HEIDENHAIN IK 5494-2D User Manual

Operating Instructions

IK 5000 QUADRA-CHEK

(QC 5000)

Video Edge Detection Systems

English (en) 2/2010

QC5200 Series

User’s Guide

Video Edge Detection Systems

QC5200, QC5210, QC5230 and QC5240

QC5200 Series User’s Guide

Video edge detection systems: QC5200, QC5210, QC5230, and QC5240

Printed in the United States of America

All information set forth in this document, all rights to such information, any and all inventions disclosed herein and any patents that might be granted by employing the materials, methods, techniques or apparatus described herein are the exclusive property of Metronics Inc., Bedford, New Hampshire

Terms, conditions and features referenced in this document are subject to change without notice

No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of Metronics, Inc.. Requests to Metronics, Inc. for permission should be addressed to the Technical Services Department, Metronics, Inc., 30 Harvey Road, Bedford, New Hampshire 03110. The Technical Services Department can be reached by phone at (603)-622.0212

Limit of liability and disclaimer of warranty

While Metronics, Inc. exercised great care in the preparation of this book, Metronics makes no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaims any implied warranties of merchantability or fitness for a particular purpose. The advice, methods and instructions contained in this book might not be suitable for your situation. When in doubt regarding suitability, you are encouraged to consult with a professional where appropriate. Metronics shall not be liable for any loss of profit or any damages, including but not limited to special, incidental, consequential or other damages

Trademarks

Metronics is a registered trademark of Metronics, Inc. and its subsidiaries in the United States and other countries and may not be used without written permission. Other trademarks are the property of their respective owners

Metronics part number:	11A10558
Publishing date:	June, 2005

Introduction

This User Guide describes the operation of the video edge series of QC5200 metrology products. This series of QC5200 instruments conducts a wide variety of precise 2-D measurements using a wide assortment of video edge detection probes. The QC5200 software supports manual part positioning and feature measurement under user control, and CNC part positioning and automated measurement under program control. While it is likely that this Guide includes some material that doesn’t apply to your specific QC5200 system, information pertaining to your system will be easy to find using the Table of Contents and Index

Who should read this Guide?

This Guide is necessary for the efficient operation of the QC5200 system. Operators and supervisors will find the contents invaluable in conducting measurements, programming automatic functions and reporting results. User setup functions are also described that will help users and supervisors customize the QC5200 measurement tools, user interface screens and report formats

Prerequisites

Operators and supervisors are assumed to have a good basic understanding of dimensional metrology theory and practice, and a good understanding of Microsoft Windows use and conventions

Conventions used throughout this Guide

The conventions used to call attention to notes, cautions and warnings, and the shorthand used to show menu navigation paths are described below

Notes, warnings and cautions

This guide uses the following icons to highlight note, warning and caution information

NOTE

The note icon indicates additional or supplementary information about an activity or concept. Notes are shown in bold type.

ii

QC5200 Series User’s Guide

CAUTION

The exclamation point icon indicates a situation or condition that can lead to equipment malfunction or damage. Do not proceed until the caution message is read and thoroughly understood. Caution messages are shown in bold type.

WARNING

The raised hand icon warns of a situation or condition that can lead to serious equipment damage, personal injury or death. Do not proceed until the warning is read and thoroughly understood. Warning messages are shown in bold type.

Menu path navigation

Throughout the Guide, many references are made to screens that must be displayed by clicking the mouse cursor on a series of menu items and screen tabs. This kind of navigation path is demonstrated in this example of displaying the Tools/Customize/Colors screen, shown in text as: Tools/Customize/Colors

Clicking the Tools menu item...

then clicking the Customize menu item...

then clicking the Colors tab... displays the Tools/Customize/Colors screen

Introduction

On-screen menu commands

iii

Many commands are displayed by right-clicking the mouse cursor in a window, and then on one or a series of menu items. This kind of command path is demonstrated in this example of using the Part View window/Print Part View command to print the part view. The command is shown in text as: Part View window/Print Part View

Right-clicking the Part View window, then clicking Print Part View prints the current part view

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QC5200 Series User’s Guide

Guide organization

This Guide contains eleven chapters and three reference appendices. An overview of the contents is provided below. Experienced users are encouraged to familiarize themselves with the first six chapters before beginning to use the QC5200. Users that are new to the QC5200 and similar Metronics products should read the first six chapters carefully and then follow the tutorial in Chapter 3: Quick Start Demonstartion before beginning

