TESA MH3D User Manual

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U S E R ' S M A N U A L

English

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User's Manual

MH3D

User's Manual

MH3D

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Contents

CHAPTER 1 - Introduction ................................................................1-1

Foreword .........................................................................................1-3

Warranty .........................................................................................1-4

Software Warranty ..........................................................................1-4

Warranty Service.............................................................................1-5

General Safety .................................................................................1-6

Description ......................................................................................1-7

Dimensions ....................................................................................1-11

Specifications ................................................................................1-12

CHAPTER 2 - Construction ...............................................................2-1

Base .................................................................................................2-3

Work Table .....................................................................................2-4

Y-Rails ............................................................................................2-5

Bridge ..............................................................................................2-6

ZX Carriage ....................................................................................2-7

Z Rail ..............................................................................................2-8

Air Control and Filter...................................................................... 2-9

Air System.....................................................................................2-10

Air Bearings ..................................................................................2-11

Measuring System .........................................................................2-12

Reference Offsets ..........................................................................2-13

Probes............................................................................................2-14

TESASTAR Probe ........................................................................2-14

TESASTAR_I Probe.....................................................................2-14

Electronic System ..........................................................................2-15

Controller ......................................................................................2-16

MH3D Rear Connections ..............................................................2-17

MH3D Control Box.......................................................................2-17

Cables............................................................................................2-18

CHAPTER 3 - Operation...................................................................3-1

Operator Safety ...............................................................................3-3

Using a Desk Mouse........................................................................3-6

Using a ZMouse ..............................................................................3-7

Starting & Stopping ........................................................................3-8

Moving the Axes ...........................................................................3-10

Homing the Machine .....................................................................3-11

The Inspection Process ..................................................................3-12

Probe Installation...........................................................................3-13

Measuring With a Ball Probe ........................................................3-14

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Contents

Probe Compensation......................................................................3-15

Measuring With an Electronic Probe ............................................3-16

Touch Trigger Probe Repeatability ...............................................3-17

Useful Probe Dimensions ..............................................................3-19

Good Measurement Techniques ....................................................3-21

CHAPTER 4 - Maintenance ...............................................................4-1

Machine Maintenance & Safety ...................................................... 4-3

General Safety Practices..................................................................4-3

The Machine's Environment ............................................................4-3

Electronics .......................................................................................4-4

Covers .............................................................................................4-4

Pneumatics ......................................................................................4-4

Maintenance Intervals .....................................................................4-5

Daily or Every 8 Hours ...................................................................4-6

Monthly or 165 Hours..................................................................... 4-6

Every Three Months or 500 Hours..................................................4-6

Maintenance Log .............................................................................4-7

Machine Troubleshooting ................................................................4-8

Cleaning Glass Scales ...................................................................4-11

Changing the Air Filter..................................................................4-12

CHAPTER 5 - Glossary......................................................................5-1

CHAPTER A - Video Optical Probe ................................................ A-1

Installation...................................................................................... A-3

Mounting Configuration.................................................................A-4

Connecting Diagram.......................................................................A-5

Adjustments.................................................................................... A-6

Qualification...................................................................................A-8

Measuring.......................................................................................A-9

User's Manual

MH3D

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CHAPTER 1

Introduction

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User's Manual

MH3D

User's Manual

MH3D

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Foreword

The TESA MH3D™ Series Coordinate Measuring Machines represent the accumulated experience of over 160 years in the design and manufacture of dimensional measuring equipment. This experience, combined with many mechanical, pneumatic, and electronic features, has produced a machine which meets the most rigid requirements for the control of dimensional quality.

The MH3D is designed to meet production needs and to produce speedy, accurate and economical verification of a variety of work pieces.

Imaginative engineering concepts make the MH3D a practical choice for small shops as well as for large operations. Such innovative design as a completely weight balanced structure and a fully supportive air bearing system allow the attainment and maintenance of high accuracies. Combining these features with the many optional accessories and software packages available, allows the most difficult measurements to be performed on a time-saving production basis.

Since minor changes may be made periodically by TESA to improve machine performance, some components of your particular system may differ from the description in this manual. In such cases, supplementary information will be furnished as needed.

This manual has been prepared to provide the proper procedures to be followed in the installation, operation, and maintenance of the MH3D. Other manuals and information are also provided where required.

CAUTION

This manual should be read in its entirety by all supervisory and operating personnel prior to installation of the MH3D. This will help to prevent human injuries as well as damage to the machine components and will assure proper installation, operation and maintenance.

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Warranty

We warrant that within twelve (12) months from the date of shipment, if the product manufactured by us and sold by us under this contract is in the possession of the original buyer (or lessee) from us (or from an authorized distributor), we will replace or repair, at our option, free of charge, any part or parts which upon examination we find defective in workmanship or material, provided that, on our request, the product or parts thereof are returned to our plant, along with satisfactory documentation that the product has been installed, used, and maintained in accordance with instructions in the User’s Manual and has not been subjected to abuse.

We warrant that within twelve (12) months from the date of shipment, if the software sold under this contract is in the possession of the original buyer (or lessee), we will replace or correct, at our option, free of charge, any modules or programs which upon examination we find defective in workmanship or function, provided that, on our request, the modules or programs are returned to our plant and, provided further, that there is satisfactory documentation that the software has been installed, maintained and operated in accordance with instructions in the User’s Manual, and provided further that there is satisfactory documentation from the customer that a software defect exists.

In addition, there may be specified Occupational Safety & Health Standards Warranties which, if applicable to the product, are set out in the attached schedule and incorporated by reference and subject to the provision hereof.

We shall not be responsible for any expense or liability for repairs due to the making of or which result from any additions or modifications upon the product without our written consent and approval or which expense or liability for repairs results from a failure to follow the Manufacturer’s Preventive Maintenance Schedule as set forth in this Manual.

THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESS OR IMPLIED WARRANTIES (INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE). IN NO EVENT SHALL WE BE LIABLE FOR ANY SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS OR OTHER DAMAGES FROM LOSS OF PRODUCTION) CAUSED BY DEFECTIVE MATERIAL, OR BY UNSATISFACTORY PERFORMANCE OF THE PRODUCT, OR BY ANY OTHER BREACH OF CONTRACT BY US.

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Warranty Service

During the warranty period, as defined previously, remedial service assistance on the machine and control will be furnished at no charge by TESA when this equipment is in operation in Europe.

In the event that you should require information or service assistance for your MH3D, it is recommended that you call the dealer from whom the machine was purchased or one of the TESA regional offices. Due to the complexity of this machine, we recommend only TESA factory authorized service centers be used.

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General Safety

This manual should be read in its entirety by all supervisory and operating personnel before installation, operation and maintenance. The MH3D has been designed to minimize possible hazards to the operator and sources of damage to the machine. While it is impossible to anticipate every situation, strict adherence to the safety rules in this manual will reduce the possibility of injury to personnel and damage to the machine.

Set up personnel and operators should be completely familiar with the controls, safety devices and operation of this machine. Safe operating procedures should be defined and applied at all times during setup, operation and maintenance.

The procedures outlined in the following pages can be used as a guide to establish safe operating and maintenance procedures. Additional information on the safe operation and guarding of machines is available from the United States Department of Labor.

Every effort should be made to keep your machine safe. A daily safety inspection should be made in addition to the normal maintenance inspection. Machine operators should be aware of safe operating procedures and apply these procedures at all times during operation. Particular emphasis should be placed on ensuring that all guards are on the machine, in good condition and fastened securely. Never operate the machine when its guards are removed.

Icons indicate the following:

Note

This symbol informs you of special circumstances.

The following symbols denote that extra caution should be exercised:

Caution

This symbol refers to safety information.

Caution: High Voltage

This symbol is associated with voltages that are dangerous to life. Use extreme caution in areas where it is posted.

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Description

The MH3D Machine

The MH3D Coordinate Measuring Machine features a lightweight, table top, bridge type design with a removable granite support.

This machine is designed to accommodate moderate sized work pieces with an economical table mounted unit.

This series of machines incorporates the following features:

• A granite worktable that provides a stable, precision measuring surface that is practically maintenance free.

• M10 threaded, stainless steel inserts imbedded into the granite table for securing the workpiece.

• Air bearings for frictionless movement of all axes.

• A fully pneumatic, counterbalanced column, infinitely adjustable for varying probe weights, with a built-in braking device.

• A Z-Rail Probe Holder that accommodates a wide variety of probes and accessories.

• A machine construction that allows accurate measurement of steel parts over a wide temperature range.

• A control interface with pushbutton access to data display and analysis.

• A bright, clear VGA monitor.

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Description

4 5

The MH3D System consists of the following main components:

1. Base

2. Granite Table

3. Y-Axis Rails

4. Bridge

5. Probe Locking Lever

6. Z-Rail

7. X-Z Carriage

8. Counterbalance Adjust Knob

9. Axis Lock Switches/Fine Adjust Engagement

10. Probe

6-13

11. Control Box and VGA Monitor

12. Stand (optional)

13. ZMouse

14. Air Supply (rear)

15. Air Bearings (not visible)

16. Measuring System (not visible)

17. Machine Leveling Feet

18. Anti-tip Bolts

19. Granite Leveling Feet (not visible)

20. Fine Adjustment Knob

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Description

1. BASE - Aluminum casting of open web design with three isolation-type leveling pads. Its construction supports the granite table and provides

rigidity and stability for accurate machine operation and measurement.

2. GRANITE TABLE - Mounted on ball and locating pin supports, the table provides a means for locating and clamping parts to be inspected.

3. Y-AXIS RAILS - Mounted to the base, they provide the means of guiding the bridge in an accurate and straight line along the Y axis.

4. BRIDGE - A movable structure that consists of the left and right legs along with the X axis rail. This structure is movable on the rails for Y axis measurements. The X axis rail forms the top portion of the unit and provides the means for guiding the carriage in an accurate and straight line along the X axis.

5. PROBE LOCKING LEVER - A lever that is used to clamp and release the probe in the Z-rail probe holder.

6. Z-RAIL - An adjustable, counterbalanced rail that is movable vertically in the carriage for making Z axis measurements. The rail houses a pneumatic counterbalance that is infinitely adjustable for varying probe weights. It is also provided with the means for attaching various types of probes and accessories.

7. X-Z CARRIAGE - A structure movable on the rail for X axis measurements. The carriage contains the air bearings for the X rail as well as the air bearings for the Z rail.

8. COUNTERBALANCE ADJUST KNOB -This knob is used to adjust the counterbalance cylinder for the varying probe weights.

9. AXIS LOCK SWITCHES - On the MH3D the switches are used to engage or release the fine adjust mechanism.

10. PROBE - Probes are either hard or touch trigger types and are used to take measurements on the piece being measured.

11. CONTROL BOX - A VGA monitor with large, easy to read characters and a choice of languages. The display provides XYZ readouts, software menu selections and data input capabilities.

12. STAND (OPTIONAL) - A support for the machine and air supply. It supports the machine at the proper height for operator movements.

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Description

13. Z MOUSE - Used with the control box for menu selection, measurement point taking, scanning and for data input.

14. AIR SUPPLY - Provides and distributes air to the air bearings for smooth, frictionless travel of the bridge, carriage and Z rail. The air supply is also used for the adjustable Z rail counterbalance.

15. AIR BEARINGS - The air bearings provide noncontact, frictionless movement of the bridge, carriage, and Z rail along their respective ways.

16. MEASURING SYSTEM - A highly accurate, opto-electric system, consisting of a scale and an encoder head, which sends electronic signals to the readout as it moves along the scale.

17. MACHINE LEVELING FEET - Three screws and pads used to isolate the machine from vibrations and to level the machine.

18. ANTI-TIP BOLTS - Two bolts in the machine base that prevent the machine from tipping if it is bumped or has an unbalanced load.

19. GRANITE LEVELING FEET - Three ball-end screws in the top of the base that provide a three point support for the table. They are also used to level the granite to the X and Y axes.

