L&W QMSOFT retrofit ki User Manual

QMSOFT®

Retrofit kit for

fully automated testing with

dial indicator test devices

© 2016-2017

L&W GmbH

Trademarks used in this document:

Microsoft Windows registered trademark of Microsoft Corporation, Redmond

QMSOFT® registered trademark of L&W GmbH

CodeMeter® registered trademark of WIBU-SYSTEMS AG

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1 Index

1 INDEX 3

2 SCOPE OF DELIVERY 4

3 TRANSPORT INSTRUCTIONS 5

4 SAFETY INSTRUCTIONS 6

5 GENERAL INFORMATION 7

6 ASSEMBLY AND SET-UP 8

6.1 ASSEMBLY OF THE BASE UNIT 8

6.2 ASSEMBLY OF THE DIAL INDICATOR TEST DEVICE 9

6.3 SET-UP OF THE DIAL INDICATOR TEST DEVICE 13

6.4 SET-UP OF THE LIGHTING UNIT 13

6.5 SET-UP OF THE CAMERA 14

6.6 QMSOFT® CONFIGURATION 16

6.6.1 CREATE THE TEST DEVICE IN THE QMSOFT®/QM-DEVICESERVER 16

6.6.2 CONFIGURATION OF THE TEST DEVICE IN THE QMSOFT®/QM-DEVICESERVER 17

6.6.3 CONFIGURATION OF THE INSPECTION PROGRAM QMSOFT®/QM-DIAL 19

7 IMAGE PROCESSING IN QMSOFT®/QM-DIAL 21

7.1 USER INTERFACE OF THE QMSOFT® CAMERA FUNCTIONS 21

7.1.1 MOTION CONTROL OF THE DIAL INDICATOR TEST DEVICE 22

7.1.2 SETTINGS FOR THE CAMERA IMAGE 22

7.2 INSPECTION PROCEDURE 23

7.2.1 OPTICAL SETTINGS 23

7.2.2 POSITIONING OF THE TESTED DIAL GAUGE 23

7.2.2.1 Analogue dial gauges 23

7.2.2.2 Digital dial gauges 23

7.2.2.3 Fully automated inspection 24

8 MAINTENANCE 25

9 TROUBLESHOOTING 26

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2 Scope of delivery

The QMSOFT® Retrofit kit for fully automated testing with motorized dial indicator test devices
(hereinafter referred to as „retrofit kit“) consists of the following components:

 1 base unit with adjustable support for height/distance adjustment of the camera and the lighting

unit

 1 pre-assembled USB camera with lens, extension ring and suitable USB-3 cable (cable included),

 1 pre-assembled lighting unit complete with plug-in power supply,

 1 QMSOFT® installation set consisting of: booklet, DVD and CodeMeter® license stick (or

electronic license extension). The CmStick contains a single license for QMSOFT®/QM-DIAL
image processing or, in case of an already existing „QMSOFT®/QM-DIAL“-license, the license

extension QMSOFT®/QM-DIAL bv (extension for image processing).

When the retrofit kit is delivered together with other QMSOFT®-software components, the QMSOFT®
installation set (DVD and CmStick) might be delivered in a separate package.

NOTE:
When you open the package, please check that the delivery is complete! Contact your supplier in case of
deviations from the scope of delivery!

Should your supplier not be available, please contact directly:

L&W Gesellschaft für Fertigungsmesstechnik und Qualitätssicherung mbH
Gostritzer Str. 67a
01217 Dresden
Germany

Tel: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.lw-gmbh.com

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3 Transport instructions

The QMSOFT® retrofit kit is delivered pre-assembled in a robust transport packaging (special carton box
with foam inserts and handles):

Fig. 1: transport box with handles

The box is intended exclusively for the transport and/or storage of the retrofit kit. It is expressly NOT
designed to hold the retrofit kit together with a mounted dial indicator test device! The transport box has
the following dimensions (slight deviations due to technical development are possible):

Length: 57,8 cm
Width: 39,5 cm
Height: 62,5 cm

The entire delivery unit has a weight of approx. 16 kg.

