Calypso C-m-m-guide 2b1w6x

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.

Color-Coding of Features Buttons When a feature is listed in the measurement plan area, the background color of its button tells you its status: – Light gray (same as measurement plan area): The feature has not been fully defined. – Dark gray: The feature has been fully defined. – Green / red: The feature has been defined and measured results have been gathered.

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Defining Features

Tips and Tricks for Defining Features – You can cancel the definition of a feature at any time, even while probing is in progress: Click on Reset and then click on OK. – You can restart the definition of a feature at any time, even while probing is in progress: Click on Reset and then repeat probing. – If the CAD image of the part’s features is not fully on the screen or is not displayed at all, the image may have been zoomed or shifted in the CAD window. Click on the Fit button to resize the model to fit into the CAD window. – If the feature does not seem to be properly defined but you have clicked OK to save it, you can delete it from the measurement plan and then define it again. See ➤“How to Delete Features or Characteristics” on page 7-11. – If you want to change the order in which features are displayed, you can easily move a feature to new location. Click on the feature (either its button or its name) and hold the left mouse button down, then drag the feature to a new location. – If the probing point you used is unsuitable, you can delete it by clicking on the Undo last probing button (or pressing F3 on the standard control ). – If you want to delete a probing point defined some time in the past, proceed as described in the section entitled ➤“How to Use the Shortcut Menu of the Strategy List” on page 5-63. – Probing or position points can be added to a feature at any time. First, open the definition template of the feature. • To add a probing point, probe the point with the CMM. The point is added automatically. • If you want to add an intermediate position, you must check that the original stylus is activated. Move the probe to the appropriate position, then press the button on the right-hand joystick to accept the position or click on the Position CMM without probing symbol in the strategy window.

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Details on Specific Part Features

Details on Specific Part Features Basics of probing

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 the time within which you want the CNC run to complete). This is particularly important when you record and evaluate shapes on a workpiece.

Inside or outside feature?

In most instances, Calypso can 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 travel paths and the calculation of the tangential features. You define a feature as an inside or outside feature in its definition template. The left button shown here is for an inside feature, while the right button is for an outside feature.

Correcting the probe tip radius

The measured value of a measurement sent to the CMM is always the center coordinates of the probe tip. The coordinates of a measured value, therefore, always differ from those of the point – the measured value you want – at the time of measurement by the radius of the probe tip.

probing direction

probing radius

measured value

desired measured value

Calypso automatically corrects the measured value, so you always receive the coordinates of the actual point. There may be a residual error despite this correction, but you can usually prevent this.

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Defining Features

The Point 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

You can measure a point anywhere on a surface.

probing direction

measured value correction

To obtain the right correction for the stylus 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. Output

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:

Mode

Type of correction/conversion

Touch Point

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)

Plane Point

Radius correction in normal vector direction.

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Mode

Type of correction/conversion

Space Point

Radius correction in normal vector direction, followed by projection on the normal of the nominal point. The radius (length of the tripod) used to measure the normal can be set using the menu point Radius for space point normal measurement in the Measurement Plan Editor - Features.

Net Point

Radius correction in normal vector direction, followed by projection on the coordinate system axis which corresponds to the reference axis of the nominal plane. The corrections which are made for the respective point type are shown in the diagram.

Probing direction

z

Nominal normal Vector Actual normal Vector

Nominal outline

Actual outline

4 3 1

2

Nominal point 1 2 3 4

x Touch Point Plane Point Space Point Net Point

The Circle 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 on any measured plane. Calypso uses the probed points to compute the circle or arc which best fits the probing points. The start angle W and the partial angle TW (for an arc) are specifed in the definition template.

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Defining Features

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.

Automatic feature recognition

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.

Feature's local coordinate system

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

Greater Accuracy in Circle Measurement (Basics of Gage Correction Qualification) Gage correction qualification is a method by which Calypso can measure circles to a very high degree of precision and at very high scanning speed. Calypso must first record the bending parameters of the probe. When a circle or arc is subsequently measured, you can instruct Calypso to correct the result by applying the bending parameters. Preconditions

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 4-3 – ➤“Defining the Clearance Planes” on page 4-72 – You know how to start a CNC run. – ➤“Defining the Scope of Measurement” on page 8-2 – The circle is measured on the same primary plane of the workpiece coordinate system as was used in recording the bending parameters.

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How to Record the Bending Parameters In order to record the bending parameters, you need a workpiece with a reference bore or a reference plug. The bore or plug must be of known diameter. NOTE hss

The bending parameters have no effect unless you have installed a measuring probe head. The plug or bore is measured as a 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 Prerequisites → Utilities → Gage Correction Qualification. Calypso adds the icon for gage correection qualification to the list of features. 3 Double-click to open the definition template. 4 Enter the calibrated diameter of the bore or the plug in field D. 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.

8 Perform a CNC run of the measurement plan so that Calypso can measure the bending parameters. Once Calypso knows the bending parameters of the probe, it will be possible to correct future measurement results of full circles and arcs in a corresponding manner (see “How to Apply the Bending Parameters”)

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Defining Features

How to Apply the Bending Parameters You can use the definition template of the circle to have all future full circles and arcs corrected with the bending parameters. To activate correction by application of the bending parameters: 1 Open the definition template of the circle to which you want to apply the bending parameters. 2 Click on the Output button. The Evaluation (Feature) dialog box appears on the screen.

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, the measuring results are corrected by the bending parameters. Optimal accuracy values are achieved when the diameter, measuring location and scanning speed are as close as possible to the values of the bending parameter definition.

The Plane 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.

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Probing strategy

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.

Result output

This illustration shows the positions of the projected angles W1 and W2.

Z

projection into the Z/X plane normal

spatial view

A1=0

Z

Y

plane

surface normal

Z

X

projection into the Z/Y plane

example plane

A2

X

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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Defining Features

The illustration below is an example showing how this applies to 5 planes of a cube.

Z Y X

origin of the respective LA

The 2-D Line Menu: Features → 2-D Line The 2-D Line feature is primarily for probing lines and straights on any plane on the surface of the workpiece. Calypso computes a meanvalue line through the points you probe. Types of representation

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 representation in the Feature representation dialog box, which you can open from the Prerequisites or via Prerequisites → Feature representation.

Probing strategy

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 CAD Entities menu and regenerate the feature as a line.

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The origin of the local coordinate system for the feature is at the first point on the line which defines the line fully when first ed – in these examples points 1, 4 and point 3.

1

2

3

4

5

6

2

3

4

or

6

5

1 or

3

Result output

1

2

4

5

After measurement, the following results are output in the definition template and in the printout. Result

Meaning

X, Y, Z

Coordinates of the origin of the coordinate system

W1 (Z/X)

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 2D-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

Scatter referenced to the best-fit computed feature

Min/Max

Minimum and maximum deviation, referenced to the best-fit computed feature

Form

Difference between minimum and maximum deviation, referenced to the best-fit feature.

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Defining Features

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.

Y

projection into the X/Y plane

spatial view Z

Y

A1 X

Z

example line

projection into the X/Z plane

X

A2

X

The 3-D Line Menu: Features → 3-D Line A 3-D line cannot be measured: it is computed from a recall of at least two features. You can, for example, employ a 3-D line to represent the axis of a shaft by using several circles for the purpose of definition. Open the Nominal Definition picklist and select Recall. This opens the Selection dialog box and you can select the features of your choice. The resulting 3-D line is placed through the center point of the selected features.

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The Cylinder 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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Defining Features

Result output

The 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

Z projection into the Z/Y plane

X

Y A2


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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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The Cone Menu: Features → Cone Use the Cone feature to probe the location and position of inside and 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 on the different planes. 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 Wk is very small, Calypso might compute a cylinder instead of a cone. The measurement 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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Defining Features

Result output

The 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

Y

example cone

Z projection into the Z/Y plane

X

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.

The Sphere 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 probe configuration 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.

Result output

There are no projected angles for a sphere. D represents the diameter of the sphere.

D

The Curve Menu: Features → Curve You can use the Curve feature to measure planar sections of bodies and lift curves (planar curves on the face of a cylinder). This feature is extremely versatile and consequently, it is described in a separate section (see ➤“Curve Measurement (Option)” on page 15-1). Bear in mind that this feature is not included in the normal Calypso scope of supply and must be obtained as an option.

The 3D Curve 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 15-1). 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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Defining Features

The Ellipse 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 representation in the Feature representation dialog box, which you can open from the Prerequisites or via Prerequisites → 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

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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.

D

M (X, Y, Z)

D2

Dgroß

Dklein

(X1, Y1, Z1)

(X2, Y2, Z2)


An ellipse is not recognized automatically by Calypso. Begin by adding the feature to the measurement plan and then take probings.


The origin of the feature’s local coordinate system is in the center of the ellipse. It is not projected on a plane of the coordinate system.

The Slot Menu: Features → Additional Features → Slot You can use the Slot feature to probe the length, width, depth and position of slots. Bear in mind that automatic feature recognition is not available for slots. Probing strategy

Probe at least 5 points. Make sure that all points are spaced as uniformly as possible over the sides of the slot. 1 Begin by probing 2 points on one side of the slot. 2 Probe a point at the apex of a curve.

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Defining Features

3 Probe a point on the other side of the slot. 4 Probe a point at the apex of the second curve.

2

1

3

5 4

You can distribute other probing points as you wish. Automatic feature recognition

A slot is not recognized automatically by Calypso. Begin by adding the feature to the measurement plan and then take probings.


The origin of the feature’s local coordinate system is in the slot’s center of gravity.

The Rectangle 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.


A rectangle is not recognized automatically by Calypso. Begin by adding the feature to the measurement plan and then take probings.

The Offset Plane Menu: Features → Additional Features → Offset Plane You can use the Offset Plane feature to define from three datum points a plane which does not actually exist on your workpiece. You can offset the reference points at will along the probing direction. Bear in mind that automatic feature recognition is not available for offset planes.

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Probing strategy

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 Point 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.

The Symmetry Point Menu: Features → Additional Features → Symmetry Point You can use the Symmetry Point feature to have Calypso compute a point which is symmetrical with two probing points. Calypso computes the coordinates of the symmetry point and displays the distance between the two points. Probing strategy

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.

Result output

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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Defining Features

The Radius Point Menu: Features → Additional Features → Radius Point Using the features Radius, Sphere and Angle Points, you can select the applicable radius correction in different situations with singlepoint measurements in order to define the point of correctly. 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 probe tip and the specified center point.

Measuring plane R

Cylinder axis

M

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.

The Sphere Point Menu: Features → Additional Features → Sphere Point Using the features Radius, Sphere and Angle Points, you can select the applicable radius correction in different situations with singlepoint measurements in order to define the point of correctly.

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With the Sphere Point, the measured value is corrected towards the connecting line between the center of the probe tip and the specified center. The sphere point is intended for probing sphere surfaces. Use the radius point for cylindrical features. Perform the following steps to measure a sphere point: 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.

pre-defined center of circle


R

Calypso cannot automatically detect a sphere point. First, insert the feature in the measurement plan, define the sphere center point and then perform probing.

The Angle Point Menu: Features → Additional Features → Angle Point Using the features Radius, Sphere and Angle Points, you can select the appropriate radius correction in different situations with singlepoint measurements in order to define the point of correctly. With the angle point, the measured value is corrected towards the normal for the probed plane. Probing strategy

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Defining Features

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. 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 a probing. Specify one plane first. Calypso computes the second plane from a probing and the origin of the specified plane. 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.

The General Surface Menu: Features → Additional Features → General Surface The General Surface feature was integrated in Calypso to allow runs programmed in DMIS to be imported to Calypso. The General Surface corresponds to the DMIS feature FEAT/GSURF. For the evaluation of a General Surface, a mathematically defined freeform surface is not computed in order to obtain the result of a nominal-actual comparison between two surfaces. The General Surface feature is merely a “container” for a set of points belonging to a surface. Particularities

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Each point of a General Surface is therefore probed, measured and processed individually. Each point possesses its own strategy and resources.

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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. NOTE hss

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 protocol and custom printout).

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 Surface.

Point from CAD model

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).

Point by probing

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.

The General Curve Menu: Features → Additional Features → General Curve The General Curve feature was integrated in Calypso to allow runs programmed in DMIS to be imported to Calypso. Particularities

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.

Strategy

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.

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Defining Features

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). NOTE hss

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 protocol and custom printout).

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.

Point from CAD model

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).

Point by probing

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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Linking Features in Constructions

Linking Features in Constructions Constructions are constructed features which cannot be probed directly on a workpiece, e.g. the center of a bore or the intersection of two features. Calypso can, however, mathematically construct regular geometric features and, in this way, define the feature you require. As constructions cannot be probed, automatic feature recognition is not available here. In the measurement plan, a construction is indicated by the blue border around the icon. Calypso s a total of 12 different constructions: – ➤“The Intersection” on page 5-42 – ➤“The Perpendicular” on page 5-53 – ➤“The Symmetry” on page 5-54 – ➤“The Projection” on page 5-55 – ➤“Average-Feature Construction” on page 5-56 – ➤“The Edge Point” on page 5-56 – ➤“Cone Addition Construction” on page 5-57 – ➤“The Maximum Coordinate” on page 5-59 – ➤“The Minimum Coordinate” on page 5-59 – ➤“The Maximum Result” on page 5-59 – ➤“The Minimum Result” on page 5-60 – ➤“The Plane with Offset” on page 5-60

How to Define Constructions The procedure for defining a construction is very similar to that for defining a feature: 1 Add the construction of your choice to the measurement plan by selecting it in the Construct menu. 2 Double-click on the icon of the construction or select it and click on the Magnifier icon. This opens the definition template of the construction. 3 Use the Feature buttons to select the features for which the construction is required. 4 Click on OK to confirm your choice. The features you selected are now interlinked in a construction.

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Defining Features

Defining Features by Recalling The recall is a special type of construction. You can use a recall to derive a new feature from one or more features in a common coordinate system. Example of application

Let us suppose you have measured four circles. You would now like to learn the circle in 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

resulting pitch circle r

circle1

circle3

circle4

How to Define a Point or a Feature by Recall You can recall the reference point (the origin of the feature‘s local coordinate system) of an element or the element as a whole. Perform the following steps to define a point or a complete element by a recall: 1 Open the definition template of the geometric element that you require to be created by a recall. 2 Select one of the recall types from the Nominal Definition list: • Recall – with this type you define a new feature from previously defined features, with each recalled feature providing its reference point (the origin of its feature‘s local coordinate system). Thus two circles define a straight line that goes through both their center points. • Recall One Feature – in this way you recall the whole selected element (possibly transformed into a different coordinate system) and derive from it a new feature of identical geometry. You then see the select window with the features.

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3 Select the feature or features you require – press the Ctrl or shift key if necessary – and click on OK. The reference point or points and the feature are accepted.

How to Recall Points with Area Specification Points recall s the recall of any previously defined points of other features to evaluate them in a different manner. You can recall individual points, single paths, specific areas (specified in coordinates or angles) or the complete feature. Perform the following steps to define a point or a complete element by a point recall: 1 Open the definition template of the geometric element that you require to be created by a recall. 2 From the Nominal Definition list, select the Recall Points recall type. The features available to you are displayed in the Recall Points window:

The list contains all the potential features for the points recall. When the Recall Points dialog box opens, two more buttons appear at the upper right of the toolbar.

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There are now two options: 3 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. 4 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 this icon to display the measured points of the feature in the CAD window with crosses. • Click on this icon and, using the mouse, drag a rectangle around the points of your choice. • Click on OK. The points are included in the new feature.

The Intersection Menu: Construction → Intersection With the Intersection construction, you can intersect straight lines, planes, circles, cylinders, spheres and cones with each other and have tangents computed. To do this, you enter the two characteristics and obtain one or more results. Depending on which characteristic 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. Depending on the intersection, one to four results are showed in the Result Selection group of the definition template, and you select the intersection result you want to proceed with.

Automatic correction

With this construction, Calypso supplies results even when 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 5-49 and ➤“Intersection of a plane with a cone” on page 5-50).

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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.

Intersection of a straight line with a straight line The straight lines can be located in any part plane. However, they must not be parallel or antiparallel.

Line 1

Inters ection

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.

Intersection of a plane with a plane The normals of the two planes must not be parallel or antiparallel.

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The result computed by Calypso is the spatially defined intersection line. The point of the computed intersection lines that is closest to the origin is used as the origin of the feature‘s local coordinate system (reference point) of the intersection lines.

Intersection of a circle with a circle Both circles must lie in one plane. A distinction must be made here between 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. If just one intersection is present because the circles are touching, two identical points are read out. – There is no intersection between the circles.

center

Calypso cannot compute a result in this case.

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Intersection of a straight line with a circle The straight line and the normal of the circle must not be parallel or antiparallel. This means that the projection of the straight line into the plane of the circle is again a straight line.

L ine

Circle

P2

P1 P rojection line

Calypso calculates as a result the intersections of the projected straight lines 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.

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– There is no intersection between the (projected) straight line and the circle.

Perpendicular Lotfußpunkt

Calypso cannot compute a result in this case.

Intersection of a straight line with a sphere Calypso computes as a result the intersections of the straight line with the sphere. If the projected straight line only touches the sphere and does not intersect it, two identical points are determined.

If computation is not possible, an error message is issued.

Intersection of a straight line with a plane The straight line and the normal of the plane must not be perpendicular to each other.

penetration point

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Calypso computes as a result the piercing point of the straight line through the plane.

Intersection of a straight line with cylinder The straight line and the cylinder axis must not be parallel or antiparallel.

g

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.

Intersection of a straight line with a cone If the check box – Wall has been activated, Calypso will calculate: the piercing points of the line through the wall of the cone

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– otherwise: the intersection point of the line with the axis of the cone.

g


Intersection of a plane with a circle The normals of the plane and of the circle must not be parallel or antiparallel.

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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Intersection of a plane with a sphere Calypso computes as a result the intersectíon circle of the sphere with the plane.


Intersection of a plane with a cylinder If the check box – Wall has been activated, Calypso will calculate: a circle – otherwise: an intersection point. z, k

K E

R

In the case of a wall intersection, Calypso will not create the “exact mathematical” ellipse as the intersected entity 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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Intersection of a plane with a cone If the check box – Wall has been activated, Calypso will calculate: a circle – otherwise: an intersection point.

E E’

Here, Calypso will not create the “exact mathematical” ellipse as the intersected entity 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.

Intersection of a sphere with a cylinder The intersection of the sphere and the cylinder is the intersection of a sphere of identical size whose center point is the projection of the sphere center point to the cylinder axis.

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The distance between the center point of the sphere and the cylinder axis must be less than half the cylinder radius.

Intersection of a sphere with a cone The intersection of the sphere and the cone is the intersection of a sphere of identical size whose center point is the projection of the sphere center point to the cone axis.

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.

Intersection of a sphere with a sphere

Calypso computes the exact intersection circle of the two spheres.

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Intersection of a cone with a cylinder If the check box – Wall has been activated, Calypso will calculate: the intersection of the cylinder with the “projected” cone – this is a cone of the same tapen angle, the point of which is the projection of the cone point on 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.

Intersection of a cone with a cone The intersection of a cone with another cone is generated in the following manner: The cone with the blunter opening angle is set coaxially to the other cone, the tip of the new cone results as the projection of the old tip to the cone axis of the cone having the more pointed opening angle. The circle resulting from this is generated as the intersection of the two cones. A condition for this is that the angle between the two cone axes is smaller than 45°. The distance between the axis of the blunter cone and the plane of the theoretical resultant circle and the center point of the circle must be less than half the radius of the circle. S spitz

θ S‘ stumpf

ϕ hϕ R

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The two cones can lie parallel or antiparallel to each other. Calypso computes the intersection circle in both cases.

R

K

The Perpendicular Menu: Construction → 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 to be feature 1. The following table shows which coordinates are used by potential characteristics: Feature 1

Using Coordinates

Point (probing)

Coordinates of probing point

Circle

Coordinates of center point

Straight line

Coordinates of the origin of the local coordinate system

Plane

Coordinates of the origin of the local coordinate system

Feature 2

With Feature 2 in the definition template, set the direction of the template. The perpendicular is vertical on Feature 2. Therefore, Feature 2 must be a spatially defined element.

Interpretation of results

The following is read out as the result of the computation:

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– The straight line on which the perpendicular is located by the specification of two projection angles. You can modify the reference to the projection angles at Spatial axis. – The length (distance) of the perpendicular. The calculated distance of the perpendicular is the distance of the point in Feature 1 to Feature 2.

The Symmetry Menu: Construction → 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

You can select any feature as Feature 1.

Feature 2

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

Calypso computes the coordinates of the symmetry point.

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– Symmetry plane of two planes

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.

The Projection Menu: Construction → Projection You can use the Projection construction to determine the position of a feature projected onto another feature (e.g. the position of a point projected onto a plane). Feature 1

Define the feature you want to project as Feature 1.

Feature 2

Specify as Feature 2 the feature onto which you want Feature 1 projected.

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Result output depends on the feature which results from the projection. The examples below will facilitate interpretation of the results: – Projection of a circle onto a plane The projection of a circle onto a plane transposes 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.

Average-Feature Construction Menu: Construction → 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.

Picklist

In the picklist, define the characteristic (radius, angle, ...) for which you want the average computed. The list contains all the main characteristics.

The Edge Point Menu: Construction → Edge Point Use the Edge Point construction to have Calypso compute a corner between two features. This corner is the intersection of two imaginary extensions of the two features. Feature 1

5-56

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.

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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.

Feature 3

You can specify a plane or a point as feature 3. If you specify a point, this point 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. 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

element 2

If the third plane is not defined, the edge point is defined centered between element 1 and element 2 (element 1 and element 2 usually differ at least slightly in height).

Cone Addition Construction Menu: Construction → Cone Addition Calypso uses the Cone Addition construction to compute the following data for the Cone feature: – Diameter Definition: The diameter of the cone at the defined height. – Position Definition: The cone height at a defined diameter. Feature

The only feature you can select is a cone, because cone additions are computed exclusively for cones.

Diameter definition

If you have selected the option Diameter Definition, 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:

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• Height L can be referenced to the Cone Origin.

cone axis cone origin reference plane

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). • Height L can be referenced to the Part alignment.

cone axis cone origin

L workpiece system

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 coordinates on this axis are 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, using the intersection point with the cone axis) defines the height of the required diameter. Only the Point, 2-D Line and Plane features are suitable here. Position definition

If you have selected the option Position Definition, 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. Only the Circle, Circle on Cone, Cylinder, Cone and Ellipse features are suitable here.

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Calypso will either calculate a specific diameter or a specific height on the cone depending on what you have selected.

The Maximum Coordinate Menu: Construction → Maximum Coordinate You can use the Maximum Coordinates construction to have Calypso compute the coordinates of the point at which positive deviation in feature geometry is at its maximum. You can reference the deviation to the feature’s actual geometry or its nominal geometry. Feature 1

Click on the Feature 1 button to open the Selection dialog box, where you can select a regular geometrical feature of your choice.


Calypso computes the coordinates of the point where positive deviation is at maximum.

The Minimum Coordinate Menu: Construction → Minimum Coordinate You can use the Minimum Coordinates construction to have Calypso compute the coordinates of the point at which negative deviation in feature geometry is at its maximum. You can reference the deviation to the feature’s actual geometry or its nominal geometry. Feature 1

Click on the Feature 1 button to open the Selection dialog box, where you can select a regular geometrical feature of your choice.


As a result, Calypso calculates the coordinates of the point having the largest negative deviation.

The Maximum Result Menu: Construction → Maximum Result You can use the Maximum Result construction to have Calypso determine which is the largest in a group of similar features. Feature selection

Click on the Feature Selection button to open the Selection dialog box, where you can select the features you want to have compared.

Picklist

From the picklist, select the characteristic (radius, angle...) 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.

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For example, you can ascertain which cylinder in a group of three has the largest diameter.

The Minimum Result Menu: Construction → Minimum Result You can use the Minimum Result construction to have Calypso determine which is the smallest in a group of similar features. Feature selection

Click on the Feature Selection button to open the Selection dialog box, where you can select the features you want to have compared.

Picklist

From the picklist, select the characteristic (radius, angle...) 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.

The Plane with Offset Menu: Construction → Plane with Offset You can use the Plane with Offset construction to define a plane offset a certain amount above a reference plane. Feature 1

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.

Offset

In the input field Offset enter the value by which the offset plane should be offset compared to the plane selected in Feature 1.


Calypso computes the coordinates of the plane with offset. Please note that the offset plane is usually a plane which does not really exist and, consequently, no probing points can be taken.

Additional Features Holos and Gear You can add the Holos or Gear feature to the measurement plan with Features → Additional Features → Holos or Features → Additional Features → Gear or via the Toolbox of the Utilities page. In this manner, you can integrate any HOLOS or GEAR macro into a measurement plan and have it executed during the CNC run. The programmed macro is started by the CMM-OS during the CNC run.

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You can add the Holos or GEAR utility to both the list of characteristics and the list of features. In this manner, the selected macros can be executed after either a characteristic or feature is run.

! hss

Entries for HOLOS or GEAR

Caution 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 ed 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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Defining a Measurement Strategy The nature of the feature and the location of the measurement must be known before Calypso can perform a measurement with the CMM. In most instances that is enough, because when the measurement plan starts Calypso automatically performs the measurements required for the characteristics. The term “measurement strategy”

Not infrequently, however, other decisions have to be made because of special considerations relating to measurement or the material, for example, or on 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: – Select Utilities and insert in the strategy list (Stop, Position CMM without Probing, Change Prober, Clearance Data, etc.) – Using Technology macros (single point mode) – Selecting a Path generation method (See ➤“Path Generation – Automatically Measuring Features” on page 5-68.) – Editing the Point list (See ➤“The Points List” on page 5-64.) – Editing the Probe routes (See ➤“Editing the Probe Routes” on page 7-22.) – Checking and editing Clearance data (See ➤“Checking the Routes” on page 7-25.) 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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Defining a Measurement Strategy

The diagram shows an example of the Strategy window with a Circle feature. Generate Path Point list

Resources

Single points/ scanning (paths)

Edit technology

Technology macro

Strategy list

This dialog box is fully described in Strategy in the Calypso Online Help.

How to Use the Shortcut Menu of the Strategy List The strategy list contains certain entries (e.g. probing points, used tools and scanning methods) for all the points and tasks that the Calypso should execute when measuring a feature (in the sense of the probe routes). To edit a list entry through the shortcut menu: 1 With the mouse, mark the list entry that you want to work on. 2 With the right mouse button, click on the list entry. The shortcut menu opens with the following options: • Execute Now!: The CMM runs the list entry immediately. Make sure that the CMM can move freely. • Copy: Copies the marked list entry. • Cut: Removes the marked list entry from the list. • Paste: Inserts a previously copied or cut element. • Edit: Opens the window with the parameters for the list entry. This can also be done with a double click on the list entry.

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3 Click on the command of your choice. The command is executed.

The Points List The points 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 optimal probe points. The illustration below shows an example of the Point List window with a plane measured at 4 points.

How to Change the Point List In the point list you can change the stylus used for measuring and change the coordinates or the normal vectors of the probing points.

! hss

Caution 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 window will open. 2 Click on the button with the icon for the point list.

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3 To change a coordinate, click in the entry field shown and overwrite the old value. 4 Click on OK. The settings are accepted.

Alternative Probing Methods (Self-Centering Probing) The probe head is usually unlocked only in the probing direction. This means that the probe head can move in one direction only, namely the direction corresponding to the movement of the joystick on the control . probing direction

Z Y

locking mechanism X

In this example, self-centering probing of the Vee-way necessitates cancellation of the lock in the X direction in order to avoid faulty probing. probing direction

Z Y

locking mechanism X

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How to Activate Self-Centering Probing NOTE

Self-centering probing is an option only for measuring probe heads.

hss

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 Prerequisites → Probe Self Centering. The Self-Centering Probing dialog box is opened. Skip to step 4. 2 If you want to activate only this function 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. • Open the probing point by clicking on the magnifier or by double-clicking. • Click on the Probe Self Centering button. The Self-Centering Probing dialog box is opened. Skip to step 4. 3 If you want to activate for all features of a measurement plan: • Check that no features are highlighted in the measuring plan. • Select Prerequisites → Probe Self Centering. The Self-Centering Probing dialog box is opened.

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4 To activate probe self centering: • Deactivate the left of the two check boxes Self-centering probing. • Activate the right of the two check boxes Self-centering probing. 5 Set the parameters for self-centering probing. 6 Click OK to save the settings. The next time it probes, Calypso will use the settings you just activated.

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Defining Features

Path Generation – Automatically Measuring Features Unlike the probing of individual points, path generation procedures feature rapid multi-point measurement in a single operation. Path generation will help you arrive at optimum and highly accurate measuring results. NOTE hss

You must have qualified your probe with the Tensor setting in order to use path generation for scanning (see ➤“Installing and Qualifying Probes” on page 4-10). The measurement strategy depends on a number of parameters, on the group of the characteristic (shape, position, size) through tolerance up to the stylus used. Calypso calculates from these parameters the starting parameters of the CMM, which lead to 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 single points, if you have a CMM with measuring probe head. – Or you can just generate a path from single points, if you have a CMM with switching probe head (pseudo scanning). Path generation is a macro which 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 standard proof required and very accurate calculation of your features. To use a path generation method, follow these steps: – Set the global settings for the 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 a path generation method. Asg the path generation method is split into three steps: – Adding the path generation method to the strategy list.

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– Check/Change general settings. These settings are common to all path generation methods. – Check/Set values for the path generation method. These settings are described separately because they depend on the chosen path generation method.

How to Add a Path Generation Method to the Strategy List First, the path generation method has to be added to the strategy list of the feature, so it can be used when generating travel paths. To adopt a path generation method for a feature: 1 Make sure that the feature is part of the measurement plan and that the definition template is open. In the definition template you see the Strategy button. 2 Click on the Strategy button. The Strategy dialog box is opened.

Path Generation Methods

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 single points if you choose it in Step 3.

General Settings for the Path Generation Method You can now change general settings for the method separately from which path generation method is set for a feature. Calypso supplies default values for the fields in the dialog box for the chosen path generation method. The data comes from: – the geometry data of the feature, – the default values and – the tolerances from • the characteristics and • the feature. If you have not defined any tolerances yet, you can do it in this section. Calypso calculates the parameters by the closest tolerance which you entered for testing the feature and the point density for the characteristics group (see ➤“Basics about Characteristics” on page 6-2). A description for these parameters for each path generation method can be found in: – ➤“Path Generation Methods for Circle, Cylinder and Cone” on page 5-71 – ➤“Path Generation Methods for Planes: the Polyline” on page 5-73 – ➤“Path Generation Methods for Planes: the Grid” on page 5-75 – ➤“Path Generation of Lines” on page 5-76

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Path Generation Methods for Circle, Cylinder and Cone The offered pages for entering the parameters for the path generation methods (for the features circle, cylinder, cone) do not differ from each other. In the following picture you see the input window for a circle segment.

Generating the path from the CAD model

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 . 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 generated different paths. (At this time the function is implemented only for the circle and arc.) If you make subsequent, manual changes to the data, Calypso does not recheck the information. This means that you have a great deal of latitude in defining paths.

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Defining Features

Entering formulas for path parameters

The entries for path generation can be parameterized. Click on the corresponding fields with the right mouse button and then select Formula in the popup 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!) – Probe – Stylus

Parameterizing single points and intermediate positions

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 List Of Points dialog box.

In the dialog box Reference system for PCM variable 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 measuring height and the resulting measurement range are explained by the illustration below: Origin of local Element Coordinate System X

min. measuring height

Measuring range

max. measuring height

Path Generation Methods for Planes: the Polyline The automatic measurement of a polyline is a valuable tool which helps you measure a track of lines, circle segments and full circles on planes. This helps you measure planes very easily that are strongly segmented or ruptured.

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Defining Features

You see the input window for the generation of polylines in the following picture.

Coordinates list

Mark frame

Make sure that you have entered a value for edge deviation in the system set up. Check this value by pressing on the Basic Settings button and then on the SCAN Limits tab.

How to Create a Polyline To create a polyline: 1 Probe the points on the plane that you want to create the polyline from. You can do this with the CAD window (you will find more information in the Online Help under „How to Define a Probing Point in the CAD Window“) or the CMM. Each measuring point which you entered is displayed in the coordinate list (from bottom to top) in its X, Y and Z coordinates. Calypso connects these points with lines by default.

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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 consists now encloses the three points from which the circle segment or full circle is 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.

Path Generation Methods for Planes: the Grid With the grid measurement, you can create a plane right down to very small sections. The input window for the path generation of planes with a grid can be seen in the figure below.

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Defining Features

Path Generation of Lines With the path generation method for straight lines, a straight line is started whose points are already defined in the feature. Calypso does not need any more details for this, and you can merely see the parameters of the CMM and the tolerance in the input window of the path generation method. The input window for the generation of straight lines can be seen in the figure below.

How to Set Parameters for a Path Generation Method To enter tolerances now and set general settings: 1 Double click on the corresponding entry in the strategy list to open the window for the path generation method. 2 Click on the Basic Settings button if you want to enter required point densities. You switch to the corresponding page in the system set up (you will find more information in the Online Help under „How to Change the Measurement Parameters of the CMM“).

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3 If you have not defined any tolerances yet, enter them in the Expected Tolerance field for the feature. 4 Click on the Calculate button. Calypso runs the calculation with the parameters from the Settings group. The default scanning speed proposed by the system depends on the required accuracy. 5 Enter the number of the stylus in the Stylus field, which you want to use for the CMM path generation method. 6 Enter the values for the path generation method. See ➤“Path Generation – Automatically Measuring Features” on page 5-68. 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 5-77. The path generation method has now been fully defined and will be executed once a CNC run is initiated.

Features you can Measure with Path Generation The available path generation methods are automatically offered with every relevant feature. The choice of a path generation method emerges from the required measuring tasks. The following path generation methods are available: Feature

Icon

Path Generation Method

Line

Line measurement

Plane

Polyline measurement

Grid measurement. The plane is acquired in a grid of -definable pitch. Circle, Cylinder, Cone

Four-Point Circle Macro. This measurement is semiautomatic. To execute this measurement, move the probe to the center of the circle (cylinder, cone) that is to be measured. Calypso takes 4 probings and calculates from these the values for the circle.

Circle

Circle Auto Path Definition (Circle Auto Path Measurement). The start angle and angle range can be adjusted.

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Feature

Icon

Path Generation Method Helical Path (Helix Measurement). Suitable for special applications (threads). Gradient, number of turns, start angle and rotation direction can be adjusted.

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 adjusted. Form lines. The number of surface lines is editable. Helical Path (Helix Measurement). Gradient, number of turns, start angle and rotation direction can be adjusted.

Sphere

Define Sphere Position. Calypso probes the sphere and in so doing defines the position of the sphere. The probing locations can not be influenced. In CNC runs, you will be requested to take manual probings. Sphere Macro. You can enter the sphere coverage for the area in which these probings are to be taken.

Cone

Circle part measuring: 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. Layer measuring: One or more intersections will be measured between the surface area and coverage area of the cone. The number of intersections and their measuring heights can be adjusted.

Curve

Curve segment measuring: Only for the Curve option (see ➤“Curve Measurement (Option)” on page 15-1). 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 of curvature is clockwise (from the “top” or “outside”).

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Chapter

6 6

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 to 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 s 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 ➤“The Calypso Desk” on page 1-5 and ➤“Measurement plan-oriented Measuring with Calypso” on page 1-9.

Included in this chapter: Basics about Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Calculation of Geometric Features . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Defining Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Details on Specific Characteristics. . . . . . . . . . . . . . . . . . . . . . . . 6-35

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Basics about Characteristics Once you have defined the features, you can set the characteristics for measuring the size (dimensions), form, position, and so on, of these features. In this way you can ascertain whether the features are within the limits you specified. You can also add a characteristic to the list of characteristics without immediately defining the associated feature. You can select the associated feature later when entering the settings for the characteristic. The characteristics are split into three groups (see table below). To evaluate these features, different point densities are required for each group, depending on which best fit method is used (see ➤“The Fit Methods” on page 6-3 and in Online Help to check the settings under “How to Change the Measurement Parameters of the CMM”). Group

Point Density

Comment

Size elements

Small

Normally these characteristics are rated by a small number of measuring points. It is recommended to use more points than required to also get a statement about the standard deviation (Sigma). For a function-oriented evaluation (peer measure evaluation) a higher number of points is required.

Location elements

Medium

These characteristics require a higher point density, because the position deviation overlaps the shape deviation of the measuring features.

Form elements

High

The evaluation of the characteristics needs a high point density on their measurement plane. Low- filtering of the measurement points is also recommended to minimize the influence of the surface roughness. You can add other special features to the list of characteristics. In this case, they are not actually characteristics, but they will be processed during the CNC run. For more information, please see ➤“The Utilities” on page 6-9.

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Calculation of Geometric Features

Calculation of Geometric Features To understand and correctly interpret measuring results, you need to know how Calypso calculates the corresponding standard geometric feature from CMM's measured points. Using the entered measuring points Calypso calculates a computed feature. Mathematically, the computed feature is the feature which best fits the resulting measured values in of the standard geometery. The computed feature is the basis for the evaluation of the measuring results. Depending on the fit method used, the features determined in this manner can differ slightly from each other. Thus, there are also different deviations of the measured feature from the specified nominal feature. Therefore, the computed feature and the associated best fit method are fundamental for the accuracy of the Nom-Act Comparison, which is performed over the characteristics. NOTE hss

The optimal 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.