Table of contents

Chapter 1: System overview

Brief introduction to the QC5200 series features and benefits

Chapter 2: User interfac

Comprehensive description of the user interface covering screens, menus, toolbars the statusbar and work-

Chapter 3: Quick Start Demonstration

Brief demonstration of using the basic functions of the QC5200 including

•Organizing the workspace

•Selecting and teaching the probe

•Recording measurement activities as a program

•Measuring & constructing datums

•Measuring features

•Applying tolerances

•Exporting data

•Reporting

•Saving the part and program

Chapter 4: Probes

Instructions for calibrating and using video edge detection measurement probes

Chapter 5: Measuring

Instructions for constructing datums and measuring, constructing and creating features.

Chapter 6: Tolerancing

Instructions for applying tolerances to measurements

Chapter 7: Reporting and templates

Instructions for organizing, formatting, exporting and printing measurement results

Chapter 8: Programming

Descriptions of programming functions and instructions for creating, editing, and debugging programs

Introduction

Chapter 9: Encoder Setup

v

Instructions for calibrating and configuring axis encoders

Chapter 10: Supervisor Setup

Descriptions of setup tools and screens used to configure and customize measurement, programming and display parameters

Chapter 11: Problem solving

Basic troubleshooting guide in the form of a simple table of symptoms, probable causes and recommended

solutions

Appendix A: File Formats

Appendix B: ASCII Codes

Appendix C: Tolerances

Index

vi	QC5200 Series User’s Guide

Safety first!

The QC5200 is inherently safe, and in proper use few if any potential safety hazards exist. However, many systems include motorized CNC stages that, as is the case with all motorized equipment, must be treated with caution to avoid collision and pinch injuries. Also, an entire system often consists of electrical equipment connected by many cables, which must be treated with care to avoid shock and tripping injuries

ARNINGS - AXIS MOTION lways stay clear of axis motion paths.

isconnect axis motor power when motor activities are not required.

Be prepared to depress the emergency off mushroom switch or other similar device quickly in the event of an emergency when motor axes are active.

ARNINGS - ELECTRICAL

isconnect the system components from electrical sources before cleaning or

ervicing.

o not allow any power cord or signal cable to be located such that it can be walked on or create a tripping hazard.

The system components are equipped with 3-wire power plugs that include a separate ground connection, or are grounded through a separate wire. Always connect the power plug to a 3-wire grounded outlet. The use of 2-wire power plug adapters or any other connection accessories that remove the third grounded connection create a safety hazard and should not be permitted. If a 3-wire grounded outlet is not available, ask your electrician to provide one. Never disconnect any separate ground wire.

Do not open the QC5200 enclosure. There are no user-serviceable components or assemblies inside.

General safety precautions

General safety precautions must be followed when configuring, maintaining or operating the system. Failure to observe these precautions could result in damage to the equipment, or injury to personnel.

It is understood that safety rules within individual companies vary. If a conflict exists between the material contained in this guide and the rules of a company using this system, the more stringent rules should take precedence

Additional safety information is included throughout the remainder of this guide

Introduction

vii

General Maintenance

Disconnect the QC5200 from the power source and seek the assistance of a qualified service technician if

•The power cord is frayed or damaged or the power plug is damaged

•Liquid is spilled or splashed onto the enclosure

•The QC5200 has been dropped or the exterior enclosure has been damaged

•The QC5200 exhibits degraded performance or indicates a need for service some other way

Cleaning

Use only a cloth dampened with water and a mild detergent for cleaning the exterior surfaces and display screens. Never use abrasive cleaners, and never use strong detergents or solvents. Only dampen the cloth, do not use a cleaning cloth that is dripping wet

Display Resolution and Units of Measure

Display resolutions in this guide are examples. User display resolutions are likely to vary according to the specific application. Metric units of measure are used in examples

Accuracy & Precision

Measurement accuracy is determined by many factors, such as the resolution of the encoders connected to axis inputs. Generally, the display resolution of the QC5200 can exceed encoder resolutions. Setting the display resolution to exceed the encoder resolution does not increase measurement accuracy

Getting Help

Help is available in this printed Guide, in the electronic version of this Guide accessed from the Help menu of the QC5200 software, from your Metronics distributor or system provider and directly from Metronics.