NOTE:
At delivery, please check the transport packaging for any shipping damage which might have damaged
the delivered goods. Should this be the case, please document any such damages in a suitable manner
(photo) and only open the package after having contacted your supplier!

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4 Safety instructions

The QMSOFT® retrofit kit is in compliance with the relevant safety provisions and has been assembled
and packed with care. Nevertheless, please observe the following safety instructions:

 Before connecting and starting the retrofit kit, please read all the enclosed documents carefully.

 Keep this manual close to the point of use of the retrofit kit, in order to have it handy in case of

need.

 The retrofit kit must only be used in accordance with its intended use for the measuring tasks

described in this manual. Any different or further use is considered to be improper use. L&W
GmbH shall not be liable for any damage resulting from improper use. The proper and intended
use also includes the observation of all the safety instructions of this manual.

 Before connecting the power supply of the lighting unit, please check if the supply voltage

indicated on the type plate of the plug-in power supply corresponds with the local voltage.
Should they not correspond, do not connect the power supply!

 Always disconnect the power supply of the lighting unit before starting any maintenance works on

the lighting unit.

 Assembly works on the retrofit kit must only be carried out by trained service personnel.

Unauthorized interventions or modifications of the retrofit kit result in exclusion of warranty and
exclusion of liability of L&W GmbH.

 The retrofit kit is not protected against the penetration of liquids. Please avoid any contact of the

kit – in particular of the camera and the lighting unit - with liquids!

 All the connections and power supply cables must be checked to be in proper operating condition

(visual inspection) prior to their use. In case of damages, the cables have to be changed
immediately by trained personnel.

Should you have any further questions, please contact your supplier or L&W GmbH.

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5 General information

The visual reading of the pointer position of dial indicators, dial comparators and dial test indicators can
be a strenuous and monotonous task for the operator of the test device, leading to fatigue and therefore
also to subjective errors in positioning the pointer or the numeric display of the dial gauges to be tested.
Thanks to the application of modern camera technology, this testing process can be optimized so as to
avoid subjective influences and tedious operating steps.

The calibration of dial indicators, dial test indicators and dial comparators with QMSOFT® and image
processing differs from the conventional calibration method only by the technology used for reading the
display of the test objects, while still respecting the basic metrologic principle to calibrate testing
equipment according to the way it is used.

The QMSOFT® retrofit kit enables you to complete your motorized dial indicator test device with the
possibility of a fully automatic reading of the displayed values of the test objects (pointer or numeric
display) by camera and image processing, which makes the testing process considerably easier. The
QMSOFT® software system controls the dial indicator test device and processes the camera image
(pointer or numeric display of the test object) and the reference measuring values of the dial indicator test
device; it also performs all the subsequent processes related to gauge management.

The license „QMSOFT®/QM-DIAL image processing“ (for new customers) or „QMSOFT®/QM-DIAL bv“
(for QMSOFT® customers already possessing a compatible QMSOFT®/QM-DIAL“ license) contains the
software functions to allow the reading of the test object‘s display by camera.

The advantages of the retrofit kit for fully automated testing at a glance:

 Measured values are read out in an objective manner, free from random errors which might be

committed by the operator.

 For digital dial gauges, the usually low data transfer rate via data cable can be replaced by a

notably higher reading frequency by camera.

 The calibration process can be carried out without fatigue or loss of concentration, allowing for a

considerably higher performance of the dial indicator test station in comparison to the
conventional method.

 During the automated testing process, the released capacities of the operator can be used for

other working tasks.

 Thanks to the integration of the dial indicator test station in the QMSOFT® system, the use of

other software systems is not necessary since all the available QMSOFT® functions for creating,
transferring and saving test certificates can be used.

You can find a detailed description of the possibilities offered by the QMSOFT® gauge management
system on the website of L&W GmbH and on the DVD included in the delivery package.

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6 Assembly and set-up

This chapter shall help you to answer any questions which might arise before or during the assembly and
set-up of the retrofit kit. Please go through the described steps one after the other.

