. You can select the file in the Explorer window that now opens.
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5 If you want to load a VDA file selectively, click on the Properties button. The VDA import settings dialog box appears on the screen.
6 Enter the criteria for selecting the points for import in the curve and click on OK to confirm. 7 If you want to load an ASCII file with axial lift data, click on the Properties button. The Input parameters for axial strokes window will open.
8 Enter the additional information required for the conversion of the lift data in Cartesian coordinates and confirm with OK. 9 Click on OK. The data will now be read from the file. If you specified selection criteria before importing from a VDA file, the data in the file is imported selectively into the curve feature in
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accordance with these criteria. The sequence of the curve points derives from the sequence of the points in the VDA file. The type and name of the converted features are written into the Comment for the curve. You have now defined the curve with its nominal data. Always remember to check the direction of the nominal vectors (see Checking the nominal vectors of a curve on page 16-27).
Axial lift data is entered in two columns. The columns require the headings Angle and Height. In each line, the value of the angle is stated in the first column and the respective height of stroke in the second column. Example:
Angle 0 10 20 30 40 50 60 70 80 90 100 ... Height 10 10 10 11 13 15.5 18 20.5 22 24 25 ...
Radial lift data is entered in two columns. The columns require the headings Angle and Radius. In each line, the value of the angle is stated before the radius belonging to the angle. Example:
Angle 0 10 20 30 40 50 60 70 80 90 100 ... Radius 500 501 502 502 502 503 504 505 505 505 505 ...
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3 You can enter formulas and parameters to suit the necessary conversion in the Start Index, End Index and Increment input fields. For more details, please refer to Entering parameters and formulas on page 15-15. 4 Click on OK when you have finished programming. Calypso evaluates the points according to your entries and loads them into the definition template.
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!
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Important If the automatic radius correction is not activated in the Digitizing mode, you must carry out the radius correction manually. For more details, please refer to Defining tolerances for a curve on page 16-31 and How to change the nominal points of a curve on page 16-23, step 3. Take the probings on a workpiece that can be used as a pattern (master workpiece), in other words a precision-manufactured part. The actual values obtained by probing are subsequently converted into nominal data. In this way, you use a master workpiece to obtain the nominal data for other, identical curves. You have two options: either take individual manual probings to define the curve, or scan the curve. To scan 2D curves, select the Unknown Cut procedure (see How to scan an unknown contour using the Unknown Cut method on page 16-13). To scan a 3D curve, you have two options: the 3D curve method you have to run three scans so that Calypso can compute the transverse curvature of the threedimensional curve (see Digitizing 3D curves on page 16-16). the Lift curve method (see How to scan an unknown contour using the Lift curve method on page 16-18).
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6 Now start recording the measured points on the workpiece. Every probing point is shown directly in the definition template and in the CAD window. As soon as you have probed three points, Calypso will calculate the curve. The entire curve is recalculated for every new point you probe. 7 As soon as you have defined the curve by probing, click on the Digitizing off button. 8 Click on OK to save the values and close the definition template. You have now determined the nominal values for an unknown curve. Note that these values correspond to the stylus center. To correct the stylus radius, please read Working with curve nominal data on page 16-23.
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3 Click on the Strategy button. The Strategy dialog box appears on the screen.
4 Select the Unknown Cut method to measure the curve as a free planar section. The entry Unknown contour 1 appears in the dialog box.
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6 Enter the parameters. For the start and the end points, you can choose the coordinate system type. Calypso recognizes the probing direction by probing the start point roughly. The coordinates of the probing will be entered in the fields for the start point. If necessary, edit the coordinates entered in the Start Point field. Enter the coordinates of the end point in the End Point field, or else probe the workpiece to define the end point. In the Space axis selection list, select a spatial axis to which the scanning plane is to be perpendicular. If necessary, click on the button to change the Direction. 7 Enter a speed for the CMM in the Speed field or select the requisite accuracy. 8 Enter a pitch between points in the Step Width field or define the number of points. Once all the parameters have been defined in full, the red Execute button appears and you can click it to start scanning. 9 Check that the CMM is ready to move and that there is no risk of collision.
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10 Click on the red Execute button to start scanning the unknown contour. The CMM starts scanning the contour.
Digitizing 3D curves
When you digitize a 2D curve using the unknown cut method, the nominal vectors are calculated by Calypso by definition, they are in the plane of the cut. A single digitization process is not enough to probe a 3D curve with transverse curvatures on the workpiece, because in this case the orientation of the nominal vectors is unknown. When you digitize a 3D curve, therefore, you have to scan an unknown contour in such a way as to obtain three cuts each a certain distance above and below the 3D curve as such. Calypso then uses this information to compute the nominal vectors and thus the transverse curvature of the 3D curve. Start the process by clicking on the Digitize 3D Curve button in the Strategy window for 3D curves.
NOTE
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If the feature does not have any nominal values, you will have to select the Digitizing On item under Nominal Definition before you open the Strategy window.
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In the Segment dialog box, go to Travel Path Definition and define the three paths, then click on Execute to start digitization.
To specify the start and end points of the three paths by probing with the CMM, first probe the three start points of the paths (points 1 to 3), then probe the three end points of the paths (points 4 to 6). When traveling along the three paths, the CMM moves in a meandering style: the direction of movement alternates from one path to the next.
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NOTE
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If the feature does not have any nominal values, you will have to select the Digitizing On item under Nominal Definition before you open the Strategy window. In the Segment window, go to Travel Path Definition and define the number of paths, then click on Execute to start digitization.
When traveling along the paths, the CMM moves in a meandering style: the direction of movement alternates from one path to the next.
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3 Click on the Strategy button. The Strategy dialog box appears on the screen.
4 Select the Lift curve method in order to measure the curve as a lift curve along an annular surface (cylinder circumference). The Unknown contour of circle face entry appears in the dialog box.
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5 Double-click the Unknown contour of circle face entry. The Segment window will open.
To specify the start and end points of the three paths by probing with the CMM, first probe the three start points of the paths (points 1 to 3), then probe the three end points of the paths (points 4 to 6).
NOTE
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Start point indicates that the CMM will start scanning at the last end point. Check the entered values and bear in mind that the lift curve is probed on an area along the cylinder section, so that the specified radius must be correspondingly larger than the radius of the reference feature. The center must also be at the central point of the lift curve. Usually, the automatically entered center is in the center of a base area of the reference feature. 6 Enter a speed for the CMM in the Speed field or select the requisite accuracy.
NOTE
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7 Enter a pitch between points in the Step Width field or define the number of points. Once all the parameters have been defined in full, the Execute button appears and you can click it to start scanning. 8 Check that the CMM is ready to move and that there is no risk of collision. 9 Click on the red Execute button to start scanning the unknown contour. The CMM starts scanning the contour.
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How to adopt nominal data of the curve from the CAD model
You can also adopt the nominal data for a curve from the CAD model into the CAD window. How to adopt nominal data of the curve from the CAD model: 1 Select CAD Modification Modify CAD Entities. The Modify CAD Model dialog box appears. 2 To generate a 2D curve: select a line in the CAD model. 3 Under Points, enter the desired number of points and click on the symbol for the curve. The 2D curve is generated and entered into the measurement plan. This can take a few seconds to complete. The vector normal to the plane of intersection is automatically calculated for each point on a 2D curve 4 To generate a 3D curve: Switch the CAD model to rendered mode and select an area on which the curve should be positioned. All edges you select subsequently will refer to this face, until you select a different face. 5 Then change to normal mode and select one or more edges (with the Ctrl key). 6 Under Points, enter the desired number of points and click on the symbol for the curve. The 3D curve is generated and entered into the measurement plan. This can take a few seconds to complete. The curve's vectors will be taken from the CAD surface that you clicked on: For a cylindrical face, the vectors are calculated perpendicular to the cylinder axis. For a conical face, the vectors are calculated perpendicular to the cone axis rotated around the opening angle (from the plane). For a planar edge, the vectors are positioned parallel to the plane vector. 7 When the process is completed, confirm by clicking on Close. You have now transferred the curve defined in the CAD model to your measurement plan. You can edit the curve in the usual way.
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You must transform the nominal values if you want to perform stylus tip radius correction after digitizing a curve. The nominal points can be transformed in several ways: Move in the direction of the normal vectors (offset curve, especially for correcting stylus tip radius) project in the direction of the cylinder axis onto the cylinder section, in order to get a lift curve move and/or turn in axis direction modify the number of points (for instance, with a very large number of points, which would lead to very slow probing).
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Important If you modify the number of points and confirm with OK, you will create new nominal values for the curve. The original curve cannot be recreated again. For this reason, it is important that you use the Simulation function to check the result beforehand. Only use this function with great care and after careful thought. To edit the nominal points: 1 Open the definition template of the curve.
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2 Select Nominal Definition Change Nominal Points. The Change probing points window will open. The entry boxes of the dialog box change depending on the set option.
3 If you want to move the curve points in the direction of the normal vectors, activate the in Vector direction radio button. Enter the value by which you wish to move the curve under Length. If you have obtained the measured values of the curve by means of digitization, click on the Stylus Tip Radius button. The radius of the stylus used is entered in the input field. If you want to project the points of a curve onto a cylinder section, activate the Lift curve check box and enter the radius and axis of the cylinder. Please note that the reference axis or the axis of the reference feature must always pass through the center of the lift curve. The origin of the base alignment must also lie on this axis. 4 To move or rotate the curve in the direction of the coordinate axes, select the Coordinate axes direction option. Enter the value for the move and/or rotation. 5 To modify the number of nominal points, select the Number option. Enter the desired value for the Step Distance, the Chord Height or the Number of Points. - or -
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Select the Coordinates option and specify the coordinate grid in the desired coordinate axis with starting point and distance in mm. New points with the specified X, Y and/or Z values are calculated. 6 Click on OK to confirm. The nominal points are modified immediately.
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Please note that the nominal points of the curve are then recalculated internally. Applying this function again may accidentally change the form of the curve.
This function has been conceived for use in conjunction with the Nominal Definition Parameter Data function (see How to generate a curve with the point generator on page 16-11). Here, you use the point generator to create a parallel group of curves which are then measured one after the other. An example is two curves on the same workpiece, whereby curve 2 is shifted exactly 100 mm from curve 1 in Y. If it turns out on measuring curve 1 that the actual deviations always lie in a certain range (e.g. approx. 0.5 mm), it can be assumed that the results also deviate by this value (0.5 mm) for curve 2. In order to avoid a collision, you can shift the nominal points of curve 2 by 0.5 mm. Another example of the application would be to use a single parameter file for all different sizes of workpieces of a certain line of products (e.g. monitors). The required curves are created from a file with only one offset for the workpiece size. In this way, the entire line of products can be measured using one file. To adopt the deviations of the reference curve: 1 Open the definition template of the 2d curve to which the deviation of a reference curve is to be added.
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2 Click on the Nominal Definition selection list and select the Move Parallelcurve command. You can see the Reference Feature window in which all defined 2D curves are listed.
3 Highlight the name of the curve you want to use as a reference curve. If no values have yet been measured for this curve, a message is issued. 4 Click on the OK button. Calypso will convert the deviations of the reference curve to the current curve immediately.
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To correct nominal curve values by an offset: 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box is opened. 2 Under Offset, activate the Offset check box and click on Parameters. The Offset window for selecting the offset calculation will be displayed.
By clicking again on Execute, the offset calculation (this time with the newly calculated values!) and the addition will be repeated. 4 Close the Offset window with Cancel.
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Important If you do not close the window with Cancel but with OK, the calculated offset will be added to the measuring results of the curve. 5 Close the Evaluation window with OK. The selected offset is now added to all nominal curve values.
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Important If a nominal vector has the wrong direction, this will invariably result in a collision because the approach direction of the CMM will be wrong. To check the nominal vectors, you can: Check out the vectors in the CAD window this is the quickest way, and the most reliable. You can display each curve point with its nominal vector (refer to Show/Hide Nominal Vectors on page 16-39). You can check the nominal vectors using the direction components in the definition template. If you just need to change the directions of all nominal vectors at once, you can also use the Change Direction button.
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2 Select Nominal Definition Edit Vectors. You define the direction in the Curve nominal vector input window.