The information contained in this guide should be adequate to customize the measurement, display and programming aspects of system, and to perform the minimal setup and troubleshooting required beyond the services provided by your Metronics distributor or system provider. However, in the event that your Metronics distributor or system provider cannot provide the assistance you need, our support staff is committed to insuring your positive experience with the QC5200 series of products. To receive technical support

Routine issues

e-mailour support staff at: [e-mail]

viii

QC5200 Series User’s Guide

Urgent issues

Telephone your Metronics distributor, or telephone our support staff at: [phone]

OTE

it becomes necessary to contact us directly, be prepared to supply the following

formation

The QC5200 series serial number

(5-Digit number printed on back label)

• A description of the equipment attached to the QC5200 computer, including the manufacturer and model number

• The QC5200 software version number, found on the Help/About QC5000

Updating your QC5200 software

The most recent version of the QC5200 software can be downloaded from the Product Support section of our web site at

http://www.metronics.com

Please carefully read all the instructions and cautions published on our site regarding your software update before attempting to perform the update

Additional publications for the QC5200

Additional application or instructional information is sometimes available for download from the Product Support section of our web site at

http://www.metronics.com

Contents 1

Contents

Chapter	System Overview
	Overview of system features
Chapter 2	User Interface
	Introduction	7
	Windows	8
	DRO	8
	Templates	8
	Results	8
	Part View	8
	Live Video	8
	Menus	9
	Toolbars	9
	Statusbar	0
	Windows
	DRO window	2
	Part View window
	Selecting features	2
	Adding feature data	3
	Live Video window	5
	Results window	7
	Template Windows	8
	Stacking and separating templates	8
	Adding and deleting template content	9
	Features template	20
	Program template	20
	Report template	20
	Tolerance templates	2
	Menus	22
	Menubar menus	22
	File menu	23
	Edit menu	25
	View menu	29
	Measure menu	35
	Datum menu	35
	Probe menu	35

Contents 2

QC5200 Series User’s Guide

		Tools menu	36
		Windows menu	39
	On-screen		4
		Template window menus	4
		Template edit menus	4
		Program edit menus	44
		Results window menus	46
		Part View window menus	50
	Toolbars	Toolbar menus	53
			55
	Changing toolbar shape		56
	Docking and undocking toolbars		56
	Customizing and creating toolbars		57
	Statusbar		58
	Workspaces		59
	Creating custom workspaces		59
	Saving custom workspaces		60
	Opening custom workspaces		60
Chapter 3	Quick Start Demonstration
	Demonstration steps		64
	Organizing the workspace		65
	Selecting templates		65
	Teaching the video probe		66
	Turning	recording ON	66
	Measuring part skew and datum		67
		Skew	67
		Datum	67
	Measuring features		69
	Applying feature tolerances		70
	Adding data to the Runs template		7
	Exporting data		72
	Printing reports		73
	Turning program recording OFF		73
	Saving the part		74
	Running the program		74
Chapter 4	Probes

Preparing to use video probes	77
System and part condition	77
Selecting video magnification	77

QC5200 Series User’s Guide		Contents 3
Adjusting light control			77
Associating lighting with magnifications			77
Enabling and disabling light associations			78
Using video probes			78
Selecting a probe type			79
Changing probe position			79
Changing probe orientation			79
Changing probe size			80
Changing	direction		80
Changing edge detection order			8
Enabling and disabling high accuracy scanning			82
Firing video probes			83
Dry firing probes			83
Continuous probe firing			83
Loading a video chart			84
Video probe descriptions			85
Crosshair probe			86
Simple probe			87
Buffer Probe			89
Average probe			9
Nearest probe			93
Farthest probe			94
Height probe			95
Width Probe			97
Circle Probe			98
Circles			98
Arcs			99
Blob Probe			10
Worm probe			102
New probe			10	5
Pattern Finder probe			108
Initial setup of the video probe system			116
Adding magnifications with associated			116
Adding magnifications to the Probe toolbar			117
Adding the highest magnification to the probe library			118
Adding other magnifications and associating Zoom positions			119
Deleting magnifications			120
Configuring the highest magnification			12
Configuring the lower magnifications			12
Calibrating auto focus			122
Calibrating video edge recognition (Teach)			124
Advanced Edge Teach			126

Contents 4

QC5200 Series User’s Guide

Calibrating pixel resolution		127
Calibrating offset		129
Compensating for	skew	132
Configuring video probe data collection parameters		135

Chapter 5	Measuring
	Measurement activities	138
	The measurement workspace	138
	The measurement process	138
	Preparing to use video probes	139
	Establishing the measurement reference	139
	Leveling the part (optional)	139
	Creating a skew alignment	140
	Creating a datum zero point	14
	Probing a datum zero point	14
	Constructing a datum zero point	42
	Probing and measuring features	144
	Measure Magic	144
	Probing features	144
	Probing specific feature types	146
	Points	146
	Lines	147
	Arcs	148
	Circles	149
	Slots	15
	Distances	152
	Angles	153
	Blobs	155
	Profile measurements	156
	Constructing features	172
	Point constructions	173
	Line constructions	178
	Distance constructions	185
	Circle constructions	19
	Arc constructions	194
	Creating features	196
	Creating a point	197
	Creating a line	197
	Creating a distance	198
	Creating a circle	198
	Creating an arc	199

QC5200 Series User’s Guide

Chapter 6 Tolerancing

Contents 5

	Applying tolerances to features	203
	Tolerance screens	203
	Tolerance menu	204
	Tolerance toolbar	204
	Display of tolerance results	205
	Naming and saving tolerances	206
	Deleting Named Tolerances	206
	Tolerance types	207
	Bidirectional	207
	True position	208
	MMC/LMC (Material condition)	209
	Runout	210
	Circularity	21
	Straightness	21
	Concentricity	21
	Profile	212
	Parallelism	213
	Perpendicularity	213
	Angularity	213
	Angle	214
	Width	214
Chapter 7	Reporting and Templates
	Template descriptions	217
	Features template	217
	Program template	21 8
	Runs template	219
	Runs charts	220
	Report template	222
	Tolerance templates	223
	Opening templates	224
	Generating new default templates	224
	Editing templates	225
	Adding and deleting data	225
	Adding data	225
	Adding multiple data fields as a single new column	226
	Adding multiple data fields as multiple new columns	227
	Appending data fields to an existing column	228
	Deleting data	229
	Deleting	229

Contents 6

QC5200 Series User’s Guide

Deleting columns	230
Sorting data within a column	230
Aligning column titles and data	23
Changing the order of columns	23
Displaying horizontal and vertical grid line	23
Headers and footers	232
Showing headers and footers	232
Editing headers and footers	233
Adding text	233
Editing text	233
Formatting text	234
Including automatic text entry	235
Prompting the user for alphanumeric information	235
Deleting text	236
Enabling text to speech output	236
Adding graphics from files	236
Drawing graphics	238
Printing reports	24
Exporting data	242
DDE Output	243
Output parameters	243
Connection	243
Data	244
General guidelines	244

Chapter 8	Programming
	Introduction		249
	Creating Programs		250
	Creating the new part		25
	Starting	recording	25
	Performing a skew and datum		25
	Choosing a measurement programming method		25
	Adding tolerances		254
	Reporting results		254
	Optimizing program steps		254
	Adding special steps to a program		255
	Finalizing feature properties		257
	Finalizing program properties		258
	Stopping	recording	26
	Saving the part		26

QC5200 Series User’s Guide		Contents 7
Editing Programs		262
Part fixturing		262
Program runtime environment		262
Palletizing multiple parts		262
Editing initial program settings		265
Probe position indicator		266
Template state		266
Light controls		267
Optical magnification		267
Probe selection		267
High accuracy mode		268
Focus lock		268
Units of measure		268
Editing feature properties		269
Hiding features		269
Displaying phantom features		269
Displaying guide features		269
Showing a note with a feature		270
Showing the feature name		270
Editing feature point filtration		270
Specifying a filtration error limit		27
Specifying a filtration standard deviation range		27
Adding special and CNC program steps		272
Comment		272
Delay		273
Play sound		273
Program image		274
User message		274
Enabling or disabling run time graphic displays		275
Enabling or disabling full CNC mode		275
Enabling or disabling power assist mode		276
Enabling or disabling focus lock		276
Setting output lines		277
Selecting	steps	278
Selecting individual steps		278
Selecting groups of steps		278
Clearing step selections		28
Editing individual steps		282
Changing the target position for probing		282
Changing parents of construction features		283
Requiring user interaction to complete a measurement		284
Optimizing program steps		285

Contents 8

QC5200 Series User’s Guide

	Cutting, copying, pasting and deleting program steps		285
	Cutting steps		285
	Copying steps		285
	Pasting steps		285
	Deleting steps		285
	Inserting new program steps		286
	Debugging programs		287
Chapter 9	Encoders
	TTL encoders		289
	Analog encoders		290
	Joystick setup and limiting maximum axis velocity		290
	Axis velocity		29
	Curvature joystick parameter		29
	Axis displacement		29
	Counter setup		292
	Limit Switch setup		292
	Calibrating analog encoders		293
	QC5200 encoder setup		296
	Specifying encoder resolution		296
	Specifying encoder unit of measure		296
	Specifying encoder count direction		296
	Specifying encoder reference marks		296
	Specifying	eference offsets	297
Chapter 10	Supervisor Setup
	Tools/Customize menu item screens		299
	Including a startup message		300
	Customizing colors		30
	Specifying	help tips	305
	Specifying		306
	Specifying status bar information		308
	Customizing toolbars		309
	Tools/Options menu item screens		3 14
	Setting up programming parameters		314
	Specifying the maximum program executions		317
	Restricting access to setup screens		318
	Configuring measurement parameters		320
	Displaying parts and probe position		322
	Configuring joystick and footswitch buttons		327
	Setting the display of resolution, time and date		330

QC5200 Series User’s Guide	Contents 9
Specifying encoder parameters		33
Specifying file names, locations and backups		332
Setting serial port, machine zero and general parameters		337
Setting up the video probes		340
Tools/CNC menu item screens		350
Setting up the joystick		350
Chapter 11 Problem Solving
QC5200 settings or appearance have changed. Everything looked		355
okay the last time you were on the system, now it’s different
A QC5200 Window is missing from the screen, but is enabled		355
in the QC5200 Windows menu
Measurements are inaccurate or inconsistent		355
An axis counts in the wrong direction		356
Cannot drag data fields from the Results window into a template		357
Changes to the QC5200 settings, window positions, etc. are not saved		357
The QC5200 program doesn’t launch, but other Windows programs do		358
Cannot print from the QC5200 program		359
A default template contains unwanted data or formatting		360
Cannot make changes to the QC5200 settings		36
The system seems slow		362
Cannot see image in the live video window		363
The auto focus does not work properly		364
The measurements finish before I’m ready		365
Cannot find captured images		365

Appendix A Import File Formats

Appendix B ASCII Codes

Appendix C Tolerances

Concentricity toleranc

Reference Feature

Reference feature called for in MMC or LMC circle toleranc

Projected zon

Index

Contents 10

QC5200 Series User’s Guide

Chapter 1:

System Overview

The Metronics QC5200 series of metrology instruments is a family of Windows PC-based products for conducting precision dimensional measurements on 2-D parts. Systems can be supplied with video systems and measuring microscopes. Systems support manual part positioning and feature measurement under user control, or CNC part positioning and automated measurement under program control.

All QC5200 systems consist of a Windows-based user interface and a dedicated Metronics axis PC card. All axis cards include input circuitry for reading the axis position. Axis cards in systems capable of CNC axis motion control also include circuitry for driving CNC stepper motor or CNC servo motor amplifiers

All systems measure 2-D part features in the X–Y plane. Additionally, systems can include a Z-axis input for height measurements and part leveling and a Q-axis for rotational measurements

Overview System 1

Basic QC5200 for video systems or microscopes with joystick part positioning

2	QC5200 Series User’s Guide

Part features can be measured, constructed from measured features, created from user data, copied from existing features or imported from .dxf, .igs and other files

Measured feature

Constructed feature

Created feature

Created feature

Constructed feature

Measured feature

Geometric tolerances include location, form, orientation, runout and size. In addition, tolerances can be applied to groups of selected features.

Tolerances are context sensitive. For example, straightness is provided for lines and circularity is provided for circles. Tolerances can be displayed for evaluation and the tolerance criteria can be edited with a few clicks of the mouse, as shown in this example of a form tolerance

Example of a report of feature data

Example of a program recorded automatically as measurements were performed

System Overview

Programs can be created in manual systems to semi-automate repetitive tasks and simplify operator interactions, or in systems that include CNC control to automate measurements eliminating measurement errors and increasing throughput. Programs can be recorded automatically as a series of measurements are performed, can be created to include conditional branching and messages, can be edited in static or single-step modes and can be created from imported CAD files. The task of

programming is simplified by programming wizards and a comprehensive program debugging environment

Reports can be custom-formatted in a wide variety of formats to satisfy the requirements of different audiences by simply dragging and dropping data selections into templates. Templates can easily be customized. Completed reports can be archived, printed, ex- portedorsavedfore-mailing. Exported data can be sent to CAD applications, Microsoft Excel and Microsoft Access for processing

The user interface conforms to standard Windows conventions and can be quickly mastered by experienced Windows users. Task-specific menus, icons and toolbars further simplify in-

teractions with QC5200 features and measurement functions. Many aspects of the user interface can be customized to suit the needs of each user. Customized arrangements of windows and toolbars can be saved as unique workspaces to facilitate the most efficient use of the system by different users

This User’s Guide can be accessed and displayed from the Help menu, and includes links from all page references in the Table of Contents and Index to Guide content

3

System 1 Overview

4	QC5200 Series User’s Guide

Chapter 2:

User Interface

The QC5200 user interface is a workspace consisting of windows, toolbars and a statusbar. The overall appearance of the user interface can vary greatly and can be customized to satisfy the requirements and personal preferences of the user. The following pages contain a detailed description of the QC5200 user interface. Here’s what you’ll find in this chapter

Introduction	7
Windows	8
Menus	9
Toolbars	9
Statusbar	0
Windows
DRO window	2
Part View window
Live Video window	5
Results window	7
Template Windows	8
Stacking and separating templates	8
Adding and deleting template content	9
Features template	20
Program template	20
Report template	20
Tolerance templates	2
Menus	22
Menubar menus	22
File menu	23
Edit menu	25
View menu	29
Measure menu	35
Datum menu	35
Probe menu	35
Tools menu	36
Windows menu	39

5

Interface User 2

6	QC5200 Series User’s Guide
	On-screen	4
	Template window menus	4
	Template edit menus	4
	Program edit menus	44
	Results window menus	46
	Part View window menus	50
	Live Video window menus	5
	Toolbar menus	53
	Toolbars	55
	Changing toolbar shape	56
	Docking and undocking toolbars	56
	Customizing and creating toolbars	57
	Workspaces	59
	Creating custom workspaces	59
	Saving custom workspaces	60
	Opening custom workspaces	60
	Launching the QC5200 program into a specific workspace	6

Introduction

Introduction

The QC5200 user interface is a workspace consisting of windows, menus, toolbars and a statusbar. The overall appearance of the user interface can vary greatly and can be customized to satisfy the requirements and personal preferences of the user. However, the individual elements of every workspace are consistent in purpose and function, and do not significantly change. Workspace elements include

•The DRO, Template, Results, Part View and Live Video windows

•Menu bar and on-screen menus

•Toolbars

• Statusbar	Menubar menus	On-screen menu

DRO window

Results window

		Toolbar docked
Template window		to the
		Part View window

Statusbar

Part View window

The overall appearance of the user interface, or workspace, can be customized to vary greatly as shown here, but individual workspace elements remain essentially unchanged

7

Interface User 2

8	QC5200 Series User’s Guide

Windows

Four window types are used to present numeric, text and graphic information:

• DRO • Templates • Results • Part View • Live Video

DRO

The Digital Readout (DRO) presents numeric position information for each axis

Templates

Template windows present tabular data describing features, programs, runs database contents and tolerance measurements. The template windows shown here are stacked. However, each window can be presented alone

Results

The Results window contains measurement data related to a feature selected in a template or in the Part View window

Part View

The Part View window contains a graphic display of the measurement reference frame and measured features

Live Video

The Part View window contains a real-time display of the video camera image including the part view at the active magnification with the active video probe superimposed over the part image