20. FINE ADJUSTMENT - Allows precise adjustment of all three axes by means of knurled knobs .(Optional)

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Dimensions

973

1625

415

670

MH3D MEASUREMENTS ARE LISTED ON THE

SPECIFICATIONS SHEETS

300

670 923

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Specifications

PERFORMANCE METRIC ENGLISH

*Repeatability 0.003 mm 0.00012 in. *Volumetric Accuracy 0.003+4.L/1000 0.0004 in. *Linear Accuracy 0.003+3.L/1000 0.0002 in. Resolution 0.00001 mm 0.0000025 in. Display Range +/-9999.999 mm +/-999.99999 in. Measuring Speed (Max.) 760 mm/sec 30 in/sec

DIMENSIONS

*Measuring Range 460 x 510 x 420 mm 18.4x20.4x16.6in. Length 970 mm 38.8 in. Width 930 mm 37.2 in. Height 1620 mm 64.8 in. Weight (Machine w/o granite) 98 kg 215 lbs Weight (Complete system) 190 kg 416 lbs Shipping Weight 250 kg 549 lbs Maximum Part Weight 227 kg 500 lbs Part Size Capability (X,Y,Z) 600 x 750 x 430mm 24 x 30 x 17.2 in.

OPERATIONAL REQUIREMENTS

Calibration Temperature 20°C±1°C 68°F±2°F Operating Temp. Range 13° to 35°C 55.4° to 95°F Storage Temperature -30° to 60°C -22° to 140°F Air Input 4.8 - 8.3 BAR 70 - 120 psi Air Consumption 21L/min @ 4 BAR .74 CFM @ 59 psi Power Requirements 100 to 240 VAC 100 to 240 VAC

50/60 HZ 50/60 HZ

Power Consumption25 VA Max. 25 VA Max.

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* Machine range when using 75 mm (3.0") long probe. Repeatability, Volumetric and Linear Accuracy is measured with a 325mm (12.8") Ball Bar in the center of machine sytem certified.

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CHAPTER 2

Construction

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Base

The MH3D is supported by a base that is an aluminum casting of open web design. This construction provides a structure that is both light and stiff.

Locknut

Three isolation pads with adjustable screws and nuts are fastened to the

Adjusting Nut

Screw

bottom of the base and are used for leveling the machine. The pads also prevent vibrations from being transmitted to the machine and the workpiece.

Two adjustable bolts are fastened to

Isolation Pad

the bottom of the base and are set with 1mm-1.5mm (.040"-.060") clearance above the top of the bench. These bolts prevent the MH3D from tipping, if it should be bumped or loaded in an unbalanced condition.

Note: These anti-tip bolts Must Not touch the bench under normal conditions. Three ball-end screws, fastened in the top of the base, provide a three point support for the work table. These screws are leveled at the factory and do not normally require adjustment. These screws should only be adjusted if the work table is not level with the X and Y axes.

The cable track is mounted to the base and houses the encoder cable and air hoses. The Y axis cable is in a loop between the rail and the base which reduces hysteresis.

Machine Leveling Screw

Anti-tip Bolt

Machine Leveling Screw

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Work Table

The work table is granite with a flat lapped surface that serves as the support for the parts to be measured. Locating pins, mounted to the bottom of the work table, rest on ball-end screws in the top of the base. The locating pins are oriented to allow the table to expand and contract with the machine.

The dark and light areas that appear in the granite are not defects but rather natural concentrations or absences of black magnetite mineral. These color variations do not affect the hardness, durability or accuracy of the granite surface.

A number of stainless steel M10 threaded inserts are uniformly spaced throughout the measuring area for clamping work pieces to the table. Note: Bolts used

for clamping the work pieces must not be overtightened, or the inserts may pull loose from the granite. Maximum torque is 20.5 Nm.

The work table should be kept clean by wiping with alcohol, particularly when this surface is being used as a datum.

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Y-Rails

The Y-Rail is a lightweight, hard-coated anodized, aluminum rail that is both bolted and epoxied to the left side of the base. The top and outside of the rail are the positive sides. The Y-Rail controls five (5) degrees of freedom. It also serves as a support and guide for the left outboard leg of the bridge. The Y-axis measuring scale is recessed into the YRail. Note: The scale s protected by a cover.

The Y-Roll Rail is also a lightweight, hardcoated, aluminum rail that is both bolted and epoxied to the right side of the base. This Roll Rail supports the right inboard leg of the bridge with air bearings on top and underneath the rail.

It is very important that the rails be kept clean and not be bumped when parts are loaded and unloaded. Never lift the MH3D by the Y-Rails.

Note: Although the guide rails are hardcoated and anodized, they can be damaged by a bang or bump from a hard object. Never place objects against the rails when loading or unloading parts.

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Bridge

The MH3D is a vertical, moving bridge type of CMM. The Bridge travels along the Y-rail at a right angle to the front of the machine. It is of modular construction and consists of a left outboard leg, a right inboard leg and an X-Rail which spans the two legs.

The left leg is an aluminum casting that results in a member that is both structurally light and stiff. The leg contains seven (7) air bearings which provide virtually frictionless movement and support in the Y direction. An air harness contains the lines for the air bearings as well as for the axes air switches located at the front of the left leg.

The air switches control the lines from the manifold to the preload bearings for each axis. On the MH3D an axis can be locked by toggling the air switch off (down) and deflating the preload bearings for that axis. On the MH3D the air switches are additionally used to engage or release the fine adjust mechanisms. These mechanisms, mounted on the X, Y and Z axes, are used for precise adjustment of the individual axes.

The Y-axis encoder is mounted in the lower part of the leg, beneath an access plate. Elastomeric bumpers on the leg act as stops when contacting the base at the end of travel.

The right leg is also an aluminum casting and contains two (2) air bearings for virtually frictionless movement. The bearings are preloaded for improved accuracy of the MH3D.

The X-rail is a lightweight, hardcoated, aluminum that spans the two legs and serves as both support and guide for the X-Z carriage. The X-rail is both bolted and epoxied to the left leg and bolted to the right leg. A cable track is provided for the X-axis loop to reduce hysterisis and improve accuracy.

The X-axis measuring scale is recessed into the back side of the X-rail. The scale is protected by a cover. The top and front sides of the rail are the positive sides.

Note: Although the guide rails are hardcoated and anodized, they can be damaged by a bang or bump from a hard object. Never place objects against the rails and avoid lifting over the rails when loading or unloading parts.

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ZX Carriage

The ZX Carriage travels along the X-rail parallel to the front of the machine. The carriage is an aluminum casting that is both structurally light and stiff. The carriage houses nine (9) air bearings which provide virtually frictionless movement and support in the X direction.

The ZX Carriage also contains eight (8) air bearings that support the Z-rail. The X-axis encoder and the Z-axis encoder are located under removable covers at the back of the machine. Removing these covers provides access to the Z-axis scale.

Cable mounts are located at the rear of the carriage and elastomeric bumpers on each end act as stops against the legs in the X direction.

A large knurled knob at the bottom of the carriage is used for the precise adjustment of the Z-rail.

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Z Rail

The Z-rail travels vertically at right angles to both the X and Y axes. The rail has an octagonal cross section and moves virtually without friction. The rail is made from a lightweight, hardcoated aluminum and is supported by eight (8) air bearings in the ZX carriage.

A pneumatic counterbalance, adjustable for varying probe weights, is mounted in the Z-rail. The counterbalance consists of a cable suspended piston in a cylinder.

The Z-axis measuring scale is recessed in the back of the rail. The scale is partially exposed when the Z-rail is in its lowermost position. Two mechanical stops with elastomeric bumpers control the travel of the Z-rail. Note: These stops must

not be removed or the rail will drop on the table.

The Z-rail has a built-in failsafe brake that operates off the pneumatic system. If air pressure is lost in the counter-balance, the Z-axis air bearings will lock, preventing the rail from dropping on the work table.

A probe holder built into the bottom of the Z-rail has a locking lever and spring plunger detent to hold the probe in place while clamping. The orientation of the locking lever can be changed by pulling the lever out to disengage it from its spline and reengaging the lever in a new location. When engaged, the lever can be turned to clamp or release the probe. The Z rail has a mouse with a button for moving the cursor on the monitor screen, a button for selecting menu items amd a button to record measurement points.

The machine is prewired to accept the optional Touch Trigger Probe. A cable is assembled thru the center of the Z-rail with a socket at the lower end of the rail for electronically connecting the Touch Trigger Probe.

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Air Control and Filter

Air is used on the MH3D for air bearing operation and for the Z-rail counterbalance. The system is designed to operate at 3.75 BAR (55+0/-1 PSI). The inlet air supply should be 4,8 - 8,3 BAR (70 - 120 PSI) and should provide for a minimum consumption of 21L/min (.74 CFM).

The supply line is connected to the input port. The air passes through a primary filter and a secondary filter. A regulator connected after the filters is used to set system pressure. When the pressure is set, the pressure adjusting knob should be locked with the friction lock knob located at the bottom of the regulator.

Pressure Adjust Lock Knob

Air Inlet

70-120 psi

(4.8-8.3 BAR)

Pressure Gage

Particle Filter

To Machine 58 psi (4 BAR)

Particle Filter

*Not Shown - Optional Air

Saver Valve

Automatic Drain

The filter-regulator unit is normally mounted at the side of the support bench. A bracket is supplied for mounting and can be attached to a customer supplied bench. The filter-regulator must be mounted vertically as shown. Failure to

do this will cause the unit to malfunction and void the machine warranty.

A second regulator controls the air pressure in the counterbalance cylinder. This regulator is mounted on the right side of the rear cover of the ZX cariage and is adjusted to compensate for varying probe weights.

Always hold the Z-rail firmly when unlocking the Z-axis and adjusting the counterbalance. The knob must be rotated clockwise to increase the lift for

heavier probes and counterclockwise to decrease the lift. If the counterbalance is adjusted with the axis lock 'on', the safety brake may be

triggered because the air pressure is set too low. If this occurs, unlock the axis and turn the pressure up until the counterbalance unlocks. Hold the Z-rail firmly as it may move suddenly when the brake unlocks.

On the MH3D machine the air switches are used both as axis locks and also to engage and release the fine adjust mechanism. The fine adjust mechanisms are used for precisely adjusting the machine's three axes.

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Air System

left preload

(049745)

4,8 bar (70 psi)

Z bearings

(049746)

4,0 bar (58 psi)

(049723)

(049749)

Air bearings Right side

(Axe Y)

back

Air bearings (Ax e X)

(Axe Y)

Right

back

Left

rear preload

back preload

Right

back

Left

(049905)

XYZ

(049905)

front preload

(049906)

(049707)

Air bearing s left side

Bearings ( Axe Z)

left preload

(049745) A

(049746)

4,8 bar (70 psi)

front p relo ad

F >

4,0 bar (5 8 psi)

(049707)

Air bearings (Axe X)

Patins jambe gauche (Axe Y)

droite

bottom

left

= 8 mm

= 4 mm

back pr eload

bottom prelo ad

right

bottom

left

(049749)

(049945)

right (Axe Y)

bottom

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Air Bearings

Twenty-two (22) air bearings are used on the MH3D to provide virtually frictionless, noncontact travel along the respective axes. Air supplied to the bearings is forced through an orifice in the active surface and is uniformly distributed throughout the surface by a system of grooves. Air pressure between the bearing and the rail causes the bearing to float, allowing air to escape. The bearing retracts until the pressure is equalized by the preload or weight on the bearing.

The air bearings are adjustable, however, since the MH3D is calibrated with the air bearings at a given setting, any adjustments will require recalibration and thus should be changed only by TESA service engineers.

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Measuring System

The measuring system on the MH3D features glass scales which are etched alternately of lines and spaces of equal width. The glass scales are firmly mounted to each of the axes rails. These mountings allow the scale to expand and contract along with the machine.

This system is represented schematically and consists of the following:

1. A light source

2. A reticle

3. A spacer

4. A line scale

5. A receiver

Source

Spacer

Receiver

Reticle

Scale

An opto-electrical procedure is used to read the incremental scale divisions. According to the principle of reflected light, the scale division at the scanning point is lit at an angle by a light source. The reflected light strikes a receiver which converts the light energy to electrical energy.

The lines on the scale consist of a highly reflective material while the gaps are non-reflective. A reticle, with divisions at the same intervals as the scale, is moved directly over the scale.

The reticle, like the scale, is made of optical glass with opaque lines and transparent divisions. As the reticle is moved over the scale, the reflective lines of the scale are alternately covered and uncovered. As the reticle lies between the scale and the light source, the intensity of the light reaching the receiver varies as the reticle or scale moves.

The light reaching the receiver generates periodic signals depending upon the variations in light intensity. These signals are converted into digital measurement signals which are used to measure the distance traveled along the scale.