6.1 Assembly of the base unit

When choosing the position of the test station, the ambient conditions required by the manufacturer of
the dial indicator test device have to be observed.

The base unit has to be placed upon a stable structure which is free from vibrations and is sufficiently able
to take load (weight of the base unit plus weight of the dial indicator testing device). When choosing the
position for the test station, you should also consider the necessary space for computer equipment
(keyboard, mouse, screen). Please also pay attention to the glare effect of the lighting unit – we
recommend to place the testing station facing a wall, or to install an optical screen between adjacent work
stations, e.g. by means of a vertical partition.

Take the base unit out of the transport packaging. Please remove the foam inserts very carefully to avoid
any deformation or damage of the pre-assembled camera and lighting unit.

Fig.2: base unit with pre-assembled camera with lens and lighting unit

Place the base unit on the chosen workplace. The column with the camera and lighting unit should be on
the front side close to the operator.

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6.2 Assembly of the dial indicator test device

The retrofit kit consists of the following components:

Fig. 3: base unit with mounted dial indicator testing device

1 lighting unit

2 USB camera with lens

3 test object

4 clamp for horizontal positioning of the slide with the lighting unit

5 slide with lighting unit (horizontally adjustable)

6 camera/lighting unit slide (vertically adjustable)

7 clamp for vertical positioning of the camera/lighting unit

8 handle for horizontal positioning of the camera/lighting unit

9 hand wheel for manual testing with the Optimar-device

10 testing device (dial gauge test device Optimar – not included in the retrofit kit)

11 column

12 hand rest (for manual testing)

13 base plate

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The base plate (13) of the retrofit kit is equipped with one fixed stop bolt and four adjustable stops in the
form of aluminum blocks with fixing screws, which can be fitted (within a limited range) to the socket of
the dial gauge test devices.

Fig. 4: Assembly scheme (top view)

First, unfasten the fixing screws of the rear and left stop (marked with red darts in the figures) and remove
them.

Fig. 5: stops to be unfastened

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Now carefully position the dial indicator test device in the designated area of the base plate („between“
the stops).

ATTENTION:
Observe the relevant safety regulations when lifting the dial indicator test device! Avoid any collision with
the lighting unit and the camera!

Position the dial indicator test device on the base plate, making sure that the base of the test instrument
fits well in between the stops on the front and on the right side of the base plate. Now replace the
unfastened stops and fix the position of the dial indicator test device by fitting the stops tightly to the
socket of the test device and re-fasten the fixing screws.

Fig. 6: front stops

To position the lighting unit (see Fig. 7), loosen the clamp (1) of the horizontal slide of the lighting unit (2)
and move the slide horizontally until the rear side of the lighting unit is positioned in a distance of 1 – 2
mm from the camera lens (see Fig. 8). Fix the slide in this position by tightening the clamp (1).

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Fig. 7: Positioning of camera and lighting unit

Finally, you may already do a first vertical positioning of the camera/lighting unit slide (4):

Take hold of the handle (5) with your right hand, and loosen the clamp (3) with your left hand. Now you
can move the slide in vertical direction, finding a position where camera, lighting unit and the dial gauge
to be tested are all in line. Fix the slide in this position by tightening the clamp (3).

ATTENTION:
Do not let go of the handle while the clamp is unfastened to avoid the risk of a collision of the slide with
the stopper!

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Fig. 8: lens with operating elements for lens aperture and focus

6.3 Set-up of the dial indicator test device

Follow the instructions of the manufacturer of the dial indicator test device to connect the test device to
the power supply and to the computer.

ATTENTION:
Please check in the Windows Device Manager if all the necessary interfaces (serial/USB or virtual ports) are
working properly and are not marked with error icons. Make sure that all the driver components are
updated and all the necessary Windows-updates are installed correctly. Only then continue with the set­up.

Now start the dial indicator test device and carry out all the operating steps for starting the testing device
required by the manufacturer to put it in operating condition.

6.4 Set-up of the lighting unit

ATTENTION:
Before setting up the lighting unit, always check that the supply voltage indicated on the type plate of the
plug-in power supply corresponds with the local voltage!