The 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 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 are evaluated. If you select Default, the fit method defined in the feature will be used. Not all fit methods are available, only those suitable for the selected feature (see ➤“Using the Fit Methods” on page 6-6). You can view and change the parameters for the best-fit method in the system setup 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 you can see in the diagram, depending on the used rectification method, there are different results for measuring sizes (e.g. example diameter), form deviation and position (e.g. center).

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Best fit According to Gauss The Gauss best fit method calculates the average best fit element. From the calculated ideal outline and the actual probed outline, a sum of square distances is calculated. The minimum this sum results in the best fit element. That means a best fit according to Gauss is insensitive against outliers and forms a clear result by using limited calculating. If there is just a small amount of points, the Gauss method is always the standard evaluation method for measure, form and location testing.

Best Fit According to Tschebyscheff The best fit according to Tschebyscheff calculates the geometric feature in a way that there is the smallest maximum deviation between calculated ideal outline and actual probed outline results. Therefore, the extreme values of the probing have an impact on the result of calculation. This makes this best fit method very susceptible for outliers. A high number of measured values can improve matters. It may, however, be advisable to eliminate outliers, depending on the measuring requirements (see ➤“How to Eliminate Outliers” on page 6-31). Used for ISO 1101 shape testing.

Calculation as Circumscribed/Inscribed Feature When calculating as circumscribed feature, the feature is as small as possible and positioned in such a way that no probing point is outside the feature. When calculating as inscribed feature, the feature is as large as possible and positioned in such a way that no probing point is inside the feature. This method is useful for pairing dimension evaluation and for evaluating the relating element on position tolerances. Requirement: Large number of points. Recommendation: Outlier elimination, because the circumscribed or inscribed feature can only be mapped on the basis of the extreme points.

Calculation as Tangential Feature The tangential feature is the largest possible feature outside which no probing points of the feature are situated, or the smallest possible element inside which no probing points of the feature are situated. Requirement: Large number of points. Recommendation: Outlier elimination, because the tangential feature can only be mapped on the basis of the extreme points.

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Using the Fit Methods For each feature, the table below shows the fit methods you can select for the feature.

6-6

Element

Gauss Minimum Circumscribed/ inscribed

Tangential element

2-D line

×

×

×

3-D 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 list of the desk. • You can choose characteristics from a toolbox of Calypso. • You can define characteristics implicitly in the definition template of a feature. See the section entitled ➤“The Definition Template for Features” on page 5-3 for a description of the check boxes of the Tolerance for: group. – You assign the features to the characteristics, please see ➤“Connecting a Characteristic to a Feature” on page 6-14. You can find more detailed information regarding the different characteristics in ➤“Details on Specific Characteristics” on page 6-35.

How to Insert Characteristics into the Measurement Plan To insert characteristics into a measurement plan: 1 Click on the Characteristics button to view the list of characteristics in the measurement plan area. 2 Choose the characteristic you want: • To select the characteristic from the menu bar of the Desk, click either on Size or Form and location and select the characteristic from the submenus. You can add other special features to the measurement plan using Prerequisites → Utilities. • To select the characteristic from a toolbox, open the toolbox. (➤“How to Work with a Custom Toolbox” on page 7-17.) Click on the characteristic and drag it into the measurement plan area. The selected characteristic is added to the list of characteristics. You can repeat these steps to add more characteristics or immediately link a feature to the inserted characteristic.

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The Characteristic Definition Templates When you select a characteristic from the Size or Form and Location menu or from the toolbox, it will be listed in the measurement plan area. If you wish to assign features and select their tolerances, the corresponding definition template must be open. NOTE hss

The content of the characteristic definition template varies with the selected characteristic. There are three ways of opening a definition template: – Mark the characteristic and click on the Open selected object button. – Right-click on the characteristic to open the popup 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 links 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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The Utilities In the Utilities group in the toolbox and in the menu under Prepare → Utilities, you can find some special elements that, strictly speaking, are not characteristics but are required for the measurement plan run in certain circumstances: – Alignment – 3D Best Fit – RPS Method – P6 Method – Stylus Qualification – Gauge Correction Qualification (see ➤“Greater Accuracy in Circle Measurement (Basics of Gage Correction Qualification)” on page 5-18) – Erosion module (option) – Textelement – Save Alignment – Load Alignment – Delete Alignment – Zero Base Alignment (see ➤“How to set a base alignment to zero” on page 4-53) The utilities are described with the runs, characteristics and features for which they are needed. Only the following utilities are described here. – Stylus Qualification – Erosion Module – Textelement – Save Alignment – Load Alignment – Delete Alignment

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The Stylus Qualification Utility Use Prerequisites → Utilities → Stylus Qualification to add the Stylus Qualification utility to the measurement plan. The definition template for this utility corresponds to that of the Probe Qualification dialog box (this dialog box is fully described in Probe Qualification Window in the Calypso Online Help):

You can use this utility to qualify any defined stylus or probe configuration defined beforehand. Calypso automatically performs qualification during the CNC run of the measurement plan. If you use a probe changer, Calypso automatically uses the correct probe. Otherwise, you will be prompted to insert the probe.

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The Erosion Module Utility NOTE

The Erosion Module is an option you can purchase and have enabled.

hss

You can add the Erosion Module utility to the measurement plan by selecting Prerequisites → Utilities → Erosion Module or via the Tool Box on the Utilities page.

The Erosion Module provides a file with translation and rotation modules for two related coordinate systems which is suitable for erosion machines. These coordinate systems refer on the one hand to the clamping device and to the erosion electrode on the other. Here, the coordinate system of the workpiece or tool (erosion electrode) (Xe, Ye, Ze) will be determined on the basis of the coordinate system of the clamping device (X, Y, Z). It will be necessary to enter the type of erosion machine that is being used along with the name of the file that will be created. During the CNC run, i.e. when measuring the feature, the coordinate systems 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 an a diskette.

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Once the Erosion Module has been executed, an ASCII file will be available in a format that can be used with the eroding machine. You can now determine the name and path of the file. NOTE

The directory path must be available. It is not created automatically.

hss

The Textelement Utility With Prerequisites → Utilities → Textelement or by using the Tool Box on the Utilities page you can enter the utility Textelement 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.

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 protocol, and the custom printout). Here, only the text itself will be output. The name of the characteristic will not appear as a header (as is usual the case of characteristics. 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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Save Alignment 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. 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 directory ...\Calypso\home\om\workaera\basesystems. 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.

Load Alignment 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. When the Load Alignment utility is executed in the CNC run (because a feature refers to this alignment, for example), 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. Particularities

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.

Delete Alignment 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 directory ...\Calypso\home\om\workarea\basesystems.

If the file name contains backslashes (“\”), the program will branch to the appropriate subdirectories. 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.

Connecting a Characteristic to a Feature A characteristic must receive information relating to the feature in the measurement plan which will be used as a basis for the check. You have several different ways of connecting the characteristic to the feature of your choice: – Use the CAD window if the feature is already defined. Click on the feature of your choice in the CAD window. Don't forget to make sure, however, that Select Already Extracted Features is set in the CAD window (you will find more information in the Online Help under „How to Select Features on 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.

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– 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

List of existing features

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 shortcut menu. This opens a list of all characteristics in which the feature you selected is used.

Overview

How to Assign an Existing Feature To assign a feature to a characteristic using the definition template, follow these steps: 1 Open the definition template by double-clicking the characteristic of your choice. The definition template is opened. 2 Click on the Feature (or Feature element1) button. The Selection (Features) dialog box is opened. All Features is generally activated by default. 3 In the list, click on the feature that you want to assign. NOTE hss

You can view a filtered, short-form list by clicking on the corresponding icon, for example.

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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 6-29. 5 If you want to eliminate outliers: activate the No Outliers check box and if necessary, click on the Settings button to define parameters for eliminating outliers. You will find more information on outliers in the section entitled ➤“How to Eliminate Outliers” on page 6-31. 6 If you want to use a method other than the default, click on the Parameters button and select the method you want in the dialog box. Note that all 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 remainder by repeating the steps described above. You will find more information on the Selection dialog box under Selection (Features) in the Calypso Online Help.

How to Assign a Feature Not Yet Defined As 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) dialog box is opened. 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.

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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 remainder by repeating the steps described above. You will find more information on the Selection dialog box under Selection (Features) in the Calypso Online Help.

How to Assign and Edit a Defined Feature If you are about to assign a feature to a characteristic and notice that something in the definition of the feature has to be changed (measuring strategy, additional probings, etc.), you can do so in the course of defining the characteristic. To assign and edit a defined feature: 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) dialog box is opened. 3 Activate the Select existing Features radio button, if it is not already activated. 4 Click on the feature you want in the list. NOTE hss

You can view a filtered, short-form list by clicking on the corresponding icon, for example. 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 ➤“The 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 remainder 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 Characteristics to Certain Features You can assign one or more characteristics to certain features in a single step. This means that the information in question has to be defined only once, while at the same time you can be sure that the common properties are exactly the same for all the features concerned. To assign characteristics to certain features: 1 Open the list of characteristics. 2 Click on the characteristics you want to assign. Press and hold down the Shift or Ctrl key if you want to highlight more than one characteristic. 3 Click on the Transfer format icon in the upper menu bar. The Characteristics assign to Features dialog box appears on the screen.

At the same time, the list of features is opened in the background. NOTE hss

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 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.

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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 for new characteristics a standard name (see above) is suggested. 8 Overwrite the names suggested by the system, if applicable. 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.

How to Define Nominals and Tolerances You can now match each nominal and tolerance that the characteristic has to check to the specifications. NOTE hss

The tolerances define calculation of the scanning speed for the measuring strategy. (See ➤“Path Generation – Automatically Measuring Features” on page 5-68).

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To enter tolerances and nominal values: 1 Open the definition template by double-clicking the characteristic. The Definition Template (characteristic) 2 will open (taper angle of a cone is shown here by way of example).

2 Enter the required nominal values (or more than one for locations) in the field Nominal (or Setting Position). 3 Now enter the tolerance values: • You can choose the tolerance group from the picklist (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 in measurement evaluation. 5 Select Last input form 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 measurement results. The elements in this dialog box are fully described in Definition Template (characteristic) 1 in the Calypso Online Help.

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Keep in mind that the icon of the characteristic is now displayed with either a green or red background, depending on if it is inside or outside of the tolerance. If the feature is not measured yet, the icon has a dark gray background (indicating that it is completely defined).

Tolerance Specifications for Characteristics Calypso has a multi-level menu that enables you to select the correct tolerance specification in the definition template for the characteristic. Tolerance Type

Tolerance

General tolerances

fine, medium, coarse, very coarse

DIN 1680 Rough castings

General tolerances GTA 12 to GTA 21 group GTA General tolerances GTB 12 to GTB 21 group GTB

DIN 1683 Rough steel castings

Linear measures

DIN 1683 linear measures GHTB 20 to GTB 16.5

Thickness measures DIN 1683 thickness measures GHTB 20 to GTB 16.5 DIN 1684 Rough castings of malleable iron

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

GTB 17 moulding / not moulding

DIN 1684 GTB 17 m. linear measures / not m. linear measures DIN 1684 GTB 17 m. thickness measures / not m. thickness measures

GTB 16/5 moulding / not moulding

DIN 1684 GTB 16/5 m. linear measures / not m. linear measures DIN 1684 GTB 16/5 m. thickness measures / not m. thickness measures

GTB 16 moulding / not moulding

DIN 1684 GTB 16m. linear measures / not m. linear measures DIN 1684 GTB 16m. thickness measures / not m. thickness measures

DIN 1685 Rough castings of cast iron with sphero

Linear measures / DIN 1685 linear measures GTB 20 to GTB 15 thickness measures DIN 1685 thickness measures GTB 20 to GTB 15

DIN 1686 Rough castings of cast iron with foliated graphite

Linear measures / DIN 1686 linear measures GTB 20 to GTB 15 thickness measures DIN 1686 Thickness measures GTB 20 to GTB 15

DIN 1687 Rough castings of heavy metal alloys

Sand rough

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Tolerance Type

Tolerance Gravity die casting

DIN 1687 GK GTB 15 to GTB 14 m: / not m.

Pressure die 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.

Gravity die casting

DIN 1688 GK GTB 20 to GTB 16 m. / not m.

Pressure die DIN 16901 Plastic tolerances

General tolerances DIN 16901 Gen. 160 A / 160 B DIN16901 Gen. 160 B / 160 B Tolerances for DIN 16901 with direct 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 6-24).

Specifying Tolerances with MMC/LMC You can apply the maximum material principle or the minimum material principle as necessary when you specify tolerances of form and position. The most-material principle is laid down in DIN ISO 2692. It applies to axes and mid-planes and allows for the interrelationships between dimensional tolerance and tolerance of form and position. When the most-material condition (MMC) or the least-material condition (LMC) is applied, tolerance extensions are permissible for tolerances of position for which diameter tolerances are not fully exploited. The procedure for applying MMC or LMC to tolerances of position is as follows:

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1 Open the definition template for the characteristic. 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 DIN Position characteristic for checking a cylinder.

Picklist

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 picklist. 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 constraining features as well. To do this click on the button of the constraint 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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Defining Custom Tolerance Tables When you have to define tolerances for a characteristic, you have a choice of entering the tolerance directly or selecting the Tolerance group from a selection list (with the name of the characteristic) (see ➤“How to Define Nominals and Tolerances” on page 6-19). Calypso s you with a multi-level menu in which you will find General Tolerances and a number of material-specific tolerances (Cast blanks of various makes, Plastic parts). You can expand this table as the need arises, in order to avoid the necessity of having to enter custom tolerances in the Upper Tolerance and Lower Tolerance . The tolerances offered in the menu are saved in XML files called “dinxxxx.xml” in the calypso\opt\om\data\toldat directory. If you want to add a tolerance table to the menu, you must create an XML file called “XXXX.xml” (e. g. “workroom1.xml”) of your own and copy it into this directory. The manner in which the file should be structured can be seen in the following example .

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XML File with Custom Tolerances (Example)

<Norm name = "Feinmessraum" group = "3" description = "Feinmessraum1">

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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 defined tolerance tables, this number defines the position at which the submenu will appear when the -def. 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=“LT” 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.

Filtration and Outliers Calypso enables you to edit measured values and exclude certain values from further analysis. A variety of filters are available for this purpose, along with the functionality for eliminating outliers. – Filters can segregate the waviness profile of a geometric feature from the effects of surface roughness. Filters, therefore, are of assistance in maximizing measuring accuracy. The following filter types are available: Gauss (ISO 11562), Spline and 2 RC (ISO 4291). The filter methods are low-, band- and high-. The new statistical data of the geometric feature are obtained from the filtered measuring data after compensation. – Individual measuring points of the geometric features 2d straight, plane, circle, cone, cylinder and sphere can be purged from the measured values as Outliers. The number of outliers eliminated is documented in the printout.

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Filtering Scanned Features The use of filters is recommended only for a large number of points, i.e. only for scanned features. Low-

Filtering a profile with low (low frequencies 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-

Filtering with high- (high frequencies 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.

Band-

A band- results from the combined use of a low- and a high. This suppresses both the long-wave (waviness) and short-wave (surface roughness) profile components that exceed the respectively specified limit.

Eliminating Outliers A measured point is tagged as an outlier if it is further than a defined threshold (threshold = factor * standard delta) from the computed Gaussian element. 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 easily propagates through the actual-value determination of the corresponding characteristic.

Defining Filters and Outlier Elimination There are several different points in Calypso at which you can parameterize and activate filtration and outlier elimination: – For an individual characteristic – For an individual feature – As defaults for the characteristic groups and the references and alignment elements of the coordinate systems.

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Which setting is valid?

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.

How to Select General Settings for Filter and Outliers You can define general settings for filtration and outlier elimination per characteristic group. Unless another setting is defined elsewhere for individual features, Calypso uses these general settings. The procedure for defining filtration and outlier elimination for characteristic groups is as follows: 1 Select Prerequisites → Filter/Outlier Elimination. The Filter/Outlier Elimination Default Settings dialog box appears on the screen.

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.

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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.

How to Set and Activate a Filter To activate a filter: 1 Open a corresponding characteristic in the measurement plan and click on the Switch to Feature Menu button. The Selection dialog box appears on the screen. At the bottom left you can see whether or not a filter is activated. If a filter is active its parameters are shown.

2 Activate the Filter check box to activate the filter.

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3 Click Settings to define the settings for the filter. The Filter dialog box appears on the screen.

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 filter type Band- – everything exceeding this range will be filtered out. 5 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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How to Eliminate Outliers To activate outlier elimination: 1 Open a corresponding characteristic in the measurement plan and click on the Switch to Feature Menu button. The Selection dialog box appears on the screen.

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 Settings to define the parameters for outlier elimination. The Outlier Mode dialog box appears on the screen.

4 Make your settings by activating or deactivating the check boxes or changing the parameter settings in the input boxes. 5 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 works Outlier Elimination now appear below the Outlier Elimination check box.

Copying Properties of Features You can copy certain properties of a characteristic and assign them to or more other characteristics. This means that the information in question has to be defined only once, while at the same time you can be sure that the common properties are exactly the same for all the characteristics concerned. The following are the properties you can copy to all features: – Nominal – Tolerance class – ISO286 – Upper tolerance – Lower tolerance

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How to Copy Properties of Characteristics into other Characteristics The procedure for copying properties of a characteristic to other characteristics is as follows: 1 Click on the characteristic from which you wish to copy the properties and click on the Transfer format icon in the upper menu bar. The Characteristics assign to Features dialog box appears on the screen. 2 Click on the characteristics icon at the bottom of the dialog box. The Copy Properties from <prüfmerkmalname> dialog box appears on the screen.

3 Activate the check boxes of the properties 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.

About the Color-Coding of Characteristics Buttons When a characteristic is listed in the measurement plan area, the background color of its button tells you its status: – Light gray (same as measurement plan area): The characteristic has not been defined yet and no nominal data has been recorded. – Dark gray: The characteristic has been defined and nominal data has been recorded. The characteristic is ready to run.

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– Green: The characteristic has been defined, nominal data has been recorded, measured results have been gathered, and the results are within the tolerances. – Red: The characteristic has been defined, nominal data has been recorded, measured results have been gathered, and the results are outside of tolerances.

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Details on Specific Characteristics

Details on Specific Characteristics Whenever you define a characteristic, you must always assign it one or two features in its definition template. Frequently, you will also have to define primary references, and less frequently secondary or even tertiary restraints as well. The most common approach to constraint definitions is as follows. A primary constraint generally constrains two of the rotational degrees of freedom and one or two translational degrees of freedom for the evaluation of a characteristic. In order to satisfy these requirements, the primary constraint must be set by a three-dimensional feature: a plane, and 3 D line, a cylinder or a cone. If required, a secondary constraint usually further constrains the remaining rotational degree of freedom. A secondary constraint can be a plane, 2 D line, 3 D line, cylinder or cone. All other features are insufficient to establish rotation frames of reference. Lastly, a single additional feature provides the remaining one or two degrees of translational constraint. The table below lists the items of information you need to define the characteristics for size, form and location:

Characteristic

MenuLocation in command toolbox Description

X value

Size → Standards

Size elements Determines the position of a given feature in X. 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.

Y value

Size → Standards

Size elements Determines the position of a given feature in Y. 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.

Z value

Size → Standards

Size elements Determines the position of a given feature in Z. 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.

Diameter

Size → Standards

Size elements Determines the diameter of a round feature such as a circle, cylinder, cone, or sphere.

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Characteristic


Radius

Size → Standards

Size elements Determines the radius of a round feature such as a circle, cylinder, cone, or sphere.

Radius measurement

Size → Standards

Size elements Determines the radius of a feature. This value is determined separately for each probing; in this way the results for a small arc segment can be enhanced.

Length of Axis

Size → Standards

Size elements Determines the length of the axis of a rotationally symmetrical body.

Polarposition Radius

Size → Standards

Size elements Determines the position of a given feature with the polar coordinate Radius. The location of each feature can be defined in 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.

Polarposition Angle

Size → Standards

Size elements Determines the position of a given feature with the polar coordinate Angle. The location of each feature can be defined in 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.

Polarposition Height

Size → Standards

Size elements Determines the position of a given feature with the polar coordinate Height. The location of each feature can be defined in 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.

Projection Angle One

Size → Angle

Size elements Determines the first projected angle of a 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

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Angle 1 Y/X Z/Y X/Z


Characteristic


Projection Angle Two

Size → Angle

Size elements Determines the second projected angle of a second projected angle of a 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 elements Determines the angle of aperture of a cone.

Half Cone Angle

Size → Angle

Size elements Determines the half angle of aperture of a cone (the angle between the axis of the cone and the cone’s lateral area).

Angle of Tilt

Size → Angle

Size elements Determines a feature’s angle of tilt from the Z axis of the part alignment.

Rotation Angle

Size → Angle

Size elements Determines a feature’s angle of rotation about the Z axis, referenced to the W axis of the part alignment.

Feature Angle

Size → Angle

Size elements Calculates the angle that the axis of rotation of a feature assumes with the part alignment.

Distance Symmetry point

Size → Distance

Size elements Determines the distance between the two reference features of a symmetry point.

Space Point Distance

Size → Distance

Size elements Determines the distance of a space point or net point referenced to its nominal.

Distance

Size → Distance

Size elements 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.

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Characteristic


Diameter 2

Size → More

Size elements Determines the second diameter of an ellipse. The first diameter of the ellipse is measured with the Diameter command.

Radius 2

Size → More

Size elements Determines the second radius of an ellipse feature. The first radius of the ellipse is measured by the Radius characteristic.

Length

Size → Size elements Determines the length of a slot or a rectangle. More → Slot Length

Width

Size → More → Slot Width

Size elements Determines the width of a slot or rectangle.

Average

Size → More → Average

Size elements Determines the average of multiple length measurements.

DIN ISO 1101 Roundness

Form and Location

Form elements

Determines the roundness or circularity of a 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 Graphically” on page 9-23).

DIN ISO 1101 Flatness

Form and Location

Form elements

Determines the flatness of a flat feature. The definition template includes a button labeled Graphic for form plots (see ➤“How to Display Variations Graphically” on page 9-23).

DIN ISO 1101 Straightness

Form and Location

Form elements

Determines the straightness of a line. 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 Graphically” on page 9-23).

DIN ISO 1101 Cylinder form

Form and Location

Form elements

Determines the cylinder form of a cylindrical feature. The definition template includes a button labeled Graphic for form plots (see ➤“How to Display Variations Graphically” on page 9-23).

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Characteristic


Form

Form and Location

Form elements

From the extreme values of features, determines form deviation as the difference between the maximum and minimum measured values normal to the feature (e.g. cone form or sphere form).

Curve form

Form and Location

Form elements

This characteristic is optional. It defines the deviation of a defined curve (see ➤“Curve Measurement (Option)” on page 15-1).

DIN Profile

Form and Location

Form elements

Defines the deviation of a plane from its nominal geometry. Its value depends on the selected shape of zone (see ➤“Basics About GDT Profile” on page 6-40).

DIN ISO 1101 Position

Form and Location

Location elements

Determines the position of a given feature in 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 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 4-42). Alternatively, you can use the “Best Fit of Bore Pattern” function (see ➤“How to Use Best Fit of Bore Pattern” on page 6-43).

DIN ISO 1101 Concentricity

Form and Location

Location elements

Determines the concentricity of a given feature (e.g. a circle) relative to one or two reference features.

DIN ISO 1101 Coaxiality

Form and Location

Location elements

Determines the coaxiality of a given feature’s axis (e.g. the axis of a cylinder) relative to another feature.

DIN ISO 1101 Squareness

Form and Location

Location elements

Determines the squareness of a planar, cylindrical, conical or a straight-line feature relative to one or two reference features.

DIN ISO 1101 Parallelism

Form and Location

Location elements

Determines the parallelism of a planar, cylindrical, conical or a straight-line feature relative to one or two reference features.

DIN ISO 1101 Symmetry

Form and Location

Location elements

Determines the symmetry of a feature relative to two reference features.

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Characteristic


DIN Angularity

Form and Location

Location elements

Determines the deviation of a feature from a reference feature and a defined angle.

DIN ISO 1101 Radial Runout

Form and Location Location → elements Runout

Determines the deviation of a feature normal to the datum axis in the radial direction.

DIN ISO 1101 Axial Runout

Form and Location → Location elements Runout

Determines the deviation of a feature in the direction of the datum axis.

Polar 2d (Distance)

Form and Location Location → elements Distance

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.

Polar 3d (Distance)


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).

Cartesian (Distance)


Determines the distance between two features in Cartesian coordinates (along the X, Y and Z axes).

Angle Between Features

Form and Location

Determines the angle between two features. You have a choice of results: acute angle, this angle’s explement to 180° and the explementary angles of both to 360°.

Location elements

Basics About GDT Profile Characteristics

The GDT profile can be determined for the following characteristics: – Plane – Cylinder – Cone – Sphere – Point – General surface

NOTE

The GDT profile corresponds to the TOL/PROFS defined in DMIS.

hss

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When defining the GDT profile, you can choose from four shapes of zone: Shape of Zone

The following are observed:

Bilateral

The deviation from the nominal surface to the inside and outside (with the same values)

One-sided (inside)

The deviation from the nominal surface to the inside

One-sided (outside)

The deviation from the nominal surface to the outside

Bilateral (unequal distribution)

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.

Result of profile

The result of the profile depends on the shape of zone.

Shape Of Zone

The following are output:

Bilateral

The largest deviation (inside and outside) times 2.

One-sided (inside)

The largest deviation inside the workpiece.

One-sided (outside)

The largest deviation outside the workpiece.

Bilateral (unequal distribution)

The largest deviation (inside and outside) from a calculated center line times 2.

Theoretical center Nominal contour

Calculation of deviations for the General Surface

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 probe touch point is calculated based on the probe center, probe 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.

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Restrictions

The following restrictions apply to the GDT profile: – No restrictions may be set for the best fit. – Negative tolerances are not permitted.

Particularities for the General Surface

The following particularities apply to the GDT profile of a General Surface: – No filters or outlier elimination. – Only the Gauss evaluation method is possible.

Profile with references

As in general, the following applies to profile with references: Either no reference – or all three references are defined. Otherwise, no result will be output.

How to Check Wall Thickness and Wall Deviation With the aid of the selection menu points in the CAD model, you can define two space points with a click of the mouse and use these points to check the wall thickness or the material deviation at this point.

How to define two space points for the distance check 1 Turn the CAD model, so that the position with the wall thickness to be checked can be seen in the foreground. 2 Click on the Selection selection list in the CAD menu bar. 3 Select menu point Distance Check. 4 Click on the position on the model at which you wish to check the wall thickness. The two opposite space points and the connection between them are shown at the selected position on the screen. Two new features of the type “space point” appear in the list of features. With the aid of these two points, you can check the wall thickness or the material deviation at the place in question.

How to check the wall thickness You have created two opposite space points using the menu point Distance Check. 1 Add a symmetry point to the list of features with Measure → Special Features → Symmetry Point. 2 Select the Recall entry in the selection list Nominal Definition in the definition template of the symmetry point.

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3 Select the available space points for the definition of the symmetry point. 4 Add the “Distance_Symmetry point” characteristic to the list of characteristics and assign it to the symmetry point that was just created. The wall thickness will be checked at the desired position during the measurement plan run.

How to check the wall deviation You have created two opposite space points using the menu point Distance Check. 1 Add two “Space Point Distance“ characteristics to the list of characteristics and assign them the space points just created. During the measurement plan run, it will be checked whether there is “too much” or “too little” material at the desired position.

Basics about Best Fit of Bore Pattern The following best fit methods are available for the best fit of bore pattern: – Gauss Best Fit. For this method, outliers have only a minimal influence. Limitations due to references are not taken into consideration. Optimal 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 references are not taken into consideration. Optimal 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 areas 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 references are not taken into consideration. Optimal setting parameters can be derived from this for the machine tools.

How to Use Best Fit of Bore Pattern The True Position characteristic offers options for bore-pattern best fit. As the result of this operation, Calypso computes the rotation and offset of the bore pattern.

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To proceed with best-fit of bore-pattern: 1 Add the True Position characteristic to your measurement plan. 2 Double-click on the button for the characteristic to open the definition template. The definition template is opened. 3 Activate the Best Fit of Bore Pattern radio button. 4 Enter the tolerance. Use the buttons labeled Primary Datum, Secondary Datum and Tertiary Datum to specify the datums so that the bore pattern can be computed later. If you do not enter a datum, 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.

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6 Click on the Select Features button to select the features you need for best-fitting the bore pattern. You can use the Select Bolt Hole Pattern picklist to incorporate bore patterns defined beforehand. All the features you select are listed in the Features List. The coordinates as shown here are referenced to the datum 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 picklist. • 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. To see a graphic representation of the best fit bore pattern, mark the check box Graphic (see ➤“How to Display Variations Graphically” on page 9-23). 9 Click on OK. The settings are saved and the window is closed.

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Chapter

7 7

Editing the Measurement Plan

.................................................................................................................................

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 understand this chapter.

Included in this chapter: Managing Measurement Plans . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 The Toolboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15 Editing a Measurement Plan. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Editing the Probe Routes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22 Using the Probe Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Multimedia Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51

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Managing Measurement Plans The Following topics cover how to work with measurement plan files (copying, saving etc.) and how to improve your efficiency by using common Windows functions:

How to Save a Measurement Plan Do not forget to save your measurement plan after you have edited it. You can either overwrite the original measurement plan or save the edited plan in another file. To save a measurement plan: 1 If you want to overwrite the original measurement plan, • click on the Save Current Measurement Plan button. The measurement plan is saved. 2 If you want to retain the original measurement plan, • Select File → Save As.

• 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.

How to Rename a Measurement Plan Calypso does not have a direct command for renaming a measurement plan. You can, however, assign the measurement plan a new name in the Save As dialog box. Calypso saves each measurement plan as a file called inspection in a directory that bears the name of the measurement plan.

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Managing Measurement Plans

Follow these steps to rename a measurement plan: 1 Select File → Save As. 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. If you want you can delete the old plan.

How to Copy a Measurement Plan to a Floppy Disk You may want to copy a measurement plan to a floppy disk to back it up or to work with it on another computer. To copy the measurement plan, you need to use Windows Explorer. Follow these steps to copy a measurement plan to a disk: 1 Minimize Calypso by clicking on the Minimize button in the upper right corner. 2 Insert a diskette into the drive. 3 In the Windows Taskbar, click on Start → Programs → Windows Explorer. 4 View the contents of the folder called C:\calypso:\home\om\workarea\inspections. This is the default path for Calypso. A subfolder is created in this folder for each Calypso measurement plan. To copy a measurement plan, you must copy its entire folder because it contains a number of files. 5 Click on the folder that is the name of the measurement plan that you want to copy. 6 Select Edit → Copy. 7 View the contents of the diskette in the floppy disk drive with Explorer. 8 Select Edit → Paste. The measurement plan folder and its contents are copied to the floppy disk. 9 Close Windows Explorer and return to Calypso.

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How to Delete a Measurement Plan You can delete measurement plans that are no longer needed. To delete a measurement plan: 1 Select File → Open. The istration dialog for the measurement plan will open. A subfolder is created in this folder for each Calypso measurement plan. 2 Mark the measurement plan that should be deleted, right-click and, in the popup menu that appears, select Delete. The selected measurement plan will be deleted. You can also use the Windows Explorer to delete measurement plans.

Combining Several Measurement Plans You can combine measurement plans and create combined evaluations. 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. The primary use of this function, however, is to generate common logs for measurements on horizontal-arm systems with two measuring columns. NOTE hss

If you want to combine the measurement plans of a horizontal arm CMM with two measuring arms, 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.

How to Create a Master Measurement Plan To create a master measurement plan: 1 Create a new measurement plan and assign it a name beginning with the character “$”. This “$” tells Calypso that this is a master measurement plan.

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2 Select Prerequisites → Import Measurement Plan. A dialog box appears in which you can import the measurement plans run to date on networked CMMs onto your computer. All nominals, actual values and tolerances are imported into the master measurement plan. The names of the individual features and characteristics have to be unique only within each single measurement plan incorporated into the master. In the master measurement plan itself, each name of a feature or characteristic is prefixed with the name of the original measurement plan, with a period as separator. 3 Edit the measurement plan: Delete superfluous characteristics and add constructions of features across individual measurement plans. 4 Save the master measurement plan. NOTE hss

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 separately in a special directory.

How to Obtain the Combined Evaluation The master measurement plan is not used to measure features: its purpose is to calculate combinations from multiple measurement plans. NOTE

The master plan is used for computation, not for measurement.

hss

To perform a computation run: 1 Open the master measurement plan. 2 Select CNC → Run to start the CNC run. The Start Measurement window is displayed. 3 Under CMM, go to the Navigate-Feature To Feature field and select Use Position Points Only. 4 If individual measurement plans have been run in the interim and you want to update the results: Tick the Clear Existing Results check box. In this case the current values (actuals, nominals and tolerances) of the individual measurement plans that make up the master measurement plan are reimported and the results are updated. 5 Click on OK to start the CNC run. 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. 61212-2010102

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If this option was not selected, the results are recalculated from the individual measurement plans' results already available on the computer.

Editing the Measurement Plan Once you have set up a measurement plan, you can edit it later. You can add, move or delete features or characteristics, group features or characteristics and rename features, characteristics or groups. You can also mirror the entire measurement plan across an axis of your choice. to save the measurement plan after you make changes to it (select File → Save). NOTE hss

All of the following sections assume that you have a measurement plan open on the Calypso Desk.

How to Undo an Action in the Measurement Plan There is currently no way of undoing an action in Calypso. The Undo command on the Edit menu is just for deleting the last probing point. However, you can revert to the last saved version of your measurement plan: 1 Save the measurement plan without saving it beforehand.

! hss

Caution All changes made since the last time the measurement plan was saved are lost. 2 Reopen the measurement plan. The contents of the measurement plan are now as they were when last saved.

How to Use Additional Options in Shortcut Menus Calypso, like many Windows software packages, has popup menus that change depending on where you are in the software. To open a shortcut menu: 1 Click on the right mouse button. The shortcut menu appears on the screen. 2 Click on the command of your choice.

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Usually, the shortcut menus offer commands that are available at the main Desk menu. Sometimes, however, the shortcut 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 shortcut menu, and you may find the function you need.

How to Edit Features or Characteristics To work with a feature or characteristic, you first have to highlight it: 1 Click with the left mouse button on the icon in the measurement plan area. 2 To highlight two or more 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 two or more features or characteristics listed one after the other: • Click on the first feature or characteristic you want to highlight. • Press and hold down the Ctrl 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, as appropriate, appears on the screen.

Adding Features or Characteristics to a Measurement Plan You can add a feature to your measurement plan at any time. You have several options. For more information, see ➤“Defining Features” on page 5-2 You can add a characteristic to your measurement plan at any time. You have two options. For more information, see ➤“Defining Characteristics” on page 6-7.

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Positioning Features in the List of Characteristics The screen will display either the list of features or the list of characteristics, but not both together. Bear in mind, however, that you can define features even when the list of characteristics is displayed. – Calypso automatically places new features in the list of characteristics if it is open. Result: A feature added to the list of characteristics in this way is measured even if it is not assigned to a characteristic – this could not happen if the feature was included only in the list of features. – New characteristics, in contrast, are automatically positioned in the list of characteristics even if the list is not currently displayed. The button above the list is a toggle for switching from one list to the other.

How to Move Features or Characteristics You can change the order of the features and characteristics in the list in the measurement plan area. The order is more important for the features, because the list order determines the order in which the characteristics are checked by the CMM when the measurement plan is executed. To move a feature or characteristic – Use the Cut and Paste buttons.

How to Copy Features or Characteristics You can make copies of a feature or characteristic and then paste it into the corresponding list. This is a quick way to add another feature or characteristic of the same type. Copying characteristics works well if you have multiple items that have similar tolerances with only minor changes to the characteristic definition. The features copied, however, do not contain the measured data in the original feature — only the nominal data. To copy a feature or characteristic 1 Click on the item to highlight it and then click on the Copy button. 2 Click on the new position in the list and then click on the Paste button. The feature or characteristic is pasted into the list at the position you selected. 3 To make additional copies of the same item, click on the Paste button again.

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4 You can also copy features or characteristics from one measurement plan to another: • Open the appropriate measurement plan. • Paste the feature or characteristic into the measurement plan at the appropriate position.

Mirroring a Measurement Plan You can mirror an entire measurement plan across a coordinate axis of the base alignment. This 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 nominals of the characteristics that mirroring can change (these include distances and X values, for example) are updated. – You have to assign probes to the mirrored measurement plan manually. 61212-2010102

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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. NOTE

The base alignment is unaffected by the transformation.

hss

! hss

Caution Parameters and patterns are not mirrored. If your measurement plan contains parameters or patterns, they have to be reentered after the measurement plan has been mirrored.

How to Mirror a Measurement Plan To mirror a measurement plan: 1 Open the measurement plan you want to mirror. 2 Select CNC → Measurement Plan Functions → Mirror Measurement Plan. The Mirror Measurement Plan dialog box appears on the screen.

3 Click on Mirror to Plane and select the mirror axis. 4 Go to Change Probe Data and select a different probe, if applicable. The data applicable to your selection is listed in the display area.

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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 “old”, unmirrored measurement plan as well.