The reticle has additional grating or sets of lines which is physically offset 1/4 of a division (90 degrees) from the first grating. This grating has its own light source and receiver. Its output signal is offset 90 degrees from the signal on the first grating so one signal either precedes or follows the other signal depending on the direction of travel. These signals are electronically evaluated to track the direction

of movement.

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Reference Offsets

• All measurements are in millimeters.

• Values for the TESASTAR and TESASTAR_I are for the probe pointing straight down. (A = 0°, B = 0°)

• Values were measured from the center of the hole in the bottom of the probe holder in the MH3D. Values are in terms of machine coordinates.

• All values were measured with the probe detent engaged in the probe holder.

• All values should be verified by the machine operator.

Ball Probe: X Axis: 0 Y Axis: 0 Z Axis: -70

TESASTAR X Axis: -10 Y Axis: 0 Z Axis: -95

TESASTAR_I X Axis: 0 Y Axis: -5.7 Z Axis: -76

+Y!

+Z!

+X!

The origin of the coordinate system shown represents the machine origin. The arrows represent the positive direction of the machine's axes (in terms of machine coordinates).

To verify the offsets, move the machine to the home position (upper, front, left position) and read the machine position. This position (X,Y,Z) is the current probe offsets.

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Probes

TESASTAR Probe

Shank Dia. 9,5 mm

009421

047866

dia. 2 mm 03969041

047714

Star Knob 047778

Probe body

047783

Probe Stylus 03969042

TESASTAR 03939020

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TESASTAR_I Probe

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Electronic System

The display screen is a VGA monitor with large easy to read characters and a choice of languages. The display provides XYZ readout, menu selections and data input capabilities. The control has an adjustable mounting so it can be set at a comfortable operating position.

A port is provided for connection of a printer

Z-Rail Mouse

The entry of menu selections and the recording of measurements are done by

means of the ZMouse

with its cursor movement, measurement and select buttons.

To select a menu item or a softkey, move the cursor using the Cursor Movement Button (Mouse) to highlight the item. Press the "Select" button on the mouse to activate the item.

Measurement XYZ

Select

Cursor Movement

Measurement points are taken by pressing the "Measurement (XYZ)" button on the mouse after positioning the hard probe on the desired surface of the part. Measurement points can also be taken by deflecting an electronic probe (TTP) on the part surface.

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Controller

The MH3D control box is a shop-hardened control unit with the following:

• A power switch under the front left edge of the console

• A MH3D Software Card

• A PCMCIA "Smart Card" for storing programs

• A 32-bit RISC processor

• A serial output/parallel port

• A bright, clear VGA monitor

CAUTION

Do not attempt to connect or disconnect any cables when the power is “on”. Personal injury and/or electrical damage may occur.

MH3D Display

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Page 2-16

Controller

MH3D Rear Connections

MH3D Control Box

Page 2-17

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MH3D

Cables

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Page 2-18

Power supplyPrinter

CHAPTER 3

Operation

Page 3-1

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Page 3-2

Operator Safety

The following are safety instructions that apply to the operation of the machine. These instructions should be supplemented by the safety instructions of your company/organization.

Every effort must be made to keep your machine safe. A daily safety inspection should be made in addition to the normal maintenance inspection. Machine operators should be aware of safe operating procedures and apply these procedures at all times during operation. Particular emphasis should be placed on

ensuring that all guards are on the machine, in good condition and fastened securely. Never operate the machine when its guards are removed.

The MH3D has been designed to minimize possible hazards to the operator and sources of damage to the machine. While it is impossible to anticipate every situation, strict adherence to the safety rules in this manual will reduce the possibility of injury to personnel and damage to the machine.

• Develop personal safety awareness. Observe all safety regulations and be alert for hazardous conditions. Discuss these conditions with your supervisor. Use the personal protective equipment specified by your employer. TESA recommends the use of safety glasses with side shields for all personnel in the machining area.

• Never remove Warning and/or Instruction plates from the machine.

• Never wire, fasten, or override any interlock, overload, disconnect, or other safety device to void its assigned function. These devices are provided to protect the machine operator and the machine.

• Do not load, unload, operate, or adjust this machine without proper instructions.

• If you are uncertain about the correct way to do a job, ask for instructions before proceeding.

• Always lock the machine axes when leaving the machine unattended.

Page 3-3

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Operator Safety

• Make sure the machine is properly located and secured. Allow sufficient access to the machine to prevent the danger of contacting other machinery.

• Ensure that all external cables are contained in their flexible cable guides.

• The electronics cabinet houses terminals that carry up to 450 VAC. Shock hazards are present. Even low voltage shocks can cause death. Make sure service is properly grounded. Be sure the electrical power cord plug and receptacle are provided with a third terminal ground connection.

• Always keep the machine’s electrical cabinet closed. Allow only authorized electrical maintenance personnel access to the electrical cabinet. Never defeat the cabinet interlocks.

• Never route cords across aisles or through water or oil. If using extension cords, regularly check for worn insulation or exposed wires. Never use defective cords.

• Never touch electrical equipment when hands are wet. Never activate electrical circuits while standing on a wet surface.

• Be sure the main air line is securely attached to the air supply system inlet port.

• Police the work area. Remove any tools left on the machine. Tools should be returned to their box after each use. Tools or materials scattered around are a leading cause of damage/injury.

• Keep the machine clean. The work areas around the machine should be clear of oil and chips. Clean the machine as required. Inspect daily for loose, worn or damaged parts.

• Never overload the machine. Always operate within the specified size and weight limitation. (See specification section of this manual).

• Always use power equipment to lift or move heavy inspection pieces into the work area.

• When lifting parts onto and off of the machine always ensure a safe escape route in case the lifting apparatus fails

• Be careful when handling workpieces. Cutting operations produce sharp edges.

• Load heavy parts in the center of the table if possible.

• Before mounting work holding devices or workpieces, be sure that all mounting surfaces are clean and free of chips.

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Page 3-4

• It is good practice to avoid loading and unloading parts over the rails.

Operator Safety

• Never lay tools on the machine where they can interfere with its operation.

• Before using the machine, look for workpiece or other obstructions.

• Report any unusual noise from the machine. Defects should be repaired immediately. Never operate the machine in a defective condition.

• Before mounting work holding devices or workpieces, be sure that all mounting surfaces are clean and free of chips, particularly the bearing surfaces.

• Keep hands away from all guards and openings in covers when moving the bridge or carriage.

• Tables, rails, housings and their related parts can create pinch points. Be sure you are clear of such locations before operating the MH3D.

• Never remove WARNING and/or INSTRUCTION plates from the machine.

• During service, it may be necessary to remove or open some guards. If so, use great caution around exposed mechanisms. Make sure all guards are returned and in place when set-up work is completed.

• Do not allow the bridge, carriage or rail to impact the end stops with a high amount of force at the ends of the measuring range. Bring the machine to a gentle stop.

• Do not allow the probe body or Z-rail to strike the workpiece or work table.

• Do not allow the probe to strike the workpiece with high force. Reference the probing technique section of this manual.

• Do not attempt to move the bridge, carriage, or Z-Rail while air pressure is below the value listed in the specification section. Serious damage to the machine will result. Do not attempt to move the machine with the axes switches down.

• Always hold the Z rail firmly when unlocking the Z axis lock.

• Lock the machine axes when the machine is not in use.

Page 3-5

User's Manual

MH3D

Using A Desk Mouse

An important tool in using MH3D is the mouse. The mouse allows you to select items by pointing at them. If you have never used a mouse before, you may need a little practice to get comfortable with it. For the best control of the mouse, hold it with the cable pointing away from you.

Without pressing any buttons, move the mouse around slowly and watch for icons to highlight on the screen. If you run out of room, you can pick up the mouse and place it on another spot. The icons on the screen will not move while the mouse is off the pad or another surface. Notice how the mouse cursor changes shape when it is in different places on the screen.

In MH3D, you press the mouse buttons to select button icons on the screen. First you move the mouse to highlight the icon you want. Then you click a mouse button to initiate some action involving the item. An action is initiated by releasing, not pressing, the mouse button on that item. Each button performs different functions.

Button 1:

For right handed mice, Button 1 is the leftmost button. This button is used to select button icons on the screen.

Button 2:

For right handed mice, Button 2 is the center button. On MH3D this button is not used.

Button 3:

For right handed mice, Button 3 is the rightmost button. This button initiates scanning on machines witha hard probe and functions as an Escape/Abort selection when the machine has a TTP installed.

Mouse Button 3 (MB3)

Mouse Button 3 (MB 3)!

Scan/Abort with hard probe

MM3: Escape/ESC Softkey! MM4/XWindows: Used to select Editor for Textbox!

Escape/Abort with TTP

Mouse Button 2 (MB 2)! MM3: Not used!

MM4/XWindows: Used to access Pop Up Menu! Hold and drag to select option!

Mouse Button 1 (MB 1)! MM3: Enter/Select/Done Softkeys!

Mouse Button 1 (MB1)

MM4/XWindows: Used to Select or Execute!

Used to select button icon on the screen

Mouse Button 2 (MB2) Not used

LOGITECH!

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Page 3-6

Using A ZMouse

The ZMouse is similar to the desk mouse in that it selects button icons on the screen. The direction of motion is defined by the direction that the cursor button is pressed (top of the button to move the cursor up, bottom of the button to move the cursor down, etc.). The speed of the cursor is determined by how hard the button is pressed. The cursor stops moving when pressure is removed from the cursor movement button.

The Select button is used to activate icons highlighted by the cursor.

The Scan/Abort button is used to initiate scanning witha hard probe, and as an Abort/Escape function when using a TTP.

Scan/Abort

Select

Cursor Movement

Page 3-7

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MH3D

Starting & Stopping

Make sure that the following steps have been taken before starting the machine:

• Check the packing list to ensure that all necessary items have been received.

• The machine and workstation is in a thermally stable environment (see Specifications).

• The machine has been leveled such that the bridge does not drift when all axis lock switches are unlocked and the probe holder is not being held.

• Check to ensure the machine was installed according to the specifications in the Installation Manual.

• Verify that all shipping brackets have been removed.

• Check the input air supply pressure. It should be between 4.8 to 8.3 BAR

(70 and 120 psi) and should provide for a minimum consumption of

21L/min (.74 CFM). The pressure should be relatively constant and not

subject to drastic changes. The air supply should also be relatively free of contaminants. NOTE: The maximum air pressure is 8.3 Bar (120 psi)

• The air supply is connected and the regulator is factory set to the correct

pressure. The pressure gage displays 3.7 BAR (55±1 psi). The pressure has been preset at the factory. If the pressure is not correct, unlock the knob at the bottom of the regulator, adjust the pressure, and relock the knob.

• All cables from the machine to the MH3D controller (ie. encoder, ground,

ZMouse and, if included, TTP, etc.) are connected (reference the schemtatics).

• Ensure that the power supply and, if included, the printer is properly connected. For additional information about the printer, refer to the manufacturer’s technical publications for operating procedures.

• Verify that all machine guards and covers are in place.

• Wipe all exposed ways and the table work surface with alcohol and a clean, soft cloth to remove dust or residue. (Reference the Cleaning Bearing Surfaces in Preventive Maintenance Section)

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Page 3-8

Starting & Stopping

• Plug the power cord for the power supply into an outlet that agrees with the specifications in the Installation Manual.

• Power up the machine. For the MH3D controller, push the front panel

rocker switch located on the front, left edge of the MH3D control box.

• Start your measurement software.

Page 3-9

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MH3D

Moving the Axes

A position at the front of the machine is a comfortable one for most operations. This permits easy access to the measuring envelope while watching the video display on the MH3D enclosure.

The movement of each axis through the measuring envelope is accomplished by pushing or pulling on the Z-rail. The Z-rail has finger pads at its lower end for gripping. Stops are provided at both ends of the three axes to prevent overtravel. Care should be taken to slow down when approaching the stops to prevent banging.

On the MH3D each axis is provided with a locking system. This system consists of three switches, mounted on the left leg, that control the flow of air to the locking air bearings. Turning a switch to "off" (down) deflates the preloaded air bearings for that axis and locks the axis.

The Z-rail counterbalance system equalizes the weight of the rail so that it moves easily up and down. The regulator that controls the counterbalance is located at the right side of the ZX carriage. It must be adjusted to compensate for varying probe weights. If the counterbalance pressure is adjusted too low, it will trigger the safety valve causing the Z-axis bearings to deflate and lock.