The lighting unit is supplied with energy via the plug-in power supply included in the scope of delivery.
Plug the supply cable into the socket on the rear side of the lighting unit. Now connect the lighting unit to
the power supply.

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6.5 Set-up of the camera

The retrofit kit includes a pre-assembled USB 3-camera of the uEye-series of the manufacturer IDS
Imaging Development Systems GmbH (Website: www.de.ids-imaging.com)

NOTE:
Please consider that a free USB-3 port is necessary for the connection of the camera! You can check
the available USB ports of your computer beforehand by clicking „Check USB bus“ in the dialog box (the
check is self-explanatory).

Fig. 9: camera (without lens)

These cameras are operated with a driver library provided by the manufacturer. To install the software,
please log on to your computer with local administrator rights. You can either download the current driver
version from the manufacturer’s website (registration required), or you can install the driver version
included on the der QMSOFT®-DVD: simply open the folder \Additional\IDS, where you can find the
program file uEye64_46000_WHQL.exe. Double-click to start the file, select „install driver“ and follow the
instructions (we recommend the setup type „complete“ for the installation of the driver). Take over the
default settings for the target directory and for the program folder. To finalize the installation process you
may choose to install the shortcut icons for the camera software also on the desktop or the quick start bar.
We recommend in any case to select the option „Show quick start HTML“, as it provides detailed
information about the camera and the proprietary software.

Once you have successfully installed the camera software, you can connect the camera with the included
USB-3 cable to a free USB-3 port of the computer.

ATTENTION:
Only use a USB-3 port (blue socket), slower ports do not reach the image transmission rate required for
real-time control!

Now test the functioning of the camera and the computer. Start the program „uEye-Cockpit“ by clicking
on the shortcut icon on your desktop or quick start bar. In the window „choose mode“ please click on the
middle icon "Live-Video“.

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Fig. 10: Start window of the camera software

Now the main window of the camera software opens. Please click on the button "open camera and live
image" on the top left side of the tool bar.

Fig. 11: main window of the camera software

You should now be seeing a black-and-white real-time image on your screen (do not forget to remove the
protective cap from the lens of the camera). Depending on the position of the lens, the brightness of the
computer image might be too high or too low: in this case you can correct the brightness by adjusting the
lens aperture on the camera (see Fig. 8). You can vary the zoom factor of the image with the help of the
icons in the tool bar.

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6.6 QMSOFT® configuration

You can find a detailed description of the basic QMSOFT® installation scenarios and further information
on other installation types (update of pre-existing QMSOFT® installations, use of the database in the
network, floating-license server, silent installation, etc.) in the QMSOFT® manual on the DVD in the
subdirectory „\Doc“.

For the configuration of the Optimar 100 please carry out the following steps:

6.6.1 Create the test device in the QMSOFT®/QM-DeviceServer

Before you can start using the dial indicator test device in the QMSOFT® system, the device has to be
created in the QMSOFT®/QM-DeviceServer.

Open the main window „QMSOFT®/GaugeMan“ and click on the first button in the section „Measuring
devices“:

Fig. 12: starting of the QMSOFT®/QM-DeviceServer

Now the main window of QMSOFT®/QM-DeviceServer opens. Please click on the button "Add device":

Fig. 13: button to add new devices in the QMSOFT®/QM-DeviceServer

Select the manufacturer (e.g. Mahr GmbH) and the device name (e.g. Optimar 100) from the lists:

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Fig. 14: Select manufacturer and device name

Now you can enter a name for the testing device. Complete the process with the "Close"-button. The dial
indicator test device has now been created in the QMSOFT®/QM-DeviceServer.

6.6.2 Configuration of the test device in the QMSOFT®/QM-DeviceServer

Select the testing device in the program window. By clicking on the right mouse button, you open a menu
where you choose the function "modify device properties“.

Fig. 15: menu “Modify device properties”

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For Optimar 100 devices, it is only necessary to configure the connection to the computer either by serial
cable (RS232) or USB cable, and to select the USB-camera to be used for reading the measured values on
the display of the test object (see Fig. 16):

Fig. 16: Modify device properties

The default settings for the axis designations shown in the window can remain unchanged. Further
settings are not required, and you can confirm the configuration with „OK“.

In the main window of the QMSOFT®/QM-DeviceServer you now click on the button

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to minimize the QMSOFT®/QM-DeviceServer and leave it running in the background. Thus, it can be
reactivated quickly in case of measurement value requests of the QMSOFT® inspection programs during
measurement.

6.6.3 Configuration of the inspection program QMSOFT®/QM-DIAL

When you start the dial gauge inspection program QMSOFT®/QM-DIAL for the first time, you are asked
to configure the connection with the test device you created. Start by clicking on the QM-DIAL symbol
(indicated by the red dart in Fig. 17):

Fig. 17: Starting the dial gauge inspection program QMSOFT/QM®-DIAL

Open the menu "Settings - Program settings", where you select program settings (Fig. 18). Select the
device connection to the dial gauge test device and confirm with „OK“.

Fig. 18: Configuration of the connection to the test device

You may choose specific settings for each type of gauge (dial gauge, dial test indicators, etc.) and the
respective group of standards. These settings are then applied to all gauge types of a certain group, or
only to a specific gauge inspection method (e.g. "dial gauges according to VDI...").

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Should the dial indicator test station mostly be used for fully automated inspection, we recommend to
pre-set the inspection mode on fully automated inspection (see Fig. 19):

Fig. 19: Activation of fully automated inspection

QMSOFT® recognizes automatically whether the connected test device is linked to a camera. No further
settings are necessary.

For detailed information on the functions and configuration options in QMSOFT® please refer to the
QMSOFT® manual.

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7 Image processing in QMSOFT®/QM-DIAL

7.1 User interface of the QMSOFT® camera functions

Fig. 20 shows the test device visualization of an Optimar 100 device with active camera function. With
respect to conventional devices, you will find new control elements here, which are shortly described on
the following pages.

Fig. 20: test device visualization Optimar 100

To facilitate the positioning of the camera, you can add the red line as shown in Fig. 20 by selecting „mark
elements“ on the right of the image. Bring the red line into alignment with the center of the test object’s

scale by using the buttons for positioning.

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7.1.1 Motion control of the dial indicator test device

Button

One click on this button sets the resolution of the hand wheel of the dial indicator test device to the value
entered in the input field left of the button (only for manual inspection).

Button

One click on this button sets the positioning speed of the dial indicator test device to the speed which has
been entered in the input field left of the button. This setting only applies to manual operation; when
running in automatic mode, the system selects the optimal positioning speed by itself.

Button

Click and hold this button to move the quill of the dial indicator test device up or down.

Button

With this function, the quill can be precisely positioned. One click on this button moves the quill of the
dial gauge test device to the position set in the input field left to the button.

Button

This button is the "emergency-stop" in case the movement of the quill has to be interrupted quickly, e.g.
to avoid collision.

7.1.2 Settings for the camera image

Button

One click on this button activates the camera image (which automatically enlarges the test device
visualization). In the automatic mode, the camera image starts without intervention of the operator. With
this function, the reading via camera can be activated also during manual positioning.

Button

This button closes the camera mode (in case it was activated manually before). The test device
visualization on the screen is reduced.

Slide control (brightness)

This control regulates the brightness (exposure time) of the image, in addition to the brightness regulation
with the lens of the camera.

Slide control (zoom)
This control regulates the size of the image section (AOI, Area Of Interest) of the camera image.

Buttons

The dart buttons pointing left/right, up/down can be used to move the AOI in the live-video image. You
can also use your mouse to drag and drop the AOI in the video image. To quickly center the scale of the
test object in the camera image, press SHIFT and click on the middle of the scale shown in the image.

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7.2 Inspection procedure

Before you start testing, make sure that the lighting unit and the test device are switched on and ready for
operation, and that the test object is inserted in the test device and correctly positioned in front of the
lighting unit and the camera. Make sure that the test object is not damaged or dirty.