How to Delete Features or Characteristics You can remove measured features and characteristics from the measurement plan in a variety of ways: – Cut an element The element that was last cut can be pasted into the same or another location using Paste. – Move an element to the Waste Basket All of the elements which were dragged with the mouse to the Waste Basket icon will be gathered in the Waste Basket (spanning all measurement plans). They can be moved to any location in any measurement plan. – Delete an element for good To cut a feature or characteristic: 1 Click on the feature or characteristic you want to delete. 2 Click on the Cut button. The feature or characteristic is removed from the measurement plan and is placed on the clipboard. To place a feature in the Waste Basket: 1 Use the mouse to drag the feature onto the Waste Basket icon. Items in the Waste Basket can be reinserted with the mouse. To delete a feature or characteristic for good: 1 Click on the feature or characteristic you want to delete forever. 2 In the popup menu, select Delete. The feature or characteristic will be deleted.

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How to Enter Alphanumeric Characters with the Mouse If you prefer using the mouse to enter text and digit strings, Calypso can display an input box with a keyboard. You generate entries in the input boxes by pointing to the individual keys with the mouse pointer and clicking. To activate this functionality: 1 Select View → Configuration. The Datum Features dialog box appears on the screen.

2 Tick the Typewriter check box. 3 Click on Close. The dialog box closes. From now on, the Typewriter dialog box will appear on the screen whenever a change is made to an input field.

How to Work with the Waste Basket All of the elements which were dragged with the mouse to the Waste Basket icon will be gathered in the Waste Basket (spanning all measurement plans). To view the contents of the Waste Basket: 1 Click on the Waste Basket button To recover an item from the Waste Basket: 1 Click on the Waste Basket button. The contents are displayed. 2 Mark the corresponding item and drag it into the measurement plan area. A copy of the feature will be added in the measurement plan area while the original copy will remain in the Waste Basket.

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To delete an item from the Waste Basket: 1 Click on the Waste Basket button 2 Mark the desired item and select Delete in the popup menu. The item is deleted from the Waste Basket.

Grouping and Ungrouping Characteristics Sometimes a measurement plan has so many characteristics that it gets cumbersome to view and edit. In that case, you can group certain characteristics, which combines all the individual characteristics that you select into one single group characteristic. If you want to evaluate only certain features, you define a feature group, known as a mini-plan, within the measurement plan. This allows you to check the mini-plan and run it, but leaves the 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.

How to Rename Features, Characteristics and Groups You can name each symbol in the measurement plan area. NOTE hss

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 feature or characteristic button that you want to rename. 2 Double click on the icon. This opens the definition template of the feature. - or Right-click and select Rename from the popup menu. The Name/Comment window is displayed. 3 Overwrite the name of the feature 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.

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How to Search for a Measurement Plan Feature You can look for a specific feature or characteristic in a measurement plan. Please be aware that the search function always checks in the currently displayed list, either in the list of features or list of characteristics. 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, click on the Match Case check box. • If you want to look for complete words only, click on 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 the correct item has not been found, click on Find Next until you find the item. 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 picklist.

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The Toolboxes

The Toolboxes With toolboxes, you can easily insert features and characteristics into your measurement plan. Using a toolbox gives you a quick way to access features, characteristics and utilities. You can also use the drag&drop functionality to create custom toolboxes that contain only the items that you most frequently use. This toolbox contains most of Calypso’s features, characteristics and utilities and is part of a window called Tool Box Builder. The Toolbox Builder also allows you to create custom toolboxes.

Here are the details on working with tool boxes: – The 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 item, drag it over to the measurement plan area on the left of the screen, and release the mouse button. – 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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Creating and Using Custom Toolboxes To create a custom toolbox, you first need to open the Toolbox Builder and the Master Toolbox. NOTE hss

Once you have saved a custom toolbox and then exited the Toolbox Builder, there is no way to edit or change 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 Tool Box(es) button. The Toolbox Selector dialog box appears on the screen.

If you have not defined any custom toolboxes, only the Master Toolbox is listed. 2 Highlight Master Tool Box and click on Open. 3 Name your new toolbox: Delete the “unnamed” label and type a name for the toolbox. 4 This name can be any combination of letters, numbers and spaces. 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 separate groups for buttons. All buttons are placed in the same list. • You cannot change the order of items in the custom toolbox (except to delete an item and add it to the bottom of the list). • 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 Tool Box Builder File → Save. The toolbox configuration you put together is saved.

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The Toolboxes

How to Work with a Custom Toolbox A custom toolbox contains the items you need most frequently in your day-to-day work. 1 Click on the Open Selected Tool Box(es) button. The Toolbox Selector dialog box appears on the screen. 2 Highlight your toolbox and click on Open. The Toolbox Builder dialog box appears on the screen. 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 into the measurement plan area. Release the mouse button. 4 As soon as you click anywhere else on the Desk, the toolboxes are hidden. To display them again, click on the Select Toolboxes button.

Deleting a Custom Toolbox To delete a custom toolbox, follow these steps: 1 Click on the Open Selected Tool Box(es) button. The Toolbox Selector dialog box appears on the screen. 2 Highlight Master Tool Box and click on Open. 3 Select File → Delete from the menu bar of the dialog box. 4 At the list of custom toolboxes, click on the appropriate toolbox to highlight it, then click OK. The toolbox has now been deleted.

Sizing and Moving Toolboxes Just as with any window in Windows NT, you can enlarge custom toolboxes or the Toolbox Builder window, and you can also make them smaller or move them: To resize a toolbox, follow these steps: 1 Move the mouse pointer to the corner of the window in question until it changes to an arrow with two points. 2 Then click on the left mouse button and drag the window in or out to make it smaller or larger.

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To move a toolbox, follow these steps: 1 Click on the left mouse button on the title bar, and hold down the mouse button. Move the mouse to drag the box to another position. 2 Release the mouse button when the box is where you want it.

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Editing a Measurement Plan

Editing a Measurement Plan The measurement plan editors (for features and characteristics) provide you with a quick and easy way of checking and, if necessary, changing important settings. You can choose whether to apply your changes to: – selected features or characteristics, or – the higher-order measurement plan setting. Calypso has an editor for features (Prerequisites → Measurement Plan Editor - Features) and an editor for characteristics (Prerequisites → Measurement Plan Editor - Characteristics). For more information about the individual dialog elements in both dialog boxes, please see in Measurement Plan Editor Features and Measurement Plan Editor Characteristics in the Calypso Online Help, and also ➤“Editing the Probe Routes” on page 7-22

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Example: Checking and Changing the Operating Mode in the Settings Editor This example demonstrates how to check and change the operating mode: 1 Select Prerequisites → Measurement Plan Editor - Features to open the features editor.

List of settings

List of defaults

Feature name Feature type Column of currently valid settings

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.

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Editing a Measurement Plan

You can mark a block of features (e.g. features 1 to 5) by holding down Shift and highlighting them with the mouse, or you can mark individual features (e.g. features 1, 3 and 5) by holding down Ctrl and highlighting them with the mouse. 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 dialog box is closed.

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Editing the Probe Routes Calypso needs probe routes in order to move the probe around the workpiece without colliding during automatic runs (CNC). Calypso generates the routes automatically, if clearance planes were defined around the workpiece (see ➤“Defining the Clearance Planes” on page 4-72. 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 the route to a feature. This is useful, for example, if you want to ensure that the probing points for a cylinder are uniformly spaced. The tasks involved in checking and optimizing the routes are as follows: – ➤“Checking the Routes” on page 7-25 – ➤“Editing Routes between Features” on page 7-26 – ➤“Editing Routes within a Feature” on page 7-31.

About Probe Routes Probe routes in Calypso can be divided into two groups: the routes between features and the routes within features. closely related with this concept include clearance plane, clearance group, retract plane, clearance distance and retract distance – these are explained briefly below. Broadly speaking, routes contain all the relevant data for the CMM to reach and probe the feature without collision. Along with the coordinates for the probing points, this data set can also include data for intermediate positions, for table control, for stylus changes, and so on. The result is a route comparable with a detailed description of how to find a particular building on a particular street in a large city.

Routes between Features The routes between features define how the probe head moves from one feature to the next. These routes are computed on the fly during a CNC run and depend on the following parameters: – Current status (current position referenced to the probe, associated clearance group, current probe, ...) – Settings for the clearance group (retract plane defined or not, ...)

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Editing the Probe Routes

– Clearance planes (sizes, edge blocking) – Other (probe-specific data, position of a probe-changer magazine, ...).

Routes within a Feature The routes within a feature influence the path traced by the probe head in carrying out the measurement strategy defined for a feature. These routes comprise: – Defined probing points, intermediate positions, scanning paths – Approach and departure positions of the probe head relative to a feature and possible intermediate positions between the probing points. These components of the route are computed on the fly during the CNC run and depend on the following parameters: • the clearance distance, i.e. the “height” of the first intermediate position in axial direction or normal vector direction, • the retract distance, i.e. the distance of the generated intermediate position from the probing point in the probing direction.

Clearance Planes/Clearance Groups When it is defined, each feature is automatically assigned a particular clearance plane. This assignment defines the approach position, i.e. the side of the clearance planes on which the probe head is located when approaching the feature. Feature orientation (e.g. direction of cylinder axis or normal of a plane) is of no consequence in this respect, and the same applies to the probing direction at the feature.

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Calypso distinguishes between clearance planes (SE) and clearance groups (SG). The clearance planes are assigned when the clearance planes are defined (see ➤“Defining the Clearance Planes” on page 4-72). The normals of the clearance planes bear designations 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

Clearance group SG+Z2

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 head 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.

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Retract Planes The illustration below shows what a retract plane signifies:

SE+Z

Retract plane

SG+Z2

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.

Checking the Routes When a measurement plan is created, some settings of crucial importance in of navigation are automatically entered in the feature. These settings (e.g. clearance group, clearance distance, ...), however, are merely defaults: prior to the first CNC run you must check and, if necessary, change these settings.

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Caution 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 head relative to the clearance planes (on the approach to the first intermediate position of the feature in question).

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– When you finish programming the measurement plan, select Prerequisites → Clearance Planes and click on the Test Drive To The Selected Clearance Plane button to perform a test move to (see ➤“How to Test the Clearance Planes” on page 4-76). This is your opportunity to recheck the assignment of features to clearance planes in the CAD model.

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Caution Other routes might be generated, depending on the characteristics selected or if the run takes place without a result reset. – 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.

Editing Routes between Features On routes between features, the intermediate position for the probe head is computed from the current position and the approach position for the next feature. NOTE hss

Consider edge blocking: It could be either a hindrance or a help, depending on the circumstances (see ➤“How to Close Edges” on page 4-77). The activities which influence the routes between features are as follows: – ➤“How to Define Clearance Groups” on page 7-26 – ➤“Asg Clearance Planes and Clearance Groups” on page 7-28 – ➤“How to Define the Retract Plane in a Clearance Group” on page 7-30

How to Define Clearance Groups When you define clearance groups, that all the features in a group must be reachable from each other and from a higher-order clearance plane.

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To define a clearance group: 1 Select CNC → Navigation → Define Clearance Group. The Define Sub Clearance dialog box appears on the screen.

2 Click on the New button. Type a name for the new clearance group into the input field. If the name includes a coordinate (e.g. HoleB -X), the name of the parent group is entered by default. 3 To assign the clearance group a different clearance plane, click on the arrow beside the picklist headed Parent Group. Press and hold down the mouse button and select the clearance plane (SE) you need by highlighting it and then releasing the mouse button. 4 Click on OK. The dialog box closes.

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How to Delete a Clearance Group You can delete a clearance group when you no longer need it. 1 Select CNC → Navigation → Define Clearance Group. The Define Sub Clearance dialog box appears on the screen.

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.

Asg Clearance Planes and Clearance Groups A feature can often have different clearance planes. Automatic assignment does not always result in optimized routes, so you have the option of changing the assignment or defining new clearance groups. To assign clearance planes or clearance groups: 1 Double-click on the icon of the feature to which the assignment will apply. The definition template is opened. 2 Click on Strategy. The Strategy dialog box is opened.

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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 picklist. 5 Hold down the mouse button and select the clearance plane () or clearance group (S) 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 used in the next automatic CNC run. Editing two or more features

Use the Features Settings Editor if you want to assign clearance planes or clearance groups to more than one feature at a time (see ➤“How to Edit Measurement Plan Settings” on page 4-78).

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How to Define the Retract Plane in a Clearance Group All features in a clearance group must be reachable from each other and from the higher-order clearance plane. To ensure this collisionfree accessibility, you can define a retract plane within a clearance group. To define a retract plane within a clearance group: 1 Select CNC → Navigation → Define Clearance Group. The Define Sub Clearance dialog box appears on the screen.

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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Editing Routes within a Feature The routes within a feature define the path followed by the probe head from one probing point to the next. Your options for editing the routes within a feature are described in the following sections: – ➤“How to Move the Approach Position Closer to the Feature” on page 7-31. – ➤“How to Change the Point List” on page 5-64, in order to define optimum probing points, for example.

How to Move the Approach Position Closer to the Feature The distance separating the approach position from the feature is defined by the Clearance Distance parameter. If the clearance distance for a feature is excessive, the result can be collisions in narrow grooves or gaps, because when it attempts to move to the clearance distance the probe comes into with the material opposite. To move the approach position closer to the workpiece: 1 Open the definition template of the feature in question by doubleclicking on the feature’s icon. 2 Click on Strategy. The Strategy dialog box appears on the screen.

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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 OK to close the dialog box. The approach position should now be close enough to the feature to improve the route.

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Using the Probe Changer

Using the Probe Changer The CMM’s automatic probe changer allows you to change probes without any manual intervention. Before you execute the automatic changing of probes, you need to define for Calypso the exact configuration and location of the probe changer rack. Calypso saves the probe used to measure a feature along with the feature. If it is necessary to change probes between features, Calypso can do this automatically. The following preconditions, however, must be satisfied: Preconditions

– Calypso must know that there is a probe changer. – Additionally, the appropriate probe must be in the probe changer.

Procedure

To configure the probe changer: – Specify the probe changer in the system settings (once-only operation) – Determine the length of the reference stylus (once-only operation), (not applicable to RDS, MCR20 and SCR200) – RDS only: determine the RDS geometry – In the Change Probe dialog box, insert an icon for each holder (MCR20 and SCR200: for one holder only, all others are automatically created when the magazine is calibrated) – Set the approach parameters – Determine the position of each holder (MCR20 and SCR200: calibrate the magazine) – Assign probes to holders The following sections will walk you through these steps. Once these steps have been performed, they do not have to be repeated as long as the probe changer is not changed in any way, for example by being moved. When the automatic probe changer is properly configured, you can easily execute an automatic change of probes, as described in the section.

Renishaw MCR20 Probe Changer The MCR20 probe-changer magazine consists of a stand and a horizontal beam with six holders. It can be approached from the four approach directions (+X, -X, +Y, -Y).

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!

Caution Always comply with the instructions in the guide supplied with the MCR20.

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NOTE hss

The Renishaw Manual 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 magazine (200 mm) is tolerated. On of the special design of the MCR20, you must bear the following in mind: – After the Store Probe operation, the probe head 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 MCR20’s zone of magnetic force causes the controller to issue collision messages. – No machine operations are triggered by a manual probe change with the MCR20. If the RDS is used with TP20, you cannot change the RDS plate manually. – In the pickup process the probe-change solenoids of an index head, if fitted, are not driven.

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Caution Never change the probe without calling the manual or automatic probe-change function (e.g. by selecting another probe in the qualification dialog and changing the probe by hand). Strong magnets affect the TP20 probe head. If probing fails switch off the solenoids if necessary or consult the guide supplied with the TP20/Renishaw. – Whenever possible, always use the manual or automatic probechange function to change probes with the TP20 and MCR20, because this is the only way that Calypso can monitor the status of the probe head (probe in probe head or probe not in probe head).

SCR200 Probe Changer The SCR200 probe-changer magazine consists of a stand and a horizontal beam with six holders. It can be approached from the four approach directions (+X, -X, +Y, -Y).

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Caution Always comply with the instructions in the guide supplied with the SCR200. On of the special design of the SCR200, you must bear the following in mind:

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– The SCR200 has a photoelectric barrier that is interrupted when a probe change takes place. Movements between the individual holders take place inside the space delimited by the photoelectric barrier. The probe does not move out of this space until the change has been completed.

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Caution If the photoelectric barrier is interrupted during a CNC run, the controller switches permanently to closed with probe head. If this happens the probe head 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 probes manually. If the machine is equipped with an articulated probe head from Renishaw (PH10), you must also bear the following in mind: – If you have qualified probe positions that could cause a collision with the probe-changer magazine when probes are subsequently changed, you must use Approach Parameters to change the parameters for the holders in question. – The route above or in front of the holder must be parameterized in such a way that the head can rotate before and after the probe change without any risk of collision.

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Caution Never change the probe without calling the manual or automatic probe-change function (e.g. by selecting another probe in the qualification dialog and changing the probe by hand). – Whenever possible, always use the manual or automatic probechange function to change probes with the TP200 and SCR200, because this is the only way that Calypso can monitor the status of the probe head (probe in probe head or probe not in probe head).

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Probe Changer for RDS The illustration shows you what distances you need between the holders as well as the probe movement when removing a stylus.

Probe movement when removing a stylus

The movement strategy to a holder is set up so that the probe changer is outside of the measurement area. Please be aware that a minimum distance of 150 mm (6 in.) between the holders is necessary. An empty area of 120 mm (4¾ in.) below the holder is necessary. Without the empty area, it is not possible to mount a lateral stylus in the RST probe.

Defining the RDS Geometry Before you can measure the probe changer magazine for the RDS, you first have to define the geometry of the RDS. Procedure

To define the geometry: – Compute the slot distance from the virtual axis intersection of the RDS axes. – Calibrate the four preset angle settings for the RDS. Calypso uses this information to compute the intersection of the axes.

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How to Define the RDS Slot Distance The slot distance is necessary only for the startup of the RDS probe changer and need only be defined once. The illustration shows an overview of the definition of the slot distance X. The stylus is shown from above, e.g. from +Z.

2

RDS probe at top in position 2

X

1

Reference edge

Probe head at top in Position 1

X

RDS probe at top in position 1

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 field Slot Distance. To define the RDS slot distance: 1 Find an appropriate vertical reference edge. An appropriate reference edge must be parallel to the machine coordinates. 2 Position the RDS probe 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 probe position. 4 Turn the RDS 180° around its A axis. In the illustration this is position 2. 5 Reposition the RDS probe so that the outer slot wall is in a plane with the reference plane.

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6 Click on Read Position. Calypso saves the current probe position. 7 Check the results in the field Slot Distance. Typical values are around 38 mm (1½ 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 firs calculate the intersection of these axes. Before Calypso can do this, you must calibrate the four additional probe positions of the master probe (refPos1 to refPos4) (styli 2 to 5): – A/B = 0°/90° – A/B = 0°/-90° – A/B = 90°/0° – A/B = -90°/0°

Setting up the Initial Probe Changer Configuration You must inform Calypso that an automatic probe changer is installed, and define the type. All other settings (e.g. defining holders) and functions of the probe changer are defined with Prerequisites → Automatic Probe Changer. To configure the automatic probe changer: 1 Select Extras → Workroom → CMM. The System Set Up dialog will be opened with the CMM Configuration notebook. 2 Click on Probe Change. 3 Activate the Probe Changer Exists check box if it is not already activated. 4 Click on the arrow for the Construction list, hold down the mouse button and select the correct entry for your holder: • Scanning Head, Old Scanning Head or ProMax (Scanning Head) for a scanning probe head • Trigger Head for a trigger probe head (ST / ST3 from Zeiss) • RDS for an RDS • MCR20 for an MCR20 • SCR200 for an SCR200 5 Click OK if you are ready to save the settings and close the window.

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6 If you want to make more changes to the CMM configuration, click Apply. 7 Select the Controller bookmark and click on the Connect button to initialize the CMM. The CMM now also has the information it needs about probe changes.

Defining the Master Probe Length If you are using a magazine for measuring or trigger probes, you have to define the length of the master probe. This is important, because the position of every single holder in the probe changer is defined relatively to the machine coordinate system and the adapter plate on the probe head. To locate a holder, use the master stylus. Calypso knows the length of the master probe from this procedure. NOTE

Magazines for RDS probes can be measured with any calibrated stylus.

NOTE

You cannot use the automatic probe change functionality for RDS with an MCR20, only the TP20 probe modules can be changed.

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Follow these steps to define the length of the reference probe: 1 Insert the reference probe (see ➤“How to Install a Probe” on page 4-11) 2 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen.

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3 Click on Length of Master Probe.. 4 A prompt appears, asking you whether the reference probe has been inserted. Check the control to make sure that stylus 1 is selected and click on OK. 5 At the prompt to probe on the adapter plate, use the joysticks to touch the adapter plate to the top surface of any holder. The area on the plate to touch the top surface of the holder is the outer perimeter of the plate where it would naturally the holder when placed in it. 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 reference stylus is shown in a separate box. 7 Click OK to close the dialog box. Calypso now knows the length of the master probe. The locations of the holders can now be defined.

Adding Holders to the Probe Changer Configuration The holders in the probe changer that you want to use have to be added to the configuration of the probe changer on your system. When you add a holder it appears as an icon in the Automatic Probe Changer window. NOTE hss

You can use only one MCR20 or SCR200 with 6 holders in conjunction with the CMM. You do not need to add holders in the case of the MCR20 or SCR200 – Calypso automatically adds six new holders in the Automatic Probe Changer dialog box. To add a holder: 1 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Changer 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 box, enter a new name and click OK to confirm your entry and proceed. An icon for this holder, accompanied by the name you assigned, appears in the Automatic Probe Changer window.

4 Add more holders as necessary, until the configuration of your probe 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 probe changes: 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 7-42). Before you can set the positions of the new holders in the machine coordinate system, you first have to determine the approach parameters.

The Approach Parameters for the Probe Changer Configuring the automatic probe changer also involves setting the approach parameters that are used to define the clearance distances from the probe holder rack. These distances are defined from each given position (e. g. before entry into the rack) to the midpoint of the probe head. The Position Over Holder distance is from the probe adapter plate (on the bottom of the probe head) to the top of the rack. The default value is 0 mm.

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You can change the settings for each holder. If you need to change these distances because of part or probe clearance problems, please be aware of how close the movements are around the probe holders and the rack.

Datum for approach parameters The approach parameters for all probe changers are referenced to the transfer point to the macro in front of the holder, and not the toholder point itself. If you enter Position Before Holder = 0, the probe head moves directly to the transfer position. The Approach In direction is the direction the CMM must travel in to access the probe holder. If your probe rack is at the back of the CMM, the approach direction will be in the positive Y-axis. If it is on the left side of the CMM, the approach will be in the negative X-axis.

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Caution An articulating probe head moves the probe 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 probe used.

The Approach for RDS The illustration shows a probe changer magazine for RDS probes. The arrow shows how the approach has to be defined.

How to Check or Change Approach Parameters Follow these steps to view or change the approach parameters: 1 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 2 Click on the holder you want to change.

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3 (MCR20 only): In the Edit list, select Edit Orientation of Changer and enter the approach direction. This setting applies to all the changer’s probe holders. 4 In the Changer list, select Approach Parameters. The window with the approach parameters is opened.

If you have an MCR20 or an SCR200, the Approach Direction is set to a default that you cannot change here. You can enter the other values. 5 To change a value: • Click in the input box and highlight the current value. • Type in the new value. 6 Click on OK. The settings are saved and the window is closed.

How to Define the Position of a Holder Every time a holder is created in a probe changer, the position has to be defined in the machine’s system of coordinates. In the case of the MCR20 and the SCR200, all holders are calibrated tly in a single operation (see ➤“How to Define the Holder Positions of an MCR20” on page 7-44).

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Caution The approach direction has to be set before you define the position of a holder (see ➤“The Approach Parameters for the Probe Changer” on page 7-41). Risk of collision if this procedure is not adopted. To define the position of a holder: 1 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen.

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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 probe for this holder. 5 If no probe has been qualified yet and you merely want to define the position of the holder, click on Cancel. If you already know which probe you want to assign to the holder, select the probe’s name and click on OK to confirm. NOTE hss

Do not click on OK as long as you have not completed the following step. In addition, ensure that the dust cover is open. 6 Calypso reacts differently, depending on which type of probe head is installed: • With a trigger probe head you are asked to bring the stylus into 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 head, a cone on the side of the holder is located by self-center probing. • With Renishaw probe heads (TP20 and TP200), you are prompted to probe points on the MCR20 or SCR200. • With a RDS probe head, the back and side reference areas are automatically probed after probing the upper reference area. When the measurement is finished, you will see a symbol for the probe head. The name is below the symbol. 7 Repeat these steps for every holder which has not yet been defined.

How to Define the Holder Positions of an MCR20 All the holders of an MCR20 are calibrated at once.

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7-44

Caution Before you define the holder positions of the MCR20, the covers must be opened and the approach direction set (see ➤“The Approach Parameters for the Probe Changer” on page 7-41). Risk of collision if this procedure is not adopted.

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To define the holder positions of the MCR20: 1 Open the covers of the MCR20. 2 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 3 Click on a holder icon in the Automatic Probe Changer window. 4 In the Changer list, select Define Holder Location.

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Caution Always use the PSR2 probe 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 guide for the MCR20). You are prompted to enter the name of the probe for this holder. 5 If no probe has been qualified yet and you merely want to define the position of the holder, click on Cancel. If you already know which probe you want to assign to the holder, select the probe’s name and click on OK to confirm. The information about the probe refer 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 probe changer is selected, only the MCR20 holders are displayed. Holders of other types for this machine configuration are deleted.

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Caution Always use Reduced Speed (potentiometer) for movement, as otherwise there is a risk of collision.

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7 Probe point 1 on the left end face of the MCR20 as prompted. P5 P4 P3

1 2

3 4

5 6

P6 P7 P1 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 closed during probe changes. 9 Click on OK. The dialog box closes.

How to Define the Holder Positions of an SCR200 All the holders of an SCR200 are calibrated at once.

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7-46

Caution 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 calibration process, in order to interrupt the signal from the photoelectric barrier (see ➤“The Approach Parameters for the Probe Changer” on page 7-41). 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 Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 3 Click on a holder icon in the Automatic Probe Changer window. 4 In the Changer list, select Define Holder Location.

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Caution Always use the PSR2 probe 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 guide for the SCR200). You are prompted to enter the name of the probe for this holder. 5 If no probe has been qualified yet and you merely want to define the position of the holder, click on Cancel. If you already know which probe you want to assign to the holder, select the probe’s name and click on OK to confirm. The information about the probe refer 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 probe changer is selected, only the SCR200 holders are displayed. Holders of other types for this machine configuration are deleted.

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Caution Always use Reduced Speed (potentiometer) for movement, as otherwise there is a risk of collision.

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7 Probe point 1 on the left end face of the SCR200 as prompted. P5 P4 P3

1 2

3 4

5 6

P6 P7 P1 Z+ Y+ P2

X+

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 dialog box closes.

How to Assign a Probe to a Holder In this step, you define which probe will belong to which holder. NOTE hss

A probe has to be qualified before you can assign it to a holder. Qualify the probes in accordance with the instructions in ➤“How to Qualify a Stylus” on page 4-22. To assign a qualified probe to a holder: 1 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 2 Select the holder to which you want to assign the probe by clicking its icon. The icon turns green.

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3 In the Changer list, select Assign Probe to Selected Holder. A list of all qualified probes is displayed. 4 Select the name of the probe you want to assign to the holder, and click on OK to confirm your choice. The probe is assigned, and by way of confirmation the probe name appears below the icon for the holder. 5 Repeat the above steps for the holders to which no probe has been assigned as yet.

How to Perform an Automatic Probe Change

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Caution When storing or getting a probe for the first time, you should be prepared to cancel the procedure. If the approach parameters are incorrect, you can avoid a possible collision by canceling. To automatically change between probes that are both stored in the probe changer rack, follow these steps: 1 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 2 Click on the holder icon that contains the probe you would like to install. 3 Click on the Changer drop-down list and select Load Probe. The CMM first stores the probe that is currently installed, then picks up the probe you selected and backs out the approach distance.

How to Perform a Semiautomatic Probe Change

! hss

Caution When storing or getting a probe for the first time, you should be prepared to cancel the procedure. If the approach parameters are incorrect, you can avoid a possible collision by canceling. To automatically store an installed probe and then manually install a different probe, follow these steps: 1 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 2 Click on the probe holder icon where the currently installed probe should be stored (the icon for the empty holder on the rack).

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3 Click on the Changer drop-down list and select Store Probe. The CMM places the probe in the selected holder. There is then no longer a probe installed in the probe head. 4 Click OK to exit the Automatic Probe Changer window. 5 Proceed with the steps for manually changing a probe, as described in ➤“How to Install a Probe” on page 4-11.

How to Change the Probe Assigned to a Holder To change the probe that is assigned to a particular holder, follow these steps: 1 Make sure the probe is qualified and is currently installed on the CMM (see ➤“Installing and Qualifying Probes” on page 4-10).. 2 Select Prerequisites → Automatic Probe Changer. The Automatic Probe Change dialog box appears on the screen. 3 Click on the icon for the new holder to which you want to assign the probe. The icon turns green. 4 In the Changer list, select Assign Probe to Selected Holder. A list of all qualified probes is displayed. 5 Click on the name of the probe you now want to assign to this holder. The probe is assigned, and by way of confirmation the probe name appears below the icon for the holder.

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Multimedia Information

Multimedia Information In Calypso, you can include audiovisual information that s can view before running the measurement plan. For example, you could include a video showing instructions on how to fixture or orient a part. Each measurement plan can have its own unique information file, or you can use the same information file for several different measurement plans. NOTE hss

If you have the appropriate utilities installed on your computer, you can view files of the following formats: *.txt, *.doc, *.bmp, *.avi, *.flc, *.pdf and *.gra. You can create video files on any personal computer with a video capture board and an attached camera. Refer to the documentation included with these devices and associated software. You can create video files on any PC with a video grabber board and a video camera. You can view this information in the Start Measurement dialog box by clicking on Information.

How to Add Information to a Measurement Plan Follow these steps to select a information file for a measurement plan: 1 Make sure you have created an audio-video file of the proper format and have stored it in the folder c:\opt\om\pictures\info. 2 Open the measurement plan with which you want to include the information file (for example, by selecting File → Open). 3 Select CNC → Select Information For Program Start → Select. The File Selection dialog box is displayed, listing all files currently in the c:\opt\om\pictures\info folder. 4 Click on the file that you want to include with this measurement plan. 5 Click Open. The file is now available to everyone who uses the measurement plan. Only one 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.

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How to View Information for a Measurement Plan After you have selected a information video file to use with a particular measurement plan, you or other s can view it when running the measurement plan. Follow these steps: 1 Make sure the measurement plan you want to run is open. 2 Click on the Start Measurement button. The Start Measurement / Measurement Plan Definition dialog box is opened.

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.

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Multimedia Information

3 Click on Information. A window pops up that shows the selected 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 how the video plays, go forward and back, and perform other functions. Refer to Windows documentation for instructions on using Media Player.

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Chapter

8 8

Running a Measurement Plan

.................................................................................................................................

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 evaluates 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 probe 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.

Included in this chapter: Defining the Scope of Measurement . . . . . . . . . . . . . . . . . . . . . . 8-2 Entering Printout Header Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5 Starting a Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7 Monitoring Measurement Plan Runs . . . . . . . . . . . . . . . . . . . . . 8-11

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Defining the Scope of Measurement If you do not want to measure all the characteristics in the measurement plan, you have the option of running only selected parts of the plan. You can do this by combining characteristics in groups or selecting individual characteristics. Actual selection

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.

Measurement plan group

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. The 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.

Feature group

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 feature group, save this group and run this mini measurement plan.

Masked

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.

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.

How to Define a Current Selection of Characteristics It is advisable to group characteristics whenever you want to test a small combination of characteristics or a measurement plan group on a single occasion. To define a current selection: – 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 8-7).

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Defining the Scope of Measurement

How to Create a Measurement Plan Group You can combine characteristics to form groups. You can run a group of this nature separately, without the other characteristics in the measurement plan. NOTE hss

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. 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 shortcut menu. 4 In the shortcut menu, click on Rename and type in the new name. It is always a good idea to assign mnemonic names to the groups. 5 Press OK to confirm the new name and proceed. 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 8-7).

How to Ungroup a Measurement Plan Group You have to ungroup the characteristics in the measurement plan group in order to view them singly in the measurement plan. To ungroup a measurement plan group: 1 Highlight the group in the measurement plan. The line is grayed. 2 Open the Edit menu and select Ungroup. The characteristics are again listed individually in the measurement plan.

How to View the Contents of a Measurement Plan Group You can view the contents of a group in order to check, for example, that you have not omitted any characteristics. To view the contents of a measurement plan group: 1 Click on the left mouse button on the group in the list of characteristics. 61212-2010102

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2 Click on the Magnifier button. The of the group are listed after a few moments. The of the group are slightly indented in the list to indicate that they belong to the group.

How to Create a Feature Group 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 iterate certain characteristics, you can create a feature group. NOTE hss

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 CNC → Feature Group → 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 8-7).

How to Select Individual Features Instead of running an entire measurement plan or individual characteristics, you can also test individual features. Measuring without characteristics is a useful way of collecting advance information about the features. To measure selected features: 1 Click on the Features button to open the list of features 2 Press and hold down Ctrl key and click on the features you want to select. You can then open the Start Measurement dialog box, select the entry Current Selection under List Of Characteristics and start the measurement plan (see ➤“Starting a Measurement” on page 8-7).

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Entering Printout Header Data

Entering Printout Header Data If you want to document the measurement in a custom printout, you must enter the printout header data before you run the measurement plan. As regards entering printout header data, a distinction has to be drawn between: – Global printout header data Global printout header data refer to the entire measurement plan and have to be entered only once for each measurement plan. The global printout header data include, for example, the name of the operator and the name of the measurement plan. – Local printout header data Local printout header data refer to the current measurement and have to be entered before measurement starts each time a measurement plan is run. The local printout header data includes entries such as “lot ID” and “order”. When you enter printout header data, the system prompts only for the items that are contained in the currently selected format file (see ➤“Preparing Header Data” on page 9-16).

How to Enter Global Printout Header Data Global header comments belong to the measurement plan and need only be entered once for each measurement plan. To enter global printout header data: 1 Select Prerequisites → Printout Header Parameters. The Input Parameter dialog box will appear.

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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 every 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.

How to Enter Local Printout Header Data Local header comments belong to a measurement and therefore must be entered before the measurement plan is run. To enter local printout header data: 1 Click on the Start Measurement button. The Start Measurement / Measurement Plan Definition dialog box is opened. 2 Make sure that the Include Header check box is activated. 3 Click on the Data Input button. The Input Parameter dialog box will appear.

4 Click with the mouse 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 istrates 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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How to Start a CNC Run Before you can start a CNC run, you have to define the details of the run in the Start Measurement dialog box. To start a CNC run: 1 Click on the Start Measurement button. The Start Measurement dialog box appears on the screen.

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 the 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 Desk to hide the listing.

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Starting a Measurement

How to Start a Manual Run In a manual run Calypso steps you through the measurement process, but you have to make all the probings manually. This section explains how to run a measurement plan manually with Calypso. You have to do this if, for example, you work with a manual CMM. In a manual run Calypso is in control, and you probe the workpiece. The procedure for starting a manual run is as follows: 1 Click on the Start Measurement button. The Start Measurement / Measurement Plan Definition dialog box is opened. 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 Tick the Custom Printout check box, if you want the system to generate a custom printout. 4 In the Run Mode list, select Manual. 5 If you want to measure the coordinate system manually as well, go to the Selection group and select Manual run for the coordinate system. 6 Click on OK to start the measurement plan. Calypso steps you through the process: The Manual CNC dialog box is the direct man-machine interface.

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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 Desk to hide the listing.

Basics about Manual Control You can influence a manual run in a number of ways while it is in progress. – You can declare the manual run as an automatic run at any time. – You can delete the last probing point if it was unsatisfactory. – You can change the number of nominal probing points if, for example, some points are not accessible, or more points should be probed. – You can cancel the manual run. You will find more information on these actions in Manual CNC in the Calypso Online Help.

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Monitoring Measurement Plan Runs

Monitoring Measurement Plan Runs Irrespective of whether the run you start is automatic (CNC) or manual, Calypso always does some of the work for you, which means that it is active the entire time that a measurement plan is running. You can intervene in the process while the measurement plan is running. For example, you can interrupt the run or cancel it if this is necessary for some urgent reason. Calypso's Stoplight dialog box is the communication interface between you and the system. Just as a stoplight regulates the flow of traffic on a busy street, this stylized stoplight helps control process flows and display important status information. The Stoplight window is always on view after you start measurement. It controls communication between the CMM and Calypso. It is also the interface that enables you to intervene in a measurement plan run. NOTE hss

Never close the Stoplight window, because if you do Calypso will lose with the CMM. You can always minimize the window or put it behind another window. 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: – Stoplight, – Base Alignment, – Move in Part Alignment, – Probe Information, – Alignment and – Data Transfer On/Off.

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The illustration below shows the Stoplight window:

How to Switch Views On and Off in the Stoplight Window The Stoplight window enables you to activate various views that show information about the measurement plan run. These views can be activated at the same time. To switch a view on or off: 1 In the menu list of the Stoplight window, click on View. A tick preceding the name indicates which views are active. 2 Click on the view of your choice to toggle its on/off status. 3 If you want to move the views or arrange them neatly, click on the Arrange button and move the views as you wish. When you are finished, exit the arrange mode by clicking on an unoccupied part of the window. 4 To save the arrangement of views, click on the Save button. The size and position of the Stoplight window are also saved.

