CALYPSO

Option 7
OVCMM Measuring
uncertainty definition

Operating Instructions
Read this first! • Please read these operating instructions before starting up the
coordinate measuring machine.
• For your own safety, please keep all relevant accompanying docu-
ments always ready at hand.

All rights pertaining to changes in the CMM and its options, the pro-
gram packages and the pertaining documents reserved.
This manual must not be circulated or copied, or its contents utilized
and disseminated, without our express written permission. Persons
misusing this manual are subject to prosecution.
All rights reserved, especially in cases of granting a patent or register-
ing a utility model.
This manual is subject to modification. All rights pertaining to changes
in the CMM and its options reserved.
All product names are registered trademarks or trademarks of the cor-
responding proprietors.

Carl Zeiss CALYPSO: Operating Instructions

Business Group Revision status: 5.0
Industrial Metrology Ltd. Date of issue: 04/10
D-73446 Oberkochen Order No.: 61212-2770502
Preface
The CALYPSO program consists of a base module and additional
options for special purposes. You can customize the scope of program
to fit your requirements.
These operating instructions describe an option of CALYPSO and are
based on the assumption that the user is familiar with the operating
instructions for the base module of CALYPSO.

NOTE The additional CALYPSO options are described in separate manuals.

hss

Reference information about the windows and dialogs can be found

in the interactive reference in the CALYPSO Online Help.

Supplementary literature
Simply Measure – And what you should know to do it right,
A metrology primer
Carl Zeiss, Industrial Metrology Division,
Order No.: 612302-9002

Text conventions and symbols

Text conventions The following text conventions and symbols are used in this manual:

Example Description
Features Text element of the graphics screen display.
Comment The Comment button on the screen.
<devicename> Variable text or placeholder for a name.
C:\windows\w.ini The w.ini file in the windows directory on the
C:\ drive.
For this section... A highlighted passage containing important
information.
➤“Preface” on This is a cross reference. If you view this book
page -1 on the screen, you can jump to the specified
point by clicking the reference.
Plan → CNC-Start The CNC-Start command in the CNC-Start
→ CNC-Start submenu of the Run menu.
Ctrl-a Press the Ctrl key and the letter a simulta-
neously.

61212-2770502 Operating Instructions Preface

Symbols Three special icons are used in this book; they always contain impor-
tant information. The icons appear in the margin, beside the associ-
ated text.

hss
! Danger!
Special care is necessary in this case. The warning triangle warns the
user about potential danger of injury.
Failure to comply with the warning could result in injury to the user.

hss
! Important!
This symbol calls attention to a situation that could result in incorrect
measurements, disruptions in the measurement process, collisions or
damage to the equipment and the workpiece.

NOTE This symbol represents important and helpful additional information.

hss

Preface 61212-2770502 Operating Instructions

Contents
Chapter 1 OVCMM Measuring uncertainty definition
Basic principles of the OVCMM . . . . . . . . . . . . . . . . . . . . . 1-2
Uncertainty of measuring results . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Influencing variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Cooperation in determining influencing variables . . . . . . . . . . . . . 1-4

Configuring the OVCMM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

How to determine the stylus characteristics . . . . . . . . . . . . . . . . . 1-5

Using the OVCMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

How to activate the OVCMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Results of the OVCMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

61212-2770502 Operating Instructions Contents 1

Contents 2 61212-2770502 Operating Instructions
 Chapter

1 OVCMM Measuring uncertainty

definition
.................................................................................................................................
With the OVCMM (Offline Virtual Coordinate Measuring Machine),
the possible deviations from the real value and thus the measuring
uncertainties of results of a measurement plan can be ascertained.
Important influencing variables that may affect the result are analyzed
to this end.
Determining the measuring uncertainty with the OVCMM is a
CALYPSO option. You can license this functionality and have it enab-
led in your system if you want to use it. Contact your ZEISS Service for
more information.
The OVCMM must be configured by ZEISS Service. ZEISS Service will
also support you in handling this option.

This chapter contains:

Basic principles of the OVCMM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Configuring the OVCMM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Using the OVCMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

61212-2770502 CALYPSO Operating Instructions 1-1

 OVCMM Measuring uncertainty definition

Basic principles of the OVCMM

Using the OVCMM, CALYPSO can determine the possible deviations
from the real value for all characteristics of a measurement plan, i.e. it
uses the method of the virtual CMM to determine the characteristic-
specific measuring uncertainty and output this in a printout.
Benefits of the OVCMM The measuring uncertainty calculation using the virtual CMM has the
following benefits:
– It is objective and in line with standards.
– It is performed automatically and requires, contrary to other
methods, no special knowledge on the part of the user.
– It is not excessively time-consuming.
– It matches the complexity of connected uncertainty components
occurring during measurements on CMMs.
– Its high degree of automation allows to meet the requirements of
the various measuring jobs performed by CMMs.