User's Manual

MH3D

CAUTION

On the MH3D do not attempt to move any axis with the air supply to that axis turned off.

Do not attempt to adjust the Z-rail counterbalance with the axis locked. Hold the Z-rail firmly when unlocking the Z-axis. The rail, if not properly adjusted, may move suddenly when the axis lock is released.

On the MH3D, the axes can be precisely adjusted by means of a rod and bearing arrangement that acts like a fine pitch screw. The rod is turned by means of large, knurled knobs mounted on both ends of the X-axis and Y-axis and at the lower end of the Z-axis. There are switches on each of the individual fine adjust mechanisms that are used to engage or release the mechanism.

Page 3-10

Homing the Machine

The home position for the MH3D is in the upper front left corner of the machine. Before any measurements can be made, the machine must be moved to its home position and that position must be recorded in the software. This is so that the machine has a reference position to which it can relate all axes movements.

• To home a MH3D, release the axis lock switches so the machine floats freely. Slowly move the Z axis to its highest point where it will hit the Z

axis end of travel stops. You do not want to slam the axis against the end of travel stops. Slowly move the ZX carriage in the -X and -Y directions until you hit the stops for the X and Y axes in the front left corner of the machine. Without moving the machine, relock the axis lock switches.

Press the Done softkey to tell the measurement software that you are now

in the “Home” position.

• Clean the reference sphere and mount it to the table. Be sure the connections are tight. It should always be positioned where it will not interfere with the mounting or measuring of workpieces. NOTE: After the reference sphere has been located it should not be moved! Refer to the Getting Started Manual for instructions for locating the reference sphere.

• Reattach the probe to the probe holder.

• Adjust the Z Axis counterbalance for your probe. It should be adjusted so the Z rail does not rise or fall when the probe holder is not being held.

• Qualify your first tip.

NOTE: The boxed letters refer to the movement! necessary for the Bridge/XZ-Carriage/Z Rail to ! reach the "home"

• Verify that the offsets and home position are correct by moving the machine back to the home and reading the machine position. The machine position (X,Y,Z) will be the current probe offsets.

• Mount the workpiece if one is not already mounted to the table.

• Begin the measurement session.

• If the machine is to be stopped overnight or longer, it is recommended that

the air supply be shut off. Whenever the machine is left unattended, the axis lock switches should be placed in the Fine Adjust or “locked” position to prevent inadvertent operation. Machines equipped with the optional air saver will automatically shutoff the air supply after a predeter-

mined time interval, if enabled. See the Software Manual for details.

• After a power loss, the procedure for starting is the same as above.

• After a power loss, the machine homing sequence must be repeated.

-Y!

-X!

+Z!

osition.!

Page 3-11

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The Inspection Process

The first step to approaching a measurement is to review the print or drawing and identify all dimensions which must be verified. One prefered method is to highlight all dimensions which must be verified. Once a good understanding of the measurement task is in place then the setup and fixturing can be identified.

To mount a workpiece for measurement:

• Remove all obstructions from the MH3D’s work table.

• Ensure that the part to be measured does not exceed the machine’s weight or size capacity.

• Locate the part within the measuring envelope of the MH3D, ensuring that the sections to be measured are within the probe measuring range and as close to the operator as possible. If table clamps are used, try to locate the workpiece conveniently with respect to the M10 threaded table inserts

CAUTION

Do not overtighten clamp bolts or the threaded table inserts may pull loose from the granite table. The maximum allowable torque on the

bolts is 15 ft. lbs.

Clamping is a very important aspect of planning a measuring strategy yet it is often overlooked. Incorrect fixturing can lead to part deformation and use up a significant portion of the part tolerance. The problem is magnified with temperature variation during the measurement period. It is impossible to define a generic method for fixturing parts since this will vary due to part geometry, material, cross section, etc. Let it surfice to say that the clamping or fixturing method deserves serious consideration when creating an inspection plan. There are many articles available on designing kinematic clamping / fixturing systems.

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Page 3-12

Probe Installation

The Z-rail has a probe holder built into the bottom of the rail. To install a hard probe:

1. Loosen the locking lever on the side of the Z-rail.

2. Insert the probe shank into the Z-rail. A spring plunger detent will help to hold the probe in place (the probe tip is normally 3" (75mm) from the end of the Z-rail).

3. Tighten the locking lever. Be sure the probe is firmly clamped.

4. Adjust the Z-rail counterbalance control to compensate for the added weight of the probe. Unlock the Z-axis. Unlock the counterbalance regulator by pulling the knob

outward. When finished, push the knob in.

Z-rail

ZMouse

Probe Locking Lever

To install a Touch Trigger Probe:

1. Loosen the locking lever on the side of the Z-rail.

2. Check the Touch Trigger Probe to be sure it has a stylus tip. If not, obtain the required tip and install it onto the probe head sensing shaft, securing the tip with the stylus tool provided. Refer to the probe manufacturer's documentation for stylus installation instructions.

3. Insert the probe head mounting shaft into the Z-rail until it engages the detent.

4. Rotate the probe head until the red light indicator faces the front of the machine.

5. Hold the probe in this position and tighten the locking lever until the probe is firmly clamped.

6. Connect the probe head lead to the probe connector located on the Z-rail.

7. If necessary, adjust the Z-rail counterbalance control to compensate for the change in weight from the probe. The proper tip type must be selected in the MH3D software.

Note: These probe installation procedures are typical and included as an example. The procedure for installing your probe may differ from these. Refer to your probe manufacturer's documentation for installation instructions. Note: Each tip must be qualified before it it used for measurements.

Page 3-13

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Measuring With a Ball Probe

Qualifying Probes

All probes must be qualified before accurate measurements can be made. There are two primary purposes for this:

• To calculate the effective tip diameter.

• To learn the location of the center of the probe tip in the measuring volume. This is important to obtain properly compensated data when the positional feedback is filtered through the error map.

Before qualifying a probe,

• Verify that the proper probe type is selected in the software.

• Verify the probe shaft diameter for your machine.

• Verify the reference offsets for your probe.

• Verify that the qualification or reference sphere diameter is correct within the software configuration.

Refer to your software manual for a detailed description of the probe calibration process.

To measure with a ball probe, firmly hold the Z-rail and gently make contact with the surface of the part with the ball probe. Be sure there are no vibrations or bouncing and that the probe has come completely to rest against the part. To measure a point with a hard ball probe, bring the probe into contact with the part surface and press the “Scan” (left) button on the ZMouse or the right hand button on the desk mouse.

The measurement software continually monitors the measuring direction or “sense” and automatically corrects or “compensates” for the probe radius.

The measurement software also continually monitors the location of the measurement point within the measuring volume. The “approach” vector, or the vector created from the last monitored point to the first measurement point, is of critical importance for all features. For planar surfaces, the approach vector is used in the calculation of the positive direction of the feature’s vector. The approach vector should be as perpendicular to the feature’s surface as possible. After the first point is taken, it is OK to slide the probe on the feature’s surface between taking points.

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Page 3-14

Probe Compensation

“What is probe compensation?” When a point is measured with a probe, the point recorded is at the center of the probe, not on the surface of the probe. Probe compensation is the process of calculations that corrects the measured feature for the probe radius error. The approach vector for the first point of a

feature is used in these calculations and is thus of critical importance.

The approach vector determines:

• The direction of probe radius compensation during measurement calculations

• A plane’s vector direction

• Which bonus tolerance calculation to use when true position tolerancing circular features

Taking Points With a Hard Probe Against a Planar Surface

The approach of the probe to the first point should be as perpendicular to the planar surface as possible.

The probe can be slid against the planar surface from point to point only after the first point has been taken.

Taking Points With a Hard Probe on a Round Surface

The approach vector for the first point for a round surface should be radial.

Points taken after the intial point can be tangential to the round surface.

Page 3-15

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Measuring With an Electronic Probe

NOTE: Carefully read the probe user’s guide before attempting to use the probe.

Measurement points are recorded when the stylus is deflected enough to either break mechanical contacts or generate enough force to trigger pressure sensitive circuitry. This generates a signal to the controller, which latches the counters and records the “point”. For manual measurements, the operator must be careful to take measurement points at a velocity which will not create damage to the probing system.

PART SURFACE

POINT TO BE PROBED

Point to be probed

Note that probe approach vectors are perpendicular

to the surface of the sphere

PROBE PATH

Probe path

APPROACH OF THE PROBE

Approach of the probe

SHOULD BE WITHIN ±80°

should be within ±20°

OF THE PERPENDICULAR

of the perpendicular

The arrangement of the contacts does cause slight errors in probing. These are reduced during probe qualification. However, the longer the probe tip extension, the larger the pre-travel error and the more residual error is left after probe qualification. Also, longer probes tend to be not as stiff as shorter probes. The more a stylus bends or deflects, the lower the accuracy. Therefore, probing with very long stylus/extension combinations should be avoided.

Probe hits (also known as “points”) should be taken perpendicular to the part surface wherever possible. If hits are not taken perpendicular to the part, skidding may occur. Skidding (probe tip sliding on the part as probe contacts are disturbed) produces inconsistent and non-repeatable results. If probe hits are taken within 20 degrees of perpendicular, skidding errors will be much less than one micron (0.000040 in.).

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Page 3-16

Touch Trigger Probe Repeatability

The touch trigger probe is designed to give optimum results when the probe hits are taken perpendicular to the probe body (perpendicular to the axis of the stylus). Wherever possible make hits perpendicular to the probe body. Probe hits taken parallel to the probe body (along the axis of stylus) give results that are not as repeatable as those taken perpendicular to the axis. Probe hits neither perpendicular nor parallel to the probe body give results that are less repeatable as those taken parallel to the probe body. Probe hits taken parallel to the stylus axis, but at an angle to the probe body, are not repeatable and should be avoided if possible.

Probe configurations causing triggering forces which are neither parallel nor perpendicular to the probe body should be avoided.

Highest Repeatability Perpendicular to the Probe Body

Neither Perpendicular nor Parallel to the Probe Body

Parallel to the Probe Body (Along axis of stylus)

Probe

Stylus Knuckle

Very Low Repeatablility (should be avoided)

Neither Perpendicular nor Parallel to the Probe Body but along the axis of stylus

Page 3-17

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MH3D

Touch Trigger Probe Repeatability

Correct Probe Contact

Another possible cause of error is shanking, when the probe contacts the part with the shank of the stylus and not the tip. The measuring system will assume the hit was taken with the tip and large errors will occur. Increasing the diameter stylus ball increases the ball/stem clearance and lessens the likelihood of shanking. The Effective Working Length (EWL) is the depth that can be achieved by the stylus before its stem fouls (or shanks) against the feature. Generally the larger the ball, the greater the EWL. Using a larger stylus ball also reduces the effect of surface finish of the component being inspected, however, the largest ball which can be used is limited by the smallest hole to be measured.

Effective Working Length (EWL)!

Ball/Stem Clearance!

The probe should be treated as a precision measuring instrument. Keep it free of dirt and handle it with care to ensure it maintains it’s size and shape.

The stylus is made of industrial quality ruby that is very hard and provides good wear resistance. The stylus ruby tip should always be kept free of contaminants. A one micron (0.000040 inch) piece of grime causes a one micron measurement error.

Shanking

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Page 3-18

Page 3-19

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Useful Probe Dimensions

TESASTAR_i

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Page 3-20

Good Measurement Techniques

The following are good techniques to use when operating the MH3D:

• Operators should qualify their own tips because of differences in style.

• Verify probe offsets after qualification.

• Clamp the part so that it doesn't move when measuring.

• Hold the Z-rail on the pads and not on the bearing surface to prevent heat transfer to the machine.

• Be sure the part, the qual sphere and the stylus are clean.

• Recertify the qual sphere for size and form at least once a year. If the qual sphere is dropped, it must be recertified.

• If the granite is used as a datum it should be cleaned, periodically certified for flatness, and realigned with the machine's X and Y rail plane surface.

• Be sure the direction vector is correct when contouring with a hard probe or when checking a complex surface contour.

• Use a perpendicular approach vector whenever possible. Make your measurements perpendicular to a surface when contouring with a Touch Trigger Probe.

• The machine should be level to the floor and the granite level to the machine without anything on the granite.