3 Select the option to edit the nominal vector Perpendicular to or Parallel to a reference feature. 4 Select the feature to be used as reference for the change from the list. The nominal vector of this feature will be shown as Reference Vector. 5 If you want to define a reference vector, go to Reference Vector and enter the NX, NY and NZ directional components. 6 If you want to rotate the vectors about the tangent of the curve: Mark the Rotation around tangent radio button. Enter the angle of rotation in the Angle field. 7 Click on OK to confirm. The new direction for the nominal vectors will be taken over from these values.
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The Direction vector for approach direction window shows the components of the current approach vector in the base alignment. 3 Define the desired approach vector: Enter the vector components directly. - or Click on Default to accept the default setting (with 2D curves the normal vector of the intersection plane and with 3D curves the normal vector of the first curve point). - or Highlight a feature in the list. The appropriate normal vector will be entered as approach vector. The direction vector will be changed automatically whenever a change is made so that you can check the effect of your entry. 4 Click on OK to confirm. The new approach direction will be accepted according to your entries.
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These entries in the definition template do not automatically define any characteristics, which are added to the list of characteristics.
lower tolerance
To enter tolerances for the whole curve: 1 Open the definition template of the curve.
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2 Click on the button for tolerances. The definition template of the curve is extended.
3 Activate the Curve check box. This hides the chart for the tolerances of individual segments. 4 Enter a value for the Upper Tolerance and/or Lower Tolerance. 5 Click on OK to close the definition template. The tolerance you entered will be checked the next time the curve is measured. The curve jump tolerance is output in the default printout.
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lower tolerance
To set tolerances for individual segments: 1 Open the definition template of the curve. 2 Click on the button for tolerances. The dialog box shown below is opened. In the right half of the window, you see a chart for the tolerances of the segments.
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3 Select the segment for which you want to enter the tolerances by clicking on the column to the left of the segment name. 4 Now click on the input field of the tolerance you want to enter and enter a value for the Upper Tolerance and/or Lower Tolerance. 5 If you want to determine tolerances for further segments, repeat the last two steps. 6 Click on OK to close the definition template. The tolerances you entered will be checked the next time the curve is measured.
Jump tolerance
In the illustration, the differences between the nominal-actual deviations from one point to the next are shown as shaded columns. As you can see, the curve jump may be greater than the actual deviation.
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To enter the jump tolerance for the whole curve: 1 Open the definition template of the curve. 2 Click on the button for tolerances. The definition template of the curve is extended.
3 Activate the Curve jump tolerance check box. The entry box then appears. 4 Enter the value for the Curve jump tolerance. 5 Click on OK to close the definition template. The tolerance you entered will be checked the next time the curve is measured.
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nominal curve
Fn
Fn
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Projection of 2D curves
For projection of 2D cures, enter a plane onto which the measured curve points are to be projected. This results in a two-dimensional curve. You can set projection onto one of the following planes: Linear projection (measuring only): Choice of several planes, the points are projected plumb onto the nominal plane. Circular projection (measuring only): Choice of several planes; the points are projected onto the nominal plane along the rotation face to be selected. Measured Planes (digitizing only): Any measured planes, e.g. to take sheet thickness values into account. X/Y-Plane, Y/Z-Plane, Z/X-Plane (digitizing only)
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Computed Plane (digitizing only): Plane derived from the measured values of the curve.
Projection of 3D curves
No projection can be set for 3D curves with the exception of lift cures and threaded curves.
Lift curves
You can set the following for lift curves under Projection: No Projection: the deviations are evaluated in the nominal vector direction. Lift curve: the deviations are projected onto the cylinder section.
Threaded curves
In the case of threaded curves (Thread check box in the Evaluation dialog box), you can carry out the evaluation of the deviations in different planes. To do this, you must first set the deviation calculation in Nominal Vector Direction and then the projection for the evaluation of the measured points: No Projection: the deviations are evaluated in the nominal vector direction. Vertical Projection: the measured values are projected onto the plane perpendicular to the thread and evaluated. Helix Projection: the measured values are projected in a helican line onto the nominal plane of the profile intersection and evaluated. The helix is predefined by the thread parameters.
Thread Intersection plane perpendicular to the thread The evaluation range is a section of the threading perpendicular to the intersection plane
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These additional commands are available only when you have the curve definition template open.
Show/Hide Deviations
Choose this command to view the calculated deviations between nominal and actual points. This command is not available until after the curve has been measured.
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Choose Hide if the deviations are visible but you want to hide them.
2D View
Choose this command if you want to view the curve's plane (2D curves only).
Magnification
Choose this option when you want to see the curve heightened. When you highlight the Curve Magnification command and keep the mouse button pressed, you can select the factor of magnification.
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Each nominal point of the curve is listed with its point number and its X,Y and Z coordinates. You can use the Normal Vector, Actual Point and Deviation buttons to decide which additional information will be listed. Normal Vector: Each nominal point is listed with the direction components of its normal vector. Actual Points: Each nominal point is compared with the calculated actual point. If no actual points have been measured, the actual points are represented by zero.
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Deviation: Each nominal point is listed together with the deviation of the actual points in the direction of the normal vector and its direction components. New segment: See How to divide a curve into segments on page 16-49. The other elements of the point list correspond to the description in Point list on page 5-87.
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How to open the point list: 1 Open the curve feature definition template. 2 Click on the Strategy button. The Strategy window will open.
3 Click on the Point List button. The list will show all points defined in the curve feature.
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4 Click on the button with the printer icon to print the point list. The list is sent to your printer. 5 Click on the button with the diskette icon to save the point list. A dialog box opens and you can define the parameters and format for saving the list.
Activate the check boxes to define the data to be saved in the point list.
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Activate the VDA File check box if you want to save the point list as a VDA file. The list is saved as an ASCII file if this check box is not activated. Click on OK to save. 6 Click on OK. The point list closes.
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You can measure a segment automatically with a CMM that has CNC capability. You can divide any curve into any number of segments and assign tolerances to each segment. A segment contains any number of points on an existing curve: These points can be selected as sequential points, adjacent points, or freely selected points from the list of points. A segment always has a defined start point and a defined end point. A given point can be used in the definition of different segments.
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The following problems can arise at the beginning and at the end of the measuring path in the case of curve measurement and curve evaluation: The controller must adjust accordingly. The calculation of the spline functions and the corresponding vectors is difficult at the open ends of a curve. To reduce the effects of these problems, you can define a pre/post travel for scanning.
The curve can be scanned with the rotary table. The Scan segment with rotary table check box must be activated for this purpose. The preconditions for this are that a known contour is scanned, the rotary table is activated for the measurement plan and the spatial axis of the feature on which the curve is located is in the direction of the rotary table axis. In order to use the movements of the CMM for unknown contours also for scanning a known curve, you can switch the technology.
Unknown contour
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As the contour is now unknown to Calypso, the definition of the travel path as well as an end criterion are required. To this end, you can use the Accept points icon to adopt the start and end points of the segment into the travel path definition and, if required, overwrite them. The end criterion used is usually the plane whose normal is formed by the line between the start and end points and which runs through the end point. If the start and end points are identical, no line and thus no plane can be formed. A certain course of a curve can also lead in some cases to a rapid end of the measurement. With the end criterion Ball = Sphere with radius around the end point, you can avoid cases of this kind.
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To define a segment from consecutive points: 1 Click on the button of the curve-segment scanning method. A new (as yet undefined) segment is added to the technology list. 2 Mark the new segment, right-click and select Edit from the context menu. The Segment window will open.
3 Enter the segment name, start point and end point, and click OK to confirm. The segment appears in the technology list.
Freely selectable points
To define a segment from freely selectable points: 1 Click on the Point List button. You will see the point list in which you define segments. 2 To select adjacent points for a segment: Click on the point with which the segment should start.
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Press and hold the shift key and click on the end point. All points between the first and the last point you have clicked on are marked with an arrow.
3 To freely select distributed points for a segment: Click on the point in the first column with which the segment should start. Press and hold the Ctrl key and click on all other points that the segment should include. All points you have clicked on are marked with an arrow.
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4 Click on the Create Segment button. This opens the Segment Definition window.
5 Change the name of the segment if the suggested name is not suitable. 6 If you want to define a tolerance for the segment, enter the values in the Upper Tolerance and/or Lower Tolerance fields. 7 Click on OK to close the definition of the segment. The segment is automatically added to the strategy list.
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Description The Curve Slope characteristic is used to check the height difference between two certain points of a curve. The Curve Stroke characteristic is used to check the axial and radial deviations of a lift curve. The Curve Distance characteristic is used to check the distance between two curves.
Curve Stroke
Size More
Curve Distance
Size More
Curve Expansion
Size More
The Curve Expansion characteristic is used to check the expansion of a curve in a predefined direction. The Curve Form characteristic is used to check the form of the complete curve or of individual segements.
Curve Form
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The following table describes the buttons and fields that are not common to other characteristics: Dialog element Feature Primary Datum Evaluation Range Function Select the curve to be checked. Select here the datum that defines the rotation axis (and the centre) of the lift curve. This is usually a circle. Defines the two points between which the slope is determined in one of the three ways: by specifying two point numbers or by specifying two point numbers or by specifying the start and end height If the angle or height specification does not exactly correspond to a point, the next closest point will be used. By clicking on Entire Curve, the evaluation from the first to the last curve point is performed.
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The following table describes the buttons and fields that are not common to other characteristics: Dialog element Axial or radial stroke evaluation Function Select here the direction in which the deviations are to be determined and enter the Tapped Radius: Radial: perpendicular to the rotation axis Axial: parallel to the rotation axis Select the curve to be checked: with radial stroke evaluation, the 2D curve to be checked (lift curve) with axial stroke evaluation, the 3D curve to be checked (lift curve)
Feature
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Function Select the datum here: for the radial stroke evaluation, the base diameter with the nominal radius, for the axial stroke evaluation, the plane perpendicular to the rotation axis to which the nominal lift data refer (if no specification is made, the corresponding coordinate plane of the base alignment is used). Shows the extreme deviations and their difference: Max : The maximum deviation in the positive direction of the nominal vector (too much material). Range : Shows the difference range between upper and lower deviations. Min : The maximum deviation in the negative direction of the nominal vector (too little material). For radial evaluation of 2D curves, the Radial Deviation deviation calculation must be entered in the Curve feature. For axial evaluation of 3D curves, the Nominal Vector Direction deviation calculation must be entered in the Curve feature.
Deviation
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The following table describes the buttons and fields that are not common to other characteristics: Dialog element Characteristics Curve Distance Function Select the two curves to be checked. Select the distance to be checked between the two curves: Maximum Value (the maximum distance between two points of both curves) Minimum Value (the minimum distance between two points of both curves) Average (the arithmetic average resulting from maximum value and minimum value)
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The following table describes the buttons and fields that are not common to other characteristics: Dialog element Feature Expansion Function Select the curve to be checked. Choose the axis direction in which the maximum expansion is to be calculated. The nominal and actual values of the expansion referenced to the current coordinate system are shown on the righthand side. The nominal and actual values of the expansion referenced to the current coordinate system.
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The following table describes the buttons and fields that are not common to other characteristics: Dialog element Curve jump tolerance Function The curve jump tolerance is checked when this check box is activated. The curve jump tolerance indicates the amount by which the curve form may deviate within a reference distance. It is generally independent of the curve form tolerance. In Calypso, the curve jump tolerance is always measured between two neighboring points. The curve is out of tolerance if the difference between the deviations of the two actual points from the respective nominal point is greater than the specified value. Shows the maximum deviation in the positive direction of the nominal vector (too much material). Shows the maximum deviation in the negative direction of the nominal vector (too little material). Shows the difference range between upper and lower deviations.
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The chart contains all defined segments. 2 Select the desired segment by clicking into the left column of the relevant line. An arrow appears in this column. 3 In the same line, enter the tolerances in the Upper Tol. and/or Lower Tol. fields. 4 Click on OK. The settings are saved and the definition template is closed.
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To obtain this deviation: 1 Open the definition template of the curve. 2 Activate the Deviation check box. The actual values on the right side of the definition template now refer to the nominal data of the curve.
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2 Click on the Evaluation button. 3 Under Best Fit, activate the Best Fit check box and click on Alignment. Calypso will create an alignment. You can see the Best Fit window in which Calypso shows the translation and rotation of the feature alignment with reference to the part alignment.
4 If you want to change the shown values, click in the relevant field and enter the values of your choice. 5 Click on Apply to accept the local feature coordinate system. The Enter Name dialog box appears on the screen. 6 Enter a name for the local feature coordinate system. 7 Click on OK to close the dialog box.