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Monitoring Measurement Plan Runs

How to Cancel a Run There are many reasons why a run might have to be canceled. Bear in mind, however, that certain preconditions have to be satisfied before you can restart a canceled run. 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 another measurement plan.

How to Interrupt a Run Interrupting means that the CMM comes to an immediate standstill, but can continue at some subsequent point in time. To interrupt a run: 1 In the Stoplight window, click on the amber light. The CMM comes to an immediate stop, the green light flashes. 2 Click on green. The run is resumed.

Reaction Following a Collision In the case of a collision between the probe and the workpiece, the CMM control switches all drives off. This is designed to prevent damage to the workpiece and the probe. In the Stoplight window, the stoplight goes red. Measurement can only be resumed if not all the buttons in the list of features are red or green.

Special Aspects of Collision with RDS If your CMM is equipped with an RDS (indexing articulating probe head, or stepping articulating probe holder), bear the following aspect in mind if a collision occurs. If the RDS collides while the CMM is not in motion and if the disk s open, the collision will not be detected when the machine subsequently moves (because the s are open). A collision can be detected only when the disk s are opened by movement of the CMM.

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How to Clear the CMM after a Collision You have to clear the CMM if the probe collides with the workpiece or the fixture. 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 probe away from the workpiece until it reaches a safe position. You can now resume your work. To ensure accurate results, check the probe and make sure that the stylus is not deformed.

How to Restart a Run after Cancellation You can restart an interrupted measurement run if not all the buttons in the list of features are red or green. To restart an interrupted run: 1 Set the stoplight to green. 2 Click on the Start Measurement button. The Start Measurement / Measurement Plan Definition dialog box is opened. 3 Deactivate the Clear Existing Results option. 4 Click on OK to restart the run. Calypso reruns the measurement plan. This time round, however, it measures only the features for which no measured values were recorded. This is the reason why compliance with the precondition described above is mandatory, as otherwise you would not obtain new results.

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Chapter

9 9

Viewing, Presenting and Editing Measurement Results ................................................................................................................................. Every time you perform a measurement, the results you obtain are presented in the default printout and the compact protocol. Calypso also offers a custom printout that you can use specifically for presenting the results of measurement. If you want to save results in files as backups or for processing in subsequent evaluation runs, you can use Calypso's export functionality that s a number of mainstream formats.

Included in this chapter: Result Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 Set up Custom Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 How to Display Variations Graphically . . . . . . . . . . . . . . . . . . . . 9-23 Saving Measurement Results to Files . . . . . . . . . . . . . . . . . . . . . 9-29 Converting Measurement results for qs-STAT . . . . . . . . . . . . . . . 9-32

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Viewing, Presenting and Editing Measurement Results

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 protocol, and the custom printout. Additionally, the measurement results can also be output to 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.

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Result Printouts

– The Compact Protocol is shorter than the Default Printout. It lists the characteristics together with the measured features for speedy assessment.

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– The Custom printout allows you to decide which elements you want to include and to arrange the sequence in which they are presented, along with the mode of presentation.

The default printout is always used by Calypso. After every evaluation it is generated and continued. Combined evaluations

You can also combine two or more measurement plans and so create combined assessments (see ➤“Combining Several Measurement Plans” on page 7-4). 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.

Output in the form of an Excel report

If you have installed Excel, you will also be able to output the measurement results in the form of an Excel report which will first have to be defined in Excel. 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 9-9); the output to Excel is set in the Start Measurement window.

How to View the Default Printout If you have not selected the custom printout option, the default printout window is automatically displayed on your screen after the measurement plan has been carried out.

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Result Printouts

If you hide the window behind the Desk, it stays hidden while the measurement plan is running. To display the measurement results: – Click on the Show Default Printout button. The default printout is displayed. You can also click on this button to display the results even if you have closed the Default Printout window.

How to View the Compact Protocol To have the compact protocol displayed by default, you must activate the Compact Protocol check box in the Start Measurement dialog box (select CNC → Run → Run). To view the compact protocol: – Select View → Compact Protocol. The compact protocol is displayed. Layout of the compact protocol

The compact protocol contains all the features of the measurement plan, with lines separating the individual features. The results of the characteristics are logged for each feature and color-coded: green means within tolerance, red means out of tolerance, brown means warning limits violated. If a characteristic belongs to the feature line, the log shows the characteristic line instead of the feature line. References and comments are also included.

Other options

You can search the compact protocol for character strings. You have a choice of two font sizes for on-screen display. The compact protocol is saved in the measurement plan directory as an ASCII file (without color-coding information) called rotocol.txt.

How to View the Custom Printout As soon as results have been calculated after a measurement, you can view and print the custom printout. – Select View → Custom Printout. Calypso opens the custom printout in a separate window. You can customize the way in which the custom printout is laid out to suit your needs and preferences (see ➤“Set up Custom Printouts” on page 9-7).

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How to Print the Measurement Results To send the measurement results to a printer, check the Send to Printer radio button in the Start Measurement window. You can select the number of copies in the Copies field beside this radio button. 1 Click on Print Results to print the default printout. 2 To print the custom printout, • select View → Custom Printout and • in the dialog box of the printout, select File → Print. The printout is output on the printer, that has been defined as the standard printer in the Windows settings.

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Set up Custom Printouts

Set up Custom Printouts The custom printout is your way of presenting measurement 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 presenting the results of measurement in detail. Custom printouts are ideal for attractive graphical presentations. Consequently, it consists of various graphics files. You can edit these graphics files as necessary. For using and modifying custom printouts, the following steps are necessary: – ➤“How to Define the Output of the Printout” on page 9-9 – ➤“Deg Custom Printouts with the Header Editor” on page 9-12.

The Structure of a Custom Printout The custom printout consists of various sections that you can include in or exclude from the printout, and arrange to suit your preferences. The data for each section are 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

Content

Edit Under

Printout header

Automatic fields with information on:

Prerequisites → Result Presentation → Printout Header File name: vphead.gra

– workpiece – measurement data – etc.

Prerequisites → Result Presentation → Header Line Editor File name: header.gra

Header Line

Specifications for presentation of the results.

Printout area

The printout area contains – the characteristics and the measurement results as well as coordinate systems etc.

Characteristics

Contains the icons, the Prerequisites → Result Presentation → names and the results of the Characteristic Editor characteristics. File name: cffra.gra

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Section

Content

Edit Under

Features

Contains the icons, the Prerequisites → Result Presentation → names and the results of the Feature Editor features. File name: me.gra

Coordinate systems

Contains the icons, the Prerequisites → Result Presentation → names and the references of Coordinate System the coordinate system. File name: cfpcs.gra

-definable pages

any

Prerequisites → Result Presentation → Defined Header

Automatic Fields in the Custom Printout The printout header contains automatic fields or dummies, as they are also known. Dummies are inserted once only. Subsequently, they are replaced by Calypso or by you when you run a measurement plan. This arrangement saves time and trouble, and the data on the measurement and the workpiece are always current. There are two kinds of dummy: – global dummies. You must enter global 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 by you or by Calypso before each measurement plan start; they include the order number and remarks, for example. For more information, see under ➤“Preparing Header Data” on page 9-16

Results Presentation in the Custom Printout The custom printout presents the measurement results as follows (shown here without the printout header):

Icon of characteristic

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Name of char.

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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. 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.

How to Define the Output of the Printout The Format Custom Printout dialog box allows you to define WHAT (e.g. characteristics) is contained in the printout and HOW (e.g. the sequence) it is presented. Additionally, you can also set the required report type for output to Excel. To specify printout: 1 Select Prerequisites → Define Printout. The Format Custom Printout dialog box appears on the screen. 2 Set the parameters defining the scope and sequence of the features in the custom printout. NOTE hss

If you want to output measurement plan groups, go to the Range column, select the Other Objects line and set the option to All. Make sure that Separate is not activated in the Output Order column. 3 To allow the measurement results to be output to an Excel file: click on the Select EXCEL Report button and select the required report type.

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NOTE

You can only use this function if you have installed Excel 2000 on your system.

hss

Requirement: You must have previously defined at least one output format as “Report” in Excel 2000. INI files with the name “ReportINI.xls” must be available in the same directory as the reports. 4 Click on OK. The settings are accepted and the dialog box is closed. 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.

Examples of Printouts – Example of a custom printout. Color highlighting is used for emphasis in the custom printout.

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– Example of a VDA printout (without values). The test report is output in a VDA printout. This printout does not contain any features.

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– Example of a condensed custom printout. The condensed form of the custom printout does not feature color highlighting.

Deg Custom Printouts with the Header Editor While creating an individual custom printout, you can freely choose the representation for the measurement results. Here, you can create various custom printout templates which can be called up in accordance with the measurement task which is to be executed for the Result Presentation. The Header Editor is a tool that you can use to create and edit graphic elements and insert measurement plan variables into the printout.

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This illustration shows the Header Editor for features. Menu bar Task bar Info bar

Graphic

Drawing area Special toolbox

You can change the following structural aspects: – Printout header, – Header line, – Characteristics, – Features, – Coordinate systems and – Additional, -defined pages. NOTE hss

You need some experience of drawing programs in order to use the editor.

The 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. 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 fields are filled either automatically by Calypso while measurement is in progress, or my the operator.

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The graphic toolbox contains the icons representing the usual tools of a graphics program for drawing simple graphical elements, and for inserting entire graphical elements (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 tool bar contains a selection of commands for controlling the Header Editor: The commands available in the menus accessible through the tool bar are as follows: Menu

Menu item

Function

File

New

Creates a new custom printout

Save

Saves the current custom printout.

Save As

Saves the current printout under a new name.

Open

Opens an existing printout.

Format

Opens the Page Layout dialog box. This dialog box is fully described in Page Layout in the Calypso Online Help.

Print

Prints the current printout.

Close

Closes the dialog box

Copy

Copies the selected element to the Clipboard.

Cut

Copies the selected element to the Clipboard and removes it from the drawing area

Paste

Pastes the contents of the Clipboard back into the printout.

Select All

Selects all elements in the drawing area.

Duplicate

Duplicates the selected element.

Make Polygon

Not yet available

Edit

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Menu

Menu item

Draw

New

Function

– Number Field

Inserts a number field for numerical inputs.

– Text Field

Inserts a text field for alphanumerical inputs.

– Output Field

Inserts an output field.

– Data Output Field

Inserts a data output field.

– Table Output Field

Inserts a table output field.

– Graphic

Inserts a graphic (file, OMView or Formplot).

Fill Color

Defines the fill color for an object.

Border Color

Defines the color for an object's border.

Line Width

Defines the line width for an object's frame

Properties

Opens the Properties (Header Editor) dialog box. This dialog box is fully described in Properties (Header Editor) in the Calypso Online Help.

Width...

Defines the width of an object.

Height...

Defines the height of an object.

Object Name...

Defines the name for the object.

Object Visibility...

Prompts whether you want to create a new view of the object.

Bring – To Front

Brings an object into the foreground.

– Forward

Brings an object one layer forward

Send – To Back

Sends an object to the background.

– Backward

Sends an object one layer back.

Group – For Symbols

Creates a group for symbols.

– For Statistics

Creates a group for statistics.

– For Comments

Creates a group for comments.

– For References

Creates a group for references.

– Group

Groups the selected objects.

– Ungroup

Ungroups a group.

Align...

Aligns selected objects vertically and/or horizontally.

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Menu

Menu item

Function

View

Refresh

Not yet available

Zoom In

Zooms in the view.

Zoom Out

Zooms out the view.

Grid Off

Switches the grid on and off.

Define Grid

Defines the size of the grid.

Scale feature

Scales an object by the defined scaling factor

Reset Page

Not yet available

Select Objects

Lists all objects that occur in the printout template.

Preparing Header Data The printout header part of the custom printout can accept data relating to the measurement environment, the operator, or the workpiece. You decide which data to include in the printout header when you structure your custom printout. There are two types of printout header data: – Local data: You have to enter these data each time you start a measurement plan – Global data: You enter these 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 also define your own printout header fields (➤“Define your own Printout Header Fields” on page 9-17). To define which data is incorporated into the printout header, select Prerequisites → Result Presentation → Printout Header.

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The available printout header data is listed in a column reserved for this purpose.

Printout header

Within the column, the printout header data is arranged in groups, as follows: Data Group

Type

Subsequently Entered

SYS

local/global

automatically by Calypso

EDIT

global

once only per measurement plan under Prerequisites → Printout Header Parameters.

START

local

for each measurement plan start in the Start Measurement dialog box, see ➤“How to Enter Local Printout Header Data” on page 8-6.

OTHER

local/global

automatically by Calypso

Define your own Printout Header Fields Input fields can be freely defined for the printout header. These fields will then be available for selection for the printout header.

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The additional input fields will have to be defined in the ASCII file “fields.txt” which can be found in the directory /opt/om/protform/. Here, it will be necessary to add one further line with the following features, separated by a comma, for each required input field: Setting (field or button) Meaning ID

will be used in the result file, must begin with “u_”

Label

will be displayed in dialogs

Display control

E = appears in the dialog when editing, R = appears in the dialog at CNC start, RE = appears in both dialogs

You can, for example, append the following three lines in the file fields.txt: u_field1,FELD 1,RE u_field2,FELD 2,R u_field3,FELD 3,E

Once you have called the Report Header File Editor using Prerequisites → 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 Prerequisites → 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. The identifications (e.g. u_field1) and the appropriate values will be output in the result header file (*_hdr.txt).

How to Work with the Custom Printout Template The template for the printout header is used here by way of example to illustrate how to create a custom printout template and what to bear in mind when you save your work.

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To work with a custom printout template: 1 Open the editor for the section you want to edit by selecting Prerequisites → 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. Calypso displays the following message:

! hss

Caution 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.

Example: Programming a Custom Printout with Input Prompt You can program a custom printout in such a way that before the printout is printed, the is prompted to enter certain items of information destined for inclusion in the printout. You do this with the aid of the variables in the printout header (see ➤“The Printout Header Data (Reference)” on page 9-21) and the Inquire query function in the PCM language.

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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 in the custom printout. 1 Select Prerequisites → Result Presentation → Printout Header. The file now shown under Sketch should now be vphead.gra. 2 Select File → Open. The printout header is now displayed on the 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”,PALLET) The effect of the first line is that a prompt box opens and the 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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The Printout Header Data (Reference) All the printout header data are listed in the table below: Data Group

Name of field

ID

SYS

CMM No.

dmesn

Time

time

of

nrpgs

Datum

date

Measurement plan name planid

EDIT

START

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dmeswv

Department:

vda_departm

Software

dmeswi

Telephone/fax:

vda_phone

No.

vda_number

Control type

Controller

Sheet

actpgnr

Machine type

dmeid

Operator

operid

Run

measRun

Clamp No.

clmpsn

Comment:

vda_remark

Clamp

clmpid

Name of probe changer

partid

Previous operation

prevop

Ser. No. workpiece

partsn

Measurement plan commentary

partcomment

Subject number:

vda_subjno

Device no.

fixtsn

Name:

vda_name

Version:

vda_version

Device

fixtid

Rev. workpiece

partrv

Audit no.

vda_auditno

Drawing number

drawingno

Comment at start

startcomment

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Data Group

Name of field

ID

Comment:

vda_remark

Name of probe changer

procid

Test ID

lotid

Lot ID

partnbLong

Subject number

vda_subjno

Name:

vda_name

Process plan

mfgdev

Order

order

Part number incremental partnbinc

OTHER

Version:

vda_version

Audit no.:

vda_auditno

Tool

tooldf

Signature:

vda_signature

Change operator

changeoper

Creation of software rev. creationswi Date of change

changedate

Created by

produceoper

Date of creation

creationdate

CMM type creation

creationdme

The IDs are used to identify the header data in the table result file (...hdr.txt).

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How to Display Variations Graphically

How to Display Variations Graphically Calypso can graphically display the deviations which are determined by form elements on the measured geometric features as Form Plots and can output these to your printer. This form plot is available for the following characteristics: – Straightness – Flatness – Roundness – Cylindricity – Best Fit of bore pattern – Curve form (optional feature). You can either select an existing format file or a format file which you have created yourself (“*.gra”) to display the deviations in graphical form.

How to Activate a Form Plot Before you can activate a form plot, you must check that the characteristic for the form plot you want to define has been measured. To activate the form plot: 1 To open the definition template, double click on the characteristics icon in the measurement plan. The definition template will appear. 2 Complete the Tolerance and Feature fields, if they do not already contain the applicable data.

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3 Click on the Graphic button. The selection window for the form plot is opened. The appearance differs, depending on the characteristic from which the form plot is called. The diagram shows an example of a window with the feature “Roundness” for a circle:

Option for the type of plot Format File Selection List

Picklist 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 plot. Default refers to the standard Zeiss format file. All characteristics for which the type of form 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 ➤“About the Form Plot Window” on page 9-26). 7 Click again on the selection window for form plots if you want to view other form plots. This moves the Form Plot window to the background. You can now display the form plots of other characteristics together with the current form plot. Repeat step 6 for this. 8 Click on OK when you are ready.

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You can always bring the form plot window back to the foreground again if you need it.

Format Files for Form Plots Calypso provides several standard format files for displaying the form plots. Additionally, you can also create your own format files. The file that is required for the form plot can be selected in the selection window for the form plot. The format files which are offered here can be found under ..\Calypso\opt\om\pictures\formplott\calypso\ in the subdirectory for the respective plot type. Plot type

Subdirectory

File Name

Straightness

Straightness

cz_sn.gra

Multiroundness

Multiroundness

cz_mr.gra

Multiroundness with diameter

Multiroundnessdia

cz_mr_dia.gra

Multiple roundness transposed

Multiroundnesstranspose

cz_mr_t.gra

Cylinder form from Circle segments in 3D

Cylinderformcircular3d

cz_cf_3dc.gra

Cylinder form from Line segments

Cylinderformline

cz_cf_l.gra

Cylinder form using many circle segments

Cumradialrunoutmulticircle

cz_crro_mc.gra

Cylinder form using a single circle segment

Cumradialrunoutsinglecircle

cz_crro_sc.gra

Flatness from Circle Segments

Circlemulti

cz_fn_mc.gra

Flatness from Line Segments

Linemulti

cz_fn_ml.gra

Multi-flatness from circle segments

Multiflatnesscircular

cz_mfn_c.gra

Multi-flatness from line segments

Multiflatnesscircular

cz_mfn_c.gra

3D Flatness View

flatness3d

cz_fn3d.gra

Curve form linear

curveformline

cz_cu_li.gra

Curve form 2D

curveform2d

cz_cu_2d.gra

Multi-curve form 2D

multicurveform2d

cz_mcu_2d.gra

Multiple curve form linear

multicurveformline

cz_mcu_li.gra

Only the format files that have been provided in the respective subdirectory and are appropriate for the plot type can be selected in the selection window for the form plot. Format files which you have created yourself should also be saved to the appropriate directory.

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Individually Structured Format Files for Form Plots In addition to the format files provided by Calypso for displaying form plots, you also have the option of creating your own format files. To do so, use the Header Editor which can be called using Prerequisites → Result Presentation → Characteristics. Details on how to work with the Header Editor can be found under ➤“The Header Editor” on page 9-13.

About the Form Plot Window The illustration below shows the Form Plot window for a roundness plot for a circle. 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.

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In this window you can edit, save and print the form plot.

How to Print a Form Plot To print the form plot: – In the Form Plot window, select the appropriate command from the File menu. A dialog box appears on the screen.

How to Change the Form Plot Settings The parameters in the form plot settings define the scope of the form plot, among other things. To change the form plot settings for the next output: 1 In the Form Plot window, select Edit → Modify Chart Settings. This opens a notebook laid out like the notebooks containing the system settings.

2 Set the parameters as necessary. 3 If you have changed the settings and want to use these for the current plot, click on OK. 4 If you want to save your settings for other form plots, click on Save. The Form Plot window reappears on the screen. NOTE hss

This dialog box is fully described in Formplot Attributes in the Calypso Online Help.

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How to Change Form Plot Settings Permanently The parameters in the form plot settings define the scope of the form plot, among other things. To incorporate the form plot settings permanently into the measurement plan: 1 Open the definition template for the characteristic. 2 Click on the Graphic button. 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 If you have changed the settings and want to use these for the current plot, click on OK. 6 If you want to save your settings for other form plots, click on Save. The Form Plot window reappears on the screen. 7 Click on OK to close all sub-windows along with the definition template for the characteristic. NOTE hss

This dialog box is fully described in Formplot Attributes in the Calypso Online Help.

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Saving Measurement Results to Files

Saving Measurement Results to Files In addition to saving measurement results in the file “protocol” in the standard manner, Calypso also s additional files types in which the measurement results can be saved as required. You can determine the mode in which Calypso saves the data in these additional files. The table below describes the file types ed at this time: File type

Description

Table

The measurement 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 C:\calypso\home\om\workarea\results under the name of the measurement plan which corresponds to the measurement results, including part number indices.

Merge file

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.

DMIS / PROVACS I

The measurement results are saved in a file in DMIS format and are suitable for the PROVACS statistics program. Files of this type are saved in C:\calypso\home\om\workarea\dmisout under the name of the measurement plan that belongs to the measurement results.

QDAS Available as option only!

The measurement 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 which correspond to the characteristic set in the measurement plan editor (Characteristic to Statistic “on“). Files of this type are saved in C:\calypso\home\om\workarea\qdas under the name of the measurement plan that belongs to the measurement results.

ASCII File Curve

The measurement results for curves are output as an ASCII file under C:\calypso\home\ASCII\prüfplanname\elementname.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 stylus-corrected curve points are written in a file as MDI (point-vector sequence).

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How to Save the Measurement Results as Files To define which file type the results will be saved under: 1 Select Prerequisites → 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.

!

Caution 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.

hss

3 Click on OK to accept the settings and close the dialog box. The measurement results will be saved after the CNC run in accordance with the settings that have been made. NOTE hss

In a QDAS file, only the results are stored for which the selection point of the characteristic Characteristic to Statistic is set to “On“ or “Default“ in the Measurement Plan Editor Characteristics. This dialog box is fully described in Results to File in the Calypso Online Help.

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Saving Measurement Results to Files

Copying the Measurement Results File The results in the default printout and the compact protocol are automatically saved in files on your computer's hard disk. Each time you run a measurement plan, these files are overwritten with the new results. The names of the files are protocol.txt and rotocol.txt, respectively. They are saved in the subfolder created for the measurement plan in the main folder C:\calypso\home\om\workarea\inspections\ (the path on your computer might be slightly different). You can use the Windows NT Explorer to copy these files to a floppy disk or to another folder on the hard drive. Custom printouts are not saved on hard disk. Consequently, they cannot be copied to floppy disk or to other folders on your hard disk.

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Converting Measurement results for qs-STAT You can evaluate measurement results, which have been saved by Calypso in the QDAS format, in the statistics program qs-STAT.

How to Convert into QDAS Calypso automatically produces a results file after a CNC run.

CNC run of CAL YP S O measurement plan with activated QDAS output QDASCONV.CON Configuration file

CALYPSO Results file

CNC-E nd

QDASCONV.EXE Conversion file for file exchange format

QDAS Description file (*.DFD)

QDAS Value file (*.DFX)

Statistics software qs-STAT

If conversion to QDAS has been activated, the conversion program QDASCONV.EXE 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. NOTE hss

In the QDAS file, only the results are stored for which the selection point of the characteristic Characteristic to Statistic is set to “On“ or “Default“ in the Measurement Plan Editor Characteristics.

QDAS Description File The name of the description file consists of the first 8 characters of the measurement plan and the extension *.DFD.

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Converting Measurement results for qs-STAT

The description file contains data particular to the part and characteristics that describe the workpiece and the separate features. The contents of these data can be taken from the printout header, the printout or the configuration file. Every time QDASCONV.EXE is called, a check is run to ascertain whether or not the description file already exists. If it does not exist, it is created and thereafter, it remains valid for all subsequent measurements. In the data acquisition module of the qs-STAT statistics program, you can perform changes, such as adding features or entering information that was not known at the time of the measurement. If you give the Calypso computer a modified description file, the QDASCONV.EXE conversion program recognizes the changes and takes them into for the next conversion. Key structure

The description data in the DFD file start with a 4-character key that indicates the data type in the file. 0 ... 999

Description of the value formats

1000 ... 1999

Part data

2000 ... 2999

Characteristic data

3000 ... 3999

Measurement plan data

Example: K1001 Engine block Where: K = Key 1001 = Part number Engine block = Information content

QDAS Values File The name of the values file consists of the first 8 characters of the measurement plan and the extension *.dfx. The actual measurements, the identification for the validity of the dimensions and the date saved are saved in the value file. 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. NOTE hss

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.

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Additional data, such as charge number, operator, and machine number can be added 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.

Configuration File QDASCONV.CON The conversion file QDASCONV.CON controls the conversion of the Calypso measurement results into the QDAS format. QDASCONV.EXE needs the data from this file for the conversion. QDASCONV.CON must be located in the directory c:\opt\home\om. You can modify QDASCONV.CON to influence the conversion (see ➤“Controlling the Conversion with QDASCONV.CON” on page 9-34).

How to save Calypso Measurement Results in QDAS Format To save the Calypso measurement results in QDAS format: 1 Make sure that QDASCONV is installed. The program QDASCONV.EXE is located in the directory c:\opt\om\bin\winnt. 2 Save the results as described in ➤“Saving Measurement Results to Files” on page 9-29. Set the option QDAS to On (Save without query) or Select at CNC Start (Save with query). NOTE hss

In the QDAS file, only the results are stored for which the selection point of the characteristic Characteristic to Statistic is set to “On“ or “Default“ in the Measurement Plan Editor Characteristics. After execution of a CNC run, the measurement results will be saved as the description file (*.dfd) and the value file (*.dfx) in the directory C:\home\om\workarea\qdas, and under the name of the corresponding measurement plan.

Controlling the Conversion with QDASCONV.CON To control the conversion of the Calypso measurement results into the QDAS format, you just need to adapt the configuration file QDASCONV.CON.

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Line Format of the Configuration File QDASCONV.CON

Every relevant line of the configuration file has the following line format: KXXXX LLL T H:

The wildcards have the following meanings: K

Key

XXXX: 4-character key for indication of type of contents

LLL

Length of field

1 ... 255

T

Type of data

A = Alphanumeric I = Number F = Floating point number D = Date

H:

Origin and field name

P = Key word from the header file, example: P:planid W = directly from this file; example: W:Prismo7

Spaces and tabs are used as separators. Spaces at the beginning are not allowed. Comments begin with ’#’.

Sections of the Configuration File QDASCONV.CON The file is divided into four sections, which are labeled with the letters B, C, D and E. Each section is opened with a separator, for example: $C------------------------------------

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 part data: K1001

Part number

K1002

Part label

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K1003

Part short label

K1004

Part modification status

K1005

Product

K1007

Part number short label

K1040

Drawing catalog

K1041

Drawing number text

K1042

Drawing change

K1043

Drawing index

K1900

Remarks

You do not necessarily need to use the keys listed here. You can add new keys at any time. Section C: Constant characteristic data to be created

Some of the specifications needed to describe features are not known by the or machine, and are not contained in the measurement protocol. Some of these data have the same values for all features. These data are therefore defined as constant feature data in this section of the configuration file. Frequently used keys and their labels for constant feature data:

9-36

K2004

Type of feature

K2005

Feature class

K2007

Type of control

K2211

Type of distribution

K2212

Normal number text: Comparison normal

K2213

Normal label

K2214

Normal temperature

K2215

Normal number

K2220

Number of tester

K2221

Number of measurements

K2303

Section/Bookkeeping

K2305

Machine number

K2306

Area in works

K2307

PTM - number

K2342

Measurement plan name

K2343

Measurement plan creation date

K2344

Measurement plan creator

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K2401

Test equipment number text

K2402

Test equipment label

K2404

Test equipment resolution

K2405

Text equipment number

K2406

Text equipment manufacturer

K2407

SPC device number

K2408

SPC device label

K2409

SPC device type

K2410

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 statistic program qs-STAT. Section D: Variable feature data to be created NOTE

Some of the feature data can be taken directly from the measurement protocol. Values for these data do not have to be entered in this section of the configuration file. Do not change data in section D

hss

Frequently used keys and their labels for variable feature data:

Section E: Additional data fields to be produced

K2001

Feature number

K2002

Feature label (Additional text from configuration file)

K2003

Label short text (Calypso feature type)

K2100

Nominal value/Target value

K2101

Nominal dimension

K2110

Lower limit

K2111

Upper limit

K2112

Lower deviation

K2113

Upper deviation

K2120

Type of lower limit

K2121

Type of upper limit

K2142

Unit label

K2151

Tolerance as text (tolerance width)

For every measurement, additional data can be saved in the value file. These data are valid only for the corresponding measurement run.

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Keys and their labels for additional data fields K0005

Events

K0006

Charge number/Identification number

K0007

Nest number/Spindle number

K0008

Tester (number from catalog)

K0009

Text

K0010

Machine number (number from catalog)

These values can change with each measurement run. It is therefore useful to use the columns from the printout. The keys in this section affect only the first measurement run. They should be evaluated only if they are valid for all measurements, for example if all workpieces come from the same 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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Example of a QDAS Configuration File

############################################################################## # 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 # ATTENTION: 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 10

The Duplex Mode

.................................................................................................................................

Very large workpieces can be measured using CMMs with two measuring columns (dual-column 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 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 dual-arm CMMs, and step you through the procedures involved.

Included in this chapter: Duplex Operation with Calypso . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Preparing the Duplex Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Using Duplex Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15

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The Duplex Mode

Duplex Operation with Calypso Very large workpieces can be measured using CMMs with two measuring columns to obtain almost twice the usable measuring volume offered by a CMM with only one column. Each of the measuring columns is connected to a computer for correction and evaluation of the measurements; one of these computers is the master, the other is the client.

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. Run Mode

There are two different modes in the 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 are required for calculating a specific feature, the measuring column will wait until these data have been provided by the other measuring column.

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Duplex Operation with Calypso

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 the Duplex Mode” on page 10-4). – Important when measuring in any given run: log on, measure, log off (see ➤“Measuring with a Dual Arm CMM” on page 10-15). NOTE hss

Analog to 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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The Duplex Mode

Preparing the Duplex Mode The preconditions for duplex mode are as follows: – The files for duplex operation are available and correct – Both computers are connected via the network – Both measuring ranges are coupled

Files for Duplex Operation Some Windows NT system files have to be configured for duplex operation. These files are preconfigured on both computers of a system designed for duplex operation. The files are in the directory ..\winnt\system32\drivers\etc and are called “services“ and “hosts“. The lines required for duplex mode are listed here just in case the system files are modified in some way. The “services“ file

Examples of entries in the “services“ file: qmaster czcol1 czoemint acis counter holos ZVICONTROL col0 col1 col2 col3 oscssd

10012/udp 9996/t 9999/t 9998/t 9888/t 4959/t 8888/t 9800/t 9801/t 9802/t 9803/t 5019/t

# Double Column CNC

# CADLINK-UX # CALYPSO # Double Column MAN # Column1 # Column2 # Column3 # VERSANT connect service

It is important to make sure that the “czcol1“ line is in the file.

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The “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 connected to the master CMM. “cmm_1 CMM_1“ is the name of the master CMM's controller.

Establishing the Connection and Coupling the Measuring Ranges The two measuring ranges have to be “coupled“ so that Calypso can combine the results from both. Reference probings have to be taken at one or three reference spheres in the zone that is common to both measuring ranges, so that the two can be coupled. The results are combined in calculation and yield the basis for common measurements and evaluations for the two measuring columns. The coupling matrix is computed on the master and sent to the client, and the client uses the matrix to convert its measured coordinates into the coordinate system of the master CMM.

Selecting the Method of Coupling for Duplex Operation The sphere normals (references) must be installed in such a way that they can be reached and probed by both measuring columns.

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The 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, so that you can proceed with coupling.

Probes

Install the appropriate reference probe in each column for coupling. This ensures maximum precision. You have the option of using some other, qualified probe if slightly less precision is sufficient.

Subsequent coupling

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:

Reason for Coupling

Method

Always after a mechanical alteration

Translational + rotational

From time to time in operation (e. g. weekly if use is frequent)

Translational + rotational

Every time the system is restarted

Translational

Every time a measuring column homes

Translational

How to Prepare Coupling for Duplex Operation A number of preconditions have to be satisfied before you can proceed with coupling the measuring ranges. The preparations are as follows: 1 On each computer, select Extras → Workroom → CMM and open the notebook to the Dual Arm page. This page is available only if the machine is defined as a horizontalarm CMM.

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2 On the designated master computer, select the option Master.

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

Client

Arm 1 = Column1

Arm 2 = Column2

Controller 1 = CMM_1

Controller 2 = CMM_2

Computer 1 = CMMWS_1 = local Computer 2 = CMMWS_2 PC

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4 Select Client as the option for the other computer.

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 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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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 basic alignments on the master PC. Under Directory path, enter the locally valid designation of the path and under Mounted as..., enter the designation valid in the network under which the client system can access the path. 10 Click on OK. The notebook is closed and the settings are accepted.

How to Set Up the Connection between the Computers Once you have completed the preparations, you can set up the connection between the two computers. Connection setup

10-10

1 Close Calypso, but do not close the Taskbar and the Stoplight window. The connection is set up in the Stoplight window only.

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NOTE

Always proceed exactly as described below, otherwise the connection will not be successful.

hss

2 In the stop light window on the client computer, select View → Multi-Arm and click on the Initialize... button.

The “Wait for Master...“ message is displayed on the client.

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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The 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 the 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 Prerequisites → Measurement Plan Editor - Features. 3 Make sure that the setting for Probe is MasterProbe across all features (or the qualified probe you are going to use). 4 Make sure that the setting for Man CNC Mode is MAN across all features. 5 Make sure that the entry under Columns that will be measured with column 2 is column 2 for all features. 6 In the list of characteristics, open the 3-D Best Fit1 characteristic. The Definition Template (Alternative Alignment Methods) dialog box appears on the screen.

7 Make certain that the entry Column2 (arm ID slave) is set under Receiver. 8 Select File → Save to save the measurement plan.

How to Define the Coupling When you are satisfied that all settings in the measurement plan (probe, base alignment, MAN or CNC, name of the second measuring column, etc.) are correct, you can run the measurement plan for the coupling. 1 Open Calypso on the master computer.

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The 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.

How to Reset the Coupling A coupling corrects the coupling matrix on the client, but the matrix is not entirely rebuilt. If you want to delete the coupling matrix on the client in order to rebuild it from scratch, proceed as follows: 1 In the stop light window, go to Multi-Arm and click on the Special button. 2 Click on the Reset connection data button that now appears. The matrix is deleted. You have to redefine the coupling before you can use duplex mode again.

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Using Duplex Mode

Using Duplex Mode It is very important to bear the following points in mind when you measure in duplex mode: – Each feature can be measured with only one measuring column. This means that large holes, for example, have to be interlinked by means of individual points. (Each feature is assigned to one and only one measuring column). Unless otherwise defined in the Strategy dialog box, the master (measuring column 1) is generally used for measuring features. – Note the geometry of the features. When you assign features, to make sure that measurement must be collision-free, and that this applies to both measuring columns. Measurements in the common measuring range of the two arms merits special care and attention. Make sure that there is no risk of an arm colliding with the other arm as it performs a retract or moves to an intermediate position without probing. Asynchronous operation

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: duplex run mode set to synchronous). – Only then test the measurement plan in asynchronous mode (measurement plan editor - features: duplex run mode set to asynchronous).

Measuring with a Dual Arm CMM The procedure for measuring in duplex mode consists of the log-on, measure, and log-off phases. You do not have to log on if you have just finished coupling the measuring ranges; the two measuring columns are already coupled. You can skip to ➤“Measuring in Duplex Mode” on page 10-16. In all other circumstances, you have to start by setting up the connection. The log-on phase is described in detail in ➤“How to Set Up the Connection between the Computers” on page 10-10.

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The Duplex Mode

Measuring in Duplex Mode The recommended procedure for measuring in duplex mode consists in successively constructing the measurement plan by manual probings and generating features, before starting the measurement plan in CNC mode. The measurement can also be constructed offline using empirical values, but this requires specialist knowledge and experience. It is, therefore, best to proceed as usual, working on the master computer as if you were measuring with a single-arm CMM, while bearing the following additional points in mind: – Each feature can be measured with only one of the two measuring columns. – The point and the position “know“ where they come from; probing the first point or the first position defines the measuring column to which the feature belongs. – You can view this information in the Measurement Plan Editor Features under Columns (default or column1 means “master“; column2 means “client“). – Clearance Planes: The measuring column flagged as “active“ by the stoplight is the arm that executes the “go to clearance plane“ movement.

!

Risk of collision Do not forget to clear the intermediate positions, as otherwise there would be a risk of collision.

!

Caution If you are preparing a measurement plan for asynchronous operation, you must make absolutely sure that the measuring columns can not collide under any circumstances. That is to say, the areas in which the measuring columns move must never overlap. Insofar as the areas of movement overlap, the possibility of a collision can not be excluded, because in asynchronous mode the measuring columns move independently of each other.

hss

hss

– Please check the following functions and settings in particular using the Measurement Plan Editor - Features: COLUMNS Probe Stylus Clearance group RDS angle

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Using Duplex Mode

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.