• When checking close tolerances, the form of the ball probe should be checked.

• When qualifying with extensions that could affect accuracy, check with a ring gage. Use for interim gage checks or probing setup.

• When qualifying tips, check form error. If not within 4µm (.000015"), requalify.

• Don't use the machine or granite plate to rest on.

• Practice your measurement techniques. You need constant practice to get good results.

• Locate the reference sphere and allow it to stabilize before measuring.

• Check air pressure. An axis drag can affect machine performance.

Page 3-21

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MH3D Notes

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Page 3-22

CHAPTER 4

Maintenance

Page 4-1

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Page 4-2

Maintenance Safety

Proper maintenance, on a regular scheduled basis, is vitally important in a plant safety program. You should be thoroughly familiar with the MH3D, including its controls, safety devices, and operation, before attempting any maintenance work. Since maintenance work often necessitates working on a machine with safety guards and covers removed, you should approach every job with the proper respect for established safety procedures.

Read this manual carefully before attempting any maintenance work on the machine. Failure to follow procedures recommended in the manual can result in injury to personnel or damage to equipment.

• If you are uncertain about the correct way to do a job, ask for instructions before proceeding.

• Your TESA machine represents a sizable investment. If maintained and used properly, it will provide you with many years of excellent service. We highly recommend that in its maintenance you use only genuine TESA replacement parts in the interest of long machine life, production efficiency and operator safety. Failure to do so may lead to unsafe operating conditions and will invalidate warranty agreements.

• Never remove the Warning and/or the Instruction plates from the machine.

• Use Isopropyl Alcohol as a solvent to clean the rails and worktable of the MH3D.

CAUTION

Never use carbon tetrachloride as a solvent for cleaning. Provide proper ventilation when chemicals and gases are used.

General Safety Practices

• Immediately report any unsafe practices or conditions you may observe.

• Make sure the machine is properly located and secured. Allow sufficient access to the machine to prevent the danger of contacting other machinery.

• Keep wrenches, tools and other miscellaneous equipment off the work table and aluminum rails. Avoid using the table as a workbench. Return tools to their box after each use. Tools or materials scattered around are a leading cause of damage or injury.

• Digging, grinding or chipping near the machine should be avoided.

Page 4-3

The Machine's Environment

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MH3D

Maintenance Safety

h n

Electronics

• Disconnect all Power sources before attempting to perform maintenance or repairs. Make certain no one can turn power ON without your knowledge. Attach warning tags to prevent unauthorized use and/or unintentional start.

• The electronics cabinet houses terminals that carry up to 450 VAC. Shock hazards are therefore present. Even low voltage shocks can cause death. Make sure service is properly grounded. Always keep the cabinet closed.

• Never attempt to modify or rework the machine’s

DANGER

DO NOT

OPERATE

This tag must not be removed, except by t person who signed a

attached it.

DATE SIGNED BY

electrical system.

• Never defeat electrical interlocks.

• Allow only authorized electrical maintenance personnel access to the electrical cabinet of the machine.

• A good earth ground (less than 5 ohms) is required for reliable operation of the electronic controls.

• This machine will operate satisfactorily at customer supplied line voltage levels within ±10% of the normal rating. Sharp line voltage changes such as those that could occur when a welder or large motor is applied to the line, can adversely affect machine operation and must be avoided.

Covers

Pneumatics

• Never touch electrical equipment when hands are wet. Never activate electrical circuits while standing on a wet surface.

• Solid state control circuits require proper grounding and shielding. Ensure that all shields are properly connected after repairs. Any unauthorized addition to machine wiring invalidates machine warranty and may result in unexpected operation.

• During maintenance work, it may be necessary to remove or to open some guards. If so, take extra care because of exposed mechanisms. Make sure all guards are returned and in place when maintenance work is completed.

• When covers are removed, mechanical pinch points are exposed. Keep hands or loose clothing away from all mechanisms, even those at rest.

• Never use compressed air to clean dust and chips from machines. Vacuum type arrangements are best for these purposes.

• Pressure in the air system must be reduced to zero before the system can be opened.

• Do not attempt to move the bridge, carriage, or Z Rail while air pressure is off. Serious damage to the machine will result.

• Before repressurizing the system after maintenance, be sure the main air line is securely attached to the air supply system inlet port.

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Page 4-4

Maintenance Intervals

This schedule of maintenance inspections must be followed to ensure continuous and safe operation of your machine. A maintenance log should be kept for each machine and all work and/or replacements recorded for future reference. Failure to follow this schedule will be cause for invalidation of the warranty. Any components not functioning properly should be adjusted for proper operation or immediately replaced.

Scheduled maintenance checks must be performed by assigning personnel who are thoroughly familiar with maintenance procedures. The more complex inspections must be done by trained maintenance personnel on a regular basis at the minimum intervals shown.

The recommended intervals for preventive maintenance are: Daily, Monthly, and Three Months. These intervals are based on eight hours per day and forty hours per week of machine operation.

If the machine is operated on longer or extra shifts or for more than five days per week, the maintenance schedule must be adjusted as follows:

• Daily or every 8 hours of operation

• Monthly or every 165 hours of operation

• Three months or every 500 hours of operation

For example, if a machine is operated for two eight hour shifts per day, the monthly maintenance should be scheduled every two weeks. If the machine is used less than eight hours per day or less than forty hours per week, the regular daily, monthly and three months schedules should be followed.

Copies of this Preventive Maintenance Schedule should be available to all personnel involved.

CAUTION

Turn Power Switch to OFF and unplug the power supply when making adjustments, removing or replacing covers, guards and components and when making inspections requiring physical contact with the machine. Some inspections and adjustments require the Main Power to be in the ON position to provide necessary power. In such cases, use extreme caution to prevent injury and machine damage.

Page 4-5

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MH3D

Maintenance Schedule

Daily or Every 8 Hours Give the machine an overall check daily. Pay particular attention to the following

steps:

1. Check guards and covers. Repair any that are damaged. Replace any that are

missing.

2 Wipe all exposed air bearing paths and the work table surface with alcohol

anda clean, soft cloth. Use clean medical gauze or the equivalent.

3. Check the air supply. It should be 3.7 BAR (55 psi).

4. Check the air filters and drain or replace, if necessary.

CAUTION

Never attempt to remove any portion of the filtration system without disconnecting the air supply to machine and bleeding off system pressure.

Monthly or 165 Hours

Every Three Months or 500 Hours

1. Inspect the machine visually for loose, worn or damaged parts. Tighten any

loose screws or nuts. Replace any that are missing.

2. Check air supply coalescing filter for buildup of water or oil. Press the rubber

knob on the filter sideways and drain the filter as required (always wear safety glasses). The air supply must be on. If a buildup is constantly found, installation of additional filtering or an air drying system may be required.

3. Check the cable and cable connections for the Z-axis counterbalance.

4. Check electronic probes and cables.

5. Check measuring scales.

6. Check air system.

1. Visually check the electronics for dirt, oil or water and for loose wires or

damaged insulation.

2. Check all machine functions to ensure proper and accurate operation.

A simple program to test the repeatability, machine geometry and linear accuracy is recommended.

3. Check the cable connections on the machine and at the control box. Be certain

cables are fastened and safely routed to prevent accidents.

4. Check the air system for loose or cracked lines.

5. Check that the machine is level.

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CAUTION

Hazardous Voltages exist inside the electronic cabinet. Service must be performed by trained, authorized personnel only. Use extreme caution in making tests and adjustments. Safety glasses should be worn while servicing the electronic cabinet.

Maintenance Log

Check guards and covers

Wipe ways and table

Check measuring scales and clean if required

Drain coalescing air filter

Check air supply

Check machine functions

Check regulator pressure

Inspect machine for loose, worn or damaged parts

Check air filters

Check Z-axis counterbalance cable

Check electronic probes and cables

Daily

Monthly

Check measuring scales

Check air system

Check that the machine is level

Check air system lines

Check all machine functions

Check electronics

Check cable connections

Three Months

Page 4-7

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Machine Troubleshooting

Axes won’t move

• Is the axis lock switch off?

• Is the air filter clogged?

• Is the air regulator set to correct pressure?

• Is the air regulator broken or leaking?

• Is the air inlet connected to air supply? Is the air supply on?

• Are any air lines broken? Broken air lines are indicated by excessive air

escaping.

• Is the counterbalance regulator broken, leaking, locked, or is adjusted

incorrectly?

• Is the counterbalance regulator set too low? Turn clockwise to increase.

Axes drag

• Is the axis lock switch off?

• Is the air filter clogged?

• Is the regulator set for the correct pressure.

• Is the counterbalance regulator adjusted correctly?

• Are any air lines broken? Broken air lines are indicated by excessive air

escaping.

• Are the rails dirty?

• Are the axis loop cables too tight or positioned wrong?

• Is an air hose dragging on one of the rails?

Machine X or Y axes drift

• Is the machine level? Place a level on top of the X and Y rails.

• Check for axis loop cables interference.

Axes locks do not work

• Are any air lines broken? Broken air lines are indicated by excessive air

escaping.

• Are the air lines properly connected?

• Are the pressures correct at the air regulator and counterbalance regulator?

Machine won’t turn on

• Is the power cord plugged in?

• Is the voltage supply correct?

• Is power supplied to the receptacle?

• Is the power switch on?

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Machine Troubleshooting

Machine won’t repeat measurement

• Are excessive vibrations occurring in the area of the machine?

• Is the part secure on the table?

• Is the probe tight in Probe Holder? Check that locking knob is tightened.

• Is the probe broken?

• Verify that the trigger force is correct for the stylus length. An incorrectly adjusted stylus is a source of non-repeatability.

• Shorter stylus lengths will give more repeatable results than longer stylus..

• Review your probing technique.

• Is the diameter of the stylus ball too small? Make sure the stem of the stylus does not hit against the part being measured.

• Is the temperature of the part, machine and the measuring environment stable and within specification?

• Is the TP2 (if supplied) screwed tightly into the probe body?

• Is the stylus screwed in tightly?

• Is the probe shanking on the part?

• Is the proper measurement plane selected (XY, YZ, ZX)?

Inaccurate measurements

• Is the part dirty or oily?

• Is the surface finish on the part poor? Using a larger diameter stylus ball will reduce the effect of surface finish of the part being inspected.

• Was the homing/initialization procedure followed correctly?

• Is an unqualified tip being used?

• Has the tip been moved after qualification?

• Has the qualification sphere been moved since the first tip was qualified? The reference offsets and tip 1 measurements must be repeated if sphere is moved.

• Has the probe been damaged?

• Check the temperature of the part, machine and the measuring environment. Are they stable and within specification?

Probe does not take hits

• Are the cables correct and properly connected?

• Is the TTP enabled? See Software Manual for details.

• Is the probe interface (PI-6) loose or not present?

• Has the probe reseated? The red light on the probe should blink off and on each time a hit is registered. If the light remains off after a hit has been taken, gently move the stylus or the probe with your finger. The probe light should turn back on.

• Are the machine and control box cables correct and properly connected?

Page 4-9

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Machine Troubleshooting

Movement is not smooth / Bearing is rubbing

• Stop using the machine immediately! Continued use could damage the guideway system.

• Check to ensure that the air pressure for the machine is set to 55 psi.

• If the machine air pressure is set to 55 psi, consult TESA for help.

Oil appears from under the air bearings

• Clean the rails as described in “Cleaning the Bearing Surfaces”

• Check the machine’s air filters and replace the cartridge if necessary.

• If oil appears frequently, the air supply may be particularly poor. It may be advisable to add a larger coalescing filter to the air supply upstream from the machine.

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Cleaning Glass Scales

If it is necessary to clean the glass scales on the MH3D, proceed as follows:

Cleaning the X Axis Scale

• Move the bridge to the rear of the

machine.

• Move the ZX cariage to one end of its travel. Lock the machine's axes.

• Clean the measuring scale with a soft, anti-static cloth that is moderately wetted with pure alcohol. Use only Isopropyl Alcohol. Allow the alcohol to dry. NOTE: Do not use any other type of cleaning fluid.

• Unlock the axes and move the bridge or carriage to the other end of its travel. Lock the machine axes. Clean the exposed part of the scale. It is important that all residue be removed from the scale.

• Check all surfaces for smudges and reclean as required.

• Unlock the axes and move the ZX carriage to the middle of the X-axis rail and

lock the machine's axes.