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2 Click on the box in front of Center of mass to place a checkmark. The coordinates of the center of mass are displayed in the left half of the template. The center of mass is also displayed in the CAD window.
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calculated curve section (a section connects two neighboring points). This can take a long time if the curve has a lot of sections. Usually, a comparison with some sections near the point is quite sufficient. You can enter the size of the area that is to be considered. To define the alignment: 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box is opened. 2 Activate the Best fit check box and click on Settings. The Best Fit dialog box appears on the screen.
3 Under Translation and Rotation, deactivate the check boxes where you do not want to permit the respective movement during the alignment. All the check boxes are activated by default. 4 To fill the point list under Mask points with data: click on the Use nominal data or Use actual data (under the list of points).
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5 Under Mask points, click on the points which you wish to mask and so which will not be taken into account during the alignment. Another click will cancel the selection. You can also select a rule for the use of points in the context menu:
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If you have used the Shift or Ctrl key for multiple selections, you can refresh the display in the CAD window by clicking on Update Graphics. 6 Under Max. Search Distance, enter the area to be considered in the Search distance for the fit field in millimeters or click on Default if you wish to use the standard Calypso value. This default is derived from the doubled sum of tolerance and stylus tip radius. 7 Click on OK to apply the definition. The alignment of the coordinate system or of the curve feature into the nominal feature is then only possible in the authorized directions, with the specified points and the entered search distance.
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Depending on the form of the curve, there may be several intersection points between the splines and normals in the case of distance evaluation. This may affect the computing time. To prevent this, you can define the maximum permissible distance from the actual point to the curve. 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box will open.
2 In the for distance evaluation field under Max. Search Distance, enter the maximum distance which will presumably suffice in millimeters. 3 Click OK to save your entry and close the dialog box. The search distances are taken into account the next time the curve is calculated.
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Smoothing a curve
In order to display a curve in a CAD window, Calypso lays spline functions through the nominal points of the curve. As a result, all nominal points will lie on the curve that is calculated in this manner. In the case of some initial values (e.g. when measured actual values are used as nominal values), the presentation of the curve may well be relatively rough. This can, if necessary, be smoothed. While doing so, the spline functions are only set in the close proximity of the points and do not actually pass through each individual point. The degree of approximation or smoothing can be defined with a number between 0 and 1: If 0 is selected, the splines nestle up to all points so that no distinction can be made to the usual method. 1, on the other hand, will produce the maximum smoothing of the curve. 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box will open. 2 Under Filter/Outlier, activate the Approximation check box and click on Settings. The Approximation window for entering the approximation parameters will be displayed.
3 Select whether you wish to smooth the presentation of the measured curve or the nominal curve. 4 Enter a Smooth factor between 0 and 1 by dragging the slider with the mouse. To check the result, click on the Simulation button the result will immediately be displayed in the CAD window.
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5 If necessary, select a method for redefining the curve points under Grid. If you select Keep number of points, the number of points of the initial curve will also apply to the newly calculated curve. 6 Click OK to save your entry and close the dialog box. The curve will be recalculated in accordance with your entries. The new nominal curve will be determined on the basis of the calculated values and displayed in the CAD window.
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Important As soon as you confirm with OK, you will regenerate the nominal points of the curve. The original curve cannot be recreated again. For this reason, it is important that you use the Simulation function to check the result beforehand.
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Bend in curve
3 Curve
The angle of this bend is slightly less than 50. If you set the limit to 50, point 2 will automatically be interchanged with point 3 although this is not desired here. The curve would then look as follows:
1 2
In this case, you will have to enter a limit that is less than the angle of the bend, i.e. approx. 45. 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box will open. 2 Activate the Sort measured points check box and click on Settings. You see the Sort measured points window for input of the angle limit.
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3 Enter the maximum angle that should be accepted or click on the Default button to enter the Calypso default value. If larger angles occur in the curve, the appropriate points will be sorted. 4 To check the result, click on the Simulation button the result will immediately be displayed in the CAD window. 5 Click OK to save your entry and close the dialog box. The curve will be sorted in accordance with your entries. The new nominal curve will be determined on the basis of the new sequence and displayed in the CAD window. 6 Close the Evaluation dialog box with OK.
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The number of considered points can be limited in the following manner: 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box will open.
2 Activate the check box under Limit evaluation and enter the number of points which should not be considered at the start and at the end of the curve in the case of the nominal points and the actual points. 3 Click OK to save your entry and close the dialog box. During the evaluation, a correspondingly fewer number of points will be considered at the start and at the end of the curve.
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There are several different points at which you can set and activate outlier elimination for curves: As defaults for the characteristic groups and the references and alignment features of the coordinate systems For an individual characteristic For an individual curve feature. This is how to activate outlier elimination in a curve feature: 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box will open. 2 Under Filter/Outlier, activate the Outlier Elimination check box and click on Settings. The Outlier Mode window for entering the parameters will be displayed.
3 Enter the Factor for Outlier as well as the Range Of Data Reduction and confirm with OK. 4 Click OK to save your entry and close the Outlier Mode dialog box. 5 Close the Evaluation window with OK. During the calculation, the outlier measured values that fall under the specified criteria are not taken into account.
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3 Select the mode of offset calculation and click on OK. 4 Close the Evaluation window with OK. The selected offset is now added to all measured curve values.
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If nothing else is defined for the measurement, use measurement in nominal vector direction and without projection. These results supply the best indication as to whether the spheres get stuck or not. To define the evaluation mode for thread measurements: 1 Open the definition template of the curve and click on the Evaluation button. The Evaluation dialog box is opened. 2 Under 3d curve, activate the Thread check box. 3 Select the feature that defines the thread axis and enter the Pattern of the thread (lead). 4 Confirm with OK and select in the definition template for the curve the Nominal Vector Direction deviation calculation and the desired projection: No Projection: the deviations are evaluated in the nominal vector direction. Vertical Projection: the measured values are projected onto the plane perpendicular to the thread and evaluated. Helix Projection: the measured values are projected onto a helicoids that is predefined by the thread parameters and evaluated. 5 Click on OK to confirm.
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2 Adjust the curve in the CAD window until it is displayed exactly as you want it in the printout. Use the CAD buttons (see Buttons in the CAD window on page 3-5) and/or the commands in the CAD context menu (see The commands in the context menu for curves on page 16-39) to display the curve exactly as you want it in the printout. When you are ready, click OK in the curve definition template.
The form plots available for the curve form characteristic are as follows: Curve form linear Curve form 2D Multi-Curve form linear Multi-Curve form 2D
Curve Slope
The form plots available for the curve slope characteristic are as follows: Slope Type 1 (portrait and landscape) Slope Type 2 (portrait and landscape) Slope Type 3 (portrait and landscape) Five parameters are displayed in addition in the form plots for the curve slope: Slope error Form error Total error Minimum Deviation fmin Maximum Deviation fmax
You call up form plots and display them as described in the section entitled How to display variations in form and location graphically on page 9-33.
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It is derived from the 2D curve form. In addition, the regression line is shown.
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It is derived from the 2D curve form. In addition, the regression line is shown. The distorted coordinate system is shown; the angle is selected so that the slope line is shown horizontally.
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It is derived from the linear curve form. In addition, the regression line is shown.
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Chapter
17
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17-1
Qualification is a three- or four-step procedure: Qualification of the RDS by Zeiss (factory qualification) Factory qualification involves generating correction files for each individual RDS: these files are a prerequisite for subsequent, computed qualification. The correction files are installed on your system together with the RDS-CAA option. Qualification of the RDS on the CMM After the RDS is mounted on the CMM, this qualification determines and saves the position of the RDS within the machine's coordinate system. Stylus qualification in twelve positions per main stylus (this is the stylus in the direction of the ram). Finally, the required stylus system and its stylus are inserted into the RDS and qualified in a few positions. Calypso/CMM-OS then calculates the correction values for all of the remaining positions. If the stylus system has only one stylus, this completes qualification of the RDS.
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Qualification of remaining styli on the stylus system (star styli) If a stylus system carries multiple styli (star styli), each of the remaining styli is then qualified in four positions. Calypso/CMM-OS calculates the correction values for all the positions of the remaining styli, and this completes qualification of the RDS.
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A further prerequisite is that the reference sphere is defined. Make sure that Calypso/CMM-OS knows the position of the reference sphere and that the shaft of the sphere points in the direction of 45/45 angular position of the RDS. For a bridge CMM, this is the position with a 135 angle of inclination and a 315 angle of rotation. For a horizontal-arm CMM, it is the position with a 135 angle of inclination and a 45 angle of rotation for column 1 and the position with a 135 angle of inclination and a 315 angle of rotation for column 2. If one of the conditions is not met (if the reference sphere's shaft points in a different direction or its position is not known), you must requalify the reference sphere (see Qualifying the reference sphere on page 4-40).
Fitting qualification (RDS on CMM) must be performed with the master stylus. This must be an RST, without extension, with a 40-mmlong stylus. (If your master stylus does not meet this requirement, you must first make a master stylus of an RST, without extension, with a 40-mm-long stylus.) Select Extras Workroom CMM, go to the Master Stylus tab and make sure that all the requisite parameters have been set. The procedure for installing the CMM's master stylus in the RDS is described in How to install a stylus system on page 4-18.
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4 Click on the RDS fitting position button. The label on this button changes, depending on the situation: the default label is Qualify Stylus. 5 After you are prompted, move the stylus towards the reference sphere and probe the sphere in the stylus direction. (If your stylus is vertical, therefore, position it over the north pole of the sphere and probe once vertically downwards.) In accordance with the selected mode, Calypso/CMM-OS automatically proceeds with qualification, performing probing operations in 12 positions to determine the fitted position of the RDS to a high degree of precision, which it then saves. The results are shown in the R, S, X, Y and Z fields. 6 Click on OK to return to the user desk. The position of the RDS has now been successfully determined, and you can begin with qualification of the individual styli.
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3 Enter the names for the new stylus system and the first stylus. Calypso does not distinguish between uppercase and lowercase characters. 4 Tick the RDSCAA check box. 5 Click on OK to close the window. The names of the stylus system and the first stylus are displayed in the Stylus System and Stylus Name / No. selection lists. If the stylus system has other styli, you now have to add them in Calypso (see How to add styli to a stylus system on page 17-8).
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To add further styli: 1 In Calypso, click on the Stylus System button in the lists of prerequisites. - or In CMM-OS, select Stylus Stylus Qualification. The Stylus system qualification window appears on the screen. You will find detailed information on this dialog box in Stylus system qualification window in the Calypso Online Help. 2 Click on the Insert new stylus button. The Create New Stylus dialog box appears on the screen.
Under Stylus No., the next higher number will be displayed automatically. 3 Enter a name for the new stylus in the Stylus field. Calypso does not distinguish between uppercase and lowercase characters. 4 In the Stylus No. field select the number of the stylus. 5 Click on OK to close the window. The name of the stylus will now appear in the Stylus Name / No. selection list. 6 If you wish to add another stylus, repeat steps 2 through 5. The next step is to qualify each stylus in turn (see Qualifying stylus systems and styli with RDS-CAA on page 17-10), and bear in mind that you must proceed in a certain sequence: beginning with the first stylus (the main stylus), and then continuing with the others (star styli).
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The direction of this stylus must match the direction of the ram. Each additional stylus for this stylus system is qualified in four physical angular positions.
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2 If it is not already displayed, select the name of the stylus system from the Stylus System selection list. 3 Select the name of the stylus to be qualified first from the Stylus Name / No. selection list. In the Mode selection list, select the Standard mode. 4 If the styli you use are very short, reduce the value for Taper Angle accordingly. The smaller the taper, the smaller is the section of the surface of the reference sphere which is probed for qualification. 5 Click on the Qualify Stylus button. Stylus qualification now begins using the 12 angular positions set by RDS-CAA. To start the process, you must perform the first probing manually. 6 When prompted, move the stylus in the RDS 0/0 position over the north pole of the reference sphere and then probe the sphere with the stylus perpendicular to the contact point on the sphere. Calypso checks the position of the reference sphere and the length of the stylus (roughly). Afterwards the 12 positions are automatically selected and qualified. The value entered in Taper Angle is taken into account as a maximum value in the selection of the positions and probing operations. The results are shown in the R, S, X, Y und Z fields (see About the results of stylus qualification on page 4-39). Under the heading Stylus, you will now see the symbol for a successful stylus qualification and below that the identifier RDSCAA.