How to Start the Duplex Mode After you have completed all the preparations and you have connected the two computers together, you can start the duplex mode. To start the duplex mode: 1 Select CNC → Measurement Start → Measurement Start. The Start Measurement window is displayed. 2 If you want to work in asynchronous mode: Under Order of Run, select the mode From Feature List. If you select From Characteristic List, the CMM will proceed as in synchronous mode. 3 Click on OK to confirm. A warning message will appear, which you must confirm. The run begins.

How to Clear Down the Coupling for Duplex Operation Clear down the connection between master and client when you have finished measuring. The procedure for logging off and terminating the duplex mode is as follows: 1 On the master computer, deactivate the Connected with “Clients“ check box. 2 On the client computer, deactivate the Connected to the Master check box. This clears down the connection.

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The Duplex Mode

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Chapter

11 11

Managing Calypso

.................................................................................................................................

This chapter is intended primarily for system s (e.g. the Master ) or experienced s, 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 s or initializing the CMM.

Included in this chapter: Installing Calypso . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 Installing a Service Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 If a Software Error Occurs – the Error Report . . . . . . . . . . . . . . . 11-8 Modifying System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11

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Managing Calypso

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 Disk

System Requirements To guarantee that Calypso runs error-free, 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 II processor with 200 MHz clock frequency – 128 MB RAM – 8 MB OPEN-GL-compatible graphics card Recommended configuration (especially for CAD options): – Processor with 2 GHz clock frequency – 1 GB RAM – 32 MB OPEN-GL-capable graphics card

Software requirements

The PC must run one of the following Operating Systems: – Windows NT 4.0 – Windows 2000

System settings

11-2

If your system was configured by Zeiss service personnel, you do not have to modify the settings. If this was not the case, click on Start → Settings → Control and select Display and set “True Color” under Colors on the Settings card.

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Installing Calypso

Installing Calypso NOTE hss

In order to install / uninstall Calypso, you must be logged on with privileges.

Uninstall existing version

If you already have an older version of Calypso installed on your computer, run the uninstall program before you install a new version.

NOTE hss

Existing data such as measurement plans, probe 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 on your computer. Windows starts automatically. 2 Select Start → Settings → Control in the Windows start menu and click on Add / Remove Programs. 3 Select the program “Calypso” on the Install/Uninstall card, click on Add/Remove and follow the instructions on the screen. 4 Select Remove from the Program Maintenance window and click on Next. 5 In the next window, click on Remove. The Calypso files on zhe PC will be removed automatically. The current status will be displayed. 6 Confirm completion of uninstall with Finish. 7 Confirm the restart message with Yes. Your computer will be restarted. Calypso has now been uninstalled.

Install current version or new release

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 If you have not already done so, switch on your computer. Windows will start automatically. 2 Insert the CMM Disk into the floppy disk drive.

NOTE hss

The write protect on the CMM Disk must be off. You can also copy the CMM Disk onto the hard drive for later selection. 3 Place the Calypso software CD in the CD-ROM drive. If the CD starts automatically, the Calypso installation window will appear immediately. Proceed to step 7. 61212-2010102

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Managing Calypso

4 If this is not the case, select the Windows command Start → Run. A prompt for a filename to run appears. 5 Click on Browse, select the CD-ROM drive and select the Calypso.exe file on the CD. 6 Click on Open, and then on OK. After a few moments, the Calypso installation window will appear. 7 Select English as the language of the installation. 8 Click on the Install button and then on Calypso. The installation program checks if there is enough space on the hard drive and asks you if the CMM Disk is inserted. 9 If the CMM Disk is in the floppy drive, then click on Yes. Otherwise, click on No, enter the path with the CMM Disk in the following prompt, and click on OK. A Welcome screen appears. 10 Click on Next to accept the copyright agreement and continue. The Information window will open. 11 Enter the information and click on Next. The Setup Type window will appear on the screen. 12 Select Standard if you do not wish to alter any of the presettings and click on Next. - or • Select Custom and click on Next if you wish to change the following settings in the windows that follow: • drives and target directories for installation • program features to be installed NOTE hss

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”. 13 Click on Install. Calypso will now be installed automatically. The current status will be displayed. Afterwards, the message “InstallShield Wizard completed” appears. 14 Click on Finish. 15 Confirm the restart message with Yes and remove the CMM Disk from the drive. Your computer will now be restarted. Calypso has now been correctly installed.

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Installing a Service Pack

Installing a Service Pack From time to time, you may receive program modifications and additions as Service Packs. Service Packs can arrive by e-mail, on floppy disk or on CD-ROM. The instructions below are based on the assumption that you have received the Service Pack on disk. Broadly speaking, though, the procedure is the same for all distribution mediums. The name of the service pack file contains information relating to the corresponding program version. “zeiss_sp3412.exe“, for example, is Service Pack 12 for Version 3.4 of the program. Installation consists of two steps: – Decompressing the Service Pack files – Installing the Service Pack files

How to Decompress the Service Pack Files The program files on the shipping medium are compressed to take up as little storage capacity as possible. You have to decompress the files before you can install them. 1 Boot your computer if you have not already done so. 2 Insert the Service Pack disk into the floppy disk drive. 3 Open Windows Explorer: • Point to Start and click on Programs. • Click on Windows Explorer. • Delete the contents of C:\TEMP. 4 Click on the 3 1/2” Floppy (A:).

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Managing Calypso

5 Double-click on the file calypso_spxxxx.exe.

1. Select drive A:

2. Double-click on the file name

This opens the WinZip Self-Extractor window.

The default folder is C:\TEMP. 6 Click on Unzip. The files are decompressed. A message appears on the screen when the files have been decompressed. 7 Click on OK and click on the Close button in the WinZip SelfExtractor dialog box. The program files are now in the directory C:\TEMP on your hard drive. They can now be installed (see ➤“How to Install the Program Files Contained in the Service Pack” on page 11-7).

11-6

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Installing a Service Pack

How to Install the Program Files Contained in the Service Pack Once they have been decompressed, the files of the current Service Pack will be on your hard drive (see ➤“How to Decompress the Service Pack Files” on page 11-5). To install the program files: 1 Select Start → Programs → Zeiss → Calypso → Service Pack from the Windows start menu. You will be prompted to select a language for the installation routine. 2 Select the installation language and then click on OK. The installation program now asks you to confirm the path for the decompressed files. The default folder is C:\TEMP. 3 Click on OK if the decompressed files are located in C:\TEMP. • Should this not be the case, enter the correct path and then click on OK. When installation completes, the following message will appear.

4 Click on OK to close the message. 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

If a Software Error Occurs – the Error Report Calypso is a program which undergoes continuous development. The target of the development is to make Calypso better with every revision. You can this process by using the error report. An error report can be generated automatically by Calypso, or you can trigger the process manually (see ➤“How to Use the Error Report” on page 11-9). The error report contains at least the following data: – the type of device – the current Service Pack version – the system's error messages – a description of a situation (what was the lead-up to this error?), which you will be required to enter The error report can be saved as a file and sent to Zeiss. If you wish, you can also add the current measurement plan to this file.

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If a Software Error Occurs – the Error Report

How to Use the Error Report The automatic error report appears anytime Calypso runs into an internal program error. To manually call up the error report: 1 Select Extras → Error Report.

2 In Comment please enter as precisely as possible the circumstances which led to the error. NOTE hss

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. 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. 61212-2010102

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Managing Calypso

7 Confirm with Yes if Customer 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 “hotl” in the directory ..\calypso\var\opt\om\hotline. 8 Send this file by e-mail to the address stipulated under Address. NOTE hss

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The other menu items under File are used for special service purposes – Open can be used by Zeiss employees to unpack the forwarded measurement plan; the menu item Record geometric calculation should only be used when instructed to do so as this triggers resource-intensive processes.

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Modifying System Settings

Modifying System Settings Click on Extras → Workroom to open the menu for the system set up. Each menu item in this menu (with the exception of Status Monitor) opens a notebook together with a matching group of settings: – Here, you can define new s and manage the existing s. This notebook can only be processed by the Master . – CMM Here you can set up the configuration of the CMM (control type, probe head, control console, etc.) and the software drivers. You also initialize the CMM here. – Status Monitor You can view all important events which occurred during the current measurement. – Environment You can modify the specific settings ( Desk and measure units, start conditions, colors of the Calypso window). – Measurement Here you can set the measuring parameters of the CMM (working speed, clearance distance, retract distance, scanning parameters, etc.). – Miscellaneous You can view the Calypso copyright and version information. When you open one of these menu items, you can check or modify Calypso’s system settings. Most settings are valid globally, i.e. for all s equally. Exceptions here are the settings for language, measure units and color. Each that has logged in can select these specifically. The same, of course, applies to the settings (privileges). You will find an overview of the settings in ➤“Settings You Can View or Modify” on page 11-11.

Settings You Can View or Modify The following table lists all of the system settings you can modify in Calypso: All the menu items listed in this table can be found under Extras → Workroom.

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Managing Calypso

The instructions (column headed “For More Information“) are in the corresponding sections in the Online Help system. Setting

Menu item

Tab

For More Information

Retract Distance

Measurement

Methods

How to Change the Measurement Parameters of the CMM

Beeping upon probing

CMM

Head

How to Change the CMM Configuration

s logged in

istration How to View or Enter a Description

Decimal Precision

Environment

Language

How to Change your Environment

Expansion coefficients of the scales

CMM

Temperature


Automatic at start

istration How to Activate Automatic

Automatic feature predefinition Measurement

Elements


Automatic feature end (and number of points needed)

Measurement

Elements


Automatic opening of a measurement plan at program start

Environment

Start


Automatic path measurement

Measurement

Methods


Control type

CMM


Add

istration How to Add New s

Deleting s

istration How to Delete a

Renaming s

istration Renaming a

istration Basics ers

Copyright of Calypso

Miscellaneous

Copyright

How to View General Information about the Program Version

Articulating probe head

CMM

Head


Rotary table

CMM

Rotary table


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Setting

Menu item

Tab

Dynalog keys

Environment

Dynalog


Single point measurement

Measurement

Methods


Window color

Environment

Window Color How to Change your Environment

Device istration

CMM

istration How to Change the CMM Configuration

Speed of CMM for positioning and scanning

Measurement

Speed


Hardware and drivers

CMM

Control


Home directory (for storing - specific settings)

Name

How to Check the Home Directory

Initialization of the CMM

CMM

Control

How to Initialize the CMM

Internal parameters of the software installation

Miscellaneous

Internals

How to View General Information about the Program Version

Coefficients (expansion) for scales

CMM

Temperature


Machine Type (CMM Type)

CMM

Machine


Master in duplex operation

CMM

Duplex


Measure unit of length (mm or Inch) ( Interface)

Environment

Language


Measure unit of length (mm or Inch) (Printouts)

Environment

Language


Maximum diameter of probe head

CMM

Head


Measured points (for automatic feature recognition)

Measurement

Elements


Measuring range of CMM

CMM

Machine


Nominal Mode

Measurement

Nominal


Reread (Internal)

Miscellaneous

Internals

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Managing Calypso

Setting

Menu item

Tab

Home position of the CMM

CMM

Machine


Path (directory) for actual values Environment

Paths


Path (directory) for measurement plans

Environment

Paths


Path (directory) for Table files

Environment

Paths


Computer allocation in duplex operation

CMM

Duplex


Assign privileges

Privileges

How to Assign General Privileges

Reference probe in sensor system

CMM

Reference probe


Rounding measure for preset nominal value

Measurement

Nominal


Scanning speed

Measurement

Speed


Interface type and address

CMM

Interface


CMM serial number

CMM

Machine


Clearance distance

Measurement

Methods


Slave in duplex operation

CMM

Duplex


Rounding to nominal value (Rounding measure)

Measurement

Rounding to nominal


Language ( Interface)

Environment

Language


Language (Printouts)

Environment

Language


Start conditions

Environment

Start


Start procedure (automatic )

istration How to Activate Automatic

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Setting

Menu item

Tab

Status log for system

Status Monitor

–

How to View the System Status Monitor

Control type (hardware and drivers)

CMM

Control


Probe holders

CMM

Changer


Probe changer

CMM

Changer


Probe head configuration

CMM

Head


Diameter of probe head

CMM

Head


Temperature unit (Celsius or Fahrenheit) ( Interface)

Environment

Language


Temperature unit (Celsius or Fahrenheit) (Printouts)

Environment

Language


Positioning speed

Measurement

Speed


Angle Unit (Measure Unit) ( Environment Interface)

Language


Angle Unit (Measure Unit) (Printout)

Language


Environment

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Chapter

12 12

The Auto-Run Interface

.................................................................................................................................

The Auto-Run interface segregates the performance of the measurement plans from the other tasks and functions in Calypso. This means that s who do not have specialist knowledge of how to work with Calypso can run measurement plans. In an Auto-Run interface, moreover, you can map typical measurement configurations as encountered in your CMM measuring range. The workpieces in the CMM measuring range correspond in size and position to the icons in the measurement plans on the AutoRun interface. The size and position of the measuring-plan icons on the interface correspond approximately to the size and position of the workpieces in the measuring range. You can use Auto-Run interfaces, therefore, to perform multiple measurement plans one after the other in a defined sequence.

Included in this chapter: Basics About Auto-Run Interfaces . . . . . . . . . . . . . . . . . . . . . . . 12-2 Auto-Run for System s . . . . . . . . . . . . . . . . . . . . . 12-6 Auto-Run for s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-23

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Basics About Auto-Run Interfaces The Correspondence between CMM Measuring Range and Auto-Run Interface

An Auto-Run interface represents the measuring table or base plate of your CMM. This means that the position of each measuring-plan icon on the Auto-Run interface approximates to the position of the corresponding workpiece on the table. In the Auto-Run interface, the icons of the measurement plans are represented as if you were looking down on them from above, with a bird’s-eye view of the table or base plate of the CMM.

Important Auto-Run A certain number of new are encountered in the context of Auto-Run interfaces. These do not occur in Calypso, but they are very important as regards your grasp of the Auto-Run concept. – Measurement Plan Icons A measurement plan icon is a symbol that represents a measurement plan (see ➤“Basics about Measurement Plan Icon” on page 12-3). – Desk A desk is that part of the Auto-Run interface which corresponds to the table or base plate of the CMM (see ➤“Basics about Desks” on page 12-4). – Branches A branch defines two or more connections between specific desks (see ➤“Basics about Branches” on page 12-5). – Pallet You can space workpieces over a defined grid on a pallet and then measure them all at once (see ➤“Basics about Pallets” on page 12-5).

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Basics About Auto-Run Interfaces

The Layout of the Interface An Auto-Run interface is superimposed on the Calypso interface. The illustration below shows the major features of the Auto-Run interface, and these features are described in more detail below.

Task bar

This area corresponds to the table or the base plate of the CMM

Buttons for controlling measurement

Measurement Plan icon here

Basics about Measurement Plan Icon Each workpiece to be measured is assigned a measurement plan. When you want to map a workpiece on the measuring range onto an Auto-Run interface, you do so by means of the workpiece’s measurement plan. On the Auto-Run interface, however, you see only an icon labeled with the name of the measurement plan, instead of the entire measurement plan as such. The size of the icons is a special aspect: the larger the workpiece, the larger the icon. Calypso derives the size of the workpiece from the size of its clearance planes.

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Basics about Desks A desk is that part of the Auto-Run interface which corresponds to the table or base plate of the CMM. A desk is characteristic of one and only one measuring configuration, as reflected by the fact that it bears the name of this configuration.

An Auto-Run interface can comprise more than one desk and you can switch from desk to desk. In this way, you can map a variety of measuring configurations in a single Auto-Run interface instead of having to define a new interface for each configuration. This is useful if the workpieces you have to measure recur, but are arranged in a variety of configurations on the table.

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Basics About Auto-Run Interfaces

Basics about Branches Along with measurement plan icons, you can also place branches on the desk. If you have defined multiple desks, a branch is a way of going from one desk to an other, specific desk. This can be useful, for example, if you want to finish measuring with one desk and then immediately continue with a certain other desk. Clicking on the branch takes you directly to this particular desk, without having to look for it in the list of desks.

Basics about Pallets You can map a pallet on your Auto-Run interface. You can arrange similar workpieces at regular intervals on a pallet and then measure them all at once. The pallet is loaded into the measuring range of the CMM as a complete unit for this purpose. Two preconditions have to be met so that Calypso can determine the positions of the workpieces on the pallet: – Calypso requires the position of the pallet itself. This means you have to define a base coordinate system for the pallet and this, in turn, means that each pallet requires its own measurement plan. – Calypso must be able to locate the individual workpieces on the pallet. This involves dividing the pallet into rows and columns, forming a grid in other words. The intersections are the reference points at which the workpieces are situated. The illustration below shows the pallet from above (–Z direction) to clarify the relationships. columns (X-division)

lines (Y-division) Y

X palette alignment

reference points on which the parts are situated

You can define how the pallet is divided – so you can map each pallet in full.

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Auto-Run for System s One of your functions as system is to set up an AutoRun interface, so that inexperienced s have a convenient way of running measurement plans. You will be familiar with some of the tasks involved from Calypso, others will be new to you. You must: – configure Auto-Run, i.e. assign privileges to the future s and check the settings of the CMM in the system configuration. (See ➤“Configuring Auto-Run” on page 12-6) – map the possible measuring configurations of the CMM, each in an interface (known as a desk) of its own. See ➤“Mapping the Measuring Configuration” on page 12-8.

Configuring Auto-Run The purpose of Auto-Run interfaces is to automate Calypso processes so that inexperienced s will encounter no difficulty running them. Before you start mapping desks, the first thing to do is assign privileges for the future s. You also have to check the parameters set in the system settings for measuring and for the CMM and make any changes that might prove necessary.

How to Load the Auto-Run Interface In order to open the Auto-Run Interface dialog box: 1 Close all measurement plans. 2 Select CNC → Auto-Run. The Auto-Run Interface dialog box is opened.

How to Assign Privileges for Auto-Run As system , you determine which tasks individual s can perform on the basis of their experience, by asg certain privileges. Only the Master has the right to edit Auto-Run.

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Auto-Run for System s

To assign privileges: 1 Select Configuration → s → Privileges. The Privileges dialog box appears on the screen.

The names of all defined Calypso s are listed on the left. 2 Highlight the name of the to whom you want to assign 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 in question can execute the action specified under Privileges. 4 Once you have defined the privileges for this , click on OK.

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The settings are saved and are active for this with immediate effect.

How to Specify the CMM The parameters for the CMM, measurement and the work environment are usually defined already in the system settings. For safety’s sake, however, you should at least check the settings and adjust them as necessary. Check the parameters for the following areas: – The CMM configuration (under Configuration → CMM). There is an Explanation in Online Help under „How to Change the CMM Configuration“. NOTE hss

On the Machine page of the CMM configuration, make sure that the Measuring Range is defined completely and correctly. – The measuring parameters for speed and probe routes (under Configuration → Measurement). There is an Explanation in Online Help under „How to Change the CMM Configuration“. – The ’s work environment (under Configuration → Environment). There is an Explanation in Online Help under„How to Change the CMM Configuration“.

Mapping the Measuring Configuration You can streamline the process of measuring different workpieces by grouping them on the table or on the base plate of the CMM. You can map the arrangement of these workpieces accurately in the AutoRun interface – you do this by defining what are known as desks. The tasks involved in mapping the measuring configuration are as follows: – Define desks – Add measurement plan – Position measurement plan icon – Place graphic on measurement plan icon – Set size of an icon

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How to Define Desks A desk is an accurate map of the workpieces as arranged in the CMM’s measuring range. You define a separate desk for each arrangement of workpieces. To define a desk: 1 If no desks have been defined as yet in this Auto-Run interface: • Go to the menu bar and select Desk Link → Rename. (When a new Auto-Run interface is defined, Calypso always creates a desk named No Name and you should first rename before using it).

• Enter the new name for the desk. • Click on OK. The default desk now has a new name. 2 If you have already created a desk: • Go to the menu bar and select Desk Link → New.

• Enter a name for the desk. • Click on OK. The name of the new desk appears in a picklist in the task bar. You have now defined a desk, in other words a two-dimensional map of the empty CMM measuring range.

How to Add a Measurement Plan to a Desk To map a workpiece in the measuring range, add the measurement plan that was defined for the workpiece to the desk. NOTE hss

Make sure that no measurement plan is open in Calypso, because it would be overwritten in an Auto-Run process.

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To add a measurement plan to the desk: 1 Click on the Measurement Plan button. The Select Measurement Plan dialog box is opened.

This dialog box contains a list of all measurement plans in the selected measurement plan folder. 2 Highlight the measurement plan of your choice or look for it, if it is some other folder. 3 Click on OK to load the measurement plan and close the dialog box. Calypso creates an icon for the measurement plan and places it in the top left corner of the desk. All you have to do is position the icons in accordance with the positions of the workpieces in the measuring range.

How to Position Measurement Plan Icons on the Desk The position of each measuring plan icon on the Auto-Run interface must correspond to the position of the corresponding workpiece on the table or base plate. To position a measurement plan icon: 1 Click the left mouse button on the icon and hold down the button. You can now drag the icon with the mouse. 2 Drag the icon to the approximate position on the desk.

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How to Place a Bitmap Image on a Measurement Plan Icon For the sake of clarity, you can superimpose images (e.g. of the relevant workpieces) on the icons on the desk. You need a bitmap of the workpiece, imaged with a digital camera, for example. You can load various images for each individual run of a measurement plan, so that you can easily distinguish between the individual runs. To place a bitmap on a measurement plan or run icon: 1 Highlight the icon. 2 Open the shortcut menu by clicking the right mouse button (twobutton mouse, or the middle button of a three-button mouse) on the icon. The shortcut menu opens. 3 Select the Load Bitmap... command. 4 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 Remove picture in the shortcut menu, you can display the icon again without the bitmap.

How to Define the Size of an Icon You can define the size of an icon in the popup menu: 1 Highlight the icon. 2 Open the shortcut menu by clicking the right mouse button (twobutton mouse, or the middle button of a three-button mouse) on the icon. The shortcut menu opens. 3 Select the Define Icon Size... command. The Defining Icon Size dialog box appears on the screen.

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4 Enter the height and width you want the icon to have on the desk. 5 Click OK to confirm and save your entries. The dialog box closes and the icon is resized to your specifications.

How to Create Branches between Desks You can use the picklist in the task bar to move from one desk to another. A branch, however, is a quick way of changing directly to a specific desk. To create a branch: 1 Make sure that the desk displayed on the screen is the one from which you want to link to another desk by means of a branch. 2 Click on the Branch button or in the menu bar on the arrow beside the picklist for desks. The selection box illustrated below opens and you are prompted to define the destination for the branch.

3 Select the destination desk: • If you want to go to an existing desk, highlight the desk’s name. • If you want to go to a desk that has not been defined at this time, highlight . 4 Click on OK. Calypso creates the icon for the branch (together with the name of the destination desk) and adds it to the source desk.

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. Calypso can deduce the positions of the workpieces from the grid of rows and columns which it superimposes on the pallet.

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How to Prepare a Pallet Preparing a pallet entails creating a new measurement plan. This step does not involve dividing the pallet into rows and columns. To prepare a pallet: – In Calypso, create a measurement plan specially for the pallet. It is important that the pallet should have a unique base alignment so that the program can unequivocally determine the location of the pallet.

How to Add a Pallet to a Desk You can add a pallet to a desk. Workpieces of similar type mounted on a pallet, arranged in a uniform grid of rows and columns. To add a pallet: 1 Click on the Pallet button. The Pallet Parameters dialog box appears on the screen: Picklist for pallet base alignment Input field for pallet name

Input fields for pitch and number of grid lines in X and Y directions

2 Select the base alignment for the pallet from the Pallet System picklist. 3 In the Pallet Name input field, enter a name for the pallet. 4 Define the grid for the pallet: • 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.

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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 12-11).

How to Add a Measurement Plan to a Pallet| The workpieces on a pallet are all similar. You must now select a measurement plan that suits this type of workpiece and add it to the pallet, so that Calypso can subsequently perform the CNC run. To add a measurement plan to the pallet: 1 Highlight the icon of the pallet. 2 Open the shortcut menu by clicking the right mouse button (twobutton mouse, or the middle button of a three-button mouse) on the icon. 3 Select the Add Measurement Plan... command. The Select Measurement Plan dialog box is opened.

This dialog box contains a list of all measurement plans in the selected measurement plan folder. 4 Highlight the measurement plan of your choice or look for it, if it is some other folder. 5 Click on OK to load the measurement plan and close the dialog box. The name of the measurement plan is displayed below the pallet.

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Defining Measuring Runs for a Pallet There are two ways of defining the workpieces on the pallet to be measured in the CNC run: – Define a loop. In this way, for example, you can measure every third workpiece on the pallet - take samples, in other words. – Select individual positions on the pallet with the mouse. This is a straightforward means of selection and enables you to exclude specific positions on the pallet before measurement commences, for example there are positions on the pallet that do not contain workpieces.

How to Define Measurement Runs for a Pallet with a Loop To define the measuring run as a loop: 1 Highlight the icon of the pallet. 2 Open the shortcut menu by clicking the right mouse button (twobutton mouse, or the middle button of a three-button mouse) on the icon. 3 Select the Define Loop... command. The dialog box for entering loop parameters is opened.

4 Enter the loop parameters: • Select the Add command from the shortcut 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. 61212-2010102

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• Click in the Step: input field and enter the step width of the loop. 5 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. 6 Click on OK to save the settings and close the dialog box. 7 Activate the Loops radio button to prepare the pallet for the CNC run.

At this point, you should define the CNC parameters (see ➤“Preparing for Measurement” on page 12-17), so that the pallet can be measured.

How to Define Measurement Runs for a Pallet Individually To select individual positions on the pallet: 1 On the pallet, click on each position you want to have measured in the run. The color of each position you click changes to green. 2 Activate the defined radio button to prepare the pallet for the run.

At this point, you should define the CNC parameters (see ➤“Preparing for Measurement” on page 12-17), so that the pallet can be measured.

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Preparing for Measurement Once you have defined desks with measurement plans or pallets, you can prepare for measurement. You can perform all preparations for measurement or only some – that depends on the privileges you have assigned to the who is going to perform measurement as such.

How to View the Position of the Probe Head In some situations it can be helpful to know the current position of the probe head. You can view the position expressed in machine coordinates. To view the position of the probe head: 1 Click on the Position button or go to the menu bar and select Tools → Display Position. The current machine coordinates for the position of the probe head are displayed in the XXX Position dialog box.

2 Click on Close. The dialog box closes.

How to Define CNC Parameters You must define the CNC start parameter before a measurement plan can be run. This is the job of the system or of a to whom the Define CNC start parameters privilege has been assigned. To define the CNC start parameter for a measurement plan (or pallet measurement): 1 Highlight the icon of the measurement plan or the pallet that you want to run. 2 Open the Measurement Plan Definition dialog box: • If you want to set parameters for a measurement plan icon, click on the CNC button.

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• If you want to set parameters for a pallet, open the relevant shortcut menu and select the Define CNC Start Parameters command. The Measurement Plan Definition dialog box appears on the screen.

You will find more information on CNC runs and on this dialog box in ➤“How to Start a CNC Run” on page 8-8 and in Start Measurement / Measurement Plan Definition in the Calypso Online Help. 3 Open the Base alignment picklist 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 Define the other parameters in the Result and CMM groups. 6 Click on OK when you have finished setting the parameters. The dialog box closes. The parameters are saved along with the measurement plan and the desk.

How to Define Probe Settings in the Auto-Run Interface The dialog boxes for changing and qualifying probes are conveniently available under the Auto-Run interface. This is the job of the system or of a , depending on how the corresponding privileges have been assigned.

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To start an automatic probe change: – Select Probe → Probe Change → Automatic Probe Changer. The dialog box for automatic probe changes is opened. For more information, see ➤“How to Perform an Automatic Probe Change” on page 7-49. To change a probe manually: – Select Probe → Probe Change → Manual. The dialog box for manual probe changes is opened. For more information, see ➤“How to Install a Probe” on page 4-11. To start stylus qualification: – Select Probe → Stylus Qualification → Manual. For information on how to qualify a stylus, see ➤“How to Qualify a Stylus” on page 4-22.

How to Change the Sequence of Measurement Plan Runs in Desks The desks of an Auto-Run interface will generally contain several measurement plans, all of which have to be run. By default, the measurement plans of a desk are run in the order in which they were defined. You can, however, change this sequence in accordance with your needs and preferences. 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 appropriate icons. 2 Click on the Sequence button.

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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 ArrowUp/ArrowDown buttons to move the measurement plan to the correct position in the sequence. • Repeat the process for the other measurement plans, until the sequence is correct. 5 Click on Reset if you decide you want to restore the original sequence. 6 Click on OK to accept the sequence as it is. The dialog box closes. 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.

istrating Auto-Run One of your functions as system 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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How to Save Auto-Run Interfaces Each Auto-Run interface is saved in a separate file. To save an Auto-Run interface: 1 Click on the Save button. The Select File dialog box is opened. 2 Select the path for saving the file. 3 Enter a file name, complete with an .arn extension. 4 Click on OK. The Auto-Run interface is saved, but remains open.

How to Rename a Desk You can rename a desk if the name originally selected is no longer practical or if you misspelled the name: 1 Make sure that the desk you want to rename is displayed on the screen. 2 Go to the menu bar and select Desk Link → Rename.

3 Enter the new name for the desk. 4 Click on OK. The desk is renamed.

How to Delete a Desk You can delete a desk that you no longer need from the Auto-Run interface. To delete a desk: 1 Make sure that you are in the desk you want to delete. 2 Go to the menu bar and select Desk Link → Delete.

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4 Click on OK. The desk is deleted from the Auto-Run interface.

How to Copy Icons To copy an icon: 1 Highlight the icon you want to copy. 2 Go to the menu bar and select Edit → Copy. The icon is copied to the Clipboard. 3 Select the desk into which you want to paste the icon. 4 Go to the menu bar and select Edit → Paste. The icon is pasted into the desk.

How to Delete an Icon You can remove icons you no longer need from a desk. To delete icons: 1 Highlight the icon you want to delete. 2 Go to the menu bar and select Plan Icon → Edit → Delete Icon.

3 Click on Yes to delete the icon. 4 Click on OK. The icon is removed from the current desk.

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Auto-Run for s

Auto-Run for s Your system has already configured the Auto-Run interface for you. This interface makes it easier for you to run measurement plans because a lot of the work has been done in advance – generally, you can start performing measurements right away. You will find basic information about the “Automatic Run” interfaces under ➤“Basics About Auto-Run Interfaces” on page 12-2.

Your Privileges The system who configured the Auto-Run interface for you will be able to tell you what tasks you have to do before or during measurement. The scope of tasks you have to perform depends on the privileges (and obligations) your system has assigned you. At some point in a session with the Auto-Run interface, you will probably encounter the message shown below:

It appears when you have attempted to execute a command for which you do not possess access privileges. Consult your system if the command in question is one you urgently require.

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Preparing a Measurement Start for Auto-Run The illustration below shows what could be a typical Auto-Run interface.

Prerequisites

The prerequisites 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 12-24). – The correct desk must be selected (see ➤“How to Select a Measuring Configuration” on page 12-25). – The scope of measurement must be defined (see ➤“How to Define List of Characteristics in Auto-Run” on page 12-26). These prerequisites must be satisfied before measurement can be started.

How to Load an Auto-Run Interface Each Auto-Run interface is stored in a separate file. You have to load your Auto-Run interface before you can start measuring. Your system will tell you which interface is yours.

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To load an interface: 1 Check the name of the current interface. The name is on the left, below the status bar. 2 Click on the Open button. Auto-Run always loads a default interface directly after starting, so Calypso issues the following prompt:

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 if you encounter difficulties with saving. The original interface is saved and the Select File to Open dialog box appears on the screen. 5 Highlight the name of your interface and click on Open. Your Auto-Run interface is loaded.

How to Select a Measuring Configuration Your Auto-Run interface might consist of more than one desk. Each desk displays a configuration of workpieces to be measured. The arrangement of the icons on the interface must correspond to the arrangement of the workpieces on the CMM, so you usually have to select the correct desk at this point. To select a desk: 1 Make sure that your interface is loaded. 2 Check whether the arrangement of the icons corresponds to that of the workpieces in the measuring range of the CMM. 3 If you want to select a different configuration, click on the arrow buttons in the task bar until the configuration you want is displayed. The name of the desk is displayed in the picklist box beside the arrow buttons. Once you have selected the appropriate desk, the next step is to select the workpieces to be measured.

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How to Define List of Characteristics in Auto-Run One of the purposes of Auto-Run interfaces is to facilitate consecutive measurement of multiple workpieces, which are generally already in position on the CMM table. 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 If you want to select measurement plans in a desk: • Click on the icon of each measurement plan to be run on the workpiece. • Press and hold down the Ctrl key to select more than one measurement plan. A thin black border appears around each icon you select. The Start button is activated. NOTE hss

A pallet can only be started on its own. Make sure that only one pallet is selected for measurement. 3 If you want to select a pallet for measurement, highlight the icon of the pallet in question. The measurement plans of all the icons you highlight are executed when you start the CNC run. See ➤“How to Start a Measurement in the Auto-Run Interface” on page 12-26 for instructions on starting a CNC run.

How to Start a Measurement in the Auto-Run Interface To start a measurement: 1 Click on the Start button. A green border appears round the selected icons of the measurement plans. Calypso begins by checking the CNC parameters. Calypso issues the following prompt:

2 Make sure that the CMM is ready and click on Yes. Calypso starts measuring. Two windows are opened: the stop light window and the default printout.

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If Measurement Fails to Start in the Auto-Run Interface An error message is issued if a measurement does not start in the Auto-Run interface. – If you have privileges to enter CNC parameters, correct the CNC parameter settings (see ➤“How to Define CNC Parameters” on page 12-17). Then restart the measurement. – If you do not have privileges to enter CNC parameters, notify your system .

Monitoring Measuring Runs in Auto-Run A measurement started by means of an Auto-Run interface can take some time to complete. While Calypso is measuring the selected workpieces, you can intervene at any time. Intervention on your part could be necessary if a collision threatens or if you have to interrupt measurement for some reason. You use the stop light window to control the measuring run. If, for example, this window is hidden behind the Auto-Run interface, you can use Tools → Stop Light to bring it back to the foreground. – If you wish to interrupt a measurement run,click on yellow. – When you wish to resume an interrupted measurement,click on green. – If you wish to cancel a measurement,click on red or on the Cancel button. You will find more information on the Stop light window in ➤“Monitoring Measurement Plan Runs” on page 8-11.

When a Measurement in Auto-Run is Complete When all the workpieces have been measured, the default printout appears on the screen. It lists all the measuring results in the sequence in which they were computed. Depending on how the CNC parameters were set, the measuring results are saved in a custom printout and/or in special files. The custom printout is displayed on screen – the result files are for evaluation by other means and are not directly viewable.

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Chapter

13 13

DMIS Import (Option)

.................................................................................................................................

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 on Calypso. You can license this functionality and have it enabled in your system if it would be of use to you. your Carl Zeiss Service for more information. The sections included in this chapter explain the basics of importing DMIS measurement plans, and guide you through the procedures involved.

Included in this chapter: Basics about DMIS Measurement Plans . . . . . . . . . . . . . . . . . . . 13-2 Configuring DMIS Import. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-6 Importing Measurement Plan from DMIS . . . . . . . . . . . . . . . . . . 13-8

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Basics about DMIS Measurement Plans Calypso is able to import a DMIS program and to have it run as a Calypso measurement plan.

What is DMIS? DMIS stands for Dimensional Measuring Interface Standard. DMIS is a programming language used for programming mechanical, laser, optical and video measuring systems. DMIS is designed to be a programming language for all or at least most 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 the measuring machine control such as positional movements, probing, geometrical elements, measurements, probe changes, temperature compensation, etc. DMIS-compatible measuring machines read the DMIS commands from an ASCII file and then perform the measurement run.

DMIS and Calypso DMIS files must be translated to ensure that they can also be used by measuring machines which are not DMIS-compatible. The translator tailored to the relevant measuring software is referred to as the post processor, because it becomes active after the production of the DMIS file. The option described here, “Calypso DMIS“ is just such a DMIS post processor for Calypso.

Which DMIS Commands are ed? Not every DMIS command is understood by every measuring machine. DMIS itself was developed in stages and is available in various versions. Therefore a characterization file is included in every post processor, in which the commands ed by the post processor are listed, and there is optionally also a specification of the ed version of DMIS. Requirements for the DMIS program

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 , there should not be any implementation problems.

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Basics about DMIS Measurement Plans

Characterization file

The “characterization file“ for Calypso is located on your system at the path ..\Calypso\home\om and has the file name CHARACTERISATIONFILE.

Displaying the Characterization File You can either display the characterization file directly with a text editor or by selecting File → Import DMIS and clicking on the Info card.

In particular, all features are listed here which can be converted by the post processor into Calypso features.

Special Features of Measurement Plans Imported from DMIS DMIS programs and Calypso measurement plans are actually quite similar. As a result, Calypso measurement plans generated from DMIS measurement runs have certain special features compared to “conventional“ Calypso measurement plans.

Run control via input parameters DMIS is designed sequentially and Calypso is more object-oriented. In order to allow the sequential structure of the DMIS measurement run to be represented in Calypso, some parts of the DMIS program are written into the input parameters of the new Calypso measurement plan.

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This mainly involves the commands needed for run control. The input parameters therefore control the sequence of the run as specified by the DMIS file. You can also find any variables, jumps or possible loops here. The run control which you know from Calypso is, therefore, only available to a certain extent. You can display the input parameters by opening the list of characteristics without highlighting any of the characteristics and then clicking on the list with the right mouse button. Then select Parameters in the shortcut menu.