Cleaning the Y Axis Scale

• Move the bridge to the rear of the machine. Lock the machine's axes.

• Clean the measuring scale with a soft, anti-static cloth that is moderately wetted

with pure alcohol. Use only Isopropyl Alcohol. Allow the alcohol to dry.

NOTE: Do not use any other type of cleaning fluid.

• Unlock the axes and move the bridge to the other end of its travel. Lock the

machine axes. Clean the exposed part of the scale. It is important that all residue be removed from the scale.

• Check all surfaces for smudges and reclean as required. Cleaning the Z Axis Scale

• Move the bridge to the rear of the machine.

• Lower the Z-axis rail to its lowest point.

• Lock the machine axes.

• Clean the exposed end of the measuring scale with a soft, anti-static cloth that is

moderately wetted with pure alcohol. Use only Isopropyl Alcohol. Allow the alcohol to dry. It is important that all residue be removed from the scale. Check all surfaces for smudges and reclean as required.

NOTE: Do not use any other type of cleaning fluid. NOTE: Because the end of the scale on the Z-axis is not normally exposed during operation, it is not anticipated that it will require periodic cleaning.

X Scale

Z Scale

Y Scale

The scales are fitted with covers that must be removed before the scales can be cleaned. Be sure the covers are cleaned and returned after cleaning the scales.

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Changing the Air Filter

CAUTION

Be sure air pressure is shut off before attempting maintenance work on the air system. Make sure the bowl is properly in place and latched before turning on air pressure.

If it becomes necessary to replace an air filter or a filter element, obtain one from the factory. To replace the filter:

1. Turn off air to machine at supply. Make sure air pressure has gone to zero.

2. Using the release latch, remove steel bowl guard shield from filter.

3. Remove plastic filter bowl.

4. Unscrew filter element.

5. Assemble the new filter element and replace bowl and shield.

Pressure Adjust Lock Knob

Air Inlet

70-120 psi

(4.8-8.3 BAR)

Pressure Gage

Particle Filter

*Not Shown - Optional Air

Saver Valve

Automatic Drain

To Machine 58 psi (4 BAR)

Particle Filter

Automatic Drain

• The coalescing filter element may be washed in safety solvent and then dried

and reused once or twice and then replaced. Air filters should be washed or replaced at intervals of 6 months if the air line is dirty.

• The coalescing filter has an O-ring on its upper surface. Be sure the O-ring is

seated properly in the groove before reinstalling.

• If the filter gets dirty fairly quickly, place another air filter/regulator upstream of the machine.

• If excessive water is present within the air system at your facility use a Refrig- erated Air Dryer

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CHAPTER 5

Glossary

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Glossary

Abort To stop (cancel) an impending action or command. Absolute Value A value which disregards the plus or minus signs of

numbers and adds their values together.

Acceleration The rate of change of velocity. Accuracy The deviation of a part or a measuring system from a

known standard. The quantitative measure of the degree of comformance to recognized standards of measurement.

Active Plane The plane in which you are currently working. Actual Probe The true size of the probe diameter.

Diameter Actual Value The measured value of a feature. Air Bearings An accurate form of support for the moving axis ele-

ments of the machine. Air is forced by pressure through the space between the bearing pad and the axis way surface creating a film of air which permits movement of the machine’s members with almost no friction.

Alignment The procedure of relating the XYZ coordinates of a part

to the coordinates of the machine, compensating for the fact that the part is not perfectly square to the machine’s table. It shows the CMM where the workpiece lies.

Angle The degree of difference between two features eventu-

ally meeting in a point.

Angle of Lines A measurement routine that computes an angular

distance between 2 line elements.

Angle of Planes A measurement routine which computes an angular

distance between 2 plane elements.

Angularity The measured angle between two features. A.N.S.I. Y14.5 An American National Standards Institute standard for

dimensioning of drawings.

Append To add to an existing part program. Applications Software that provides the computer with instructions

Software for a specific task, such as inspecting a part.

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Glossary

Approach Vector The vector that the measurement software takes to

calculate a pre-measurement position and approach the surface point on the part.

Array An allocation of memory to be used in a program. Axial Length The deviation from the known length of a standard Accuracy placed parallel to the axis measured. Includes probe

error.

Axis A reference line from which distances or angles are

measured in a coordinate system.

Axis Direction The direction of any line parallel to the motion direction

of a linear moving component.

Axis Feature The centerline of a cone, cylinder or step cylinder. B89.1.12 The American Standard (ANSI/ASME) for determining

Coordinate Measuring Machine accuracy and performance.

Backoff Distance The distance the probe backs off the part after a touch. Backup Copy A duplicate of a part program.

Ball Bar A three-dimensional gage consisting of two precision

balls of the same diameter, separated by a bar and used for determining volumetric accuracy. The bar must be sufficiently rigid that its length is constant during a set of measurements.

Ball Bar (Socketed) A ball bar held by a socket which allows repeatable

relocation at one or both ends.

Ball Probe A type of rigid probe used for measuring curves, lines

and holes.

Bandwidth The total bidirectional deviation from a nominal value

(Maximum-Minimum range).

Best-Fit Feature A feature constructed through the measurement points

that most approximate a perfect feature.

Bilateral Tolerancing A tolerancing method where the feature dimension is

allowed to vary in both the positive and negative directions from the nominal.

Bolt Circle A measurement routine which constructs a circle

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Page 5-4

through previously measured circle center points.

Glossary

Booting a System The process of activating or loading the software into the

computer. Powering the computer system so that the operating software becomes functional.

Boss A circular raised projection on the surface of the work

piece.

Bridge The bridge is an inverted “U” shaped member that

moves in the Y direction and supports the X and Z moving members.

Buffer A storage (holding) area in a computer for measurement

data.

CAD/CAM Computer-Aided Design, Computer-Aided Manufacture. Calibrate To adjust a measuring instrument or inspect it for

accuracy.

Calibration Sphere An accessory used in qualifying the probe. A master

sphere.

Cartesian Feature output expressed as X, Y, and Z. Cartesian A system used to describe points in space in terms of X,

Coordinates Y, and Z axes. The axes are perpendicular to each other.

The points are expressed in relation to some fixed origin (zero point).

Cartesian Coordinate A measuring system that uses three independent, Measuring System mutually perpendicular, axes to form a grid. The

coordinates of a point are measured as distances from each of these axes.

Centroid The weighted center of all points that make up an

element.

Character Any letter, number, or punctuation mark that can be

typed from a keyboard or displayed on a screen.

Circle A geometric element defined by a minimum of three

points equidistant from a centerpoint. A measurement routine used to compute the diameter and location of a bored hole or a cylinder.

Circle-Circle A measurement routine which computes the shortest Distance two-dimensional distance (working plane) between 2

circle center points.

Circularity The condition of a circle as it lies in a tolerance zone

formed by two concentric circles. Also called roundness.

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Glossary

CMM Coordinate Measuring Machine. A machine that per-

forms physical movements necessary to inspect a part in three dimensions.

CMS Coordinate Mesuring System. A system for part

inspection that includes a coordinate measuring machine, controller, system computer and software.

Computer Assist The use of a computer to process raw data into meaning-

ful measurements. Probe movements are directed manually by the operator.

Concentricity The location of a feature’s axis in relation to another

axis. A measurement routine that computes the TIR (Total Indicator Reading) between two circle centers.

Cone A three dimensional space formed by a base and angled

sides running from the base to the tip or apex. A minimum of six points are required to define a cone.

Contact Probes Probes which must touch the part in order to make a

measurement. They can be either rigid or electronic.

Contact Velocity The speed of the probe as it actually takes a measure-

ment and touches the part.

Coordinate The X, Y, and Z values that identify the location of a

point in space.

Coordinate System A method of locating a point in space by assigning it a

value according to its distance from a reference. Two types are Cartesian coordinates and polar coordinates.

Cosine Error The measurement error in the motion direction caused

by angular misalignment between the measuring system and the part being measured.

CPU Central Processing Unit. The ‘brain’ of the computer. CRT Cathode Ray Tube. Another name for the computer

screen or video display.

Cursor An underline mark, arrow or rectangle that appears on

the computer screen and marks the position of the next character to be entered.

Cylinder A circular three dimensional space. A minimum of five

points are required to define a cylinder.

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Glossary

Cylindrical Expressing a point in space by its (r, phi, z) in relation to Coordinates some fixed origin. The same as Polar Coordinates.

Cylindricity When all points of a cylinder surface are an equal

distance from a common axis.

Data Information that a computer understands and stores. Database An area of computer storage holding the part programs. Data Fit Coordinate points in space that are put together by a

computer to form geometric features such as planes, circles, lines, spheres, etc.

Datum An origin or starting point for measurement, usually a

major feature or surface. A reference point, line or plane to which the location or geometric characteristic of a feature is related.

Datum Feature An actual, physical part feature on which a reference

point is established.

Datum Reference The perpendicular intersection of the primary, secondary Frame and tertiary datum planes

Default The preset value that a computer will assign to a variable

if the operator does not enter a value.

Deviation The difference between the actual measured dimension

and the nominal dimension. Deviation is positive if the actual dimension is larger than the nominal. Deviation is negative if the actual dimension is smaller than the nominal.

Device An auxiliary storage unit, such as a disk drive. Diameter of a The maximum diameter of a rotary table supplied with a

Rotary Axis measuring machine. This is the maximum diamter on

which a part can be fixtured.

Direction Cosine One of three trignometric directional values (I, J and K)

used to identify a feature’s orientation in space.

Directory A storage area for programs located in the database. Disk A storage device used to store part programs and other

data collected by the computer.

Disk Drive A device used to read and write information from the

computer to a disk.

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Glossary

Distance The shortest length between features.

Done A function that signifies completion of the current

display by the user.

Drift Test (Thermal) A type of test for measuring temperature variation error

on a machine.

Edge Finding Probe A rigid probe with a flat side for measuring the edges of

parts.

Edit A mode in which the user or programmer may make

changes to an existing part program or routine.

Effective Probe The actual probe diameter minus the response time of Diameter the touch trigger probe.

Element A feature on the part that requires machine input. There

may be more than one element for a feature.

Envelope The measuring range of the CMM Error Mapping Computer correction of local errors with the measuring

envelope of a Coordinate Measuring Machine. It requires a stiff, stable mechanical structure.

E-Stop Emergency stop. A button that will immediately stop all

systems.

Execute The process of executing previously learned moves and

measurements on the CMM. To run a part program.

Feature A feature is the same as a measurement or alignment

routine name. A feature contains elements which in turn contain CMM hits (measurements). An actual portion of a part such as a hole, slot or surface.

Feature Name A user defined name assigned to a measurement

routine’s measured values.

Feature Substitute In a multi-element routine, it gives the user the ability to

substitute a previously saved feature routine.

Feature Type Denotes the menu level feature name, such as Circle,

Point, etc.

File An organized collection of information stored in the

File Name A name used to store a file in the computer.

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computer as a unit.

Glossary

Firmware Specific program functions stored on PROMs rather than

in software.

First-Named Axis The first letter in the name of the working plane. For

example, in the XY working plane the first-named axis is X.

Flatness A measurement routine that computes the deviation from

true flatness of a plane.

Form The amount a feature deviates from perfect. If form

equals zero, the feature is perfect.

Form Tolerance A type of geometric tolerance that controls the shape of

a feature. Form tolerances include flatness, roundness, straightness, etc.

Free Floating A mode of CMM operation where the probe is moved Manual Mode manually from point to point without use of a motor

drive. Used only on machines with nearly frictionless bearings.

Gage A mechanical artifact used either for checking a part or

for checking the accuracy of a machine. A measuring device with a proportional range and some form of indicator, either analog or digital.

Geometric The use of geometric shapes to define part features. Dimensioning

Geometric Elements Seven shapes used to define a part and its features. The

shapes are point, line, plane, circle, cylinder, cone, and sphere.

Granite A dense, wear resistant, mineral used in the construction

of CMM work tables. It is capable of being finished to excellent flatness.

Hard Disk A rigid disk used for storing programs and data collected

by the computer. It is usually permanently installed inside the computer.

Hard Probes Solid probes. Mechanical probes terminating in balls,

cylinders or taper shapes, or as rotating edgefinders. Can only be used with manual machines.

Hardware The physical components of a computer system, includ-

ing the CPU, keyboard, disk drive, monitor and printer.