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2 Click on the Qualify Stylus button. This is not the main stylus, so the CAA star qualification dialog box is displayed with the list of positions.
If data has been saved for the stylus system to be qualified, the list is already filled out. 3 Under Position (1 to 4) in the list of positions, select one of two RDS positions in each case by clicking on Alternative. 4 If you want to estimate which position is suitable: Click on the show button. The RDS then rotates to the corresponding position. 5 Select the desired probing mode under Mode: normal semiautomatic qualification: the first probing is manual; all others are automatic, manual manual qualification. 6 If necessary, enter additional qualification positions with Add. Four positions are generally enough; additional positions are necessary only if the qualification accuracy is insufficient. 7 Under recal, activate at least two positions in the list that are to be approached during requalification in the CNC run. 8 Click on OK to start qualification. Calypso/CMM-OS steps you through the rest of the procedure. 9 If necessary, repeat steps 1 through 8 for additional styli. 10 Click on OK to confirm your entries and close the Stylus System Qualification dialog.
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If you do not confirm by clicking on the OK button, all unsaved data from the stylus qualification is lost. It is advisable to close the Stylus System Qualification dialog box from time to time during the process by clicking on OK, so as to save intermediate states.
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Calypso/CMM-OS returns to the user desk. The styli have been successfully qualified. In Calypso, the Stylus System button is now green.
Qualification log
Calypso/CMM-OS generates a log, which you can either print out or save as an ASCII file. The stylus system qualified with the RDS and its styli can now be used by all users and in all RDS positions.
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Chapter
18
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The measurement inaccuracy calculation using the virtual CMM has the following benefits: It is in line with standards and objective. It is automatic and requires no special knowledge on the part of the user. It is not excessively time-consuming. It matches the complexity of CMMs with their wide variety of influencing factors. It takes account of flexible measuring jobs.
The OVCMM determines the measuring uncertainties in compliance with GUM, ISO 14253 and ISO 15530. To this end, the CNC run is simulated for all characteristics of a measurement plan. The result of this simulation corresponds to the dispersion range of a measurement of 128 workpieces with a random variation of the known influencing factors. In this way, a range that is representative for the measuring results is calculated. Finally, the resulting variance is used to ascertain the uncertainty for each characteristic and to output it in the measurement report.
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A measuring result can only be an estimated value of the value to be measured. This means it is complete only if it is accompanied by a specified measuring uncertainty. This is summarized in the following formula: Y=yU Here, Y is the value to be measured, i.e. the real value; y is the measured and possibly corrected estimated value (the measurement result); U is the measuring uncertainty. No exact value is specified for Y in the equation, only a range in which Y lies.
Coordinate measuring machines are extremely complex, universal measuring machines for practically any workpieces. This is why coordinate measuring machines have a great many sources of inaccuracy, whose mutual overlaps are difficult to describe and analyze. It is not possible to describe the measurement process for a nontrivial measuring task with a complete mathematical model. The uncertainty of a coordinate measurement also depends on the relevant measuring job: How many and which measurements are included in the result? How are the individual measurements linked?
Influencing variables
The following influencing variables are taken into account by the OVCMM: Systematic residual deviations of the geometry of the CMM Fluctuations of the geometry deviations due to temporal and spatial temperature gradients Direction-dependent systematic residual deviations of the probing system Random deviations of the probing system Uncertainty caused by linear workpiece expansion Uncertainty in qualification of the stylus tip diameter Uncertainty in qualification of the stylus tips of a stylus system Roughness of the workpiece surface Uncertainty of the normals used for connection to the international SI units The following influencing variables are not automatically taken into account: Measurement deviations due to operator influence
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Deformation of the workpiece due to clamping Deformation of the workpiece due to probing forces Temperature gradients in the workpiece Shape influence of the workpiece (position and distribution of the measured points) These influencing variables must be set manually and individually taken into account if it can be assumed that each influence makes a significant contribution to the measuring uncertainty in each job.
The most important systematic errors of a CMM must be determined in advance. The specific errors for each CMM type (geometry, effect of ambient influences on the geometry, dynamic effects) have been determined by Zeiss and recorded in a device file.
An accredited laboratory (e.g. Zeiss Service) measures your CMM with great precision and creates the database of the OVCMM. To this end, geometry deviations in the entire measuring range are recorded using perforated-plate measurements in different positions. Depending on the specific environment of your CMM and your requirements for use, the laboratory generates for your CMM and its specific purpose one or more ambient conditions as a basis for the OVCMM.
To ensure the device accuracy, measure qualified workpieces or gages at regular intervals (weekly). In order to be able to take the uncertainty from measurement errors of the styli used into account, the OVCMM requires the stylus characteristics. You can determine these stylus characteristics by probing the reference sphere. When you set up a new measurement plan and each time the influencing variables change, start the simulation using the OVCMM.
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The ambient conditions of your CMM must have been determined and applied by Zeiss Service or another accredited laboratory.
Standard definition
In most cases, determining the stylus characteristics with the standard definition is fully adequate. To determine the stylus characteristics with the standard definition: 1 Select Extras Workroom Measurement and click on the VCMM tab in the Measurement Methods notebook. A notebook page opens with the Settings for measuring uncertainty data VCMM.
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2 Click on the Default setting button in the Definition of stylus influence group. The Stylus Influence window will open.
3 Enter the name of the stylus characteristics and confirm with OK. The CMM now starts qualifying the stylus. 4 Save and close with OK.
Advanced definition
For some stylus systems, the default settings are not sufficient to determine the errors to an adequately precise extent. This is where you use the advanced definition. To determine the stylus characteristics with the advanced definition: 1 Select Extras Workroom Measurement and click on the VCMM tab in the Measurement Methods notebook. A notebook page opens with the Settings for measuring uncertainty data VCMM.
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2 Click on the Advanced setting button in the Definition of stylus influence group. The Stylus Influence: Extended Qualification Mode window will open.
3 Enter the name of the stylus characteristic. 4 Change the default settings for the number of probing points in the corresponding input field. 5 Click on OK to confirm. The CMM now starts qualifying the stylus. 6 Save and close with OK.
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For this, you will find two additional fields in the stylus administration: Stylus Characteristic and Base Characteristic. These two additional fields are only visible if the OVCMM is activated.
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The environmental conditions must have been configured by Zeiss Service or an accredited laboratory.
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To activate the OVCMM and set the environmental conditions: 1 Select Extras Workroom Measurement and click on the VCMM tab in the Measurement Methods notebook. A notebook page opens with the Settings for measuring uncertainty data VCMM.
2 Activate the Measuring uncertainty data active check box. 3 If the work of the OVCMM is to be entered in a log file, activate the Inspection outputs check box. This can make sense for tests and checks performed by Zeiss Service. 4 In the Environmental conditions group, activate the Conditions active check box. 5 In the Conditions selection list, select the relevant specific environmental condition. 6 Save and close with OK. The OVCMM is now active. It is automatically started after the next CNC run and takes the selected conditions into account for the uncertainty calculation.
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Do not forget to deactivate the OVCMM after the CNC run and output of the log, as it will otherwise become active again after every CNC run and will repeat its calculations.
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Important At the moment, the base alignment must not be created using a CMM and the OVCMM option. Recommended procedure: 1.) Measure the data without activating the OVCMM option at first. 2.) Then perform the simulation in another CNC run without resetting the results.
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Chapter
19
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You can use the Characteristic Input option to generate a largely complete Calypso measurement plan from suitable CAD data automatically. For this purpose, the geometry information, tolerances and references are taken from the CAD model data. You can send the executable measurement plan to the CMM computer or export it into the DMIS format using the DMIS Out option. The Stylus Simulation and the Stylus System Library as well as the DMIS Export are options. This is why they are described in separate chapters.
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Prerequisites
If identical characteristic numbers are used for the same characteristics when constructing variables, this also forms the basis for uniform measuring planning and measurement program creation throughout the different branches of a company.
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PE-Inspect
1
DMIS Measurement Program STEP AP 203 QDAS Data EXCEL Table (ASCII)
Calypso
offline
6
QDAS Data Results
Statistics System
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All shafts and bores contained in the CAD data are transferred as cylinders to the measurement plan without any special preparations. This type of measurement for the test target is often too complex, however, and is therefore not practical. You can therefore define prior to the generation which cylinders are to be transferred as circles from the CAD data to the measurement plan. After generation you can edit this list and start the conversion of the cylinders to circles.
Prior to generation, you can define the default measurement strategy for the line, plane, circle, cylinder and cone feature types. Thus you determine at the same time the technology settings of Calypso which are effective throughout the measurement plan. To generate a measurement plan from CAD data, proceed as follows: To prepare the generation of the measurement plan, you must carry out the following: Enter the rules for the conversion of cylinders Determine the default measurement strategies Specify the characteristic list and CAD-STEP file Start generation Transform cylinders to circles Complete the characteristics Define the coordinate system Set the clearance planes Insert styli into the features Test and save the measurement plan Add information to the measurement plan
Procedure
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To ensure that all data and settings are available for generation of the measurement plan, you have to set Calypso to the Simulation operating mode. To set Calypso to Simulation: 1 Select Extras Workroom CMM. The CMM Configuration notebook opens to the Control page. 2 Click on the Simulation tab and on Connect. Calypso and the measurement plan generator are thus set for the Simulation operating mode.
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Make sure that no other connection to a CMM is active. Otherwise, you must clear the connection down by closing the Stoplight window. For later simulation of the CNC run, you require the stylus data of the stylus system to be used to measure the workpiece. You have two possibilities to obtain the stylus data: You export the stylus data from Calypso on the CMM to Calypso offline (Simulation operating mode). To do so, select Stylus System Management, open the Catalog, mark the relevant stylus system and select the Export menu item in the Edit menu. The stylus data is saved in the intermediate storage on your hard disk (e.g. in C:\Temp). Then clear down the connection to the CMM. Now, create the connection to CMM Simulation (as described above), open Stylus System Management and import the data from the intermediate storage. Use the Stylus System Library to create the stylus data. For more details, please refer to Stylus simulation and stylus system library (option) on page 20-1. You can use the Stylus System Management to select the stylus system to be used for measurement in Calypso. The current stylus system is available in the Stylus System Management catalog; it must be selected with a double-click.
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2 Assign a name to the new measurement plan. 3 Under Feature list, enter the path of the QDAS file or click on Find and select the required file in the default Windows dialog. 4 Under STEP File, enter the path of the STEP-AP-203 or STEP-AP214 file or click on Find and select the required file in the default Windows dialog. 5 Activate the Rules tab and enter the criteria according to which cylinders are to be transferred from the CAD data to the conversion list for conversion to circles. By activating one or more of the offered characteristics, all those cylinders are entered in the list for which no additional
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characteristics are defined in the measurement plan than those characteristics activated. Additionally, you can specify a geometric rule according to which the cylinders to be entered in the list are further specified. 6 Activate the Technology defaults tab. 7 Activate the check boxes for all feature types for which you want to define a default strategy and click on each Settings button. 8 In the Strategy window, specify the default measurement strategy according to which the features of the corresponding type are to be measured.
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Thus you determine at the same time the technology settings of Calypso which are effective throughout the measurement plan. For all feature types which are not activated, the available technology defaults of Calypso will be used. If a certain feature is to be measured using a strategy that deviates from the default measurement strategy, you must enter this for the feature concerned after the automatic generation. 9 If all entries are correct, click on Generate Measurement Plan. The measurement plan generator loads the files and creates the characteristics and features. After generation, you will see on the Generate tab under Program Status how many features and characteristics have been created and how many of which are completely defined.
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Converting cylinders
During generation, the Selected cylinders will be converted to circles dialog box appears.
The list shows all cylinders of the CAD data. The designations of the cylinders (identifiers) have been taken over from the STEP data record of the CAD system. If you specified rules for the conversion of cylinders to circles, those cylinders to which the rules apply are selected. The CAD window displays the cylinders selected purple-colored. By pressing and holding down the Ctrl key you can mark additional cylinders or exclude certain cylinders from the conversion. The changes made are shown in the CAD window. Click on OK to confirm your choice. All selected and dark-shaded cylinders in the measurement plan are converted to circles.