The method of the virtual CMM

In order to determine the uncertainties, CALYPSO uses the method of
the virtual CMM to calculate an uncertainty range for each individual
measurement.
In the case of complex measured values (construction, theoretical ele-
ment), this range consists of the uncertainties from the entire measu-
rement chain. For this, the OVCMM considers the influencing
variables and deviations of all measuring jobs involved in the measure-
ment, i.e. also the alignment and references.
Procedure The OVCMM determines the measuring uncertainties in compliance
with GUM, ISO 14253 and ISO 15530. To this end, the CNC run is
simulated for all characteristics of a measurement plan.
The result of this simulation corresponds to the dispersion range of a
measurement of 128 workpieces with a random variation of the
known influencing factors.
In this way, a range that is representative for the measuring results is
calculated. Finally, the resulting variance is used to ascertain the
uncertainty for each characteristic and to output it in the measure-
ment record.

1-2 61212-2770502 CALYPSO Operating Instructions

 Basic principles of the OVCMM

Uncertainty of measuring results

Measuring uncertainty Measuring results are afflicted with uncertainties resulting from the
imperfectness of the CMM, the environmental conditions and the
measuring process. This means a result is complete only if it is accom-
panied by a specified measuring uncertainty. This is summarized in the
following formula:
Y=y±U
Here, Y is the value to be measured, y is the measured and possibly
corrected measuring result and U represents the measuring uncer-
tainty. No exact value is specified for Y in the equation, only a range in
which Y lies.
Uncertainty of Coordinate measuring machines are extremely universal measuring
coordinate measure- machines for practically any workpiece. This is why coordinate measu-
ments ring machines have a great many sources of inaccuracy, whose
mutual overlaps are difficult to analyze.
The uncertainty of a coordinate measurement depends on the rele-
vant measuring job: How many and which measurements are inclu-
ded in the result? How are the individual measurements linked?
Which is the measurement strategy applied to the geometry features?

Influencing variables
The following influencing variables are taken into account by the
OVCMM:
– Systematic residual deviations of the CMM geometry
– Fluctuations of the geometry deviations due to temporal and spa-
tial temperature gradients
– Direction-dependent systematic residual deviations of the stylus
system
– Random deviations of the probing system
– Uncertainty caused by thermal workpiece expansion
– Uncertainty in qualification of the stylus diameter
– Uncertainty in qualification of the styli within a stylus system
– Roughness of the workpiece surface
– Uncertainty of the standards used for connection to the internatio-
nal SI units
The following influencing variables are not automatically taken into
account:
– Measurement deviations due to operator influence

61212-2770502 CALYPSO Operating Instructions 1-3

 OVCMM Measuring uncertainty definition

– Deformation of the workpiece due to clamping

– Deformation of the workpiece due to probing forces
– Temperature gradients in the workpiece
– Shape influence of the workpiece
These influencing variables must be set manually and individually
taken into account if it can be assumed that each influence makes a
significant contribution to the measuring uncertainty in each job.

Cooperation in determining influencing

variables
Use of the virtual CMM method requires cooperation between a
number of parties: the manufacturer, a calibration laboratory, and the
user.
What does Zeiss do? The most important systematic errors of a CMM must be determined
in advance.
The specific errors for each CMM type (geometry, effect of ambient
influences on the geometry, dynamic effects) have been determined
by Zeiss and recorded in a device file.
What does the An accredited laboratory (e.g. ZEISS Service) measures your CMM
accredited laboratory with great precision and creates the database of the OVCMM. To
do? this end, geometry deviations in the entire measuring range are recor-
ded using perforated-plate measurements in different positions.
Depending on the specific environment of your CMM and your
requirements for use, the laboratory generates for your CMM and its
specific purpose one or more “ambient conditions” as a basis for the
OVCMM.
What do you do? To ensure the device accuracy, you measure calibrated workpieces or
gages at regular intervals (e.g. weekly).
To enable the OVCMM function to consider the uncertainty influences
of the styli used, the OVCMM must know the stylus characteristics.
You can determine these stylus characteristics by probing the refe-
rence sphere.
When you set up a new measurement plan and each time the influen-
cing variables change, start the simulation using the OVCMM.