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Glossary

Hit A CMM input point of the current X, Y, Z coordinates

originated by the user through a switch or touch trigger probe signal. A measurement.

Home Machine zero. The 0, 0, 0 point (intersection) of the

three machine axes X, Y and Z.

Host Computer The computer that controls the CMM. Hysteresis A component of bi-directional repeatability caused by

mechanisms such as drive train clearance, guideway clearance, mechanical deformations, friction and loose joints. The three types of hysteresis are setup, machine and probe.

IJK A three-dimensional line that defines the direction of a

vector. The directional components (cosine) of a vector in XYZ space.

Included Angle An angle of less than 180° that is located between

vectors.

Input The information entered into a computer system. Inspect To manually check a part, not using the DCC mode of

the machine. A mode where the operator uses all measurement capabilities yet does not save the steps to a part file.

Intersection The creation of new geometric elements when two

existing geometric elements cross each other.

Joystick A lever on the joystick box used to control the move-

ment of the axes of the CMM.

Keyboard A part of the workstation resembling a typewriter used

for communicating with the computer.

Laser Laser interferometers are used to determine scale

accuracy of Coordinate Machines as well as to check geometry. They are considered an absolute length standards, since they use the unchanging wavelength of light.

Learn To manually inspect a part with all moves and measure-

ments being saved for future use under a specifically named program.

Least Square The interpolation of a function to all points in a given Method data set.

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Glossary

Level A part feature specified as a reference that is used during

an alignment.

Length A measurement routine that determines a measured

perpendicular distance between a point and a line.

Lift The thickness of the air film in an air bearing. Limit Tolerancing A method of tolerancing that specifies the maximum and

minimum size of a feature.

Line A geometric element that consists of two points and has

direction from one point to the other point.

Linear Coordinates A method of locating a point by its distance from zero

point along any of the three axes (X,Y,Z). Also called Cartesian Coordinates.

Linear Accuracy A non-specific term sometimes used in reference to

positional accuracy or to axial length accuracy.

Linear Displacement The difference between the true displacement of the Acuracy probe along a straight line and that indicated by the

machine measuring system.

List To display a part program on the CRT. LLF The learned list file or the part program. Lobing A systematic error in the measuring accuracy of probing

systems such that a measured value depends on the displacement direction of the probe tip.

involves typing a password.

Machine Axes The X, Y, and Z axes built into the CMM. Each type of

machine (vertical, horizontal, etc.) has different axes arrangements.

Machine X, Y, and Z values that have not been altered by part Coordinates alignment compensation.

Machine Hysteresis The hysteresis of the machine system when subjected to

loads.

Machine Named The two axes of the machine’s working plane. In the XY Axes working plane, X is the first-named axis and Y is the

second-named axis. The Unnamed Axis is the axis not named in the working plane, in this case Z.

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Glossary

Machine Setup The routine operations performed on a CMM, such as

calibrating probes and selecting measurement units.

Major Radius The greatest possible distance between the outermost

edge of an ellipse and its center.

Manual CMM A Coordinate machine without motor drives on the axes. Manual Control The user controls the movements of the X, Y, and Z axes

as well as the setup parameters.

Master Sphere Same as Calibration Sphere. An accessory used in

qualifying the probe.

Maximum Traverse The maximum speed along any given machine axis. Speed

Mean Ambient The mean temperature of the ambient environment Temperature surrounding a machine. It should be computed from at

least two readings taken at the center of the machine’s work zone during the interval of the test.

Mean Gage The mean temperature of a gage used for machine Temperature testing. It should be computed from at least two readings

taken on the gage during the interval of the test.

Mean Scale The mean temperature of a machine scale computed Temperature from at least two temperature readings taken on the scale

during the test interval.

Mean Temperature The average temperature computed from a number of

temperature measurements at a specified location at equally spaced time intervals.

Measure A mode where the operator uses the measurement

capabilities and creates a part program saving all the steps into a learn list file.

Measurement Machine inputs taken on the surface of the work piece

where the location, diameter, etc. are computed.

Measurement Line A line in the machine’s work zone along which measure-

ments are taken.

Measurement Point A point in the machine’s work zone at which machine

coordinates are recorded as part of a measurement.

Measurement The instruction program that tells the computer how to Software calculate the measurement data.

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Glossary

Memory A part of the computer that stores information and

program instructions.

Menu A list of items displayed on the computer screen for

selection.

Microprocessor A device that performs the function of a computer

except that the intelligence is built into the hardware and is not accessable for change by the user.

Menu A screen showing choices of the activities the software

can perform.

Midplane A plane located between two points or lines and perpen-

dicular to an imaginary line connecting them.

Midpoint A point located at the center of a line segment. An

alignment routine that locates the origin for the part’s coordinate system midway between two elements and where the Minor axis is perpendicular to the Major axis.

Minor Radius The smallest possible distance between the outermost

edge of an ellipse and its center.

Minus Tolerance The negative amount that an actual measurement can

deviate from its nominal value.

MMC Maximum Material Condition. The condition of a

feature in which that feature contains the maximum amount of material that is allowed by the toleranced dimensions (i.e. the smallest hole or the largest shaft).

Moire Fringe An optical principle used on most Coordinate Measuring

machines. It consists of a fixed glass or reflective steel scale and a moving reader head that counts (measures distance) as it passes along the scale.

Monitor The video display on a computer. Also a screen. Movable Component A major structural component of the CMM which is

movable relative to the machine base during measurement.

Multiplier A value that effectively pushes the target point deeper

into the part.

Named Axes The two axes of the machine’s working plane. Same as

Machine Named Axes.

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Glossary

Nominal The standard or desired dimension or size of a feature.

The print values for the measurement as opposed to the measured values.

Nominal Coefficient An estimate of the coefficient of thermal expansion of a of Thermal body. The effective coefficient of a scale and its mount- Expansion ing to the mcahine as measured in line with the scale.

Nominal Differential The difference in thermal expansion between a Expansion machine’s scales and a test part

Non-Contact Probes Probes which do not touch the part being measured,

using vision or laser scanning to measure the part.

Non-Seating Probes A hard probe that requires force applied by the operator

to maintain its position with respect to a measurement point.

Normal A surface, plane or axis that forms a 90 degree angle

with a datum plane or axis.

Normal Vector The vector that is normal to the surface of the part at a

particular point. The negative of the Approach vector.

Numeric Variable A value which contains only numbers. Off-line The condition in which a device, such as a printer, is not

connected to or communicating with the computer

OIT Operator Interface Terminal On-line A method of creating a part program on the CMM. This

allows the programmer to create a program as the machine takes measurements.

Operating System The software that controls the computer. It includes user

commands, input and output routines, and normal computer operations.

Orientation (Part) The alignment of an object with respect to a known

reference.

Orientation (Probe) The process of establishing the center of the probe tip

with respect to an object, feature or other reference.

Origin The zero point or center of the current coordinate system

and alignment. It is a designated reference point for all measurements taken of the part.

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Glossary

Out-of-Tolerance The condition in which a feature is larger or smaller than

its specified dimension.

Output Information displayed or printed by a computer. Parallelism The condition in which all points on a surface or axis are

equidistant from a datum plane or axis. A measurement routine where two features are parallel within a specified tolerance of size. One feature is the datum and the other is the toleranced line.

Part Alignment The process of mathematically aligning the measurement

axes of the CMM with the part axes.

Part Axes The X, Y, and Z axes of a part. Part Coordinates X, Y, and Z values that have been modified by part

alignment.

Part Orientation The alignment of an object with respect to a known

reference.

Part Program A list of coded instructions that tells the system how to

measure a part on a CMM.

Part Program A storage area that holds part programs. Directory

Part Program Name A label assigned to a part program. It is saved, retrieved

and reused by means of this name.

Part Reference The axes alignment, datum position and working plane Frame under which measurements are made.

Part Unnamed Axis The axis not named in the part’s working plane. Passive Probe A solid or hard probe which mechanically fixes the

movable components relative to the workpiece.

Password A word entered at the computer keyboard to gain access

to programs or information stored in a computer.

Performance Test Any of a number of test procedures used to measure

machine performance.

Periodic Error An error in the linear displacement accuracy of a ma-

chine that is periodic over an interval which normally coincides with a natural period of the machine scales.

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Glossary

Perpendicularity The condition of a feature forming a 90 degree angle

with another feature one of which is a datum feature. An alignment routine where the origin for the part’s coordinate system is located at the intersection of the major and minor axes.

Perpendicular An alignment routine where the origin for the part’s Intersect coordinate system is located at the intersection of

perpendicular lines formed by the major and minor axes.

Pitch Vertical deviation from a level plane, as applied to the

travel of a CMM component along a given axis. The angular motion of a carriage, designed for linear motion, about an axis perpendicular to the motion direction and perpendicular to the yaw axis.

Pixel The smallest element into which an image is divided,

such as the dots on a television screen.

Plane The surface of a part defined by at least three points. It is

always straight in two directions.

Plus Tolerance The positive amount that a measurement can deviate

from the nominal value.

Point A measurement routine consisting of one element

(CMM input) which yields an X, Y, Z location. A point is the simplest geometric element.

Point Distance A measurement routine used to compute the straight line

distance between two X, Y, Z locations.

Point of Origin The zero point or datum point. Polar Feature output expressed as a radius and an angle. Polar Angle In a polar coordinate system, the angle between the polar

radius and the fixed reference line.

Polar Coordinates Points in space that are described in terms of radius and

angle (r, phi, z) in relation to some fixed origin. Another type of coordinate system.

Polar Coordinate A method of locating a point by its distance from System zero along a measurement line and by the angle between

the measurement line and a reference line.

Polar Radius The line that measures the distance from zero point to

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the located point in polar coordinates.

Glossary

Positional Accuracy Deviation in readings between the CMM’s display and

those of a laser interferometer, usually taken at 1" intervals over the length of a single axis. Not a measure of machine accuracy, it indicates the linearity of the scales.

Position Velocity The speed of the probe between measurements. Post Hit Multiplier Same as multiplier. A value that pushes the target point

deeper into the part.

Prehit Distance The distance of the probe from the part when it changes

from position velocity to contact velocity. Also called the Probe Approach Distance.

Primary Datum The datum established with at least three points of

contact between the most important functional surface and the inspection surface.

Probe On a CMM the component that touches and measures

the part.

Probe Approach The distance to the part at which the machine traverse Distance speed is reduced to the probe approach rate for measure-

ment.

Probe Body The cylindrical part of a probe into which the stylus is

mounted.

Probe Diameter The diameter of the probe tip whose value (radius) is

used to compensate for measurements.

Probe Head The mounting portion of a probe that attaches to the

Z Rail of the machine. The probe body is attached to the probe head.

Probe Hysteresis The hysteresis of the mechanical or electrical elements

of a probe.

Probe Sense The inner or outer (+/-) consideration of the probe when

measuring.

Probe Tip The part of the probe that actually makes contact with

the part.

Profile A cross-section of a part, projected into some reference

plane.

Program Listing A line-by-line list on the computer screen or on a

printout showing the steps in a part program.

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Glossary

Projection The reproduction of an existing feature on another

existing feature.

Projection Plane The plane to which a feature is moved during a projected

measurement, usually the working plane.

Prompt A question or statement on the video screen of a com-

puter. A prompt asks for information or gives instructions.

Proportional Probe A probe that gives a signal proportional to its displace-

ment from the free position.

Prototype A sample part that serves as a mode for production parts. Qualification A procedure for establishing true size, such as probe

qualification against a known reference sphere.

Qualification Sphere An accurate sphere with a known diameter, mounted on

a post that can be fastened to the machine’s table. Used to qualify the machine and the probes to be used.

Qualify To inform the computer of the location and size of the

probe.

Ram The moving component of a machine that carries the

probe.

Range The difference between the maximum and minimum

values of a set of measurements.

Readout The display of X, Y, and Z coordinates. Recall To retrieve information that is stored in a computer. Rectangular Expressing a point in space by its (X,Y,Z) position in

Coordinates relation to a fixed origin. A Cartesian coordinate mea-

suring system.

Reference Sphere Same as Qualification Sphere. Repeatability Deviation among multiple measurements of a feature or

part. A measure of the ability of an instrument to produce the same measured value when sequentially sensing the same quantity under similar mesurement conditions.