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. 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 setting Automatic. In this case, select the setting Use Position Points Only.

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Basics about DMIS Measurement Plans

Saving, Loading and Deleting the Coordinate System DMIS always defines only the current coordinate system. The other coordinate systems are based on the relevant current coordinate system. Therefore the iterative alignment in DMIS works in a different way from that in Calypso. To avoid placing the current coordinate system into a loop in an unexpected way, it is necessary to save the current coordinate system in the intermediate memory. There are DMIS commands to save, load and delete a coordinate system. These commands are converted into corresponding Calypso features, which you can find in Calypso in the Utilities section. NOTE hss

! hss

These measurement plan features are intended for the translation of DMIS programs. They can also be used in other Calypso measurement plans. Caution - Risk of collision Extreme care is also needed for the subsequent addition of these features into measurement plans imported from DMIS, because the coordinate systems are defined in the features at the time of import and should only be changed there.

Other Special Features These and other differences not listed here (for example in the definition of features) are implemented by the post processor so that a valid Calypso measurement plan is produced.

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Configuring DMIS Import You have the option of making various presettings for the DMIS import. To do so, select File → Import DMIS and click on the card Config. NOTE hss

This card is only intended for special circumstances. For standard installations, you do not need to do anything here; the settings are correct.

On this card, 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 Search, you can assign a directory if necessary. – Calypso Hostname 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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Configuring DMIS Import

– Take GOTOs which are outside 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 setting Automatic under Navigate-Feature To Feature. – Don't 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 Calypso grafics view with each 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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Importing Measurement Plan from DMIS In order to import a measurement plan from DMIS, you must simply choose the menu item DMIS Import and select the relevant file. The procedure for certain parameters depends on your settings for the DMIS import configuration. Save measurement plan

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.

How to Import and Start a DMIS Program With DMIS Import, you can import a DMIS program and convert it immediately into a measurement plan. If you want to run the measurement plan immediately after that, you should make certain preparations first: – Click on Extras → Workroom → CMM and set up the connection to the CMM by clicking on Connect. If you import the DMIS program without connecting Calypso to the CMM, the probe data can not be taken over. – Make sure that the probes defined in the DMIS program are located on the CMM. If no probe with the same name as the measurement plan exists, a probe is created during the import. All used styli with the names used in the DMIS file are allocated to this probe. You can define and use this probe later in Calypso.

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Importing Measurement Plan from DMIS

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 Select the 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. NOTE hss

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 reports have been created during the import, you can view them and save them. 5 After a successful import, click on Close. 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 symbol Switch to Probe Qualification Menu and calibrate the probes. 8 Select Prerequisites → Select Probe for this Measurement Plan..., click in the Measurement Plan Editor Features on the option For Measurement Plan and choose from the list the probe that has just been imported.

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9 Start the CNC run by clicking CNC → 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.

! hss

Caution If you do not switch off the 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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Importing Measurement Plan from DMIS

Evaluating Reports about the DMIS Import If a DMIS command can not be processed by the post processor or by Calypso during the translation, a message is displayed. You must then decide whether you can ignore the misunderstood instruction in the Calypso measurement plan or not. The translation is resumed by clicking OK. You can end the process with Cancel. A message is displayed as soon as the end of the DMIS file has been reached. Displaying reports

All problems that occur during the translation are logged. Two different reports are generated: – Syntax report The printout “DMIS file syntax check report“ is produced before the actual translation. Any possible 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 report The “Calypso Import report“ contains all messages about special features relating to the measurement plan which have been noted during the import by the post processor, for example the impossibility to assign a stylus because of no connection to the CMM. The printouts are displayed on the card Report.

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Saving reports

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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 reports button and select a directory. The file name is preset, but can be overwritten.

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Chapter

14 14

Parameter-coded Measurements (Option) ................................................................................................................................. In Calypso you can define parameter-coded measurement runs using PCM, the programming language developed expressly for this purpose. This chapter explains how to define variables, set parameters and use parameterized measurement runs. On of the complexity involved, programming in PCM is suitable for experienced s with basic knowledge of programming structures (e. g. Pascal or C). PCM is one of Calypso’s optional features. You can license this option and have it enabled in your system if the PCM functionality would be of use to you. your Carl Zeiss sales partner for more information.

Included in this chapter: Introduction to PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2 Variables, Parameters and Formulas in Calypso. . . . . . . . . . . . . . 14-9 Entering Parameters and Formulas . . . . . . . . . . . . . . . . . . . . . . 14-15 Examples for PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-33 PCM Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-47 Tips and Tricks for Working with PCM . . . . . . . . . . . . . . . . . . . 14-63

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Parameter-coded Measurements (Option)

Introduction to PCM Calypso uses the PCM programming language for variable control of measurement 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-ed and interactive control of measurement runs. What is PCM?

PCM is a development system for parameterizing measurement runs. PCM is short for “parameter-coded measurement”. PCM enables you to simplify and rationalize measurement 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.

NOTE hss

A yellow input box in Calypso always contains a parameter or formula. In Calypso, you are using 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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Using PCM in Calypso – First Steps

Using PCM in Calypso – First Steps You will use PCM primarily to parameterize measurement plans in Calypso. You are, in fact, using PCM indirectly when you define a condition or a loop. You also have the option of defining variables of your own and asg them parameters or formulas. The easiest and most reliable way of generating variable measurement plans is to begin by creating an ordinary measurement plan with fixed coordinates and values in Calypso in the usual way. You can then substitute variables for the specific coordinates that vary from workpiece to workpiece. The various measurement plans you need derive from the formulas and parameters you enter for the variables.

Programming with PCM Over and above parameterization of measurement plans, PCM provides an extensive programming functionality: – You can program dialogs that Calypso uses in the course of a CNC run to query the operator for quantities, so that the figures supplied in this way can subsequently be used in different ways as the run progresses. – You can determine and reuse measured values and system parameters. – In the case of conditions or loops, you are not bound to the forms specified in the dialogs – you can enter them directly in PCM. – You can issue direct control and motion commands to the CMM. You can use these functions in many different ways, individually and in combinations, so these instructions cannot cover all possible circumstances in detail – that PCM is a programming language, designed for you to use to the best possible effect. This chapter, therefore, describes the basics of the run structures of Calypso and the syntax of PCM, tells you how to enter parameters and formulas in Calypso, and contains a reference library of functions and commands. The examples (see ➤“Examples for PCM” on page 14-33) demonstrate the versatility of PCM and show you how to utilize the performance of this programming language.

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Variable Measurement Plans in PCM Calypso employs the principle of parameterization so that you can use a single measurement plan to measure workpieces that are similar but not identical. This principle is based on the premise that the quantities that are the same for both workpieces are defined in the measurement plan in Calypso as fixed quantities; the quantities that vary from workpiece to workpiece, on the other hand, are defined as variables.

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 or the holes are different. Different geometries, differences in the number of certain features, the presence or absence of features – all these can be parameterized.

Parameters for Variables in PCM Note, however, that a measurement plan with variables cannot be run unless the variables are assigned specific values. These specific values, the parameters in other words, have to be known to Calypso: you define them in the measurement plan before it is run. Instead of the variables, Calypso then uses the coordinates or values you entered.

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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 off-center. 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

Parameters for workpiece No. 1

Parameters for workpiece No. 2

Number_holes

1

2

hole1_center

point(-40,30,40,0,0,1) point(-20,30,40,0,0,1)

hole2_center

any

point(-60,30,40,0,0,1)

hole1_radius

20

10

hole2_radius

any

10

Set up in this way with only five different parameters, the measurement plan is able to measure two different workpieces.

Parameters in Parameter Files The process is even more straightforward when you provide Calypso with the parameters of the current workpiece or the measurement plan variant you intend using in the form of a prepared, reusable ASCII file. All you have to do when a new version of a workpiece is due for measurement is load a new ASCII file containing the requisite information. Another advantage is that ASCII files can be edited independently of Calypso.

Parameterizing Characteristics with PCM Characteristics can sometimes be the same despite differences in features, as is the case, for example, with the diameter of a circle of given size that only has to be measured at different positions on a workpiece. Other characteristics can vary as a function of the parameterized measurement plan. This, in turn, means that if the value of the characteristic, and not just the measured values of a given feature, varies from workpiece to workpiece, you have to parameterize the characteristic as well.

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You do this by defining a variable for the characteristic in question and asg it the corresponding value.

Parameter Files for Measurement Plans The advanced way of setting up variable measurement plans is to use parameter files. A parameter file contains the set of value assignments for the variables in a measurement plan. When you parameterize fixed defining aspects of a workpiece you are in a position to measure different workpieces with a single measurement plan: all you have to do is enter different parameters, either directly in Calypso or by specifying and loading a parameter file. You can create different parameter files for a particular measurement plan and load whichever file you need for a given workpiece and the aspects you want to measure. You need a dedicated parameter file per workpiece.

*.para

Workpiece1.para

Measurement Plan

*.para

Workpiece2.para

*.para

Workpiece3.para

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There are two ways of creating a parameter file – you can save the parameters set in a measurement plan, or you can use an ASCII editor to enter the parameters directly. If you want to use this second method, you need experience with measurement plans and a thorough knowledge of the PCM syntax. Like the programming languages Basic, C, Fortran and so on, PCM uses a functional syntax (see ➤“PCM Syntax” on page 14-47). When you create a parameter file it is important to that the filename extension has to be “.para”, so that Calypso can recognize it as a parameter file.

Conditions and Parameters for the Run Structure of Calypso After the CNC start, Calypso runs the measurement plan. PCM commands and parameter assignments come into effect at a very wide variety of points. – You can define “input and output parameters” for each feature and each characteristic, and for the measurement plan as a whole. This means that you can enter PCM commands when these elements are defined. The “input parameters” are processed before the element is run, the “output parameters” are processed after the run. – You also have the opportunity of setting “start parameters” once or loading a file before the measurement plan is run. – You can set a condition and a loop for each characteristic. – You can enter “input and output parameters” for each condition and each loop. Utilizing these Calypso functions in this way, therefore, you can construct complex, nested structures. Wherever you set input parameters, output parameters or start parameters, moreover, you can program conditions and queries directly with PCM.

Sequence of measurement plan Processing in PCM The sequence adopted by Calypso to process the data is as follows: 1 Calypso begins by processing the commands in the start parameters. 2 The input parameters are evaluated before the measurement plan is run; the output parameters are evaluated when the run completes.

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3 Calypso checks each characteristic in succession, in the order in which they appear in the list of characteristics. The condition and the loop are processed first (depending on the order in which they were entered) followed by the input parameters of the characteristic. Once the characteristic has been determined, its output parameters are evaluated. 4 Before a feature defined for a characteristic is measured, its input parameters are evaluated. The feature’s output parameters are evaluated when measurement completes. 5 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 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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Variables, Parameters and Formulas in Calypso

Variables, Parameters and Formulas in Calypso When you want to run variable measurement plans for different workpieces in Calypso, you have to use variables instead of absolute values to describe the workpiece.

What are Variables? Variables, by definition, are quantities that can vary. In Calypso and in PCM all defining aspects required in descriptions of workpieces or runs in measurement plans can be characterized as variables. The variables are stored “locally” together with the element (feature, characteristic, condition, loop) for which they were defined. The assigned values, the parameters in other words, are stored centrally for the entire measurement plan. Types of variables

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: hugo[1], hugo[2], hugo[3], hugo[4] In this case, “hugo“ is an array with four variables.

What are Parameters? Parameters are specific values for variables. When variables are used in a measurement plan instead of fixed numbers or texts, you can vary the measurement plan by asg certain fixed values (parameters) to the individual variables. You assign values either by entering them directly or by means of statements in a file. Use the following syntax: Variable_name=value

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You can enter the value using one of the following formats:

NOTE hss

Variable type

Format for values (example)

number

-3.141529

vector

vector(10,12,0)

point

point(-10,12.5,0,0,0,1)

string

“circle”

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”.

Value Assignments and Variable Definitions It follows that the PCM commands listed below are value assignments: – P1=10 – hugo=vector(10,20,30) – hugo_1=point(10.1,20.5,30.02,0,0,1) – text_1=“This is a text in the text_1 variable” A value assignment also defines the variable and makes it known to Calypso. There are no explicit variable definitions (constructors) in PCM. Variables in the arrays can be defined either individually “one by one“ or in a loop instruction. Example: – hugo[1] = point(-10,12.5,0,0,0,1) hugo[2] = point(-12,12.5,0,0,0,1) hugo[3] = point(-14,12.5,0,0,0,1) hugo[4] = point(-16,12.5,0,0,0,1) Here, “hugo“ has been defined as an array consisting of four variables of type point.

Formulas and Functions in PCM As well as using individual variables in measurement plans, you also have the options of using functions of variables and formulas with variables.

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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

Return value

variable_name.x

x value of the “point” variable

variable_name.y

y value of the “point” variable

variable_name.z

z value of the “point” variable

variable_name.nx

x value of the normal vector of the “point” variable

variable_name.ny

y value of the normal vector of the “point” variable

variable_name.nz

z value of the normal vector of the “point” variable

You can access variables of the “vector” type as follows: Function

Return value

variable_name.x

x value of the “vector” variable

variable_name.y

y value of the “vector” variable

variable_name.z

z value of the “vector” variable

Arithmetic Operators and Functions The most important operators and functions with variables are: – Arithmetic operators: +,–,*,/ – Comparative operators (used in conditions and loops): <,>,==, <>, <=, >= – Mathematical and angle functions: sqrt, squared, abs, exp, int, ln, log, mod, round, sign, sin, cos, tan, arcsin, arccos, arctan, arctan2 – Functions for determining values (query): getNominal, getActual – Character string functions: asc, chr, format, inStr, len, mid, strElement, val

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There are also a number of functions for input and output, for run control and for CMM movement commands (see ➤“PCM Quick Reference” on page 14-47).

Programming with PCM You can vary the way in which the measurement plan runs by setting conditions and loops. – A characteristic or feature with a condition is not executed unless the condition is satisfied. The characteristic is either calculated or not calculated depending on the truth value returned for the condition, which means that the measurement plan run either proceeds or is interrupted. – A loop around a characteristic or a feature results in the characteristic or feature being run repeatedly, possibly with changed variables for each run. You trigger these functions by selecting Condition or Loop in the shortcut menu and entering the settings for the condition or loop, as applicable (see ➤“Setting Conditions” on page 14-19 and ➤“Inserting Loops in PCM” on page 14-22).

Programming Conditions and Loops Over and above the options at your disposal in Calypso, you can use PCM to insert conditions and loops explicitly in parameter files or in the input and output parameters of features or characteristics. In this way you can utilize conditions and loops much more comprehensively – you are in control of the measurement run. During the CNC run, the truth values of the conditions are determined, the loop index is incremented automatically and the definitions, the value allocations and the commands are processed accordingly. The following control elements are available for both the input and output parameters: – The Simple Operation (if - endif) – The Condition with Alternative (if - else) – The Defined Loop (for - next) – The Conditional Loop (repeat - until)

The Simple Condition The syntax of the simple condition is as follows: if CONDITION then DEFINITION endif

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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.

The Condition with Alternative The syntax of the condition with alternative is as follows: if CONDITION then DEFINITION1 else DEFINITION2 endif

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 variable “result” 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

The 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

The following must be inserted: – for index – the name of the loop variables (random), – for start, end and step – full figures,

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– 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

The 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.

! hss

14-14

Caution Please note that infinite repetitions are possible with the conditional loop, if the condition is never fulfilled.

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Entering Parameters and Formulas

Entering Parameters and Formulas In Calypso you can use parameter-coded measurement runs as follows: – You can enter parameters for the variables of a measurement plan – You can enter formulas directly – You can test the value of a PCM expression – You can set a condition for the entire measurement plan and for each individual characteristic – You can place a loop around the entire measurement plan and around each individual characteristic to force repeated runs – You can enter input and output functions for features, characteristics, conditions and loops – You can use the Point Generator to read in the points of a curve or define them with a mathematical expression. You enter parameters for a measurement plan in the Settings window. In so doing you assign formulas or values to existing or newly defined variables. You can enter the parameters directly in the window or you can load them from a parameter file. You can create a parameter file by saving the parameters of a measurement plan or explicitly by generating the file with an ASCII editor of your choice. NOTE hss

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)).

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How to Enter Parameters for a Measurement Plan Directly To enter parameters for a measurement plan directly: 1 Select CNC → Measurement Plan Functions → 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 14-11 and the parameter syntax (see ➤“Example for PCM: ASCII Parameter File” on page 14-46). 3 Click on OK. The dialog box closes. 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).

How to Save the Measurement Plan Parameters in a File Once parameters have been defined in a measurement plan, you can save them in a file. In this way they are readily available for subsequent use in other measurement plans. To save the measurement plan parameters in a file: 1 Select CNC → Measurement Plan Functions → Parameter. The Parameter Input dialog box opens. 2 Use Shift + click to select the parameters you want to save in the file.

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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 Save. The variables and parameters you selected are saved in the file.

How to Load Measurement Plan Parameters Saved Beforehand You can integrate parameters saved in a parameter file (file name “*.para”) into your current measurement plan. To open a *.para file: 1 Check that the Parameter Input dialog box is open (CNC → Measurement Plan Functions → Parameter). 2 Click on the icon for opening a file. 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.

How to Enter Formulas By entering formulas you can – calculate function values of measurement results (sin, cos...) – use operators to link measurement results with constants – use operators to interlink multiple measurement results. The value returned by the formula is displayed in the input box from which you called formula input.

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To define a formula: 1 Open the definition template for the feature in which you want to assign the formula to an input box. 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 shortcut 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 14-11). 4 Click on the Function button to open a list of all operators, functions and commands. Select the element of your choice from this list and double-click it to copy it to the formula input box. 5 To insert a parameter into the formula: click on the Settings button. Double-click on the parameter of your choice in the Parameters 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.

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Setting Conditions You can link computation of characteristics to conditions that enable Calypso to execute jumps in the CNC run in accordance with the measurement results. NOTE hss

A basic knowledge of programming structures will help you understand the following. – You can choose whether to have the condition queries 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.

NOTE hss

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 14-12). 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 measurement run – continue. If a loop has been defined around the characteristic, processing depends on what was defined first.

How to Link a Condition to a Characteristic To set a condition for a characteristic: 1 Open the list of characteristics in the measurement plan area. 2 Highlight the characteristic for which you want to set a condition.

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3 Right-click and select Condition from the shortcut menu. The Dialog Box for Conditions dialog box appears on the screen.

4 Set the condition first: • Right-click in the yellow input box to open the shortcut menu. • Select Formula. The Formula dialog box appears on the screen. • Enter the condition in the Formula dialog box and click OK to confirm your entry (see ➤“How to Enter Formulas” on page 14-17). NOTE hss

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 14-49) 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 set the presettings or postsettings, click on the Settings button and enter the settings.

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6 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.

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 measurement run.

How to Link the Entire Measurement Plan to a Condition You can also link the entire measurement plan to a condition. In this case the measurement plan is executed or not, depending on the truth value of the condition. To set a condition for the measurement plan: 1 Open the list of characteristics and make sure that no characteristics are highlighted. 2 Right-click and select and select Condition in the popup menu. The Condition window will appear on the screen (this dialog box is fully described in Formula in the Calypso Online Help).

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3 Set the condition first: use the yellow input box to open the Formula window (see ➤“How to Enter Formulas” on page 14-17) and enter the condition. Click OK to confirm this entry and close the window. NOTE hss

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 14-49) 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 measurement run.

Inserting Loops in PCM If you place a loop around a characteristic or the entire measurement plan, the characteristic or measurement plan is processed several times in succession. NOTE hss

This section is intended for advanced s 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. A loop is defined by a Start Index, an End Index, and an Increment. Each time the loop repeats the increment is increased by the defined value and compared with the end value. The loop is repeated until the end value is greater than or equal to the increment.

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You can define multiple cycle levels in a loop (nested loop), so you can process two-dimensional or three-dimensional repetitions. In each of these levels a dedicated loop counter variable, the loop index, is incremented in steps. The loop variables have fixed names and in each loop they are called “LOOP1” to “LOOP4”. In the characteristic and the associated features you can use these loop variables in formulas to vary the way in which the characteristic is processed. NOTE hss

Note that you cannot enter loops directly in the input/output parameters with PCM. If a condition is also linked to the characteristic, the sequence of processing depends on what was defined first.

How to Place Loops around Features To place a loop around a characteristic or the measurement plan: 1 Open the list of characteristics in the measurement plan area. 2 Highlight the characteristic you want to loop. If you are going to place a loop around the entire measurement plan, make sure that none of its characteristics are highlighted. 3 Right-click and hold down the mouse button. Select Loop from the shortcut menu and release the mouse button. The Loop Interface dialog box appears on the screen. 4 Click Insert to insert a new loop level in the dialog box. 5 Set the values for Start, End and Step by clicking the corresponding input boxes and typing in the values.

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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 14-15 and click on OK to confirm and terminate your entry. This returns you to the Loop Interface window. NOTE hss

You can define only one break condition per loop. 9 If necessary, enter a break condition in the box provided for the purpose. 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 loop variables LOOPi (i = 1,...,4) 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.

How to Include Features in Loops 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). If you defined a loop by a characteristic, the data of the associated feature have to be varied in each loop run in order to ensure that the loop can be executed correctly. You accomplish this by using the loop variables in the definition of the feature, or incorporating a pattern into the feature. To incorporate a pattern into a feature: 1 Open the list of features. 2 Double-click on the name of the feature in question. The feature template is opened.

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3 In the Nominal Definition picklist, select the Pattern command. The Selection (Pattern) dialog box opens.

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 (use for scallop)). 6 Click OK to confirm your choice. The dialog box for defining the pattern of your choice appears on the screen.

7 Enter the values for the pattern. Make sure that the value of 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.

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The loop is executed as soon as you start an automatic measurement run (see ➤“Running a Measurement Plan” on page 8-1).

Use of Loops in Alignment according to RPS You can place a loop around a base alignment. If you do this, the alignment is repeated for the defined number of loop repetitions – unless the abortion condition is satisfied beforehand. RPS alignment, for example, works only with the aid of a loop. The effect of this loop is to repeat alignment until it achieves your defined fit. The illustration below shows the definition of the loop.

The abortion condition “baseSystem().valueA<0.1“ (for syntax, see ➤“baseSystem (Base Alignment)” on page 14-57) means that once measuring has commenced, the measuring process will continue until the Best Fit Value valueA is less than 0.1.

Points to Note about Nest Level The form of brackets in the Nest Level box defines the nesting of loops: you set these brackets when you define the loop in the Loop window. Nested loops required different brackets for each level. You can use round brackets “(” and “)” for loop1, and angle brackets “<” and “>” for loop 2. Calypso has four types of bracket for four loop levels.

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The type of bracket can also be important for non-nested loops, however. You have to use brackets of different types in independently defined loops if: – you align two or more coordinate systems iteratively and – features with the same name are used in this context. The example below is based on the assumption that a part alignment was created after RPS alignment (see ➤“How to Use an Alternative Alignment Method” on page 4-55). Example

If, for example, coordinate system A uses the feature called “3-d straight _1” and coordinate system B also uses a feature of this name, “3-d straight_1” is not measured again when coordinate system B is measured if you used the same type of brackets whey you defined the two iterations in the Loop window. Calypso assumes that the straight 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 “3-d straight_1” is measured again when coordinate system B is aligned. You could do this, for example, by selecting round brackets “(” and “)” in loop 1 and angle brackets “<” and “>” in loop 2.

Points to Note about Multiple Measurements If you want to use a loop to measure one and the same feature more than once or repeat probings, you must use the LOOP1 loop variable in the definition template of the feature. Calypso re that it has already measured a feature and simply recalls the measured value instead of probing for a second time. Under these circumstances, however, this does not produce the desired effect. You can use a workaround to avoid this difficulty. In the nominal definition insert a formula in which you add the product 0*LOOP1 (to the X value, for example). This means that the X value remains the same every time the loop is run, but Calypso perceives each iteration as a new calculation and a new probing.

Basics about Input and Output Parameters in PCM Input and output parameters can be set for each characteristic and feature, and for each condition and loop. The settings in the input and output parameters can be used to set temporary variables, print values in the default printout, and trigger functions.

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Input and output parameters are defined in the Settings window.

You can define input and output parameters for the following objects in Calypso: – entire measurement plan, – 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.

Notes on Evaluating Input and Output Parameters The commands and value assignments you enter as input parameters are evaluated before the object in question is executed or evaluated. The commands and value assignments you enter as output parameters are evaluated after the object in question has been executed or evaluated.

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An object, in turn, can consist of two or more 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.

How to Enter Input and Output Parameters In Calypso you can set input and output parameters for each feature and each characteristic, and for each condition or loop and for the entire measurement plan. To do so, use the Settings window. To enter input and output parameters: 1 To open the window for the entire measurement plan: • Open the list of characteristics and make sure that no characteristics are highlighted. • Right-click and select Parameter from the shortcut menu. 2 To open the settings for a specific characteristic: • Highlight the characteristic in the list of characteristics. • Right-click and select Parameter from the shortcut menu. 3 To open the settings for a specific feature: • Highlight the feature in the list of features. • Right-click and select Parameter from the shortcut menu. 4 To open the window for a condition: • In the Condition window, click on Settings. 5 To open the window for a loop: • In the Loop window, click on Settings. The Settings dialog box appears on the screen. 6 Enter the input parameters in the box at the top and the output parameters in the box at the bottom. 7 Click on OK. The dialog box closes and your settings are accepted.

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Basics about the Point Generator The point generator has the same characteristics as a loop. You can enter a variable in each input box by right-clicking, opening the Formula window and selecting the variable:

You will find more information on this dialog box in Points 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.

How to Work with the Point Generator You can define a curve with the aid of a point generator. The point generator acts like a loop in which another point on the curve is defined in each successive step. The loop variable used by the point generator is “index”.

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1 In the definition template of the curve, select Nominal Definition and then select the Parameter Data function. 2 The Points Generator dialog box will appear.

3 Enter the Start Index, the End Index and the Increment. Each input box also accepts a formula. If you want to enter a formula, right-click in the box, select Formula from the shortcut 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 shortcut 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 Calypso’s table file. You can activate output to the table file by selecting Prerequisites → Results to File in the Results to File dialog box. 6 Click OK to close the Point Generator window. You have now defined the nominals of the curve.

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How to Test a PCM Printout You can test a PCM printout in order to ascertain whether the results are in line with your expectations or whether the PCM printout requires improvement. To test a PCM printout: 1 Make sure that the Settings window is open with the PCM printout.

! hss

Caution 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 printout in question and right-click. 3 Select Compute from the shortcut menu. The highlighted printout 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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Examples for PCM

Examples for PCM The examples below illustrate the versatility at your disposal using PCM with Calypso. – Using Variables – Condition with alternative – Principle of parameterization – Loading parameter values into a curve – Defining curve using cosine function – Rechecking characteristic after tolerance excursion – Parameterizing coordinate system – Loading a PCM file via dialog – Defining loop with linear offset – Nested loop for field (array) – Parts family and variant control – ASCII parameter file

Example for PCM: Using Variables This example shows how to define variables, how to access them, and how to use them in computations or other operations. – The measurement plan contains the following variables: • P1=10 • hugo=vector(10,20,30) • hugo_1=point(10.1,20.5,30.02,0,0,1) • text_1=“This is a text in the text_1 variable” – Parameter accesses to the vector hugo: • hugo.x

=>

return value is 10

• hugo.y

=>

return value is 20

• hugo.z

=>

return value is 30

– Parameter accesses to the point hugo_1: • hugo_1.x

=>

return value is 10.1

• hugo_1.y

=>


• hugo_1.z

=>


• hugo_1.nx

=>

return value is 0

• hugo_1.ny

=>

return value is 0

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• hugo_1.nz

=>

return value is 1

– Examples for calculations with variables: • Pnew = P1 *2. The return value is 20 • Pnew = (hugo.x–hugo_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: NOTE hss

The Print command is not executed unless you have activated the Test printout check box in CNC → Measurement Plan Functions → PCM Test settings. • 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

Example for PCM: Condition with Alternative You can enter conditions with alternatives (IF - ELSE) in the input and output parameters. The syntax is: if CONDITION then DEFINITION1 else DEFINITION2 endif

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 is:” ,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

Example for PCM: Principle of Parameterization 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 CNC → Measurement Plan Functions → 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. 3 You do this by substituting variables for the fixed X, Y and Z coordinates:

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• Open probing point “point_A”, click in the input field for the X value and select Formula from the shortcut menu. • Click on Settings. 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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Examples for PCM

Example for PCM: Loading Parameter Values into a Curve This example illustrates how to generate a curve from 12 individual points, using the point generator. 1 Create the following parameter file: type103[1]=point(-65.386, -46.674, 139.666, -0.019, -0.022, 1.0) type103[2]=point(-81.733, -58.343, 139.007, -0.026, -0.028, 0.999) type103[3]=point(-98.08, -70.011, 138.154, -0.034, -0.033, 0.999) type103[4]=point(-114.426, -81.68, 137.101, -0.043, -0.039, 0.998) type103[5]=point(-130.773, -93.348, 135.821, -0.053, -0.046, 0.998) type103[6]=point(-147.12, -105.017, 134.29, -0.063, -0.054, 0.997) type103[7]=point(-163.466, -116.685, 132.499, -0.073, -0.061, 0.995) type103[8]=point(-179.813, -128.354, 130.44, -0.084, -0.069, 0.994) type103[9]=point(-196.159, -140.023, 128.113, -0.094, -0.077, 0.993) type103[10]=point(-216.593, -154.608, 124.829, -0.107, -0.087, 0.99) type103[11]=point(-220.679, -157.525, 124.122, -0.109, -0.089, 0.99) type103[12]=point(-224.766, -160.442, 123.4, -0.112, -0.092, 0.99)

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 variable name103[index] in the Comment box. 2 Open the “Curve” feature definition template. 3 Go to Nominal Definition and select Parameter Data. The Point Generator dialog box appears on the screen. 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 shortcut 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 window.

Example for PCM: Defining Curve Using Cosine Function You can use the point generator to define a curve by its mathematical description. This example, by way of illustration, shows how to define a curve with the aid of the cosine function. When you do this you are using implicit variable definition and value assignment by means of a formula. To define a curve, for example: 1 In the point generator, enter 1 as the Start Index, 50 as the End Index, and 1 as the Increment. 2 Right-click in the Point input box to open the Formula Interface window. 3 Enter the following: point(index*10,50*cos(index*10),0,0,0,1)

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 window.

Example for PCM: Rechecking Characteristic after Tolerance Excursion You can use PCM to recheck a characteristic in the event of an excursion past a tolerance limit. This is useful, for example, if the excursion is due to the presence of foreign matter. Once the foreign matter has been removed by cleaning, a repetition of the measurement will furnish the actual values.

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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 shortcut 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)

5 You can now run the measurement plan.

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Example for PCM: Parameterizing a Coordinate System You can parameterize the angle of rotation of a system of coordinates. This entails creating the angle as a value of a variable in radian measure. You can also parameterize the offset of a system of coordinates. In this example, the system of coordinates has to be rotated 180 or 0 degrees, depending on the value of a variable. You accomplish this by asg a variable, for example “PartRotationActive” a value of 0 or 1 in the input parameters at the applicable points in the measurement plan. 1 Open the base alignment. 2 Select Change active Base Alignment and click on Special. 3 In the Special Functions window, click Rotate by an angle. 4 Right-click in the input field for the angle to the shortcut menu, open the Formula dialog box and enter the following: 3.14159265359 * PartRotationActive

In radian measure 180° corresponds to the number π = 3.14159265359. The result of the formula depends on the variable PartRotationActive: – When “PartRotationActive=0” is set, the formula’s return value is 3.14159265359 * 0 = 0°. The base alignment is not rotated. – When “PartRotationActive=1” is set, the formula’s return value is 3.14159265359 * 1 = 180°. The base alignment is rotated 180°.

Example for PCM: Loading PCM File Using Dialog You can manually load a PCM file for the current measurement plan by clicking CNC → Measurement Plan Functions → Parameter. With the command readPCMFile, you can have the same function run automatically. If you are using character chain 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:/home/om/PCMFILES // Load PCM file readPCMFile (PCM_filename)

Example for PCM: Defining Loop with Linear Offset Let us assume that you want to parameterize a hole pattern with linear offset in X. You can use the Pattern function or PCM to accomplish this task. The PCM is illustrated here. You must parameterize the X, Y and Z coordinates, along with the diameter and the offset in X. 1 Select CNC → Measurement Plan Functions → 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 characteristics. Then combine the characteristics in a group and place the loop around the group. 4 Parameterize the nominal.

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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 “Curve” definition template, select “Formula” from the shortcut menu opened by right-clicking in the X Nominal field. The field for the X value contains the variable “circle_position.x”. 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.

Example for PCM: Nested Loop for Field (Array) In this example a perforated plate is to be parameterized. The number of holes and the positions of the holes are both randoms. Build up the circles as an “array“ (field) and use a loop in the measurement plan which you use to through the array index. An array can be obtained by indexing a variable with square brackets. The array will, of course, have to be set as a parameter for the actual processing process. In this case, use the Loop index LOOP1.

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Examples for PCM

1 Create the following ASCII file for PCM: // Circle coordinates as points with values for x,y,z // CirclePos[1] = point(10,20,-5,0,0,1) CirclePos[2] = point(15,30,-5,0,0,1) CirclePos[3] = point(22,28.3,-5,0,0,1) CirclePos[4] = point(40.5,30.8,-5,0,0,1) Circle_diameter[1] = 70 Circle_diameter[2] = 50 Circle_diameter[3] = 25 Circle_diameter[4] = 22 Number_circles = 4 // Comment strings for each circle textCircle[1] = “This is circle A” textCircle[2] = “This is circle B” textCircle[3] = “This is circle C” textCircle[4] = “This is circle D”

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 loop variable LOOP1) and read in the parameter file “perplate_A.para”. The parameters from the file are assigned to the variables. 6 Open the feature definition template for the circle. • In the X nominal input box, enter “CirclePos[LOOP1].x”. • In the Y nominal input box, enter “CirclePos[LOOP1].y”. • In the Z nominal input box, enter “CirclePos[LOOP1].z”. • In the D nominal input box, enter “Circlediameter[LOOP1]”. • Open the commentary field with Formula in the Name/Comment window and enter the text parameter “textCircle[LOOP1]”. 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.

Example for PCM: Parts Family and Variant Control PCM enables you to measure different variants of a workpiece using a single measurement plan. 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 CNC → Measurement Plan Functions → 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 shortcut menu. • Click in the input box for the condition to open the shortcut 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 variable “MeasureAdditionalHolePatternActive” is equal to 1. 5 Run the measurement plan. The “Additional hole pattern variant B” group is measured. 6 Select CNC → Measurement Plan Functions → Parameter and enter the following:

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// Measure additional hole pattern variant B when parameter is 1 MeasureAdditionalHolePatternActive = 0

7 Run the measurement plan again. The “Additional hole pattern variant B” group is not measured in this run.

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Example for PCM: ASCII Parameter File Example of an ASCII parameter file (*.PARA file): // Text-Parameters ------------------------------------------who = “File generated by ZEISS-IMT Training Center” nameOfCircle_1 = “Circle_1” nameOfCircle_2 = “Circle_2” nameOfCircle_3 = “Circle_3” text1 = “type034_n2_p2” nextText = “This is in Front” // Text-Parameters as an array --------------------name101[1] = “type101_n1_p1” name101[2] = “type101_n2_p2” name101[3] = “type101_n3_p3” name101[4] = “type101_n4_p4” name101[5] = “type101_n5_p5” name101[6] = “type101_n6_p6” name101[7] = “type101_n7_p7” name101[8] = “type101_n8_p8” name101[9] = “type101_n9_p9” name101[10] = “type101_n10_p10” // Numeric-Parameters -----------------------------Partnumber = 10 PartRotationAktiv = 1 CREATION_DATE = 950516 CREATION_TIME = 0000 DESIGN_DATE = 950516 NUMBER = 772209709750 PART_HEIGHT = 316.000 PLACE = 2 X_Circle_1 = 10 Y_Circle_1 = 20 Z_Circle_1 = 15 D_Circle_1 = 40 X_Circle_2 = 250 Y_Circle_2 = 40 Z_Circle_2 = -15 D_Circle_2 = 25 X_Circle_3 = -12 Y_Circle_3 = -20 Z_Circle_3 = 50 D_Circle_3 = 12 // Numeric-Parameters as an array type vector ------------------type086[1] = vector( 10.0, 0.0, 0.0 ) type086[2] = vector( 0.0, -20.0, 0.0 ) type086[3] = vector( 30.0, 20.0, 10.0 ) type086[4] = vector( 17.5, 13.8, 50.0 ) // Numeric-Parameters as an array type point -------------------CurveFront[1] = point( 216.023, 0.0, 69.698, 0.984, -0.0, 0.176 ) CurveFront[2] = point( 206.34, 0.0, 102.988, 0.916, -0.0, 0.401 ) CurveFront[3] = point( 180.14, 0.0, 141.726, 0.707, -0.0, 0.707 ) CurveFront[4] = point( 130.593, 0.0, 181.254, 0.575, -0.0, 0.818 ) CurveFront[5] = point( 107.046, 0.0, 197.639, 0.57, -0.0, 0.822 ) CurveFront[6] = point( 80.825, 0.0, 216.02, 0.557, -0.0, 0.83 )

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PCM Quick Reference

PCM Quick Reference You need the following information in order to program with PCM: – ➤“PCM Syntax” on page 14-47 – ➤“Variables in PCM” on page 14-48 – ➤“Arithmetic and Comparative Operators in PCM” on page 14-49 – Overview of PCM functions: • Mathematical functions Contains the syntax for mathematical functions such as sine, cosine, etc. • Character chain functions Contains the syntax for functions using character chains such as asc, chr, len, etc. • Input and output Contains the functions that control screen input and output. • File commands Contains the functions that are required to work with files and directories. • Measurement-specific functions Contains the functions that process measured values generated by a measurement plan run and that read probe properties. • CMM movement commands Contains the functions that control the CMM. • Use custom printout Contains the functions for activating and deactivating the custom printout. – Overview of the various types of condition (IF-instructions)

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 – 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.