Result
After generation, you will see on the Generate tab under Program Status how many features and characteristics have been created and how many of which are completely defined. After the files have been loaded, a list is generated that contains the characteristics that require additional data. This list is set up to be interactive, and permits the direct input of missing data.
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In the rest of the procedure, you now use this root measurement plan to specify the coordinate systems and the clearance planes as well as to run the automatic stylus allocation.
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2 Open the incompletely defined characteristics one after the other. The reference entered as the feature in each case is highlighted in color in the CAD window. 3 Enter the necessary references, nominal dimensions and tolerances. To complete the measurement plan, the coordinate system, clearance planes and the stylus system must be defined.
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2 To set the stylus simulation for the measurement plan, select Planner Simulation Stylus System. More detailed information on stylus simulation can be found under Stylus simulation on page 20-2. 3 Select Plan CNC-Start CNC-Start. The measurement plan will now be processed. If appropriate, you receive reports on errors, deficiencies or collision risks. 4 Evaluate the reports and edit the measurement plan accordingly. 5 Then repeat steps 3 and 4. After you have corrected any errors that might have been in the measurement plan, you can save it and release it for further use. You can run the measurement plan, e.g. on a CMM with Calypso, or you can use the DMIS Export function to convert it into a DMIS measurement program that can run on all DMIS measuring machines.
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Chapter
20
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Stylus simulation
When you activate the stylus simulation, not only the workpiece but also the movement of the currently used stylus system are shown in the CAD window during the CNC run. You can conveniently trace the stylus system in the CNC run on the screen. You see exactly which stylus is used and which movements and rotations the stylus makes relative to the workpiece. If Calypso knows the corresponding dimensions, the probe, base plate, rotary table and the measuring range of the CMM can also be shown. In this way, you have a completely new possibility to check the run. Any weaknesses (risk of collision) in the measurement plan become visible and can be corrected.
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This option is particularly important for testing, for example, a measurement plan created using the Calypso Planner away from the machine.
To be able to display additional features, you must make the cooresponding entries under Extras Workroom CMM: Probe: Selection on the Probe page. Base plate and measuring range: Input of the dimensions on the Machine page. Rotary table: Input on the Rotary Table page.
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Stylus simulation
You activate the stylus simulation with Planner Stylus System Simulation. The Simulation dialog box appears on the screen.
The icons have the following meanings: Icon Function You can use the Stop, Start and Step recorder keys to stop the CNC run and thus the stylus simulation, to restart it or let it run in the single-step mode. You use the icons for Stylus and Stylus System to control the extent of the display: With Stylus, only the currently used stylus is displayed. You use the icons for the display to control the display of the probe, base plate and rotary table. You can also show the clearance planes on the screen. The green semi-transparent cuboid represents the measuring range of the CMM. With the slider, you can control the accuracy of the collision observation. By activating the Collision observation icon, the dialog box is enlarged. Calypso registers each collision and enters it in the list. If you probe a very large workpiece, you can use the Follow stylus icon to have the zoom window always follow the movements of the stylus. Simultaneously, the workpiece is automatically rotated in the CAD window in such way that you always see the stylus system in front of the workpiece. If the Show navigation icon is activated, the path of the stylus movement is marked as light traces in the CAD window.
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The base plate or the rotary table must be shown in the CAD window (Planner CMM Dimensions). To position a CAD model: 1 Rotate the CAD model in the CAD window so that you can click on the desired surface. 2 Select CAD Modification Modify CAD Entities. The Modify CAD Model dialog is opened. 3 Click on the Position button on the Edit body tab. To cancel positioning, click on the Position button. 4 Click in the CAD model on the surface to be positioned on the base plate. 5 Click the position on the base plate upon which the CAD model is to be placed. The CAD model is positioned on the base plate.
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With the Stylus System Library, you have two different possibilities to create styli: You can load existing standard styli, and change and save them if necessary. To this end, Zeiss supplies a library with the usual styli and stylus parts (see Catalog 60-25-035-5 Carl Zeiss). Individual features can be selected on the loaded stylus. The selected feature is highlighted in color, and you can change its dimensions as well as set the color and material attributes. You can create completely new styli and entire stylus systems from the cone, cylinder, sphere and cube basic features. With the design, a 3D model of the stylus tip, stylus or entire stylus system is created in the CAD window.
Storing styli
After you have set up or modified the stylus as desired, save it under the name of the original. This enables Calypso to access this data during the stylus simulation.
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This window provides you with the following possibilities: You can load an existing stylus system to edit it. You can assemble a completely new stylus system. You can save an edited stylus system. You can edit the attribute table for the stylus system elements. A loaded stylus system is displayed beside the Stylus System Elements window in the CAD window, as is a stylus system or stylus you are currently defining. In this way, you can follow what you are assembling directly on screen.
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The selected element is highlighted in color. In the list of stylus system elements, you can change its dimensions and use Attributes to set its color and material attributes. 4 To save the modified stylus system: In the Stylus System Elements window, select the File Save as menu item and enter a file name.
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To define a new color for the selection, enter its name. You define the color values via sliders or direct input of the color values for red, green and blue. With Save, the color is included in the list of additional colors. To define a new material type for the selection, enter its name as well as its density. The density is used to calculate the weights of the individual stylus system elements and thus of the entire stylus. With Save, the new material is included in the list of additional materials. Click OK to return to the Stylus System Elements window, where you can immediately assign the additionally defined attributes.
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Assembling a stylus
In the Stylus System Elements window, you can fully reassemble the styli you are using and save them under different names. To do so, take the following systematic steps: Assemble the stylus system body Assemble stylus and stylus parts from the stylus system elements Add the stylus parts and styli to the stylus system body Save the stylus system Enable the stylus system for the stylus simulation
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3 To change the dimensions set as standard: Click on the relevant table cell in the element list and overwrite the details of Diameter and/or Radius1, Length, Width and Height.
4 Click on the relevant element in the element list and then on the Attributes button. The Stylus attributes dialog box will open. 5 Select the Color and Material attributes. Available here are the default attributes as well as the attributes additionally defined in the table of attributes. 6 Save the stylus system body with the menu item in that window: File Save as; assign a meaningful name that can be found easily later.
Always start constructing a stylus at the clamping point of the stylus and never at the stylus tip.
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To assemble the first node of a stylus: 1 Select Planner Stylus System Library. The Stylus System Elements dialog box opens with a menu and different dialog elements. 2 Click in the necessary order on the buttons for the cone, cylinder, sphere and cube geometric basic bodies. Elements named cone_n, cylinder_n, sphere_n or cube_n are included in the element list, whereby n is the serial number of the element. Simultaneously, you see how the first node of the stylus is assembled from the selected basic bodies in the CAD window. 3 To change the dimensions set as standard: Click on the relevant table cell in the element list and overwrite the details of Diameter and/or Radius1, Length, Width and Height.
To add the stylus tip: 1 The last thing to add is a basic body in the shape of the stylus tip (sphere, cone base, cylinder) and set its dimensions. You can now set the attributes for the individual elements:
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2 Click on the relevant element in the element list and then on the Attributes button. The Stylus attributes dialog box will open. Select the Color and Material attributes. Available here are the default attributes as well as the attributes additionally defined in the table of attributes. Only in the case of stylus tip, enter the name of the stylus and the stylus number under Stylus name in the Stylus group. In the CAD window, a small flag with the stylus data points to the stylus tip. 3 Save the stylus with the menu item in that window: File Save as; assign a meaningful name that can be found easily later.
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In the Stylus System Elements window, select the corresponding stylus element of the stylus system body in the table.
In the Select connecting point window, select the point on the assembled stylus system to which the new stylus is to be applied and confirm with OK.
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If you are unable to see the connection point because the model is rendered, click on the Render icon to display the wire frame model again, or rotate the CAD model using the icons in the CAD window and the mouse. Select the required stylus from the file selection window. The stylus is applied to the selected point. 4 Repeat step 3 until all the styli have been applied.
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5 As soon as all the styli have been applied to the stylus system body: Select the File Save as menu item in the window and enter a meaningful name for the new stylus system.
Connecting nodes
To change the direction of the attachment and to create more complex forms, use the possibilities of Connect. Select a stylus element of a node in the table, click on Connect or on Load + Connect and define the desired connecting point in the Select connecting point window. The point is displayed in the CAD window as a small, conical tip. If you are unable to see the it because the model is rendered, click on the Render icon to display the wire frame model again. You have two options to continue: Connect forms a new node (the element list is emptied), and the next basic body you click on becomes the first element of the new node. Load + Connect forms a new node (the list is emptied), and the file selection window is opened. The stylus selected there (*.prb) is added at the connection point. The result is immediately displayed in the CAD window; in the event of errors, you can undo and start again.
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Important If you confirm this query, the current stylus data will be overwritten and thus will no longer be available. 3 Click on Yes to overwrite the current stylus data. The stylus from the Stylus System Library can now be used by Calypso for the stylus simulation in the CAD window and the collision calculations.
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21
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The VAST Navigator makes recording measured values when scanning cylindrical features (bores and shafts) much faster and more convenient. Stylus movements and probing methods are faster and more harmonious. At the same time, the interplay between sensors, control technology, processes and software ensures maximum accuracy.
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By using the VAST Navigator, the measuring time is reduced considerably without affecting the accuracy or, in the same usual time, increase the measuring certainty considerably.
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The VAST menu contains the following new setting options: Menu item Tangential probing Speed Step Width Number of Points Corner rounding within features Meaning Switches tangential probing on and off. Specification of the desired speed, or setting automatic calculation of the ideal speed. Specification of the desired increment, or setting automatic calculation of the ideal increment. Specification of the desired number of points, or setting automatic calculation of the ideal number of points. Sets corner rounding to a value between 0 and 100 for measurement of a feature.
Corner rounding between Sets corner rounding to a value between 0 and 100 for moving features between features. Display styli and safety group Shows the styli and safety group assigned to each feature.
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Calypso does not calculate and determine the optimum speed until immediately after the start of the CNC run, because the scope of measurement (number of characteristics to be tested) is not determined until that point.
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You call the Reference dialog box by opening the strategy window in the definition template of the feature, the definition template of the corresponding path generation method and clicking on the Datum Features button.
In this case, you will have to repeat the CNC run including the characteristic in question. The optimum speed will be redetermined taking the characteristic into consideration.
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Dynamic stylus qualification may be performed only with a 30-mmdiameter reference sphere. The reference sphere must be positioned so that the stylus can scan the entire sphere at the equator (the direction of the stylus determines the axis of the sphere). This means that you must use two reference spheres in different locations for two styli that point in opposite directions.
Sphere 2
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To ensure complete CNC qualification, you may need even a greater number of reference spheres this depends on the quantity and arrangement of the styli to be qualified. When using virtual reference spheres, one single real qualification sphere is sufficient (see Working with virtual reference spheres on page 21-8).
Validity
The dynamic stylus parameters remain valid for as long as the stylus remains physically unchanged. Regular requalification (approx. every three months) is however recommended. Thus, it is not necessary to carry out the dynamic stylus qualification each time when qualifying a stylus. If changes in the stylus geometry (e.g. due to a temperature change) have to be compensated, select the Geometry Repeat Mesurement or Tensor Repeat Measurement each time when qualifying styli. Dynamic stylus qualification can be performed as a measurement plan in the CNC run.
The virtual reference sphere procedure is based on the premise that the precise position of the reference sphere, which must be known for the determination of the stylus geometry, must not be known for the dynamic stylus qualification. You can therefore replace the necessary additional reference spheres required for dynamic stylus qualification with virtual spheres you create by copying in the Reference Sphere Management. You can also change the shaft direction in the Reference Sphere Editor (How to create the virtual reference sphere on page 21-8). The spheres created in this way only exist in the Reference Sphere Management, but not in reality.
In reality, the real reference sphere must be applied to the correct position and turned in the direction which corresponds to the current virtual reference sphere. Prior to dynamic stylus qualification, you must reposition the real reference sphere in the correct position and in the shaft direction, determine the position of the virtual sphere roughly by probing and carry out the dynamic stylus qualification using these position data.
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3 Select in the Edit menu (lower right) the Copy as virtual reference sphere menu item.
4 Enter in the dialog the number of the (real) reference sphere which you want to copy as virtual reference sphere as well as the number under which this new virtual reference sphere is to be saved. Another reference sphere is entered in Reference Sphere Management and Yes appears in the virtual reference sphere line. Under X Offset, Y, Z the same data as in the column for the real reference sphere appears at first.
NOTE
hss
The position to which the real reference sphere is applied is entered only after probing from the shaft direction during the dynamic stylus qualification.
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5 Enter under Inclination angle and Rotation angle the correct angles according to the desired shaft direction. 6 Repeat steps 3 through 5 if you want to create additional virtual reference spheres for other measuring positions and shaft directions. When using a virtual reference sphere, you must probe this manually in the shaft direction (also in the CNC run). The position of the sphere is then automatically determined during the qualification process.
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Dynamic stylus qualification is permissible only with a reference sphere measuring 30 mm in diameter. 4 Under Geometry, select Sphere as the shape of the stylus tip. 5 Select the Dynamic tensor qualification mode from the Mode selection list. 6 Click on the Qualify Stylus button.
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7 Specify the measuring force in mN that you would like to use with the stylus. If you want to use a particularly long and thin stylus or if the material to be probed is soft, enter a value for dynamic probing in %. Here, the discrete-point probing dynamic is reduced (during qualification and later measurements). This helps to avoid that, for example, thin styli break.
NOTE
hss
The settings in this dialog box do not have any influence on the dynamic stylus qualification. This information is stored with the stylus data and can be viewed in the Measurement Plan Editor Features and overwritten for individual features. 8 After prompting, probe in the shaft direction. Calypso carries out the static stylus qualification. Calypso checks the qualification routes for possible collisions with the reference sphere post. The following message will appear if a collision is possible:
Dynamic qualification is not possible for the current stylus with the reference sphere in this position. Please rotate the reference sphere so that the entire equator can be scanned without collisions.
9 In this case, select a reference sphere in a different location and restart qualification.
NOTE
hss
Intermediate points to possible additional reference spheres are freely programmable for the CNC run. or Change the reference sphere position, select the corresponding virtual reference sphere as the reference sphere and start in the Dyn. Tensor Repeat Measurement mode. Calypso qualifies the stylus according to the set mode. The results are saved.
NOTE
hss
By proceeding according to the virtual reference sphere procedure, you first measure all styli statically in one position of the reference sphere and only thereafter rotate the sphere to carry out the dynamic stylus qualification. Otherwise, you must qualify the sphere again. 10 Click on OK to return to the user desk. The stylus has now been statically and dynamically qualified. This allows the VAST Navigator to achieve higher scanning speeds with the stylus without affecting accuracy.
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The stylus data administration displays that the stylus has been dynamically qualified. The static and dynamic scatter are also shown. An excessive scatter value is a sign of possible shaft probing during qualification or indicates adhering dirt. If the qualified stylus is too soft (rigidity 10 N/mm), the system will indicate this with a message specifying the measured stylus rigidity in N/mm. The dynamic correction is also in this case valid for measurements with this stylus. Alternatively, you can also replace the stylus with a more rigid stylus and qualify the stylus again.
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The illustration shows the scanning movements for dynamic stylus qualification.
1st great circle, half 2nd gr. circle, complete
End
After probing with a scanning speed of 5mm/s, the entire process is repeated with a scanning speed of 50mm/s.
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Tangential probing
Tangential probing
Tangential probing is probing without an intermediate stop. This means that the navigation speed is reduced to the defined or calculated scanning speed just prior to stylus contact. This optimizes the approach movement, and reducing the number of intermediate stops saves time. Tangential probing is possible only for circle measurements, and it may be activated or deactivated as desired. Tangential probing is not possible: when scanning with a rotary table for discrete-point measurement for circle segments.
Path angle
Since inaccuracies are possible during approach and departure movements, the VAST Navigator always scans circle paths with a certain amount of overlap. VAST Navigator automatically determines the size of the overlap. The path angle is always 450 in the case of outside diameters (shafts). The path angle is variable in the case of outside diameters (shafts), ranging from 380 for large diameters up to 500 for small diameters. This ideally adapts the overlap to the inside/outside feature and reduces the measuring time for large diameters.
Check of the angle range
When switching tangential probing on, Calypso checks the current angle range. If this value is to small, you will be asked the question:
"Angle too small for tangential probing! Use angle anyway?" Yes / No
If you answer this question with Yes, the minimum angle range will be calculated based on the diameter of the circle and this value will be used. If you answer this question with No, tangential probing will be switched off again.
NOTE
hss
The value you originally entered for the value range will be retained for subsequent measurements performed without tangential probing.
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Tangential probing
To activate tangential probing in the technology window: 1 Click on Strategy in the definition template for the feature in question. 2 Open the technology window for path generation of the circle section.
3 Activate the Tangential probing (default) check box if you want to use the settings from the Measurement Plan Editor Features. Depending on the setting in the Measurement Plan Editor, tangential probing is now activated or not. 4 Activate the Tangential probing Yes check box if you want to activate tangential probing independently of the settings in the Measurement Plan Editor Features. If the set angle range is too small for tangential probing, you will be asked the question:
5 By clicking on Yes, the angle range will be adapted to the required value.
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Single points
Conventional scanning
Helical scanning
With this method, the scanned points are much more uniformly distributed in space. Calypso can thus very rapidly make valid statements concerning the diameter, shape and position of the cylinder. The other possibilities of the VAST Navigator are available here as well. You can have the ideal speed and/or increment and number of points calculated automatically. You can achieve higher scanning speeds with a dynamically qualified stylus.
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3 Open the technology window for the helix line by double-clicking, or click on the Magnifier symbol.
4 Make your settings. Speed Specify the speed or select automatic calculation. Step Width and Number of Points Select one of the two values or have the ideal values calculated automatically. The ideal numbers of points are selected so that there is sufficient information for the respective mode and the computing time for evaluation is kept to a minimum.
NOTE
hss
If you change the Diameter, Section height, Number of rotations or Number of circles, this will affect the ideal number of points via the measurement length. Number of circles Determines the number of additional circles to be measured. This selection has the following effect: 0: only the helix line is scanned
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2: a semicircle is scanned at the top, a circle is scanned at the bottom, and the supplementary semicircle is then scanned at the top 4: a full circle at the starting height, helix line forward up to target height, two circles there, helix line back to starting height, another full circle there.
NOTE
hss
Additional circles are useful especially for short cylinders this increases the accuracy in determining the cylinder axis. 5 Click on OK to confirm the entries.
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Edge deviation
Edge deviation
You can use the VAST Navigator to activate edge deviation for the movements when measuring a feature as well as for the movements between features. Edge deviation is always used for the entire measurement plan and not for individual features.
NOTE
hss
Edge deviation is also called rounding-off of detour. Without edge deviation activated, the probe approaches directly the defined intermediate points, stops and continues to move in the new direction. When edge deviation is activated, the concerned intermediate points are not approached. Instead, the probe begins to make an arc movement according to a predefined radius shortly before the intermediate point and then continues to move in the new direction.
Edge deviation produces a continuous movement of the probe to reduce the travel time between the elements to be measured. With the VAST Navigator, you activate the desired type of edge deviation for the entire measurement plan. Corner rounding within features: Each feature has one probing detour point (intermediate point) before and one after the feature. These are rounded off. Corner rounding between features: There may be additional probing detour points (intermediate points) between the individual features. These are rounded off. Enter the name of rounding-off. If this value is too large, this will be limited automatically by the VAST Navigator: The rounding-off radius may not exceed 25% of the shortest travel path (between two consecutive intermediate points).
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Example: You enter 500 and the shortest travel path is 20 mm. Result: The value 5 is used for edge deviation.
Imax = 50 mm
Intermediate point
Imax = 50 mm
!
hss
Important! There is a risk of collision with long travel paths. Collisions can be avoided by increasing the distance a in the clearance planes or default range.
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Chapter
22
.................................................................................................................................
Automation (option)
The Automation option (together with the CMM-OS option) permits the use of Calypso in automation projects.
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Automation (option)
In an automation project, Calypso is controlled by external signals sent to Calypso by a higher-order Flexible Automation and Control System (FACS), for example. In this way, Calypso can be integrated in an automated measuring chain with infeed, measurement and evaluation systems.
AAI interface
Control of Calypso by the FACS and feedback from Calypso to the FACS take place via the AAI interface, which must be configured and started for this purpose. After the AAI interface is started, Calypso will be in the mode you set previously: automatic mode or manual mode. You can operate Calypso in the usual manner in manual mode. However, Calypso can be switched to automatic mode via the AAI interface. As soon as Calypso is in automatic mode, Calypso can be externally controlled; control by the user is restricted. Switchover back to manual mode can take place both by means of an FACS command and manually by you.
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Automation (option)
To configure the AAI interface: 1 Select Extras Workroom CMM and click on the AAI tab.
2 Select the Mode after start: Automtic mode: Calypso is in automatic mode after the start of the AAI connection. Manual mode: Calypso is in manual mode after the start of the AAI connection. 3 Select Mode for opening measurement plans via AAI: Show in Calypso User Desk: If a measurement plan is opened via AAI, it is displayed as usual on the screen. Open without display in background: If a measurement plan is opened via AAI, it runs in the background without the user desk displayed on the screen. This mode enables fast execution of the processes.
NOTE
hss
When setting Open without display in background, the CAD view cannot be output as plot. 4 If necessary, change the default connection settings (host name, port number, shared path). 5 Click on Apply or OK.
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Automatic mode
Automatic mode is used for external control of Calypso (by an FACS) via the AAI interface. User control is very limited in automatic mode. You can operate only the following windows in automatic mode: the Stoplight window the System Set Up the default printout
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Automation (option)
the custom printout All other windows cannot be used and are minimized when Calypso switches to automatic mode.
Changing to manual mode
Calypso changes from automatic mode to manual mode: when the FACS sends a corresponding command via the AAI interface. when a new connection is established to the CMM (if manual mode is set as the Mode after start in the System Set Up). if there is a problem with the connection via the AAI interface. An error message will be issued. when you click on the Switch to manual button in the System Set Up (AAI page). Calypso prompts you to enter an administrator password. The change to manual mode reactivates the Calypso user interface for the logged on user. The program window is restored to its original size.
Manual mode
Calypso can be manually controlled without restriction in manual mode and cannot be externally controlled (with one exception). The only external command that is accepted is the command to switch over to automatic mode.
Changing to automatic mode
Calypso changes from manual mode to automatic mode: when the FACS sends a corresponding command via the AAI interface. when a new connection is established to the CMM (if automatic mode is set as the Mode after start in the System Set Up). When Calypso changes to automatic mode, open dialog boxes (if necessary) and measurement plans will be closed.
!
hss
Important When Calypso changes to automatic mode, it closes the measurement plans without saving them. This means that all changes made since the measurement plans were last saved will be lost. If a measurement plan is currently in the CNC run, Calypso cannot switch over from manual to automatic.
NOTE
hss
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Automation (option)
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Index
0-9
1-sphere method (rotary table) 4-89 2D curve adopting actual deviations curve 1 for nominal data curve 2 16-25 2-sphere method (rotary table) 4-92 3D best fit 4-76 on the CAD model 4-76 3D curve 5-33 adopting from CAD model 16-22 Automation, basics 22-2 Auto-Run assigning keywords 12-30 basics 12-2 branches 12-6 CNC parameters 12-32 configuring 12-16 controlling measuring runs 12-13 creating branches 12-31 defining desks 12-22 defining sequence 12-36 desks 12-3 displaying printouts 12-14 finding measurement plan 12-9 for users 12-7 keywords 12-6, 12-29 loading interface 12-9 managing 12-39 mapping pallet 12-25 measurement end 12-14 measurement plan icon 12-4 measuring configuration, selecting 12-10 pallets 12-5 placing bitmaps on icons 12-23 positioning measurement plan 12-23 preparing for measurement 12-31 specifying scope of measurement 1210 structure 12-3 user privileges 12-16 Average 6-47 Axial lift data settings 16-9 Axial runout 6-49
A
AAI 22-2 AAI interface activating 22-5 configuring 22-3 starting 22-5 ACR3 defining holder positions 7-57 particularities 7-46 Add styli 4-22 Additional feature GEAR 5-43 HOLOS 5-43 addToFile 15-60 Administering Auto-Run 12-39 Alignment 3D best fit 4-76 Angle 6-49 Angle of inclination 6-45 Angle point 5-40 Angle Range characteristic 6-49 Angularity 6-49 Approach direction for curve 16-29 Arithmetic operators (reference) 15-53 Array via loop (example) 15-46 Arrays 15-52 ASCII files (curve) 9-46 ASCII parameter file (example) 15-50 Asynchronous mode 10-2 Audiovisual information 7-65 Automatic feature recognition 1-12 Automatic stylus change 7-63 Automatically measuring 5-95
B
Base alignment 1-13 adapting 4-54 basics 4-48 creating new 4-51 customizing iteratively with abortion condition (example) 4-56 defining 4-46 editing 4-58 loading 4-50 loading secondary alignment 4-69 moving 4-60 offsetting 4-60 rotating by distances 4-62
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Index
baseSystem 15-62 Basic concept Calypso 1-12 Basics 4-2 Auto-Run 12-2 characteristics 6-2 clearance planes/clearance groups 7-30 computed alignment 4-47 curve measurement 16-2 measurement plans 4-2 probing 5-20 retract planes 7-31 travel paths 7-29 Best fit 3d ~ on the CAD model 4-76 3D best fit (alignment) 4-76 as circumscribed/inscribed feature 6-5 as tangential element 6-5 Gaussian 6-5 Tschebyscheff 6-5 Best fit of bore pattern 6-52 Best-fit methods 6-3 Bore-pattern best fit 6-54
C
CAD file, importing 5-9 CAD window 3-1 Calypso starting 1-3 Calypso Planner 1-14 Canceling measurement plan run 8-14 Cartesian characteristics 6-46 Changing point list 5-87 stylus assignment 7-64 Changing the point list 5-87 Characteristic data constant 9-66 Characteristic input (option) 19-2 Characteristics 1-12 adding 7-5 assigning to multiple features 6-20 basics 6-2 best-fit methods 6-3 calculation 6-3 color coding 6-41 copying 7-6 copying properties 6-40 defining 6-7 definition templates 6-8 deleting 7-7 finding 7-10 grouping 7-8 index exchange 6-23
list of all ~ 6-43 moving 7-7 nominals 6-25 rechecking (example) 15-42 renaming 7-9 setting references 6-42 tolerances 6-25 ungrouping 7-8 with indexes 6-22 Characteristics, tasks, details on 6-42 angle 6-49 angle of inclination 6-45 angularity 6-49 average 6-47 axial runout 6-49 cartesian 6-46 coaxiality 6-48 concentricity 6-48 cone angle 6-45 curve form 6-48 cylinder form 6-48 diameter 6-43 diameter two 6-46 distance_symmetry point 6-46 feature angle 6-45 flatness 6-47 flatness in a zone 6-47 form 6-48 half cone angle 6-45 length of axis 6-43 parallelism 6-48 perpendicularity 6-48 polar 2d 6-45 polar 3d 6-45 polarposition angle 6-44 polarposition height 6-44 polarposition radius 6-44 position 6-48 profile 6-48 projection angle one 6-44 projection angle two 6-45 radial runout 6-49 radius 6-43 radius 2 6-47 radius measurement 6-43 rotation angle 6-45 roundness 6-47 simple distance 6-46 slot length 6-47 slot width 6-47 space point distance 6-46 straightness 6-47 symmetry 6-49 X value 6-43 Y value 6-43
Index
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Z value 6-43 Characterization file 13-3 Checking wall thickness 6-56 Circle 5-23 Circle in contour best fit 5-80 details 5-82 Circle path on plane 5-106 Clearance distance 7-40 approach each time 7-41 copying into other features 5-17 Clearance groups assigning 7-35 defining 7-33 retract plane in 7-36 Clearance paths rotary table 4-104 Clearance planes 1-13 assigning 7-35 closer to workpiece 7-40 copying into other features 5-17 RT clearance planes 4-106 Clearing after collision 8-15 Clearing the CMM 8-15 closeSocket 15-68 CMM travel commands (PCM) 15-64 CNC parameters Auto-Run 12-32 CNC run ~structure 15-7 RT prealignment 4-104 starting 8-10 cncBreak 15-64 Coaxiality 6-48 Collision reaction following ~ 8-15 special aspects with RDS 8-15 Color coding characteristics 6-41 features 5-18 prerequisites 4-13 Compact printout 9-3, 9-7 Comparative operators (reference) 15-53 Computed alignment basics 4-47 Concentricity 6-48 Conditions reference 15-72, 15-73 setting 15-19 with alternative (example) 15-38 Cone 5-31 Cone addition (construction) 5-78 Cone angle 6-45 Cone angle, half 6-45 Conf.dat 6-12 Configuration file, erosion module 6-12
configuring Auto-Run 12-16 confirm 15-57 constant feature data 9-66 Constructions 5-50 average 5-77 cone addition 5-78 edge point 5-74 intersection 5-61 maximum point 5-76 maximum result 5-77 minimum point 5-76 minimum result 5-77 plane with offset 5-79 constructions 5-50 Context menu 1-8 Control console Dynalog / Dynalog P 2-1 Controlling measurement plan run 8-13 Controlling measuring runs Auto-Run 12-13 Coordinate system access to the origin 6-54 copying into other features 5-17 defining 4-46 deleting 6-16 FLCS 1-13 from best fit of bore pattern 6-53 loading 6-15 parameterizing (example) 15-44 saving 6-15 with index 4-47 coordinate system Defining references 4-50 copyFile 15-60 Copying characteristic 7-6 characteristics 6-20 feature 7-6 icons 12-42 measurement plans 7-3 result file 9-49 Copying ISO286 6-40 Copying lower tolerance 6-40 Copying tolerance class 6-40 Copying upper tolerance 6-40 Coupling measuring ranges (duplex mode) 10-5 Current selection 8-2
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Index
Curve 5-33 adopting deviations of a reference curve 16-25 adopting from CAD model 16-22 changing approach direction 16-29 changing nominal points 16-23 defining via function (example) 15-42 deviation of threads 16-74 deviations graphical 16-75 loading parameters (example) 15-41 projection of results 16-37 Curve (2d) 5-33 Curve (3D) 5-33 Curve distance 16-56 Curve expansion 16-57 Curve form 6-48, 16-58 Curve jump tolerance 16-58 Curve measurement 16-1 3D curve 16-3 basics 16-2 changing nominal vectors 16-28 characteristics 16-52 checking clearance planes 16-30 checking nominal vectors 16-27 context menu 16-39 defining nominal data 16-7 defining the curve feature 16-5 deviation in actual vector direction 16-36 deviation in grid coordinates 16-36 deviation in nominal vector direction 1636 digitizing 16-12 digitizing 3D curve in area 16-17 digitizing 3D curves 16-16 editing nominals 16-23 entering nominal data manually 16-21 face curve, definition 16-3 flat curves 16-2 formatting printout 16-74 importing ASCII file 16-7 importing nominal data from file 16-8 jump tolerance 16-34 lift curve, definition 16-3 loading axial lift data 16-9 loading VDA file selectively 16-9 lower deviation 16-58 max deviation 16-55 measurement strategy 16-41 measuring tolerance 16-31 min deviation 16-55 nominal vectors, changing 16-28 outliers 16-71 point list 16-42 radial deviation 16-37 range 16-55, 16-58
scanning 16-46 segments 16-49 spatial curves 16-3 upper deviation 16-58 using CAD model 16-39 Curve measurement, results 16-36, 16-60 best fit 16-63 calculating deviations 16-60 center 16-62 deviation 16-60 Curve slope 16-52 Curve stroke 16-54 Custom printout 9-4 automatic fields 9-15 defining printout output 9-5 displaying 9-7 global dummies 9-16 local dummies 9-16 PCM commands 15-70 result presentation 9-16 setting up 9-14 structure 9-14, 9-15 Cylinder 5-29 Cylinder form 6-48
D
date 15-68 dateAndTime 15-68 dateInNumbers 15-68 Default names file structure 4-6 loading file 4-5 Default printout 9-2, 9-6 Defining characteristics 6-1 characteristics curve 16-52 clearance groups 7-33 desks 12-22 features 5-1 nominal data for curve 16-7 printout output 9-5 stylus 4-21 Defining a pattern 5-16 Defining inside 5-20 Defining outside 5-20 Defining references 4-50 Defining the master stylus length 7-50 deleteFile 15-60 Deleting characteristics 7-7 desks 12-42 features 7-7 measurement plans 7-3 part alignment 4-75 toolboxes 7-28
Index
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Desks adding measurement plans 12-23 deleting 12-42 renaming 12-41 Determining measuring uncertainty 18-1 Diameter 6-43 Diameter two 6-46 Digitizing 3D curve in area 16-17 DIN true position with best fit of bore pattern application 6-54 basics 6-52 display 15-57 displayPositionCMM 15-65 Distance_symmetry point 6-46 DMIS commands supported 13-2 DMIS export prerequisites 14-3 run 14-3 DMIS files 9-45 DMIS import configuring 13-6 reports 13-11 run 13-8 DMIS measurement plans basics 13-2, 14-2 Dummies global 9-16 local 9-16 Duplex mode, basics 10-1 Dynalog configuring Calypso 2-6 function keys 2-9 general information 2-1 operating toolboxes 2-10 operation 2-6 Dynalog / Dynalog P display 2-2 keyboard 2-2 overview 2-2 touchpad 2-2 Dynalog P configuring Calypso 2-3 operation 2-3 special aspects 2-4
tolerances 6-25 Entering text with the mouse 1-8 Entries with the mouse 1-8 Erosion module 6-11 configuring 6-12 Error report 11-9 Evaluation settings copying into other features 5-17 Excel report examples 9-11 Export measurement plan to DMIS 14-1
F
Feature angle 6-45 characteristic 6-49 Feature data variable 9-67 Feature recognition, automatic 1-12 Feature's local coordinate system 1-13 Features 1-12 3D curve 5-33 adding 7-5 angle point 5-40 circle 5-23 color coding 5-18 cone 5-31 copying 7-6 copying properties 5-17 curve 5-33 cylinder 5-29 deleting 7-7 details 5-20 ellipse 5-34 finding 7-10 general curve 5-42 general surface 5-41 in loops 15-25 line, 2d 5-26 line, 3-D 5-28 measuring individually 8-5 moving 7-7 offset plane 5-37 plane 5-24 point 5-21 radius point 5-38 recall of 5-51 rectangle 5-37 renaming 7-9 rotary table parameters 4-107 slot 5-35 sphere 5-32 sphere point 5-39 splitting 5-14 symmetry point 5-38
E
Eliminating outliers general settings 6-35 Ellipse 5-34 End angle characteristic 6-49 Entering nominals 6-25
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Index
Features, defining from CAD file 5-9 using templates 5-4 with feature recognition 5-7 File commands (reference) 15-60 Filters activating 6-36 basics 6-32 general settings 6-35 minimum number of points 6-32 Filtration 6-32 Flatness 6-47 in a zone 6-47 Flatness in a zone basics 6-51 FLCS 1-13 Form 6-48 Form plot 9-33 activating 9-35 CAD view as plot 9-38 changing settings 9-43 changing settings permanently 9-43 dialog box 9-41 format files 9-38 fourier analysis 9-41 printing 9-36, 9-42 setting type 9-35 Form plots curve 16-75 Format files for plots 9-38 designing 9-40 Formulas definition 15-10 entering 15-17 functions and operators 15-11 Functions (PCM) character string~ (reference) 15-56 introduction 15-10 mathematical (reference) 15-54 measurement-specific 15-62
getRecordHead 15-70 getStylus 15-65 getTemperatureCorrection 15-66 getWD 15-60, 15-61 Grouping creating 7-8 renaming 7-9 ungrouping 7-8 Groups forming 8-3
H
Holos 5-43 Homing the CMM 4-15 Horizontal-arm CMMs combining measurement plans 7-16 in duplex mode 10-1
I
Icon copying 12-42 deleting 12-42 labeling with bitmaps 12-23 Import CAD data 5-9 measurement plan for RT axis 4-101 measurement plan from DMIS 13-1 UMESS measurement plan 13-2 Importing files for curve 16-8 Importing ASCII file for curve 16-7 Importing DXF files 16-8 Importing PAB files 16-8 Index exchange 6-23 Input/output commands (reference) 15-57 Input/output parameters 15-30 inquire 15-57 inquireList 15-58 inquireNumber 15-57 inquireParameterList 15-58 inquirePasswordText 15-58 inquireText 15-59 Installation Calypso, program version 11-3 service pack 11-6 Interrupting measurement plan run 8-15 Intersection 5-61 Introduction 1-1
G
Gage correction qualification 5-47 Gap characteristics 6-49 GDT profile basics 6-50 Gear 5-43 General curve 5-42 General surface 5-41 getActual 15-63 getActualInspectionDir 15-60 getCNCMode 15-65 getNominal 15-64 getPositionCMM 15-65
K
Keywords assigning 12-30 for icons 12-29
Index
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L
Least-material condition 6-28 Length of axis 6-43 Lift curve format of nominal data 16-10 marking 16-6 unmarking 16-6 Lift data format 16-10 Line, 2d 5-26 Line, 3-D 5-28 LMC 6-28 Loading interface Auto-Run 12-9 Loading PCM file via dialog (example) 15-44 Location plot 9-33 activating 9-35 CAD view as plot 9-38 changing settings 9-43 changing settings permanently 9-43 dialog box 9-41 format files 9-38 printing 9-36, 9-42 setting type 9-35 Loop around characteristic 15-24 loop index 15-23 loop variable 15-23 Loops alignment to RPS 15-26 features in ~ 15-25 for multiple measurements 15-28 linear offset (example) 15-45 nest level 15-27 nested 15-27 nested for array (example) 15-46 setting 15-22
M
Macro ~- parameterizing measurement plan 7-18 advantages 7-18 basics 7-19 create 7-20 editing 7-24 in the measurement plan 7-18 integrating 7-22 naming conventions 7-19 updating 7-25 using 7-20 Manual run starting 8-11
Manual stylus change 4-18 Master measurement plan, horizontalarm CMMs 7-16 Master stylus entering data 4-24 MCR20 defining holder positions 7-58 particularities 7-44 measure 15-64 Measured values eliminating outliers 6-32 filtering 6-32 Measurement ending, Auto-Run 12-14 preparing Auto-Run 12-31 running 8-2 starting 8-9 Measurement cylinder method (rotary table) 4-95 Measurement plan controlling run 8-13 editing 7-11 export to DMIS 14-1 import from DMIS 13-1 multimedia information 7-65 starting a CNC run 8-10 starting manual run 8-11 Measurement plan area 1-6 Measurement plan editor 7-11 features 4-122 features, RT parameters 4-108 Measurement plan features finding 7-10 Measurement plan group forming 8-3 Measurement plan run canceling 8-14 interrupting 8-15 restarting 8-16 Measurement plan settings 4-120 Measurement plans 1-12 combining (HAM) 7-16 copying 7-3 creating 4-2, 4-4 deleting 7-3 editing 7-5 integrating user information 7-65 managing 7-2 mirroring 7-14 opening 4-4 opening existing 4-4 renaming 7-2 running 8-2 saving 7-2 variable 15-4
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Index
with variant control (example) 15-48 Measurement strategy 5-85 copying into other features 5-17 Measuring automatically 5-95 with rotary table 4-100 Measuring configuration, selecting Auto-Run 12-10 Measuring offset via loop (example) 15-45 Measuring results copying result file 9-49 printing 9-7 saving 9-45 saving as ASCII file 9-46 saving as DMIS 9-45 saving as PDF 9-46 saving as PostScript 9-46 saving as QDAS 9-45 saving in a merge file 9-45 saving in table file 9-45 Menu bar 1-5 Merge file 9-45 message 15-59 Midpoint 5-22 Minimum number of points, filters 6-32 MMC 6-28 Mode when qualifying 4-33 Most-material condition 6-28 Mouse with 2 or 3 buttons 1-6 Multimedia in measurement plans 7-65 Multiple measurements with loops 15-28
Opening measurement plan 4-4 openSocket 15-68 Origin of the coordinate system 6-54 Outliers basics 6-32 eliminating 6-32, 6-38 Output commands (reference) 15-57 Output files defining name 9-46 Output parameters 15-30 OVCMM 18-1 basics 18-2 stylus characteristics 18-5 using 18-9
P
P6 Alignment 4-77 Pallet mapping 12-25 Parallelism 6-48 Parameter ASCII file (example) 15-50 loading values into curve (example) 1541 Parameters definition 15-9 functions and operators 15-11 input and output parameters 15-30 loading 15-17 saving 15-16 Part alignment 1-13 basics 4-47 creating new 4-51 defining 4-46 deleting 4-75 loading 4-50 rotate distance 4-66 rotating 4-61 rotating by distances 4-62 Part data 9-66 Parts family, measuring (example) 15-48 Path generation circle 5-99 circle path on plane 5-106 cone 5-99 cylinder 5-99 lines 5-107 measuring range 5-101 overview 5-108 planes 5-103, 5-105 unknown contour 5-97 Pattern 5-14 basics 5-14
N
Navigation check automatic 7-37 Nest level in loops 15-27 Net point 5-22 Nominal data for curve point generator 16-11 Nominal points of a curve changing 16-23 Nominal values of a curve adding an offset 16-26 Nominals 6-40 defining 6-25 notational conventions 1-7
O
Offset adding to curve values 16-73 by nominal curve values 16-26 Offset plane 5-37 Open measurement plan 4-4
Index
61212-2010602
Pattern procedure 5-15 PCM debugging and testing 15-36 programming 15-12 searching for text 15-35 syntax (reference) 15-51 testing printout 15-34 variables (reference) 15-52 PDF files 9-46 PDF output configuring 9-49 Perpendicularity 6-48 Plane 5-24 Plane Point 5-22 Point 5-21 Point generator 15-32 for curve 16-11 Polar 2d 6-45 Polar 3d 6-45 Polarposition angle 6-44 Polarposition height 6-44 Polarposition radius 6-44 Position 6-48 positionCMM 15-66 positionRS 15-67 Preparations r otary table 4-81 Prerequisites color coding 4-13 Prerequisites, list of 4-12 presentationOff 15-71 presentationOn 15-71 print 15-59 Printing measuring results 9-7 Printout displaying 9-6 Printout header data entering 8-6 global 8-6 local 8-7 Printout header fields defining own 9-22 INI file 9-24 TXT file 9-23 Printouts ~ defining output 9-5 INI file for header data, example 9-26 text output 6-14 Printouts, subsequently (Auto-Run) 1214 Profile 6-48 Projection angle one 6-44 Projection angle two 6-45
Projection plane copying into other features 5-17 PROVACS 9-62 PstScript files 9-46
Q
QDAS description file 9-63 QDAS files 9-45 QDAS format 9-62 QDAS values file 9-63 QDASCONV.CON 9-64 QDASCONV.EXE 9-62 qs-STAT 9-62 Qualification indirect (holder) 7-55 Qualification method 4-33 Qualifying mode 4-33 Qualifying styli with measurement plan 4-36
R
Radial runout 6-49 Radius 6-43 Radius 2 6-47 Radius measurement 6-43 Radius point 5-38 Range specification, recall points 5-58 RDS after collision 8-15 creating stylus list 4-25 defining geometry 7-47 loading a stylus list 4-27 qualifying with CAA 17-1 Recall 5-51 Recalling points with range specification 5-58 Rectangle 5-37 redrawCAD 15-59 Reference axis secondary reference rotating 4-64 Reference sphere determining 4-40 renameFile 15-61 Renaming characteristics 7-9 desks 12-41 features 7-9 groups 7-9 measurement plans 7-2 stylus 4-22
61212-2010602
Index
Restarting measurement plan run 8-16 Result presentation 9-16 Retract distance copying into other features 5-17 Retract plane 7-36 Rotary table defining 4-81 homing 4-84 importing measurement plan for axis 4101 login 4-82 manual positioning 4-84 measuring features 4-100 mechanical alignment 4-103 parameters in the feature 4-107 prealignment at CNC start 4-104 qualification methods 4-87 qualifying axis 4-86 rotational pattern 4-111 setting the axis 4-100 setting the position 4-83 status of axis 4-102 Rotate distance 4-66 Rotation angle 6-45 Rotation in plane 4-47 Rotation in space 4-47 Rotational pattern 4-111 Roundness 6-47 RPS Alignment 4-77 RPS alignment with loop 15-26 RT axis importing measurement plan 4-101 RT clearance planes 4-106 RT homing 4-84 RT parameters measurement plan editor features 4-108 Run measurement plan 8-2 Running individual features 8-5 measurement 8-2 measurement plan 8-2 Running a measurement plan printout header data 8-6
S
Saving measurement plans 7-2 measuring results 9-45 parameters 15-16 Scanning 5-95 curve 16-46 general settings 5-97
several styli 5-101 Scope of measurement forming group 8-3 individual features 8-5 specifying for Auto-Run 12-10 SCP600 defining holder positions 7-56 SCR200 defining holder positions 7-60 particularities 7-45 searchDistance 15-67 Searching characteristics 7-10 features 7-10 for PCM text 15-35 Secondary alignment loading 4-69 Secondary reference rotating reference axis 4-64 Selecting coupling method (duplex operation) 10-5 Self-centering probing 5-89 restrictions 5-89 Self-centering qualification (rotary table axis) 4-98 Service pack installing 11-6 unzipping 11-6 setCNCMode 15-67 setProtocolSetting 15-71 setRecordHead 15-71 Setup stylus changer 7-49 Shape of zone 6-50 Simple distance 6-46 Slot 5-35 Slot length 6-47 Slot width 6-47 Space point 5-22 Space point distance 6-46 Sphere 5-32 Sphere point 5-39 Start alignment basics 4-49 creating new 4-51 loading 4-50 loading secondary alignment 4-69 Starting Calypso 1-3 CNC run 8-10 manual run 8-11 Starting a measurement plan 8-9 manual run 8-11
Index
10
61212-2010602
Statistics program 9-62 stepRS 15-68 Stoplight window canceling a measurement plan run 814 interrupting a measurement plan run 8-15 Stopping measurement plan run 8-14 Straightness 6-47 Stylus adding 4-22 adding styli 4-22 angle range in automatic mode 5-93 automatic search 5-90 copying into other features 5-17 creating list for RDS 4-25 defining 4-21 editing 4-20 installing 4-18 qualifying for RDS with RDS-CAA 171 renaming 4-22 Stylus changer adding holders 7-51 assigning styli 7-62 automatic stylus change 7-63 changing stylus assignments 7-64 defining holder positions 7-55 for RDS 7-47 indirect qualification 7-55 setting approach parameters 7-52 setting up 7-49 special features of MCR20 7-44 special features SCR200 7-45 special features with ACR3 7-46 Stylus characteristics for OVCMM 18-5 for virtual CMM 18-5 Stylus System copying into other features 5-17 symbols 1-7 Symmetry 6-49 Symmetry point 5-38 Synchronous mode 10-2 System requirements 11-2 systemCall 15-69 systemCallForResultAccess 15-69 systemCallWithWait 15-70
Textelement 6-14 Three-button mouse 1-6 time 15-70 timeInSeconds 15-70 TOL/PROFS 6-50 Tolerances defining custom 6-30 entering 6-25 file with custom 6-31 LMC 6-28 MMC 6-28 Toolbar 1-5 structuring 1-10 Toolbar editor 1-9 Toolbox operating via Dynalog 2-10 Toolboxes 7-26 creating 7-26 deleting 7-28 moving 7-28 zooming out 7-28 Travel editing 7-29 Travel commands (PCM) 15-64 Travel paths basics 7-29 checking 7-32 Turbine blade additional feature 5-45 CNC run 5-46 Two-button mouse 1-6 Types of bracket in loops 15-27
U
UMESS, importing measurement plan 13-2 Unknown contour 5-97 User desk 1-5 CAD icons 1-6 CAD window 1-6 measurement plan area 1-6 menu bar 1-5 toolbar 1-5 User information calling 7-66 integrating 7-65 User privileges Auto-Run 12-16 Using distance check 6-56 Utilities erosion module 6-11 overview 6-9 stylus system qualification 6-10 textelement 6-14
T
Temperature compensation configuring 4-130 general information 4-123
61212-2010602
Index
11
V
Variable feature data 9-67 Variables definition 15-9 reference 15-52 Variant control (example) 15-48 VDA file importing 16-8 loading selectively 16-9 Virtual CMM 18-1 configuring 18-5 stylus characteristics 18-5 using 18-9
W
wait(nSeconds) 15-70 Window CAD window 3-1 writeActualsToVDA 15-61
X
X value 6-43
Y
Y value 6-43
Z
Z value 6-43
Index
12
61212-2010602