Repeatable Socket A socket that allows the accurate repositioning of one

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end of a ball bar.

Glossary

Resolution The least increment of a measuring device. On a CMM,

the least reading on the display.

Response Time The distance traveled by the probe from the time of

actual contact with the part until the computer registers that contact.

Retract The distance the probe backs up after contacting the part. RFS Regardless of Feature Size. A method of tolerancing that

does not allow increased tolerance as the feature size varies. The tolerance must be met regardless of the size of the feature.

Right Hand Rule A rule based on the right hand that defines the major,

minor and third axis of a coordinate system.

Roll The twist of an axis about a centerline. It is most obvious

in the Z axis when using an extended horizontal probe. The angular motion of a carriage, designed for linear motion, about the linear motion axis.

Rotate An alignment function used to rotate the part’s coordi-

nate system about the origin the specified amount of degrees.

Roundness The condition of a circle as it exists within a tolerance

zone formed by two concentric circles. Also known as circularity. A measurement routine which computes the deviation of a circle from true roundness.

Run To execute a part program. Runout The deviation of a feature form from nominal during

rotation of the part on the datum axis.

Safe Operating The temperature reange in which a CMM may be Temperature Range expected to operate without physical damage to the

machine or its support systems.

Scale The fixed portion of a measuring device. Scaler A modifier to a feature that defines a specific

characteristic.

Screen The video display on a computer. Seating Probe A hard probe that will maintain its location with respect

to a measurement point without operator contact.

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Glossary

Secondary Datum The datum established by at least two points of contact

between a datum feature and the inspection surface.

Second Named Axis The second letter in the name of the working plane. Select To choose from a list displayed on the computer screen. Separate Origin An alignment routine that requires three features and

locates the origin at the third feature. The minor axis is perpendicular to the major axis.

Settling Time The time required between contact of a hard probe with

a measurement point and the time at which valid data may be taken.

Setup A softkey function used to access the setup screen. Setup Hysteresis The hysteresis of various elements in a test setup,

normally due to loose mechanical connections.

Setup Parameters Values such as position velocity, contact velocity,

acceleration, retract distance, and prehit distance that are programmed into the system.

Significant Mean The change in mean ambient temperature surrounding a Temperature Change CMM that, in the manufacturer’s judgment, will cause

sufficient degradation in machine performance to require the performance evaluation to be repeated.

Single Tip A qualification procedure for a single tipped probe. Slot A measurement routine that computes a slot length and

center distance from the origin.

Software The intelligence of a system. Stored in chips or on

diskettes, it contains the mathematical and geometric capability to perform inspection routines and to communicate with the operator.

Sphere A three dimensional space in which all points on its

surface are equidistant from the centerpoint. A measurement routine that computes a diameter and the center distance from the origin of a spherical shape. A sphere is defined by at least four points.

Spherical Expressing a point in space by its (r, phi, rho) in relation Coordinates to some fixed origin.

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Glossary

Spline The interpolation of a series of functions between two

given data points, for all the points in the set.

Squareness Deviation of the axes from 90° in their relationship to

each other.

Staging The moving of a gage from first position to second

position.

Static Motionless. Statistical Analysis The examination of numerical information. Step Gage A gage consisting of a rigid bar with calibrated steps

used for determining the accuracy of distance measurements in a direction of linear motion.

Straightness A measurement routine that computes the deviation of a

line from true straightness. Also, the deviation of an axis from a perfect path.

Store To save information into a computer memory. Stylus The portion of a probe that contacts the part. Usually a

synthetic ruby ball mounted on a steel shank.

Symmetry The midpoint between two features. A symmetry feature

is the mathematical bisector of two features.

Systematic Error That portion of a machine error that results from com-

puting the mean of a very large number of similar measurements.

Taper Probe A type of rigid probe used primarily for hole location. Target In DCC, a specified point on the part that is being

measured.

Target Tolerance A zone around each specified target that allows for Zone minor errors in the position of the target.

Temperature An estimate of the maximum possible measurement Variation Error error induced solely by deviation of the environment

from average thermal conditions.

Tertiary Datum The datum established by at least one point of contact

between a datum feature and the inspection surface.

Tolerance Limiting values added to nominal dimensions that allow

variations of a measured feature.

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Glossary

Tolerance Value An acceptable deviation from a specified dimension.

Touch Trigger A precise switching device (contact probe) that holds a Probe (TTP) stylus. The stylus deflects slightly upon contact with a

surface causing a mechanical change in the probe that is converted into a change of electrical voltage. Since the system knows its location at that moment, the X,Y,Z position of the probe is known.

Transformation Conversion of machine coordinates into part

coordinates.

Translate An alignment function used to move the part’s origin by

a specified amount in the X, Y, Z direction.

Translation The deliberate shifting of a datum to a predetermined

location through numerical input to the computer.

Travel The measuring range of a CMM. Traverse Speed The speed of the tip of the ram of a CMM, measured

with respect to the part mounting surface, when the machine is moved between nominal locations without measuring.

True Position The exact location of a point line or plane with respect to

a datum or other feature.

True Position MMC Allows for an increase in positional tolerance as the size

of the feature changes.

True Position RFS Refers to the feature having a true position regardless of

a change in the size of that feature.

Unnamed Axis The axis not named in the machine’s active working

plane. For example, in the XY working plane, Z is the unnamed axis.

U Value The value of the polar radius in the polar coordinate

system.

Variable Any value that is subject to change or revision. Vector Referred to as I, J, K. It indicates the direction of a

feature’s centerline. In the case of a plane, the vector is orthogonal to the measured surface, pointing in the direction from which the plane was probed.

Vibration Amplitude Peak-to-peak amplitude of a given frequency

component.

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Glossary

Video Terminal A CRT. Another name for the computer screen. V Value The value of the polar angle in the polar coordinate

system.

Volumetric Accuracy Deviation among measurements of a ball bar or length

standard.

Working Plane Any of the orthogonal planes or surfaces of the part/

machine in which the operator may take measurements. The active plane in which features are measured.

Workpiece The object to be measured. Work Zone The measurement volume of a CMM. Working Tolerance The maximum acceptable range in the measurements for

any performance test. This applies to repeatability, linear displacement accuracy, volumetric performance, bi-directional length measurement capability and pointto-point probing performance measurement results.

X-Axis The axis of a CMM that goes from left to right as you

stand in front of the machine. Positive direction is to the right. One of the reference lines or axes in a Cartesian coordinate system.

Y-Axis The axis of a CMM that goes from front to rear. Positive

direction is to the rear. One of the reference lines or axes in a Cartesian coordinate system.

Yaw Side to side deviation from a straight line, as applied to

the travel of a CMM component along an axis. The angular motion of a carriage designed for linear motion, about a specified axis perpendicular to the motion direction. In the case of a carriage with horizontal motion, the specified axis shall be vertical, unless otherwise specified.

Z-Axis The vertical axis of a CMM. Positive direction is up.

One of the reference lines or axes in a Cartesian coordinate system.

Zero Point The point in a coordinate system where the X, Y, and Z

axes intersect.

Z Rail The vertical moving component that holds the probe.

Also called Z Ram.

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MH3D Notes

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CHAPTER A

Appendix

Page A-1

Appendix

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Page A-2

CCD Optical Probe - Installation

CAUTION

The optical probe is a delicate instrument and must be handled with care. When not in use it should be stored in its original foam lined box with the protective cap on the objective lens.

To install the optical video probe on the MH3D refer to the mounting configuration and the connecting diagram and proceed as follows:

1. Lock the Z-rail.

2. Mount the optical probe in the probe holder at the end of the Z-rail and tighten the clamping handle (2).

CAUTION

Never unlock the Z-rail until you are sure that the counterbalance pressure is set correctly or the rail is firmly held.

3. If necessary, set the counterbalance pressure by holding the probe and unlocking the Z-rail and then adjusting the counterbalance regulator.

4. To measure tall parts it may be necessary to invert the mounting bracket (4) as shown. The support must be securely tightened.

5. Attach the cable support bracket (5) to the middle of the black cable tray behind the X-rail.

6. Tie the the video cable, and the zoom control wire together using stay straps

7. Secure the cables to the brackets (4 and 5) with stay straps. The cables must not interfere with the movements of the Z-rail or the ZX carriage.

8. Connect the components as shown in the connecting diagram. The optional fiberoptic illuminator must be located as far away as possible because of the heat generated by the illuminator.

Refer to the CCD Optics Instruction Manual for additional information.

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Mounting Configuration

RAM Optical Probe - Installation

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Page A-4

RAM Optical Probe - Installation

Connecting Diagram

Page A-5

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CCD Optical Probe - Adjustments

Probe Parfocality

If you plan to change the magnification (use zooming) while measuring, check to see that the probe remains in focus (parfocal) throughout the zooming range as follows:

1. Focus on a part or on the MH3D's granite table using the probe's highest magnification.

2. Zoom to the lowest magnification while observing the image on the monitor screen. If the image goes out of focus, the parfocality of the probe should be adjusted.

3. Refer to the Instruction Manual for the procedure on parfocality adjustment.

Crosshair generator

The crosshair generator provides two pairs of reference lines on the monitor screen (two vertical and two horizontal). The location can be electronically controlled. The lines can be made black or white, solid or dashed. The ideal placement of the reference crosshair is in the middle of the screen.

Note: Never change the location of the reference crosshair on the screen while performing measurements.

a. General Purpose

b. Can be Used for Referencing Straight Edges and Lines

c. Convenient for Referencing Small Features of the Same Size Do Not Zoom During Measurements

Origin

Reference Crosshair (Channel 1)

Move the Remaining Crosshair to the Border of the Screen to Avoid Confusion

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CCD Optical Probe - Adjustments

The possible configurations of the reference crosshairs are shown on the preceeding page. If you change magnification (use zooming) while measuring, be sure that the reference crosshair is coincident with the optical axis of the probe. Refer to the RAM Instruction Manual for the procedure on adjustment of the crosshair position.

Crosshair Alignment

It is recommended that the crosshairs on the monitor screen be aligned to the X-axis and Y-axis of the MH3D. To align the crosshairs:

1. Lock the Y-axis.

2. Using a sharp pencil, draw a line on the surface of the granite by holding the pencil tight to the Z-rail and moving the ZX carriage along the X-axis.

3. Using the lowest magnification, focus the probe on the pencil mark on

the granite table.

4. Holding the optical probe with one hand, release the clamp (2) and

rotate the probe in the Z-rail until the crosshair is parallel to the image of the pencil line.

5. Tighten the clamp (2).

GRANITE TABLE

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CCD Optical Probe - Qualification

Note: In order to use a RAM Optical Probe with MH3D you will have to install a desk mouse in addition to the ZMouse. This is because the RAM Optical Probe covers the buttons of the ZMouse. Select the "System Options" softkey and the "Languages, etc." and change the mouse type to "Desk Mouse".

Probe Qualification

To qualify the optical probe:

1. Turn the MH3D electronic box "Off" and then "On".

2. Remove the probe from the Z-rail.

3. Clamp the MH3D qualification sphere to the granite table in the right rear corner (or any location where it will not interfere with the part being

measured).

4. Home the MH3D and press "Done". Tell the system it has an optical probe.

5. Place the MH3D Z-rail on the qualification sphere and press "Done".

6. Clamp the optical probe in the Z-rail.

7. Align the crosshairs on the monitor screen to the X-axis and the Y-axis

of the MH3D.

8. Focus the probe on the equatorial plane of the qualification sphere using the lowest magnification.

9. Take three measurement points equally spaced on the circumference (refer to the following section on measuring with the optical probe).

10. Focus the probe on the top point of the sphere and bring this point to the

origin of the reference crosshair on the monitor screen.

11. Take a measurement point and press "Done".

Part Alignment

To perform a part alignment:

1. Select "Measurements" from the Main Menu.

2. Focus on the plane to be measured by moving the probe towards the part (as if measuring with a hard probe).

3. Focus on and measure at least three points on the working plane spaced as far apart as practical. Press "Done".

4. If a direction point is requested, elevate the probe and take it. This will

insure the consistent orientation of the part coordinate system.

5. Select the "Set Level" softkey.

6. Focus on and measure at least two points to define the major axis. Press

"Done".

7. Select the "Set Axis" softkey.

8. Measure either a point or a circle to define the origin. Select the "Set Origin" softkey.

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TESA MH3D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual