MAKE : CARL ZEISS

MODEL : CARMET C12

Document By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
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 THE NEED FOR MEASURMENT
 WHAT IS A CMM
 CONCEPT OF COORDINATE METROLOGY
 USES & ADVANTAGES OF CNC CMM
 SELECTION CRITERION OF ZEISS CMM
 BASIC WORKING OF CMM & MAIN COMPONENTS
 LENGTH MEASURING SYSTEM
 PROBE SYSTEM OF CMM
 FUNCTIONS OF CMM COMPUTER
 ERROR OR UNCERTAINITY OF CMM
 ERROR COMPENSATION IN TESO SOFTWARE.
 MEASURMENT MEANS COMPARISON.
 COMPARISON OF THE PRODUCT OR PROCESS WITH AS
ACCURATE A STANDARD AS POSSIBLE.
 ONLY BY COMPARISON IT IS POSSIBLE TO EVALUATE OUR
PROCESS & PRODUCT IN ORDER TO MAKE ANY CHANGES IN
THEM.
 WITHOUT MEASURMENT NO CORRECTIVE ACTIONS CAN BE
TAKEN.
 WITH THE GROWING USE OF MODERN TECHNOLOGY ,
INCERASINGLY COMPLEX PARTS & STRINGENT QUALITY
STANDARDS COORDINATE METROLOGY IS FAST REPLACING
THE CONVENTIONAL GAUGES & METERS.
 CMM MEANS COORDINATE MEASURING MACHINE.
 THERE IS A LACK OF AWARENESS OF CMM TECHNOLOGY . THIS MAY
BE DUE TO 3 REASONS.
 1) IT IS A RELATIVELY NEW TECHNOLOGY
 2) IT IS A COMPLICATED SUBJECT.
 3) IT IS A VERY EXPENSIVE TECHNOLOGY.
 THERE ARE DIFFERENT TYPES OF CMM
 A) HORIZONTAL ARM CMM
 B) BRIDGE TYPE CMM
 IN HORIZONTAL ARM THERE ARE 3 MAIN TYPES.
 1) CARMET (RECIRCULATING LINEAR BALL BEARINGS)
 2) SMC ( AIR BEARINGS)
 3) SMM (HIGH SPEED , HIGH ACCURACY WITH BALL BEARINGS).
 ALL THESE COME IN EITHER MANUAL MOTORISED OR CNC
 WHAT IS A COORDINATE SYSTEM
 TYPES OF COORDINATE SYSTEM A) MACHINE
COORDINATE SYSTEM B) PART(WORKPIECE)
COORDINATE SYSTEM.
 RELATION BETWEEN BOTH THE COORDINATE
SYSTEMS IN THE CMM
Length between bores = L

Length between bores =

L*cos@
 MEASURES THE DIMENSIONS , FORMS & ALL
POSSIBLE GEOMETRIC ELEMENTS LIKE NO
OTHER MACHINE
 CMM HAS A MUCH LOWER UNCERTAINITY
(ERROR) THAN OTHER MEASURING DEVICES
 A VERY COST EFFECTIVE REPLACEMENT
FOR GAUGES & SINGLE PURPOSE
MEASURING EQPT
 REPEATS MEASURMENT AUTOMATICALLY
 PROVIDES HIGH ACCURACY & REPEATIBILITY
 AUTOMATIC PROBE CALLIBRATION POSSIBLE
 UNIVERSAL APPLICATION
 SHORT MEASURING TIMES
 VERSATILITY
 ECONOMIC CNC PROGRAMMING
 MATHEMATICAL REVERSION (MIRRORING ) OF CONTROL
DATA
 OBJECTIVE DATA ACQUISITION
 MEASURED RECORD
 CMM IS SELECTED OF THE BASICS OF
 A) LENGTH OF THE BODY
 B) ACCURACY OF THE SYSTEM.
 C) COST
 D) SERVICE SUPPORT IN INDIA
 MEASURING RANGE :- X = 6200mm , Y = 2560mm , Z = 2100mm.
 MEASURING ACCCURACY / COLUMN :
 U1 = 25+L/50 <= 60 micron
 U3 = 30+L/50 <= 80 micron
 MEASURING ACCURACY IN DUPLEX MODE:
 U3D = 40+L/35 <= 100 micron.
 TRAVEL SPEED:- 150 mm/s (max)
 PERMISSIBLE LOAD :- 5000 Kg.
 MAX POWER CONSUMPTION :- 3.8 KVA
 AMBIENT TEMP FOR OPERATION :- 10 TO 35 deg C
 TEMP CONDITIONS FOR SPECIFIED UNCERTAINITY (U1 &U3 ) :- 20
degC +- 4 deg
 BASE PLATE DIMENSIONS :- 7030 X 2800 X 625 MM
 THE CMM MAKES MEASURMENT IN THE SAME WAY AS WE
TRACE LOCATIONS ON A MAP.BUT INSTEAD OF A FINGER
THE CMM USES A PROBE TO MEASURE POINTS ON THE WORK
PIECE.
 EACH POINT OF THE WORKPIECE IS UNIQUE TO THE
MACHINES COORDINATE SYSTEM.
 THE CMM COMBINES ALL SUCH PROBED POINTS TO FORM A
FEATURE.
 WORKPIECES ARE GENERALLY MADE UP OF SIMPLE
GEOMETRIC ELEMENTS LIKE ,CIRCLE ,SPHERE ,
CYLINDER,CONE,PLANE,EDGES ETC
 THERE ARE SPECIFIC PROGRAMS FOR COMMON GEOMETRIC
ELEMENTS.
 THE CMM CAN CALCULATE ALL REQUIRED PARAMETERS FOR
THE ELEMENT FROM THE PROBED POINTS.
FOR A CMM TO COMPUTE THE GEOMETRY OF A SHAPE
SOME MINIMUM NO OF POINTS SHOULD BE PROBED
 Table shows the minimum & recommended points to
be probed
Element Therotical no Recommended
of points no of points
Point 1 1
Circle 3 4
Plane 3 4
Sphere 4 6
Clyinder 5 8
Cone 6 12
Parabola 6 9
 .A SURFACE PLATE OR BASE FOR KEEPING THE WORK PIECE
 .MAIN MACHINE WITH 3 INDEPENDENT MOVABLE ARMS WHICH
MOVE IN THE 3-AXES
 .A PROBE FOR MEASURMENT OF THE WORK PIECE ALONG WITH
THE PROBE HOLDING SYSTEM.
 .ELECTRONIC CONTROL UNIT FOR CNC MODE OPERATION OF
ALL THE AXES MOTORS & SENDING THE MEASURMENT RESULTS
TO THE WORKSTATION.
 .A DISPLAY UNIT / OPERATOR PANEL FOR DISPLAYING THE
MEASURMENT IN THE 3 AXES, CONTROL IN MANUAL MODE
(THROUGH JOYSTICK) & SWITCHING ON/OFF, SPEED CONTROL
OF THE MACHINE.
 .A COMPUTER WITH SOFTWARE FOR CALCULATING ALL
PARAMETERS FROM THE MEASURMENT RESULTS.
 IN THE MAIN MACHINE ALL THE ARMS HAVE INBUILT GOLD
PLATED SCALES WHICH TRANSFER DATA ELECTRONICALLY TO
THE COMPUTER AS THE ARMS MOVE ON THE AXES.
 THIS IS CALLED A LENGTH-MEASURING SYSTEM. THE FUNCTION
OF THIS SYSTEM IS TO TAKE THE MEASURMENT POINT
DETERMINED BY THE PROBE HEAD & REPRESENT IT IN A 3
DIMENSIONAL COORDINATE SYSTEM.
 THE NORMALLY USED LEANGTH MEASURING SYSTEM OPERATES
ON THE FOLLOWING PRINCIPLE. IT CONSISTS OF INCREMENTAL
ENCODERS USING A GRATING SCALE AS A MEASURMENT
STANDARD.
 THE MAIN COMPONENTS OF THIS SYSTEM ARE
 A)LIGHT EMITTING DIODES

 B)ILLUMINATION OPTICS

 C)GRATING SCALE (MEASURMENT STANDARD)

 D)IMAGING OPTICS

 E)PHOTO SENSITIVE DIODES.

 THE LIGHT EMITTING DIODES EMIT LIGHT WHICH IS FOCUSSED IN THE

RIGHT DIRECTION BY THE ILLUMINATION OPTICS. THIS LIGHT PASSES
THROUGH A GRATING SCALE, WHICH IS A GRID WITH 8-MICRON WIDE
LINES SEPERATED BY SPACES OF IDENTICAL WIDTH. AS THE ARM MOVES
THE LIGHT GETS FOCUSSED ON THE PHOTOSENSITIVE DIODES THROUGH
THE IMAGING OPTICS.THE LIGHT SENSITIVE DIODES THE GENERATE A
CORRESPONDING SIGNAL WHICH IS THE VALUE OF THE DEFLECTION OF
THE ARM.
 THIS SYSTEM YIELDS A RESOLUTION AS LOW AS 0.2-MICRON.
 THIS OPTICS & DIODE ASSLY IS CALLED AS READER HEAD.THIS READER
HEAD IS SUPPLIED BY REINSHAW.
 THERE ARE DIFFERENT TYPES OF PROBE SYSTEMS FOR THE CMM.
 THE COMMONLY USED ONES ARE REINSHAW MANUAL PROBE ,
ZEISS RDS, ZEISS DAC.
 IN MANUAL PROBE THE POSITION OF THE PROBE HOLDER IS TO
BE CHANGED MANUALLY FOR DIFFERENT MEASURING POSITIONS.
 ZEISS RDS IS ROTARY DYNAMIC SENSOR.
 THE RDS CAN MOVE IN A & B AXES AUTOMATICALLY THROUGH
THE COMMANDS FROM THE DYNALOG.
 FOR THIS MOVEMENT THERE ARE 2 MOTORS WHICH ARE
OPERATED THROUGH A SEPARATE RDS CONTROLLER MOUNTED
BESIDE THE C-99.
 THE RDS IS LOCKED ON TO THE MOUNTING DEVICE BY A
MAGNET.THIS ARRANGEMENT REQUIRES A AIR SUPPLY OF 5.5
BARS FOR ITS OPERATION.
 THE RDS MOVES IN A & B AXES IN STEPS OF 2.5 DEGREES.
 ROTATIONAL (A) AXIS FOR RDS IS +-180 DEGREES.
 BUT THE SWIVEL AZIS (B) IS LIMITED TO 115 DEGREES. THIS
IS TO PROTECT THE PROBE FROM COLLIDING WITH THE
HOLDER WHEN EXTENTIONS ARE USED.
 THE RDS HAS A BUCKLING SYSTEM FOR PROTECTION . IN
CASE THE PROBE HEAD IS EXCESSIVELY LOADED OR IN THE
EVENT OF A COLLISION THE BUCKLING PROTECTION DEVICE
INTRRUPTS THE SWITCHING CIRCUIT.
 THE PROBES WHICH CAN BE USED WITH THESE SYSTEMS ARE
 A) TOUCH TRIGGERED PROBE (MECHANICAL CONTACT)
 B) TRIGGERED PROBE (PIEZOELECTRIC )
 C) MEASURED PROBE
 D) LASER PROBE.
 THE COMPUTER OF THE CMM PERFORMS THE MAIN FUNCTION OF
ANALYSING THE INDIVIDUAL POINTS RECORDED ON A WORKPIECE &
DERIVES THE INFORMATION ON DIMENSIONS, FORM & POSITION OF THE
PROBED FEATURES.
 THE COMPUTER ALSO PERFORMS THESE ESSENTIAL FUNCTIONS.
 .CORRECTION: GUIDEWAY DEVIATIONS, SQUARENESS DEVIATIONS,

BEND INFLUENCES, THERMAL COMPENSATION, PROBE TIP RADIUS

& MIDPOINT PROBE BEND & PROBE HEAD DEFLECTION.
 .TRANSFORMATION: MACHINE COORDINATE MACHINE (MCS) ,

WORKPIECE (PART) COORDINATE SYSTEM (WCS). ROTARY TABLE

COORDINATE SYSTEM (RTCS).
 .COMPUTATION: SUBSTITUTE ELEMENTS , LINKING FUNCTIONS ,

FREE FORM CONVERSIONS.

 .EVALUATION: NOMINAL / ACTUAL COMPARISON, RECORDING

STATISTICS, DATA TRANSFER.

 .CONTROL: POINT, STRAIGHT LINE & SCANNING PATCHES.
 LIKE ALL MEASURING MACHINES THE CMM ALSO HAVE
A INHERENT ERROR OR UNCERTAINITY.
 IT IS DEFINED AS THE MAXIMUM VALUE BY WHICH THE
DISPLAYED VALUE MAY DEVIATE IN POSITIVE OR
NEGATIVE DIRECTION.
 THERE ARE MAINLY 2 TYPES OF ERRORS AS PER
VDI/VDE.
 A) U1 = 25 + L/50 =< 60 Micron (Parallel to axes)
 B) U3 = 30 + L/50 =< 80 Micron (Volumetric)
 For e.g. if a length of 400 mm is to be measured by a
CMM with the above errors then the length measured
may vary between 399.967 mm and 400.033 mm when
measured parallel to the axes.
 1) GUIDEWAY DEVIATIONS (FOR CARMET IN X AXIS
GUIDEWAY IS INTEGRATED WITH THE SURFACE PLATE
& DOES NOT HAVE COVER.)
 2) BENDS
 3) PROBE RADIUS
 4) THERMAL INFLUENCES
 5) SQUARNESS DEVIATIONS.
THESE ERRORS CAN BE MINIMISED AUTOMATICALLY
IN THE CMM BY USING ITS POWERFUL SOFTWARE.
FIRST THE MACHINE IS ALINGED MECHANICALLY TO
THE MAXIMUM POSSIBLE ACCURACY USING SPECIAL
GAUGES.
 AFTER SETTING ALL MEASURMENTS ARE TAKEN WITH A
LASER INFEROMETER & SAVED IN THE CONTROLLER IN A
FILE.
 THE FILE IS CALLED CAA - COMPUTER AIDED ACCURACY.
 THERE ARE 180 NO OF PARAMETERS IN THIS FILE WHICH
AFFECT THE WORKING OF THE CMM.
 THESE PARAMETERS REGULATE THE VELOCITY,
ACCLERATION, LAG ERROR,VOLTAGE ETC.
 THIS DATA IS OBTAINED GRAPHICALLY & THE
PARAMETERS CAN BE CHANGED FOR BETTER RESULTS.
 AFTER SUCCESSFUL COMMISSIONING ALL SUCH GRAPHS
ARE STORED IN THE SERVICE SOFTWARE FOR FUTURE
REFERANCE.
 PROBE CORRECTION BY CMM COMPUTER

Probe radius corrected

Measured value by CMM computer

Probing direction
 THESE PARAMETERS CAN BE CHANGED BY USING THE
SERVICE SOFTWARE TESO-2000.
 IT IS PROTECTED WITH A PASSWORD AGAINST
UNAUTHORISED USE.
 IT CAN BE USED TO CHECK THE PROPER OPERATION
OF ALL THE AXES MOTORS
 FOR PREPRAING EMERGANCY BACKUP DISK
 IMPROVING ACCURACY OF MACHINE BY CHANGING
THE PARAMETERS IN CAA.
 CHECKING THE REPEATIBILITY OF THE CMM.
 TO BE USED BY AUTHORISED PERSONS ONLY
 C99 CONTROLLER IS NOT MODULAR
 ALL ADJUSTMENTS ARE CORRECTED IN SOFTWARE
 DELICATE & COSTLY COMPONENTS
 ANY REPAIR WORK MAY AFFECT ACCURACY OF THE
MACHINE.