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– 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:

Arrays

Variable type

Examples of value assignments

number

pi=-3.141529 hugo=2.0 P1=80

vector

Axis=vector(10,12,0)

point

CylinderB=point(-10,12.5,0,0,0,1)

string

Text_1=“Circle” Text_2=“Enter the number:”

Arrays can also be defined with variables using special value assignments with square brackets. Example:

hugo[1] = point(-10,12.5,0,0,0,1) hugo[2] = point(-12,12.5,0,0,0,1) hugo[3] = point(-14,12.5,0,0,0,1) hugo[4] = point(-16,12.5,0,0,0,1) In this case, “hugo“ is an array consisting of 4 variables of the type point. 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

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You can gain direct access to a specific element in an array by specifying the array index. Example: Length = output values[4]

Arithmetic and Comparative Operators in PCM You can use the following arithmetic operators in PCM: Operator

Result

+

Sum

–

Difference

*

Product

/

Quotient

You can use the following comparative operators for conditions in PCM: Operator

Result

<

Truth value of “a

>

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”

Mathematical functions in PCM Angle Conversions You can use the following functions to convert angle values in PCM: Function

Result

rad (angular degree)

Radian value of angle degrees

deg (radian angle)

Gon angle value of radian angle

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Angle Functions PCM s the following angle functions: Function

Result

sin (angular degree)

Sine value

cos (angular degree)

Cosine value

tan (angular degree)

Tan value

arcsin (value)

Arcsine in degrees

arccos (value)

Arccosine in degrees

arctan (value)

Arctangent in degrees

arctan2 (dividend,divisor)

Arc tangent from the quotient

Other Functions Other mathematical functions are available: Operator

Result

squared(value)

Value squared

sqrt(value)

Square root of value

exp(value)

evalue

ln(value)

Natural logarithm of value

log(value)

Common logarithm of value

mod(value1,value2)

Value1 modulo value2

int()

Integral proportion of value

abs(value)

|Value| (=absolute value of the value)

round(value[,figures]) Value, rounded to the given number of places; if specification of number of places omitted: 0 places sign([value1,]value2)

Sign of value2 times value1: – Value1, if value2<0 0, if value2=0 + value1, if value2>0

Examples: squared(3) = 9 sqrt(225) = 15 exp(0) = 1 ln(1) = 0

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PCM Quick Reference

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

Character Chain Functions in PCM You can use the following character chain functions in PCM: Function

Result

asc(character)

ASCII code (number) of specified character

chr(number)

Character with the specified ASCII code

format(number)

Character chain consisting of the figures and characters of the number

val(character chain)

Number represented by the character chain

len(character chain)

Length of the character chain

inStr([startIndex,] character chain1, character chain2)

Position of the first occurrence of character chain2 within character chain1 after the startIndex-th character or the first character

mid(character chain,startIndex[,length]) Character chain, consisting of the characters from the startIndex-th character to the end of the character chain or to the (startIndex+length-1)-th character strElement(n,char,character chain)

The n-th element of the character chain, when char is regarded as a separator between the elements

Examples: asc("8") = 56 chr(111) = "o" format(3278,45) = "3278,45" val("3278,45") = 3278,45 len("This is a character chain") = 25 inStr(3,"Manna","a") = 5 inStr("Manna","a") = 2 mid("PCM Functions",1,3) = "PCM" 61212-2010102

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strElement(4,",","hello,here,we,are,again") = "are" strElement(4,"e","here,we,are,again") = "ar"

PCM Functions: Input and Output 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”) endif else if P1 <> 1 then message(“You do not want to continue measuring.”) endif endif

Example 2: hugo = 10 P1 = inquireNumber("Last word was: ",hugo,cr(), "Enter new number:") message("You have entered the number:",P1)

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")

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")

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PCM Quick Reference

Here the optional elements “cr()“ each cause a line break on the screen. Examples: string1 = inquireText(“Enter the name”)

inquireList The inquireList command can be used to create a menu for querying a character chain. 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 chain 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",)

inquire Corresponds to the inquireNumber command, but is ed by PCM only for the sake of upwards compatibility. The syntax is: variablename = inquire("Dialog text for poll")

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. The syntax is: print(variable;variable;variable;...) NOTE hss

The print command will not be active unless you have activated the Activate print command check box after selecting CNC → Measurement Plan Functions → PCM Test Settings in the PCM Test Functions window. This means you can use the command for test purposes.

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Examples: print(“Print this dialog text in the printout”) print(“Print the value of variable P1 in the printout”; P1)

PCM Functions: File Commands addToFile Adds a line to a file. If the file does not exist, it will be specially created. The syntax is: addToFile(file name,value1,...)

Whenever the file name or path name is used, 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, which contains a path specification.

deleteFile Deletes the specified file. The syntax is: deleteFile(file name)

Whenever the file name or path name is used, 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()

Example: wd = getWD()

readPCMFile reads in a PCM file. The syntax is: readPCMFile (file name)

Whenever the file name or path name is used, 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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PCM Quick Reference

The new parameters which are read in will, in each case, overwrite the current parameters of the same name. NOTE hss

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 ")

PCM Functions: Measurement-specific Functions getActual In conjunction with an argument returns a certain current value of a feature. The syntax is: NOTE hss

Coordinate values returned by getActual and getNominal always refer to the base alignment of the current feature. getActual(“feature_name”).characteristic

The "feature_name" can be indexed directly or with a variable (for example, a loop variable): getActual("cone",3).x

“characteristic” is a dummy for the following: Function

Return value

x

X value of the reference point

y

Y value of the reference point

z

Z value of the reference point

a1

Angle 1

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Function

Return value

a2

Angle 2

inclinationAngle

Angle of inclination

rotationAngle

Angle of rotation

diameter

Diameter

radiusD2

Radius 2

radius

Radius

angle

Angle

len

Length

sigma

Scatter

form

Form error

coordPolRadius

Polar coordinate, radius

coordPolAngle

Polar coordinate, angle

coordPolHeight

Polar coordinate, height

apexAngle

Cone angle

apexAngleHalf

Half cone angle

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

See the table above for the possible values of “characteristic”.

getProbe Returns characteristics of the probe. The syntax is: getProbe(“probe_name”,“plate_name”).characteristic

Probe name and plate name must be strings enclosed in straight quotes ("). The possible values of “characteristic” are: “radius” or “probeName”. The current probe name can be omitted. Examples: Command / assignment

Return value / effect

getProbe().radius

The current probe radius is returned.

getProbe(“probe_+Y”).radius

The probe radius of “probe_+Y” is returned.

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PCM Quick Reference

Command / assignment

Return value / effect

getProbe(“probe_+Y”,“plate_A”).radius

The radius of “probe_+Y” is returned from “plate_A”.

ProbeDiameter= getProbe(“probe_+Y”,“plate_A”).radius

The variable “ProbeDiameter” receives the radius of “probe_+Y” from “plate_A”.

getRecordHead Returns the current value of a printout-header variable. The syntax is: getRecordHead(“printout header variable”)

You will find a complete list of all printout header variables in ➤“The Printout Header Data (Reference)” on page 9-21.

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 ➤“The Printout Header Data (Reference)” on page 9-21.

baseSystem (Base Alignment) 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

Return value

baseSystem().x

X value of base alignment

baseSystem().y

Y value of base alignment

baseSystem().z

Z value of base alignment

baseSystem().valueA

valueA value of base alignment

baseSystem().euler1

euler1 of base alignment in rads (angle of inclination)

baseSystem().euler2

euler2 of base alignment in rads (angle of inclination)

baseSystem().euler3

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° / π

Example: result=baseSystem().x

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The X value of the base alignment is written into the “result” variable.

date Returns the current date and 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.

PCM Functions: CMM Movement Commands positionCMM Moves the probe head to the specified position (in machine coordinates). The CMM moves in Z first, then X, and finally Y. The syntax is:

! hss

Caution This is a direct movement command addressing the CMM. Risk of collision. The head moves directly to the position, the clearance planes are ignored. positionCMM(X,Y,Z)

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 -100 mm, then in Y to -200 mm and then in X to +500 mm in the machine’s system of coordinates.

searchDistance Sets the search distance. The syntax is: searchDistance(distance)

In this case “distance” is the distance traveled by the probe head 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:

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PCM Quick Reference

searchDistance(10.000) => Search distance before nominal probing is

1 mm searchDistance(60.000) => Search distance before nominal probing is

6 mm

cncBreak Breaks off the CNC run. The syntax is: cncBreak()

The CNC run is broken off, the stop light changes to red.

systemCall Calls system commands. The syntax is: systemCall(“filename”)

The file “filename” is called and executed immediately. “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.

systemCallWithWait Calls system commands and waits for them to be processed. The syntax is: systemCallWithWait("filename")

The file “filename” 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.

PCM Functions: Custom Printout presentationOn Switches on a custom printout. The syntax is: presentationOn()

presentationOff Switches off a custom printout. The syntax is:

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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.

Overview: Conditions in PCM The 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. DEFINITION can be formulas, value assignments, functions, conditions or loops of your choice, always with line breaks as separators.

The Condition with Alternative The syntax of the condition with alternative is as follows: if CONDITION then DEFINITION1 else DEFINITION2 endif

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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PCM Quick Reference

Example of a Condition with Alternative

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)

Overview: Loops in PCM The Defined Loop The defined loop has the following syntax: for index=start to end [step] DEFINITION next index

The following must be inserted: – for index – the name of the loop variables (random), – for start, end and step – full figures (integers), – 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 the step each time. Example

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The 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.

! hss

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Caution Please note that infinite repetitions are possible with the conditional loop, if the condition is never fulfilled.

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Tips and Tricks for Working with PCM

Tips and Tricks for Working with PCM The PCM programming language provides you with a wide choice of functions and commands that you can use to automate many of the routine procedures in Calypso. There is also a possibility of Calypso becoming slower when you program with PCM. Debug functions are useful for locating bugs in programs (see ➤“How to Test PCM Commands” on page 14-63).

Enhancing the Speed of Calypso You will be able to use Calypso's speed to best effect if you bear the following in mind: – When you perform local calculations required only for a particular feature or characteristic, you should always try to define new variables. If you re-use existing variables, there is a possibility of Calypso becoming slower because the “old” variables always have to be overwritten. Defining new variables is more efficient. – Use the PCM command getActual sparingly in theoretical elements. – Activate the print command only for test purposes.

How to Test PCM Commands The procedure for testing PCM commands is as follows: 1 Select CNC → Measurement Plan Functions → PCM Test settings. The PCM Test Functions dialog box appears on the screen.

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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 dialog box closes. The settings are used the next time the measurement plan is run.

Two-button vs. Three-button Mouse The descriptions in this documentation are based on a two-button mouse. If you have a three-button mouse: click the middle button to open shortcut menus.

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Two-button mouse

Three-button mouse

Left button

Left button

Right button

Middle button

Ctrl + right button

Right button

Alt + right button

Alt + right button

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Chapter

15 15

Curve Measurement (Option)

.................................................................................................................................

Geometric features 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 “2D curve“ and “3D curve“ measuring options and the “Curve form“ feature are for measuring and evaluating known and unknown open and closed 2D and 3D curves. Curve measuring 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. your Carl Zeiss Service for more information. This chapter assumes that you are familiar with the procedures for defining features (see and characteristics).➤“Defining Features” on page 5-2 ➤“Defining Characteristics” on page 6-7

Included in this chapter: Basics about Curve Measurement . . . . . . . . . . . . . . . . . . . . . . . 15-2 Defining the Curve Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-5 Defining Tolerances for a Curve . . . . . . . . . . . . . . . . . . . . . . . . 15-26 Using Curves in the CAD Model. . . . . . . . . . . . . . . . . . . . . . . . 15-31 The Measuring Strategy for the Curve . . . . . . . . . . . . . . . . . . . 15-33 Scanning a Known Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-38 Defining Curve Form Characteristics. . . . . . . . . . . . . . . . . . . . . 15-43 Working with the Results of Curve Measurement. . . . . . . . . . . 15-46

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Basics about Curve Measurement Because curves are geometric elements, there are some important things you should know about how Calypso evaluates their form and location.

Definition and Display of Curves In Calypso a curve is defined by a finite set of points. Calypso uses spline functions to interpolate between the curve points in order to display the curve as a continuity in the CAD window. Both the specifications and the actual values of the curve points are each defined by 6 values: – 3 point coordinates (X, Y, Z) – 1 normal vector (U, V, W) or its 3 direction cosines (NX, NY, NZ). The three curve types which can be measured and calculated by Calypso are presented in the following examples. These examples will help you to understand the principles. – Flat curve (2D curve) Flat curves are produced when a plane (imaginary) intersects with a body. Flat curves occur, for example, on workpieces such as camshafts, which exhibit two-dimensional curves. All the points which constitute a flat curve are on a single plane that can (also) have any orientation in space. The normal vectors of the curve points, too, consequently, are all in the measuring plane.

Z Y

X

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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, which run across cylinder sections. A lift curve maintains a constant distance from the axis of the cylinder, so only two values are variable: namely the deviation of the curve in a given direction (the X axis in our example) and the angle of rotation on the surface of the cylinder. Like the 2D curve, therefore, the lift curve has only two degrees of freedom. Lift curves in Calypso are special forms of the 3D curves. Z

R

Y X

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Performing Curve Measurement The procedure for curve measurement is no different from that for other measurements. The procedure for performing measurements is described in ➤“Running a Measurement Plan” on page 8-1 You can measure a complete measurement plan, a mini-plan, or a single characteristic or feature.

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Defining the Curve Feature

Defining the Curve Feature The definition of a curve feature differs from the definition of other features. Within the curve feature definition template, Calypso offers four ways of defining nominal data. You can – import a file (in VDA, ASCII, PAB or DXF format), – define the curve with the point generator, – digitize a curve from measurements, – use the keyboard to enter the nominal data of the curve, – adopt the nominal data of the curve from the CAD model. As with other features, you use a definition template to define twodimensional and three-dimensional curves. You will already be familiar with most of the buttons and input fields from the other definition templates, but this template includes some elements that are new.

You will find more information on this definition template under Definition Template (Curve) in the interactive Calypso reference in Online Help.

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2D Curves, 3D Curves and Lift Curves – The Differences The definition templates for both types of curve are, broadly speaking, the same: they differ only in a small few points: – The definition template for the 3D curve (lift curve) contains the menu Projection. – The definition template for 3D curves (not lift curve) has no Projection menu, because the curve does not have to be embedded in a plane. – For all practical purposes, the deviation for 3D curves can be calculated only in the actual vector direction and the normal vector direction. – The Move Parallelcurve option in the Evaluation menu is not available for 3D curves. How curves are displayed

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 using Evaluation → Tape width. 0 means: no tape.

Marking and demarking lift curve Lift curves are 3D curves which are projected onto a cylinder section. You can see here that the menu Projection Lift Curve is contained in the definition template of the lift curve in addition to the features of the 3D curve. You can mark 3D curves as lift curves (while generating the lift curve) or cancel the marking again. – To mark a 3D curve as a lift curve, you have two options: In the window Change nominal values, select the option In vector direction, activate the check box Lift curve and specify the radius and axial direction of the cylinder. In the menu Evaluation→ Lift curve in the window Parameter Data, activate the check box Lift curve. – To cancel the marking of a 3D curve as a lift curve, you have two options: In the window Change Nominal Values, select the option In vector direction, deactivate the check box Lift curve and enter “0“ explicitly for the Length and Cylinder radius. In the menu Evaluation→ Lift curve in the window Parameter Data, deactivate the check box Lift curve.

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Defining Nominal Data for a Curve When defining a curve feature, you first need to define the nominal data of the curve you want to measure. NOTE hss

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 must 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. – 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 by means of the keyboard, for example taken from a technical drawing. – Extract the nominal data from the CAD model: using the popup menu CAD modification 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.

! hss

Risk of collision! Always check the normal 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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How to Import the Files for Nominal Definition of a Curve Calypso s import of the following file formats: – VDA (the points in a VDA file must be described as Cons, Curve, MDI, PSET, POINT or CIRCLE), – ASCII (for more information on ASCII files, see ➤“Defining Nominal Data for a Curve” on page 15-7), – PAB (a format used by SOM), and – DXF (created by ScanWare DXF converters, creates only 2D curves). To import a file in one of these formats: 1 Make sure you have the curve feature template open and displayed on your screen, and that the chosen coordinate system fits to the curve to be imported. 2 Select Nominal Value Definition Read Nominal Values. A file selection window is opened.

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.

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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. 5 If you want to load a VDA file selectively, click on the button Properties. 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 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 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 to check the direction of the normal vectors (see ➤“Checking the Normal Vectors of a Curve” on page 15-24).

How to Generate a Curve with the Points Generator Calypso s the VDA, PAB and DXF file formats. If the data you need is in some other file format, you can program formulas to import the information and convert the data to Calypso curve data. You can also use the points generator to compute the points of the curve freely from mathematical formulas.

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To generate a curve using the points generator: 1 Open the curve feature definition template. 2 Select the Parameters Data command from the Nominal Definition picklist. The Points Generator dialog box appears on the screen.

3 You can enter formulas and parameters to suit the necessary conversion in the Start Index, End Index and Increment input fields. See ➤“Entering Parameters and Formulas” on page 14-15. 4 Click on OK, when you are finished programming. Calypso evaluates the points according to your entries and loads them into the definition template.

Creating Nominal Values of a Curve by Digitizing You use digitalization when you do not have nominal data for a curve. Digitalization means obtaining the nominal data of a curve by a series of probings (i.e. probing an unknown contour).

! hss

15-10

Caution Automatic stylus radius correction does not take place when you digitize. See ➤“Defining Tolerances for a Curve” on page 15-26 and ➤“How to Change the Nominal Points of a Curve” on page 15-22, Step 3, for instructions on how to implement radius correction.

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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 procedure “2D section“ (see ➤“How to Scan an Unknown Contour using the “Unknown Cut” Method” on page 15-12) 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 a 3D Curve” on page 15-14) – the “Lift curve“ method (see ➤“How to Scan an Unknown Contour using the “Unknown Circle” Method” on page 15-16)

How to Generate the Nominal Values of a Curve by Manual Probings To digitize a curve by means of individual probings: 1 Open the definition template of the curve. 2 Click on the Nominal Definition picklist. 3 Select the command Digitizing on. The place of the Nominal Definition picklist is now taken by a red button labeled Digitizing off. 4 Click on the Open/Closed Curve button to select an open curve. 5 If you want to project the nominal points, select a projection plane from the Projection picklist. 6 Now start with taking the measuring points into the workpiece. Every probe 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 refer to the stylus center. In order to correct the stylus radius, please read .➤“Working with Curve Nominal Data” on page 15-22

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How to Scan an Unknown Contour using the “Unknown Cut” Method To scan an unknown contour as an unknown cut: 1 Open the 2D curve feature definition template. 2 In the Nominal Definition picklist, select the Digitizing on command. The place of the Nominal Definition picklist is now taken by a red button labeled Digitizing off. 3 Click on the Strategy button. The Strategy dialog box appears on the screen.

4 Select the “Free planar section” method to measure the curve as a free planar section. The entry Unknown contour 1 appears in the dialog box.

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5 Double-click on the entry. The Segment dialog box appears on the screen.

6 Enter the parameters: • Enter the coordinates of the start point in the Start Point field, or else probe the workpiece to define the start point. • Enter the coordinates of the end point in the End Point field, or else probe the workpiece to define the end point • Probe a Direction Point so that Calypso knows the reference direction of the plane, or use the Reference Axis picklist to select an axis normal to the scanning plane. • 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 Distance 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 a 3D Curve When you digitize a 2D curve using the unknown cut method, the normal vectors are calculated by Calypso – by definition, they are in the plane of the cut. A single digitization is not enough to probe a 3D curve with transverse curvatures on the workpiece, because in this case the orientation of the normal 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 normal 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 hss

15-14

If the feature does not have any nominal values, you will have to select the item Digitizing On 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 tracks, then click on Execute to start digitization.

Track specification by probing

To specify the start and end points of the three tracks by probing with the CMM, first probe the three start points of the tracks (points 1 to 3), then probe the three end points of the tracks (points 4 to 6).

Directions during travel

When traveling along the three tracks, the CMM moves in a meandering style: the direction of movement alternates from one track to the next.

Digitizing 3D Curve in Area Using the 3D Curve feature you can also digitize a three-dimensional curve over an entire area. Calypso employs the technique of probing surfaces along intersection lines to effect a meander-formed probing of an entire surface area and in this way creates a 3D curve. It will be necessary here to enter the four edges of surface that is to be digitized. These four points must more or less form a rectangle. Start the process by clicking on the Digitize 3D Grid button in the Strategy window for 3D curves. NOTE hss

If the feature does not have any nominal values, you will have to select the item Digitizing On under Nominal Definition before you open the Strategy window.

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In the Segment window, go to Travel Path Definition and define the number of tracks, then click on Execute to start digitization.

Directions during travel

When traveling along the three tracks, the CMM moves in a meandering style: the direction of movement alternates from one track to the next.

How to Scan an Unknown Contour using the “Unknown Circle” Method To scan an unknown contour as an unknown circle: 1 Open the 3D curve feature definition template. 2 In the Nominal Definition picklist, select the Digitizing on command. The place of the Nominal Definition picklist is now taken by a red button labeled Digitizing off.

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3 Click on the Strategy button. The Strategy dialog box appears on the screen.

4 Select the “Unknown Circle” method in order to measure the curve as an unknown circle along an annular surface (cylinder circumference). The Unknown Circle entry appears in the window.

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5 Double-click Unknown Circle. The Segment dialog box appears on the screen.

6 In the Travel Path Definition list, select Point or Angle as the means of defining the travel path. 7 If you select Point: • Enter the coordinates of the start points in the Start Point field, or else probe the workpiece to define the start points. • Enter the coordinates of the end points in the End Point field, or else probe the workpiece to define the end points. • If necessary, click on the button to change the Direction. To specify the start and end points of the three tracks by probing with the CMM, first probe the three start points of the tracks (points 1 to 3), then probe the three end points of the tracks (points 4 to 6). 8 If you select Angle: • Enter the start angle in the Start Angle field. • Enter the range for scanning in the Angle Range field. • If you do not select a reference feature, enter the center in the Center field and the radius of the unknown circle in the Radius field.

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• If there is a suitable reference feature, select it from the Reference Feature list. The Center and Radius fields are filled automatically. NOTE hss

Check the entered values and make sure that the unknown circle is probed on an area along the cylinder section, so that the specified radius is accordingly always greater than the radius of the reference feature. The center must also be at the central point of the unknown circle. Usually, the automatically entered center is in the center of a base area of the reference feature. 9 Enter a speed for the CMM in the Speed field or select the requisite accuracy. 10 Enter a pitch between points in the Step Distance 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. 11 Check that the CMM is ready to move and that there is no risk of collision. 12 Click on the red Execute button to start scanning the unknown contour. The CMM starts scanning the contour.

How to Enter Nominal Data of the Curve Point by Point You also have the option of defining a curve by entering the nominal data directly into the definition template. Bear in mind, however, that the volume of data produced in this way can rapidly become very large. 1 Make sure you have the curve feature template open and displayed on your screen. The nominal fields for entering the X, Y and Z coordinates and the direction cosines NX, NY and NZ are on the left. 2 In the Nominal Data picklist, select Nominal Input. You have two options for input: point by point or with the aid of the nominals editor. You can use the buttons to toggle back and forth between the two display modes in the curve definition template. • If you use point by point input you begin by entering the first point number and continue by entering the coordinates.

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Then enter the next point number or click on the arrow to increment the number by one, and enter the coordinates of this point. • Click on the button if you want to use the Nominal Editor. The tabular list is an overview in which you can use edit, copy, paste and delete functions. Click on the button to toggle back to the normal display mode. 3 Click OK to confirm your entries. Note that each point on the curve must have a normal vector. See ➤“How to Change the Nominal Vectors of the Curve” on page 15-21.

How to Adopt Nominal Data of the Curve from the CAD Model. You can also adopt nominal data for a curve from the CAD model. 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 rendering 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).

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• For a “planar edge“, the vectors are positioned parallel to the plane vector. 7 When transfer is completed, confirm by clicking on Close. You have now transferred the features curve defined in the CAD model to your measurement plan. You can edit the curve in the usual way.

How to Change the Nominal Vectors of the Curve Each curve point is determined by three point coordinates and a normal vector. For each curve you can work in Calypso the normal vectors of the nominal points are in the same direction. (See ➤“Basics about Curve Measurement” on page 15-2). The direction of the normal vectors can be changed as follows: – Vertical to the axis of a reference element – Parallel to the axis of a reference element – Rotated through a given angle about the tangent of the curve or – Manual entry The procedure is similar for all these paths: 1 Open the definition template of the curve. 2 Select Nominal Definition → Edit Vectors. You define the direction in the Curve Nominal Vector Input window.

3 Select the option to edit the normal vector Perpendicular To or Parallel To a reference feature.

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4 Select the feature to be used as reference for the movement from the list. The normal 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 directional components NX, NY and NZ. 6 If you want to rotate the vectors about the tangent of the curve: • Mark the Rotation about tangent radio button. • Enter the angle of rotation in the Angle field. 7 Click on OK to confirm. The new direction for the normal vector will be taken over from these values.

Working with Curve Nominal Data If the nominal values for a curve have already been determined, you have the following possibilities for editing the nominal values: – Change nominal points: Here you can move the curve in various ways, including rotating and shifting. – Checking normal vectors.

How to Change the Nominal Points of a Curve You can transform the nominal values of a curve in order to move the curve to a position of your choice. For example, this could be necessary for curves whose value you have read from a file and whose position you would like to modify on your workpiece. Or perhaps you have received a 3D curve by digitizing and you want to convert it into a lift curve. NOTE hss

You must transform the nominal values if you want to perform stylus radius correction after digitizing a curve. The nominal values can be transformed in several ways: – Move in direction of the normal vectors (offset curve, especially for correcting stylus radius) – Project in the direction of the cylinder axis on to 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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! hss

Caution If you modify the number of points and confirm with OK, you will create new nominal values for the curve. The original curve can not 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. 2 Select Nominal Definition → Change Nominal Points. The Change Nominal Points dialog box appears on the screen. 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“. • When you have the measurement values of the curve from the digitalization, click on the Stylus Radius button. The radius of the used stylus is entered in the input field. • If you want to project the points of a curve on to a cylinder section, activate the check box Unknown circle and enter the radius and axis of the cylinder.

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Please note that the reference axis or the axis of the reference feature must always through the center of the unknown circle. 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 axis, select the option Coordinate axes direction. • Enter the value for the move and/or rotation. 5 To modify the number of nominal points, select the option Number. • Enter the desired value for the Step Distance, the Chord Height or the Number. 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. 6 Click on OK to confirm. The nominal points are modified immediately.

Checking the Normal Vectors of a Curve In Calypso, the curve is only defined by points and directions. Therefore, after defining the curve’s nominal data, you should check two important things concerning the normal vectors: – Is there a normal vector defined for each curve point? If there are no normal vectors for some (or all) points, you can enter them manually (see ➤“How to Change the Nominal Vectors of the Curve” on page 15-21). – Is the direction of the normal vectors OK? The normal vectors must always “look away” from the part. A normal vector must never point into the material of the part.

! hss

Caution If a normal vector has the wrong direction, this result in collision because the approach direction of the CMM will be wrong. To check the normal 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 normal vector (refer to ➤“Show/Hide Vectors” on page 15-31). – You choose this way especially for checking the vector’s direction. If you just need to change the directions of all normal vectors at once, you can also use the Change Direction button.

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Checking the Clearance Planes of a Curve When you define a feature, Calypso assigns clearance planes to the feature. In the case of curve measuring, you should check this automatic assignment to make sure that the clearance planes really guarantee a safe approach for the CMM. If the approach is not safe, make the requisite changes as described in ➤“Editing the Probe Routes” on page 7-22.

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Defining Tolerances for a Curve There are two ways of entering tolerances for the Curve feature: – For the whole curve – For individual curve segments You can also define the curve jump tolerance for the entire curve here. NOTE hss

These entries in the definition template do not automatically define any measurement characteristics, which are added to the list of characteristics.

How to Define Tolerance for the Whole Curve The entry of the measuring tolerance refers to the nominal-actual comparison of the curve points. You can enter an upper and/or lower tolerance.

upper tolerance nominal curve

lower tolerance

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Defining Tolerances for a Curve

To enter tolerances 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 check box. This cuts out 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 out put in the default printout.

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How to Define Tolerances for Individual Segments The entry of the measuring tolerance refers to the nominal-actual comparison of the curve points. You can enter an upper and/or lower tolerance for each segment you have defined.

upper tolerance nominal curve

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.

3 Select the segment for which you want to enter the tolerances by clicking on the column to the left of the segment name.

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Defining Tolerances for a Curve

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.

How to Define Jump Tolerance for the Whole Curve The curve jump tolerance refers to the differences between the nominal-actual deviations of the curve points. So this is, so to speak, a “second derivative“ – the difference of the differences. 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.

Nominal curve Actual curve

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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Using Curves in the CAD Model

Using Curves in the CAD Model The principles for using the CAD model in measuring curves are the same as those described in ➤“Working with the CAD Window” on page 3-1. There are, however, a number of other, useful commands for working with curves. You access these commands by means of a shortcut menu. NOTE hss

These additional commands are available only when you have the curve definition template open.

The Commands in the Shortcut Menu for Curves Show/Hide Nominal Points Choose this command to view the individual nominal points. Each point is represented by a cross. Choose Hide if the nominal points are visible but you want to hide them.

Show/Hide Vectors Choose this command to view the individual nominal vectors. This is an easy way of checking the directions of the vectors. Choose Hide if the tolerances are visible but you want to hide them.

Act-Points Show/Mask Out Choose this command to view the individual measured points. Each point is represented by a cross. This command is not available until after the curve has been measured. Choose Hide if the nominal points are visible but you want to hide them.

Show/Hide Act Curve Choose this command to view the measured curve. The curve is displayed as a continuous line. This command is not available until after the curve has been measured. Choose Hide if the curve is visible but you want to hide it.

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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. Choose Hide if the deviations are visible but you want to hide them.

Show/Hide Tolerance Lines Choose this command to view the tolerance lines of the curve. These lines are displayed along with the curve. Choose Hide if the deviations are visible but you want to hide them.

Show Point Numbers Choose this commend to view the point numbers. Choose Hide if the point numbers 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).

Scaling 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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The Measuring Strategy for the Curve

The Measuring Strategy for the Curve There is no difference in layout between the Strategy window for the curve and the Strategy window for the other features (see ➤“Defining a Measurement Strategy” on page 5-62). The only difference is in the point list, which has an extended function in itself and in connection with creating segments. Consequently it is described separately for the curve option.

Options for Displaying Points As this illustration shows, the point list of a curve contains more functions in the Group section.

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.

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– 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. – Deviation: Each nominal point is listed together with the deviation of the actual points in the direction of the normal vector and its direction component. – New segment: See ➤“How to Divide a Curve into Segments” on page 15-39. The other elements of the point list correspond to the description in ➤“The Points List” on page 5-64.

How to Work with the Point List You can view the points of a curve in the points list and process them. The tasks you can undertake in the points list are as follows: – Divide the curve into segments (see ➤“How to Divide a Curve into Segments” on page 15-39). – Select display options for points (see ➤“Options for Displaying Points” on page 15-33). – Save and print the point list (see ➤“How to Save and Print the Point List” on page 15-36). The point list has to be open if you want to use any of these functions.

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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 dialog box appears on the screen.

3 Click on the Points List button. The list will show all points defined in the measuring element curve.

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How to Save and Print the Point List To save or print the point list: How to open the point list: 1 Open the curve feature definition template. 2 Click on the Strategy button. 3 Click on the Point List button. The Point List dialog box appears on the screen.

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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Scanning a Known Contour Curves are scanned along the segments of a curve whose points were defined beforehand in the feature. The procedure for defining the scanning method for curves differs slightly from that of the other scans. You must begin by defining the parts (segments) of the curve you want to scan. Defining a scanning method is a three-step procedure: – Check the parameters for the scanning method (see ➤“Scanning Methods for Curves” on page 15-38). The parameters for scanning were defined beforehand when the segments were defined. – Define a segment (see ➤“How to Divide a Curve into Segments” on page 15-39). – Define the general settings (see ➤“General Settings for the Path Generation Method” on page 5-70). – These settings are the same in all scanning methods.

Scanning Methods for Curves The scanning method for curves employs nominal values and segments, but points can also be interpolated between the nominal points. You can also define and represent the entire curve as a single segment. Segments of a curve

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.

Pre-/Post-scanning

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.

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Scanning a Known Contour

To reduce the effects of these problems, you can define a pre-/postscan in the file curveparameter.txt. This file can be found in the directory Calypso\home\om\. The relevant parameter is called distExtraPolScan; it is set to “0“ as standard. Entry box for scanning curves

The dialog box for scanning of curves is shown below.

How to Divide a Curve into Segments The Strategy window offers you two ways of defining a segment of an existing curve: – Specify start point and end point (consecutive points) – Specify individual points (free choice) Consecutive points

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.

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2 Mark the new segment, right-click and select Edit from the shortcut menu. The Segment dialog box appears on the screen.

3 Enter start point, end point and segment name, 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. • Push down and hold the shift-key and click on the ending point.

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Scanning a Known Contour

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 fields Upper and/or Lower Tolerance. 7 Click on OK to close the definition of the segment. The segment is automatically added to the strategy list.

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Defining Curve Form Characteristics

Defining Curve Form Characteristics For curves, too, you can define the features for tolerance in the definition template of the curve (see ➤“Defining Tolerances for a Curve” on page 15-26). Curve Form is another feature you can use for measuring the curve. This feature enables you to measure the shape of the entire curve or individual curve segments. The basics of defining Curve Form characteristics are common to the other characteristics recognized by Calypso. If you are not familiar with defining characteristics, refer to ➤“Defining Characteristics” on page 6-7.

About the Curve Form Template Whenever you define a Curve Form characteristic, the following template is displayed. To open the definition template: – Select Form and Location → Curve Form.

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The following table describes the buttons and fields that are not common to other characteristics: Element

Function

Curve jump tolerance

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.

Deviation upper

Shows the maximum deviation in the positive direction of the normal vector (“too much material”).

Deviation lower

Shows the maximum deviation in the negative direction of the normal vector (“too little material”).

Range

Shows the difference range between upper and lower deviation.

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Defining Curve Form Characteristics

How to Define Tolerance for Segments Separately After defining individual curve segments you can also assign them separate tolerances with the curve form characteristic. Proceed as follows: 1 Define a feature for the characteristic as you have done with other characteristics. When you have correctly defined the feature, the following chart for the segments appears in the definition template of the characteristic.

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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Working with the Results of Curve Measurement After measurement, the actual values are displayed in the actuals fields of the curve definition template. In contrast to most other definition templates, the curve template enables you to perform additional operations with the results. You have the following options for evaluating measuring results: – Calculation and display of deviations – Optimization of coordinate system with best-fit alignment. – Fit actual values to nominal values. – Define or restrict the alignment. – Determining a reference curve. – Specifying search distances. – Smoothing the curve display. – Sorting the measured points. – Excluding measured points from the evaluation. – Eliminating outliers.

Basics about Curve Deviations Deviation in Nominal Vector Direction Deviation in nominal vector direction is measured in the direction of the normal vector at each nominal point.

Deviation in Actual Vector Direction Deviation in the actual vector direction is calculated from each actual point along the normal of the corresponding nominal point on the nominal curve.

Space Point Evaluation (2D Curves Only) Calculating deviation with space point evaluation employs the curve functionality to determine the point on the measured spline (before radius adjustment) in the nominal vector direction. The point obtained in this way is radius-adjusted in the same way as the Space Point feature.

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Deviation in Grid Coordinates (2D Curves only) This deviation is the distance between the actual points and the nominal points in grid direction, where the direction of the normal vectors is defined.

Radial Deviation (2D Curves only) The deviation is calculated in the radial direction towards a point of reference of a reference element as the distance from the nominal points.

Fn

nominal curve

Fn

Fn

actual curve reference point

measured curve

How to Calculate the Deviations of a Curve The deviation between the measured and specified values for a curve can be calculated in a number of ways (see ➤“Basics about Curve Deviations” on page 15-46). To calculate deviation: 1 Open the definition template of the curve. 2 Select the mode of calculation you want from the Nominal to Actuals picklist. Calculation will be carried out immediately if there already are actual values. If not, calculation will commence as soon as actual values are available.

How to Display Deviations The actual values refer to the workpiece coordinate system. When dealing with a curve, however, the deviation in the coordinates X,Y and Z between the nominal and the actual values can be of greater interest. To obtain this deviation: 1 Open the definition template of the curve. 2 Activate the Deviation check box.

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The actual values on the right side of the definition template now refer to the nominal data of the curve.

How to Optimize the Coordinate System with Best-Fit Alignment Inaccurate coordinate systems produce inaccurate measured values. This, in turn, means incorrect form errors following a nominal/as-is comparison. To eliminate this positional offset, Calypso automatically performs best-fit for standard geometric features when it measures form characteristics. You have the option of defining automatic best-fit following every measuring run. Calypso can also correct the current coordinate system by applying the rotational and translational components of the best-fit result. To optimize measurement of form characteristics: 1 Open the definition template of the curve. 2 Click on the Evaluation picklist.

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3 Select Best Fit → Coordinate System from the picklist. Calypso will create a coordinate system. You can see the Best Fit window in which Calypso shows the translation and rotation of the element coordinate system 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 Accept to accept the local element coordinate system. The Enter Name dialog box appears on the screen. 6 Enter a name for the local element coordinate system. 7 Click on OK to close the dialog box.

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How to Calculate the Curve's Center of Mass With the center of mass the location of the curve is evaluated. The coordinates of this point can be displayed. To show the center of mass: 1 Make sure you have the curve feature template open and displayed on your screen. 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 nominals and actuals fields in the middle of the template. The center of mass is also displayed in the CAD window.

How to Obtain a Best Fit What is understood as ”best fit” is the mathematical separation of form and location. You may use best fit to make a mathematical correction of the positive deviation referring to the applicable nominal curve. The actual values of the curve are shifted and/or rotated until the sum of the deviation squares reaches a minimum (Gaussian best fit). This operation leaves only the curve's form deviation. To obtain a best fit: 1 Make sure you have the curve feature template open and displayed on your screen. 2 Activate the Best Fit check box. Calypso performs the fit, without changing the form. All coordinate transformations are usually employed to fit the measured curve to the nominal curve. You can restrict or specify the fit if you want to exclude certain transformations (see ➤“How to Define a Best-Fit Alignment of a Curve” on page 15-50).

How to Define a Best-Fit Alignment of a Curve When you activate the Best Fit check box to have the curve aligned, Calypso separates form deviations from positional deviations for the purposes of computation. For this purpose, only the LSQ Best Fit (3D alignment) is used.

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You have several options to influence this alignment: – You have the option of restricting the alignment for certain movements: you can prevent translation toward or rotation about axes of your choice. This restriction applies to best fit of the measured curve to the nominal curve and to best fit of a coordinate system. – You can determine that certain points are not taken into during the alignment by masking them. The masked points are also not shown in the representation in the CAD window. – For the alignment, the medium deviation between actual and nominal is minimized. Here, every curve point is compared with a calculated curve section (a section connects two neighboring points). This can take a long time if the curve has a lot of sections. Usually, it is quite sufficient to compare some sections near the point. 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. 2 Click on the Evaluation picklist and select the command Best Fit. 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.

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4 Under Masking points and under the list of points, click on the button Use nominal data or Use actual data, to load the required data into the list. 5 Under Masking points, click on the points which you wish to mask and so which will not be taken into during the alignment. Another click will cancel the selection. You can also click on the list of points with the right mouse button and select a rule for the use of points:

NOTE hss

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 graphic. 6 Under Max. Search Distance, enter the area to be considered in the field For Best Fit 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 probe 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 in the entered search distance.

How to Define a Reference Curve With Calypso you can add the deviation of a measured curve C1 (the reference curve) to a curve C2. In this way you can determine the second curve if the same curves reoccur in different places on the workpiece. To determine a reference curve: 1 Open the definition template of the curve to which the deviation of a reference curve should be added.

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2 Click on the Evaluation picklist and select the command Move Parallelcurve. You can see the window Reference Feature in which all defined curves are listed.

3 Highlight the name of the curve you want to use as a reference curve. 4 Click on the OK button. Calypso will convert the deviation of the reference curve to the current curve immediately.

How to Limit Search Distances during Curve Evaluation Distance evaluation

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.

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To prevent this, you can define the maximum permissible length of the distance from the actual pint to the curve. 1 In the definition template of the curve, click on the Evaluation picklist and select the item Max. Search Distance. A window opens in which you can see the maximum search distance.

2 Under For Distance Evaluation, enter the maximum distance which will presumably suffice in millimeters or click on Default, if you wish to use the standard Calypso value. 3 Click OK to save your entry and close the dialog box. The search distances are taken into the next time the curve is calculated.

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 default 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 smoothened. While doing so, the spline functions are only set in the close proximity of the points and do not actually through the individual points. 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 other methods. 1, on the other hand, will produce the maximum smoothening of the curve.

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1 In the definition template of the curve, click on the Evaluation picklist. 2 Select the item Approximation from the selection list. The Approximation window for entering the approximation parameter will be displayed.

3 Select whether you wish to smoothen the presentation of the calculated curve or the nominal curve. 4 Activate the check box cnc if you wish all the curves in the measurement plan that have been measured to date to be smoothened in accordance with the entries below. 5 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. 6 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 default curve will also apply for the newly calculated curves. 7 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.

! hss

Caution As soon as you confirm with OK, you will regenerate the nominal points of the curve. The original curve can not be recreated again. For this reason, it is important that you use the Simulation function to check the result beforehand.

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Sorting the Points in a Curve When scanning with a high point density or in positions which display a high degree of curvature, it may well be that measured points are not transferred in the right sequence. Normally, this is of no great significance. This is, however, significant when you are measuring curves as the sequence of the points influence the form of the curve. Calypso therefore, sorts the points in a meaningful manner. On the other hand, there may also be curves that actually contain a sharp “bend” and, consequently, should not be sorted: Sorting curves such as these would alter the form of the curve in a manner not required (see example). For this reason, you can control sorting using an Angle limit. Here, an angle is determined on the basis of the last three points that were calculated (Points 1 to 3 in the example). The points will only be sorted if the calculated angle is smaller than the angle limit. Example: The run of a curve contains a bend.

2

1

Bend in curve

3 Curv

The angle of this bend is less than 50°. If you set the limit to “50”, point 2 will automatically be interchanged with point 3 although this is not required here. The curve would then look as follows:

3

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 In the definition template of the curve, click on the Evaluation picklist.

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2 Select the item Sort measured points from the selection list. The Approximation window for entering the angle limit will be displayed.

3 Enter the maximum angle that should be accepted or click on the Default button to enter the Calypso default value. If greater angles occur in the curve, the appropriate points will be sorted. 4 Activate the check box cnc if you wish all the curves in the measurement plan that have been measured to date to be smoothened in accordance with the entries. 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.

Limiting the Evaluation of the Curve Values 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 will have to readjust to the correct nominal path. – The calculation of the spline functions and the corresponding vectors is difficult at the open ends of a curve: A slight deviation here has a much greater effect here that in other positions. To reduce the effects of these problems, you can limit the number of points that should be used for the evaluation. A distinction must be made here between basing the calculation on the nominal points on the measuring spline or the measured points on the nominal spline:

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– When evaluating in the nominal vector direction all measured points will be considered. The limitation only applies to the nominal points. – When evaluating in the actual vector direction, all nominal points will always be used. Here, the limitation only applies to the actual points. The number of considered points can be limited in the following manner: 1 In the definition template of the curve, click on the Evaluation picklist. 2 Select the item Limit evaluation from the selection list. The Limit evaluation window will appear.

3 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. 4 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.

How to Eliminate Outliers from a Curve 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 easily propagates through the actual-value determination of the corresponding characteristic. There are several different points at which you can parameterize and activate outlier elimination for curves:

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– As defaults for the characteristic groups and the references and alignment elements of the coordinate systems – For an individual characteristic – For an individual curve feature. This is how to activate outlier elimination in a feature: 1 In the definition template of the curve, click on the Evaluation picklist. 2 Select the item Outlier from the selection list. The Evaluation window will appear. 3 Activate the check box Outlier Elimination and click on the Settings button. 4 In the Outlier Mode dialog box, enter the Factor for Outlier and the Range of Data Reduction and confirm with OK. 5 Click OK to save your entry and close the Evaluation dialog box. During the calculation, the outlier measuring values which fall under the specified criteria are not taken into .

How to Format the Printout for the Curve Calypso enables you to map the curve exactly into your printout. The procedure is as follows: 1 Make sure you have the curve feature template open and displayed on your screen. 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 ➤“The Buttons in the CAD Window” on page 3-4) and/or the commands in the CAD shortcut menu (see ➤“The Commands in the Shortcut Menu for Curves” on page 15-31) to display the curve exactly as you want it in the printout. When you are ready, click OK in the curve definition template.

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Graphical Evaluation of Form Deviations for Curves The formplots available for the curve characteristic are as follows: – Curve form linear – Curve form 2D – Multiple curve form linear – Multi-Curve form 2D You call up formplots and display them as described in the section entitled ➤“How to Display Variations Graphically” on page 9-23. The illustration below shows the Curve form 2D formplot by way of example.

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Chapter

16 16

Qualifying the RDS with CAA (Option) ................................................................................................................................. If you have the RDS-CAA option (Computer Aided Accuracy), you can determine the probe data for all angular positions of an RDS in a single operation, using no more than a small number of probings. Only a few angular settings are actually qualified physically. The data for the other positions is derived using a mathematical model (calculated qualification). As a consequence, the qualification procedure is completed much more quickly and all physically possible angular positions of the RDS are subsequently available for probing the workpiece. Subsequent requalification, too, is faster. The RDS-CAA option is available for both Calypso and CMM-OS. The procedure for both programs is described in this documentation.

Included in this chapter: Basics of RDS-CAA Qualification . . . . . . . . . . . . . . . . . . . . . . . . 16-2 Qualification of the RDS on the CMM . . . . . . . . . . . . . . . . . . . . 16-4 Qualifying Probes with RDS-CAA . . . . . . . . . . . . . . . . . . . . . . . . 16-7

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16-1

Qualifying the RDS with CAA (Option)

Basics of RDS-CAA Qualification Given the stepping adjustment of 2.5 degrees, a stylus on the RDS can, in theory adopt 20,736 positions, but, depending on the device geometry, not all of these are physically possible. Without RDS-CAA each position is considered as an individual stylus, which must also be qualified. Conventional qualification has generally been restricted to qualifying a subset of the RDS positions. Calypso/CMM-OS s this procedure for the RDS with a qualification table in which each of the required positions is entered as a stylus with its own name. If you use the RDS-CAA option, however, you can determine the probe data for all possible angular positions of an RDS with just a small number of probings. Only a few angular settings are actually qualified physically: the values for the other positions are computed using a mathematical model. As a consequence, the qualification procedure is completed much more quickly and all angular positions of the RDS are subsequently available for probing the workpiece. Subsequent requalification, too, is faster. Three- or four-step procedure

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. – Fitting qualification on the CMM After the RDS is mounted on the CMM, this qualification determines and saves the position of the RDS within the device's coordinate system. – Stylus qualification in twelve positions per main stylus (this is the stylus in the direction of the quill). Finally, the required probe 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 probe has only one stylus, this completes qualification of the RDS.

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Basics of RDS-CAA Qualification

– Qualification of remaining styli on the probe (star probes) If a probe carries multiple styli (star probe), 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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Qualification of the RDS on the CMM After the RDS is mounted on the CMM, this qualification must be performed to determine its position in reference to the device's coordinate system. This is a prerequisite for qualifying the scanning probes and styli on the RDS. This qualification need only be done once for the RDS. The probes and styli used with the RDS can then each be qualified without requalifying the installed RDS every time.

Establishing the Preconditions for Qualification of the RDS on the CMM Your RDS has been qualified at the factory. In this case, the requisite correction files for the RDS are available. Reference sphere is defined

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 ➤“Determining the Reference Sphere Position” on page 4-24).

The reference probe is inserted

Fitting qualification (RDS on CMM) must be performed with the reference probe. This must be an RST, without extension, with a 40 mm long stylus. (If your reference probe does not meet this requirement, you must first make a reference probe of an RST, without extension, with a 40 mm long stylus.) Select Extras → Workroom → CMM, go to the Reference Probe tab and make sure that all the requisite parameters have been set. The procedure for installing the CMM's reference probe in the RDS is described in ➤“How to Install a Probe” on page 4-11.

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Qualification of the RDS on the CMM

How to Perform Fitting Qualification You must open a measurement plan before you start fitting qualification in Calypso. To perform fitting qualification: 1 In Calypso click on the Probe button in the prerequisites list. - or In CMM-OS select Probe → Stylus Qualification. The Probe Qualification Window dialog box appears on the screen. You will find detailed information on this dialog box in Probe Qualification Window in the Calypso Online Help. 2 If it is not already displayed, select the name of the reference probe from the Probe name selection list. The stylus name and No. (the reference probe possesses only one stylus) are shown in the Stylus name / Number picklist. Under Sphere coverage, 180° is selected. 3 From the Qualification Mode picklist, select Six Points.

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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 Probe definition. 5 After you are prompted, move the stylus in towards the reference sphere and probe the sphere with the stylus perpendicular to the point on the sphere. (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 to a high degree of precision the fitted position of the RDS, which it then saves. The results are displayed in the R, S, X, Y and Z fields. 6 Click on OK to return to the 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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Qualifying Probes with RDS-CAA

Qualifying Probes with RDS-CAA Even with the RDS-CAA option, the basic procedure for using probes remains the same: When you create a measurement plan, you must always make certain that you have installed the correct probe and that it is qualified. In qualifying a probe, you indicate which probe you are using and then initiate a routine in which the probe measures the reference sphere. (In Calypso the Probe button turns green, if this has already been performed for the displayed probe.) Only a few angular settings are actually qualified physically with RDSCAA, however: the values for all other positions are then computed and are available for measurement.

General Information about Qualification The probe must be qualified if: – If you have installed a new probe that has not been qualified. – If you want to requalify a probe that is already installed, for example after a collision or due to thermal changes. To qualify a stylus, instruct Calypso/CMM-OS to use this stylus to probe the reference sphere, mounted on the measurement table, in a special manner (which will be explained in greater detail later). With RDS-CAA, the probe data will be determined automatically for all angular positions of the RDS.

Defining Probes and Styli In Calypso/CMM-OS, each probe and stylus is given its own name. Styli are also assigned numbers. Calypso/CMM-OS uses the names and numbers to identify the probe and stylus and when saving their data. Consequently, each stylus has to be defined. You cannot qualify the angular positions of a stylus with RDS-CAA until the stylus has been defined. In most cases, a probe has only one stylus. Star probes, as the name suggests, have more than one stylus.

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How to Define a New Probe for RDS-CAA To define a new probe: 1 In Calypso click on the Probe button in the prerequisites list. - or In CMM-OS select Probe → Stylus Qualification. The Qualification dialog box appears on the screen. You will find detailed information on this dialog box in Probe Qualification Window in the Calypso Online Help. 2 Click on the Define New Probe Name button. The Create new Stylus dialog box appears on the screen.

3 Enter the names for the new probe and the first stylus. Calypso does not distinguish between uppercase and lowercase characters. 4 Tick the RDSCAA check box. 5 Click OK to close the dialog box. The name of the probe and the first stylus are displayed in the Probe name and Stylus name / Number picklists. If the probe has other styli, you now have to add them in Calypso (see ➤“How to Add Styli to a Probe” on page 16-8).

How to Add Styli to a Probe If a probe has more than one stylus, Calypso/CMM-OS must be informed of the other styli. After defining a new probe or modifying an existing probe, therefore, you must add the additional styli, if any, and qualify them.

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To add a stylus: 1 In Calypso click on the Probe button in the prerequisites list. - or In CMM-OS select Probe → Stylus Qualification. The Qualification dialog box appears on the screen. You will find detailed information on this dialog box in Probe Qualification Window in the Calypso Online Help. 2 Click on the Define New Probe Name button. The Create new Stylus window will open.

Under Stylus Number, 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 Number field select the number of the stylus. 5 Click OK to close the dialog box. The name of the stylus will now appear in the selection list Stylus name / Number. 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 Probes and Styli with RDS-CAA” on page 16-10), 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 other (star styli).

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Qualifying Probes and Styli with RDS-CAA Qualification of a probe's first stylus is not the same as qualification of the probe's other styli, if any. – The first (and possibly the only) stylus is qualified in 12 physical angular positions. NOTE hss

The direction of this stylus must match the direction of the quill. – Each additional stylus for this probe is qualified in four physical angular positions.

How to Qualify the First Stylus with RDS-CAA We assume that the probe to be qualified is mounted and that all of its styli are known to Calypso/CMM-OS. To qualify the first stylus (the main stylus, parallel to the quill) of a probe with RDS-CAA: 1 In Calypso click on the Probe button in the prerequisites list. – or – In CMM-OS select Probe → Stylus Qualification. The Probe Qualification Window dialog box appears on the screen. You will find detailed information on this dialog box in Probe Qualification Window in the Calypso Online Help.

2 Select the name of the probe from the Probe name picklist if it is not already shown.

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3 Select the name of the stylus to be qualified first from the Stylus name / Number picklist. In the Qualification mode picklist, select the Standard mode. 4 If the styli you use are very short, reduce the value for Taper accordingly. The smaller the taper, the smaller is the section of the surface of the sphere which is probed for qualification. 5 Click on the Probe definition 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 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 “Sphere coverage” is taken into as a maximum value in the selection of the positions and probing operations. The results are shown in the R, S, X, Y and Z fields (see ➤“About the Results of Stylus Qualification” on page 4-24). Under the heading Qualification results, you will now see the symbol for a successful stylus qualification and below that the identifier “RDS-CAA”.

How to Qualify Additional Styli with RDS-CAA If you want to qualify other styli for this probe (as is the case with star probes), you can do so immediately after qualifying the main stylus. Each additional stylus is measured in four RDS positions in order to achieve the best possible precision. Each of these measurements can either be performed manually or semiautomatically. Requirement: The Probe Qualification dialog box is open and the first stylus of the probe has already been qualified. To qualify the other styli of a probe with RDS-CAA: 1 Select the name of the stylus to be qualified next from the Stylus name / Number picklist.

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2 Click on the Probe definition button. This is not the main stylus, so the dialog box shown here is displayed:

3 Select one of two RDS positions under RDS Position (1 to 4). 4 If you wish to estimate which position is more suitable: Click on the Show button. The RDS rotates to the corresponding position. 5 Select the probing mode under Mode: • Standard – semiautomatic qualification: first probing is manual, all others automatic, • Manual – manual qualification. 6 Click on OK to start qualification. Calypso/CMM-OS steps you through the rest of the procedure. 7 Repeat steps 1 through 6 for each additional stylus. 8 Click on OK to confirm your entries and close the Probe Qualification dialog. NOTE hss

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 Probe Qualification dialog box from time to time during the process by clicking on OK, so as to save intermediate states. Calypso/CMM-OS returns to the Desk. The styli have been successfully qualified. In Calypso the Probe 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 probe and its styli that were qualified together with the RDS can now be used by every in every RDS position.

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Index 0-9

selecting a measuring configuration 12-25 privileges 12-6 average 6-38 average value construction 5-56 axial runout 6-40

3D best fit 4-53 3D curve 5-29

A add styli 4-15 addToFile 14-54 istrate Auto-Run 12-20 alignment 3D best fit 4-53 delete 6-14 load 6-13 save 6-13 angle 6-40 angle of tilt 6-37 angle point 5-35 angularity 6-40 area specification, recall points 5-41 arithmetic operators (reference) 14-49 arrays 14-48 ASCII files (curve) 9-29 ASCII parameter file (example) 14-46 asynchronous mode 10-2 audiovisual information 7-51 automatic measurement 5-68 automatic probe change 7-49 Auto-Run istrating 12-20 basics 12-2 branches 12-5 CNC parameters 12-17 configuring 12-6 creating branches 12-12 define list of characteristics 12-26 defining desks 12-9 defining sequence 12-19 desks 12-4 end of measurement 12-27 for s 12-23 loading interface 12-24 mapping pallet 12-12 measurement plan icon 12-3 monitoring measuring runs 12-27 pallets 12-5 placing bitmaps on icons 12-11 positioning measurement plan 12-10 preparing for measurement 12-17

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B base alignment adapting in an iterative process with abortion condition (example) 439 basics 4-31 create new 4-34 editing 4-41 loading 4-33 moving 4-43 offsetting 4-43 rotating by distances 4-45 setting 4-30 updating 4-37 baseSystem 14-57 basic concept 1-7 basics Auto-Run 12-2 characteristics 6-2 clearance planes/clearance groups 723 computed alignment 4-31 curve measurement 15-2 probe routes 7-22 probing 5-15 retract planes 7-25 Best Fit 3D best fit (alignment) 4-53 best fit as circumscribed/inscribed feature 65 as tangential feature 6-5 Gaussian 6-5 Tschebyscheff 6-5 best fit of bore pattern 6-43 bore pattern best fit 6-43

C CAD file, importing 5-6 CAD window 3-1 Calypso starting 1-3

Index

1

Calypso Desk 1-5 canceling measurement plan run 8-13 Cartesian 6-40 change probe assignment 7-50 changing point list 5-64 changing the point list 5-64 characteristic copying properties 6-33 characteristic data constant 9-36 characteristic, details angle of tilt 6-37 characteristics asg to multiple features 6-18 basics 6-2 best fit methods 6-3 calculation 6-3 color-coding 6-33 copying 7-8 defining 6-7 definition templates 6-8 deleting 7-11 grouping 7-13 moving 7-8 nominals 6-19 rechecking (example) 14-38 renaming 7-13 searching 7-14 tolerances 6-19 ungrouping 7-13 characteristics, details angle 6-40 angularity 6-40 average 6-38 axial runout 6-40 cartesian 6-40 coaxiality 6-39 concentricity 6-39 cone angle 6-37 curve form 6-39 cylinder form 6-38 diameter 6-35 diameter2 6-38 distance 6-37 distance_symmetry point 6-37 feature angle 6-37 flatness 6-38 form 6-39 half cone angle 6-37 length 6-38 length of axis 6-36 parallelism 6-39

Index

2

61212-2010102

Calypso (Rev. 3.5)

polar 2D 6-40 polarposition angle 6-36 polarposition height 6-36 polarposition radius 6-36 position 6-39 profile 6-39 projection angle one 6-36 projection angle two 6-37 radial runout 6-40 radius 6-36 radius 2 6-38 radius measurement 6-36 rotation angle 6-37 roundness 6-38 space point distance 6-37 squareness 6-39 straightness 6-38 symmetry 6-39 width 6-38 X value 6-35 Y value 6-35 Z value 6-35 characteristics, tasks, details on 6-35 characterization file 13-3 checking wall thickness 6-42 circle 5-17 clearance distance 7-31 copying to other features 5-12 clearance groups asg 7-28 defining 7-26 retract plane in 7-30 clearance plane copying to other features 5-12 clearance planes 1-8 asg 7-28 closer to workpiece 7-31 clearing after collision 8-13 clearing the CMM 8-13 CMM movement commands (PCM) 14-58 CNC run structure 14-7 starting run 8-8 CNC parameters Auto-Run 12-17 cncBreak 14-59 coaxiality 6-39 collision reaction following ~ 8-13 special aspects with RDS 8-13 color coding Prerequisites 4-6 color-coding characteristics 6-33 features 5-13

compact printout 9-3 compact protocol 9-5 comparative operators (reference) 14-49 computed alignment basics 4-31 concentricity 6-39 conditions reference 14-60, 14-61 setting 14-19 cone 5-27 cone addition (construction) 5-57 cone addition construction 5-57 cone angle 6-37 cone angle, half 6-37 configure Auto-Run 12-6 constant characteristic data 9-36 construction edge point 5-56 maximum coordinate 5-59 maximum result 5-59 minimum coordinate 5-59 minimum result 5-60 plane with offset 5-60 constructions 5-39 intersection 5-42 coordinate system copying to other features 5-12 parameterizing (example) 14-40 setting 4-30 copy characteristics 6-18, 7-8 feature 7-8 icon 12-22 measurement plans 7-3 result file 9-31 copying ISO286 6-32 copying lower tolerance 6-32 copying tolerance class 6-32 copying upper tolerance 6-32 coupling measuring ranges (duplex mode) 10-5 current selection 8-2 curve 5-29 ~ characteristic, defining 15-43 defining using function (example) 1438 loading parameters (example) 14-37 curve (3D) 5-29 curve form 6-39 curve jump tolerance 15-44 curve measurement 15-1 3D curve 15-3 basics 15-2 flat curves 15-2

61212-2010102

Calypso (Rev. 3.5)

spatial curves 15-3 curve measuring changing normal vectors 15-21 checking clearance planes 15-25 defining nominal data 15-7 defining the curve feature 15-5 deviation in actual vector direction 15-46 deviation in grid coordinates 15-47 deviation in nominal vector direction 15-46 deviation lower 15-44 deviation upper 15-44 digitizing 15-10 digitizing 3D curve in area 15-15 digitizing 3D curves 15-14 editing nominals 15-22 entering nominal data manually 1519 face curve, definition 15-3 formatting printout 15-59 import ASCII file 15-7 importing nominal data from file 158 lift curve,definition 15-3 load VDA file selectively 15-9 measuring strategy 15-33 normal vectors, changing 15-21 outliers 15-58 point list 15-34 radial deviation 15-47 range 15-44 scanning 15-38 segments 15-39 shortcut menu 15-31 using CAD model 15-31 curve measuring, results 15-46 best fit 15-50 calculating deviation 15-47 center of mass 15-50 deviation 15-47 custom header PCM commands 14-59 custom printout 9-4 automatic fields 9-8 customizing 9-7 defining printout output 9-9 global dummies 9-8 local dummies 9-8 result presentation 9-8 structure 9-7 cylinder 5-25 cylinder form 6-38

Index

3

D date 14-58 dateAndTime 14-58 default printout 9-2, 9-4 define clearance groups 7-26 desks 12-9 nominal data for curve 15-7 printout output 9-9 defining characteristics 6-1 features 5-1 probes 4-14 defining inside 5-15 defining outside 5-15 defining printout output 9-9 defining the master probe length 7-39 delete desk 12-21 icons 12-22 toolboxes 7-17 deleteFile 14-54 deleting characteristics 7-11 features 7-11 measurement plans 7-4 part alignment 4-52 desk deleting 12-21 renaming 12-21 desks adding measurement plans 12-9 diameter 6-35 diameter2 6-38 digitizing 3D curve in area 15-15 distance 6-37 distance_symmetry point 6-37 DMIS commands ed 13-2 DMIS files 9-29 DMIS import configuring 13-6 reports 13-11 run 13-8 DMIS measurement plans basics 13-2 dummies global 9-8 local 9-8 duplex mode, basics 10-1 dynalog configuring 2-3 control 2-2 display 2-2

Index

4

61212-2010102

Calypso (Rev. 3.5)

function keys 2-2 keyboard 2-2 operating 2-5 touchpad 2-2

E edit probe routes 7-22 ellipse 5-30 enter nominals 6-19 tolerances 6-19 erosion module 6-11 error report 11-8 evaluation settings copying to other features 5-12

F feature angle 6-37 feature data variable 9-37 features 1-7 3D curve 5-29 adding 7-7 angle point 5-35 circle 5-17 color-coding 5-13 cone 5-27 copying 7-8 curve 5-29 cylinder 5-25 deleting 7-11 details 5-15 ellipse 5-30 general curve 5-37 general surface 5-36 in loops 14-24 line, 2d 5-22 line, 3D 5-24 measuring individually 8-4 moving 7-8 offset plane 5-32 plane 5-20 point 5-16 radius point 5-34 recall of 5-40 rectangle 5-32 renaming 7-13 searching 7-14 slot 5-31 sphere 5-28 sphere point 5-34 symmetry point 5-33

features, defining 5-2 features,defining from CAD file 5-6 using feature recognition 5-5 using templates 5-4 field (array) using loops (example) 14-42 file commands (reference) 14-54 filter activating 6-29 fit methods 6-3 flatness 6-38 form 6-39 form plot 9-23 formula definition 14-10 formulas entering 14-17 functions and operators 14-11 functions (PCM) character chains~ (reference) 14-51 introduction 14-10 mathematical (reference) 14-49 measurement-specific 14-55

G gage correction qualification 5-18 GDT profile basics 6-40 Gear 5-60 general curve 5-37 general surface 5-36 getActual 14-55 getActualInspectionDir 14-54 getNominal 14-56 getProbe 14-56 getRecordHead 14-57 getWD 14-54 group creating 7-13 grouping ungrouping 7-13 groups forming 8-3 renaming 7-13

H Holos 5-60 homing the CMM 4-8 horizontal arm CMM in duplex mode 10-1

61212-2010102

Calypso (Rev. 3.5)

horizontal arm CMMs combining measurement plans 7-4

I icon copying 12-22 deleting 12-22 icons labeling with bitmaps 12-11 icons list 1-5 import files for curve 15-8 measurement plan from DMIS 13-1 import DXF files 15-8 import PAB files 15-8 import VDA files 15-8 importing CAD data 5-6 importing ASCII file for curve 15-7 input/output commands (reference) 1452 input/output parameters 14-29 inquire 14-53 inquireList 14-53 inquireNumber 14-52 inquireText 14-52 installation Calypso, program version 11-3 service pack 11-5 installing probes 4-11 interrupting measurement plan run 8-13 intersection 5-42 introduction 1-1

L least-material condition 6-22 length 6-38 length of axis 6-36 lift curve demarking 15-6 marking 15-6 line, 2d 5-22 line, 3D 5-24 list of characteristics defining for Auto-Run 12-26 LMC 6-22 load interface Auto-Run 12-24 loading PCM file using dialog (example) 14-40 loading VDA file selectively 15-9

Index

5

loops alignment according to RPS 14-26 features in ~ 14-24 for multiple measurements 14-27 inserting 14-22 linear offset (example) 14-41 nest level 14-26 nested 14-26 nested for field (example) 14-42

M main menu options 1-5 manual probe change 4-11 manual run starting 8-9 master measurement plan, horizontal arm CMMs 7-4 MCR20 defining holder positions 7-44 particularities 7-33 measure automatically 5-68 measurement ending, Auto-Run 12-27 running 8-2 starting 8-7 measurement plan basics 4-2 editing 7-19 import from DMIS 13-1 monitoring run 8-11 starting CNC run 8-8 starting manual run 8-9 viewing 7-52 measurement plan area 1-5 measurement plan editor features 4-80 measurement plan features search 7-14 measurement plan group forming 8-3 measurement plan run canceling 8-13 interrupting 8-13 restarting 8-14 measurement plan settings 4-78 Measurement plans open 4-4 measurement plans 1-7 combining (HAM) 7-4 copying 7-3 creating 4-3 deleting 7-4 editing 7-6 integrating information 7-51

Index

6

61212-2010102

Calypso (Rev. 3.5)

managing 7-2 mirroring 7-9 multimedia information 7-51 opening 4-4 renaming 7-2 running 8-2 saving 7-2 variable 14-4 with variant control (example) 14-44 measurement results copying result file 9-31 printing 9-6 save as ASCII file 9-29 save as DMIS 9-29 save as PROVACS I 9-29 save as PROVACS II 9-29 save as QDAS 9-29 save in merge file 9-29 save in table file 9-29 saving 9-29 measurement strategy 5-62 copying to other features 5-12 measurement, preparing Auto-Run 12-17 measuring configuration, selecting Auto-Run 12-25 measuring curves jump tolerance 15-29 measuring tolerance 15-26 measuring linear offset via loop (example) 14-41 measuring runs, monitoring Auto-Run 12-27 merge file 9-29 message 14-53 MMC 6-22 monitoring measurement plan run 8-11 most-material condition 6-22 mouse with 2 or 3 buttons 14-64 movement commands (PCM) 14-58 multimedia in measurement plans 7-51 multiple measurements with loops 14-27

N nest level in loops 14-26 net point 5-17 nominal 6-32 nominals defining 6-19 normal vectors, checking 15-24 notational conventions 5

O offset plane 5-32 open measurement plan 4-4 opening Measurement Plan 4-4 output commands (reference) 14-52 output parameters 14-29

P P6 alignment 4-54 pallet mapping 12-12 parallelism 6-39 parameters ASCII file (example) 14-46 definition 14-9 functions and operators 14-11 input and output parameters 14-29 loading 14-17 loading values into curve (example) 14-37 saving 14-16 part alignment 1-8 basics 4-31 create new 4-34 deleting 4-52 loading 4-33 rotate distance 4-49 rotating 4-44 rotating by distances 4-45 setting 4-30 part alignment systems, basics 4-31 parts data 9-35 parts family, measuring (example) 14-44 path generation circle 5-71 cone 5-71 cylinder 5-71 lines 5-76 measuring range 5-73 planes 5-73, 5-75 PCM debugging and testing 14-63 programming 14-12 syntax (reference) 14-47 testing printout 14-32 variables (reference) 14-48 plane 5-20 plane point 5-16 point 5-16 point generator 14-30

61212-2010102

Calypso (Rev. 3.5)

polar 2D 6-40 polar 3D 6-40 polarposition angle 6-36 polarposition height 6-36 polarposition radius 6-36 position 6-39 positionCMM 14-58 prerequisites color coding 4-6 rotary table 4-58 prerequisites, list of 4-5 presentationOff 14-59 presentationOn 14-59 print 14-53 results of measurement 9-6 printout header data entering 8-5 global 8-5 local 8-6 printout header fields defining your own 9-17 printout/protocol text output 6-12 probe adding styli 4-15 copying to other features 5-12 probe changer adding holders 7-40 asg probes 7-48 automatic probe change 7-49 changing probe assignments 7-50 defining holder positions 7-43 for RDS 7-36 particularities, MCR20 7-33 particularities, SCR200 7-34 setting approach parameters 7-41 setting up 7-38 probe routes basics 7-22 editing 7-22 probes defining 4-14 preparing 4-13 qualifying for RDS with RDS-CAA 161 profile 6-39 projection angle one 6-36 projection angle two 6-37 projection plane copying to other features 5-12 PROVACS 9-32 PROVACS I files 9-29 PROVACS II files 9-29

Index

7

Q

measurement 8-2 measurement plan 8-2 running a measurement plan 8-2 header data for printout 8-5

QDAS description file 9-32 QDAS files 9-29 QDAS format 9-32 QDAS values file 9-33 QDASCONV.CON 9-34 QDASCONV.EXE 9-32 qs-STAT 9-32

S

R radial runout 6-40 radius 6-36 radius 2 6-38 radius measurement 6-36 radius point 5-34 RDS after collision 8-13 creating stylus list 4-16 defining geometry 7-36 loading a stylus list 4-20 qualifying with CAA 16-1 recall 5-40 recall points with area specification 5-41 rectangle 5-32 reference sphere determining 4-24 rename characteristics 7-13 desk 12-21 features 7-13 groups 7-13 renaming measurement plans 7-2 stylus 4-16 restart measurement plan run 8-14 result presentation 9-8 results printing 9-6 retract distance copying to other features 5-12 retract plane 7-30 rotary table definition 4-58 rotate distance 4-49 rotation angle 6-37 rotation in plane 4-31 rotation in space 4-31 roundness 6-38 routes checking 7-25 RPS alignment 4-53 with loop 14-26 run individual features 8-4

Index

8

61212-2010102

Calypso (Rev. 3.5)

save measurement plans 7-2 measurement results 9-29 parameters 14-16 scanning 5-68 curve 15-38 general settings 5-70 scope of measurement forming group 8-3 individual features 8-4 SCR200 defining holder positions 7-46 particularities 7-34 searchDistance 14-58 searching characteristics 7-14 features 7-14 selecting coupling method (duplex operation) 10-5 self-centering probing 5-66 service pack decompress 11-5 installing 11-5 set up probe changer 7-38 setRecordHead 14-57 settings editor 7-19 shape of zone 6-41 shortcut menus 7-6 slot 5-31 space point 5-17 space point distance 6-37 special feature GEAR 5-60 HOLOS 5-60 sphere 5-28 sphere point 5-34 squareness 6-39 start manual run 8-9 start alignment basics 4-32 create new 4-34 loading 4-33 start measurement manual run 8-9 starting Calypso 1-3 CNC run 8-8

starting a measurement plan 8-7 statistics program 9-32 stop light window canceling a measurement plan run 813 interrupting a measurement plan run 8-13 stopping measurement plan run 8-13 straightness 6-38 styli preparing 4-13 stylus adding 4-15 copying to other features 5-12 creating list for RDS 4-16 renaming 4-16 symbols 6 symmetry 6-39 symmetry point 5-33 synchronous mode 10-2 system requirements 11-2 systemCall 14-59 systemCallWithWait 14-59

T temperature compensation configuring 4-88 general 4-81 textelement 6-12 three-button mouse 14-64 TOL/PROFS 6-40 tolerances defining custom 6-24 entering 6-19 file with custom 6-25 LMC 6-22 MMC 6-22 toolboxes 7-15 creating 7-16 deleting 7-17 moving 7-17 sizing 7-17 true position best fit of bore pattern 6-43

61212-2010102

Calypso (Rev. 3.5)

two-button mouse 14-64 types of bracket in loops 14-26

U desk CAD symbols 1-6 CAD window 1-6 icons list 1-5 measurement plan area 1-5 menu bar 1-5 information integrating 7-51 privileges Auto-Run 12-6 using distance check 6-42 utilities erosion module 6-11 stylus qualification 6-10 textelement 6-12

V variable feature data 9-37 variables definition 14-9 reference 14-48 variant control (example) 14-44

W width 6-38 window CAD window 3-1 with alternative (example) 14-34

X X value 6-35

Y Y value 6-35

Z Z value 6-35

Index

9

Index

10

61212-2010102

Calypso (Rev. 3.5)

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