When QMSOFT®/QM-DIAL recognizes the camera connection, the live image of the test object opens.

7.2.1 Optical settings

 Set the brightness (exposure time) as low as possible (approx. between a value of 3 and 10). This

can reduce the overall duration of the inspection procedure.

 The scale of the test object should fill the camera image.

 Make sure that the camera image is neither too dark nor too bright. Use the lens of the camera to

regulate the brightness; if necessary, make further adjustments with the slide control for
brightness.

 Avoid disturbing lighting sources, which could cause reflections on the surface of the test object.

Make sure that the scale is always well illuminated and shadow-free.

 Adjust the definition of the image with the focus regulation on the camera (Fig. 8).

7.2.2 Positioning of the tested dial gauge

7.2.2.1 Analogue dial gauges

Position the quill of the dial indicator test device, so that the test object is in a position shortly before its
mechanical pointer's zero point and make sure there is a contact between the quill of the test device and
the test object.

A symbol in the top left corner of the camera image shows the expected position of the "0"
(top, bottom, left or right). By clicking on this symbol the expected zero-position can be
changed (this setting remains also after closing the software).

The pointer has to be positioned in an area between a quarter turn before the "0" and a quarter turn after
the "0". There has to be a movement range of at least 30 scale units until the end of the measuring range
of the test object (dial comparator).

7.2.2.2 Digital dial gauges

To test digital dial gauges, set the display of the test object to zero close to the mechanical start of the
measuring range. Bring the quill to a position where the test object shows a value smaller than zero. The
dial gauge test device has to be in contact with the dial gauge to be tested.

The „0“ always has to be within the measuring range of the test object.

There have to be at least 5 digits before the "0" in the measuring range (usually it is possible to set digital
measuring devices to zero at any point).

There has to be a movement range of at least 30 digits until the end of the measuring range.

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7.2.2.3 Fully automated inspection

Once you have optimized the optical settings and the position of the test object, you can start the fully
automated testing by clicking on the button "Start fully automated inspection" in the QMSOFT®/QM­DIAL program window.

The software now first starts trying to recognize the scale of the test object or to evaluate the numeric
display. In doing this, the test object is being moved slightly by the movement of the quill of the test
device. After this short recognition process starts the inspection of the test object in automatic mode.

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8 Maintenance

The entire retrofit kit has been designed to allow a virtually maintenance-free operation under normal
laboratory conditions.

From time to time, remove any dust deposits on the components, especially on the camera.

Pay attention to possible dirt deposits on the guide elements of the positioning slides.

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9 Troubleshooting

In this section you can find some of the most frequent problems:

 Lighting unit does not work

Has the power supply of the lighting unit been connected correctly? If there is a cord switch, has it
been activated? Try if the power supply of the lighting unit works when using another power
outlet.

 No camera image

Make sure that the driver software of the camera manufacturer has been installed correctly. If you
also do not see any image in the manufacturer's software (uEye-Cockpit), please refer to the
technical documentation of the camera manufacturer.

 The camera image appears, but remains black

Have you removed the protective cap from the lens? Adjust the lens aperture to a smaller value
(this enhances the brightness of the image) and increase the brightness with the slide control in
QMSOFT®.

 The camera image flickers

Increase the brightness (exposure time) in QMSOFT®, and decrease the brightness on the lens of
the camera

 QMSOFT/QM-DIAL does not show the test device visualization

Has the connection between QM-DIAL and QMSOFT®/QM-DeviceServer been configured? Is the
QMSOFT®/QM-DeviceServer active? Can the test device be called up in the QMSOFT®/QM­DeviceServer? Are the settings for the communication with the test device correct?

 Test object is not recognized

Should the test object not be recognized at the beginning of the inspection, the message “scale
not recognized” is shown. In this case please check if the focus and brightness are properly set,
and make sure that the testing device is in contact with the test object. Should the problem
persist, you can use the following error dialog to save the relevant data and/or images in order to
send them to L&W GmbH for an external problem analysis.

Should you have any problems or special questions regarding the maintenance or repair of the retrofit kit,
please do not hesitate to contact us.

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