1-4 61212-2770502 CALYPSO Operating Instructions

 Configuring the OVCMM

Configuring the OVCMM

In order to use the OVCMM in CALYPSO, you must configure it first.
To do so, determine the stylus characteristics for the stylus (styli) used
and, if appropriate, select the ambient condition.

NOTE The ambient conditions of your CMM must have been determined by
hss
ZEISS Service or another accredited laboratory and entered in the
OVCMM.

How to determine the stylus characteristics

All of the styli used for measurement must be qualified by the
OVCMM, as each stylus has its own specific error influences. You
measure these influences by scanning a point pattern on the refe-
rence sphere using the stylus.
For the OVCMM, you can specify the determination of the stylus cha-
racteristics: you can define how the CMM is to measure the stylus
characteristic on the reference sphere (e.g. the number of axis inter-
section points).
Each stylus characteristic is stored under a separate name in the stylus
data management. This means you can use stylus characteristics that
have already been determined for a similar stylus system by assigning
it that name.
CALYPSO offers two possibilities to determine stylus characteristics:
– Standard definition: You only enter the name of the stylus cha-
racteristic. The specific values are set by default.
– Advanced definition: You enter the name of the stylus characte-
ristic and change the default values for probing the reference
sphere.

Standard definition
In most cases, determining the stylus characteristics with the standard
definition is fully adequate.
To determine the stylus characteristic with the standard definition:
1 Select Extras → Workroom → Measurement and click on the
VCMM tab in the Measurement Methods notebook.
A notebook page opens with the Settings for measuring uncer-
tainty data VCMM.

61212-2770502 CALYPSO Operating Instructions 1-5

OVCMM Measuring uncertainty definition

2 Click on the Default setting button in the Definition of stylus

influence group.
The Stylus Influence window will open.

3 Enter the name of the stylus characteristics and confirm with OK.
The CMM now starts qualifying the stylus.
4 Save and close with OK.

Advanced definition
The advanced definition is used for analysis purposes.
To determine the stylus characteristic with the advanced definition:
1 Select Extras → Workroom → Measurement and click on the
VCMM tab in the Measurement Methods notebook.
A notebook page opens with the Settings for measuring uncer-
tainty data VCMM.

1-6 61212-2770502 CALYPSO Operating Instructions

 Configuring the OVCMM

2 Click on the Default setting button in the Definition of stylus

influence group.
The Stylus Influence window opens: Extended qualification
mode.

3 Enter the name of the stylus characteristic.

4 Change the default settings for the number of probing points in
the corresponding input field.
5 Press OK to confirm.
The CMM now starts qualifying the stylus.
6 Save and close with OK.

61212-2770502 CALYPSO Operating Instructions 1-7

OVCMM Measuring uncertainty definition

Assigning stylus characteristics

Configuration of the OVCMM has now been completed. In the stylus
data management, you can assign the corresponding stylus characte-
ristics to the stylus required for the measurement.

The following fields are provided for this in the stylus data manage-
ment:
– Base Char. in the display area <Stylus system name>
– Stylus Char. in the display area Stylus
These two additional fields are only editable if the OVCMM is activa-
ted.

1-8 61212-2770502 CALYPSO Operating Instructions

 Using the OVCMM

Using the OVCMM

You use the OVCMM to determine the uncertainty of the results of a
certain measurement plan. To do so, you usually proceed as follows:
– You activate the OVCMM and set the ambient conditions relevant
for the current measurement.
– Start the CNC run. After the CNC run, the OVCMM is automati-
cally active and determines the measuring uncertainty.
The determined measuring uncertainties for each characteristic are
output with the printout.
– Then, deactivate the OVCMM. The measuring uncertainties deter-
mined for the current measurement plan do not change from one
CNC run to the next.
It is only when you want to run a changed or new measurement
plan or the influencing variables have changed (e.g. the measure-
ment location or a physically changed stylus) that it is important to
reactivate the OVCMM to determine the characteristic-specific
measuring uncertainties that now apply.

How to activate the OVCMM

Before the OVCMM can take effect after the CNC run, you have to
activate it.
If the OVCMM is to consider additional influencing variables
(e.g. workpiece expansion coefficients or temperature changes with a
certain course), you must select the corresponding environmental
condition.

NOTE The environmental conditions must have been configured by ZEISS

hss
Service or an accredited laboratory.

61212-2770502 CALYPSO Operating Instructions 1-9

OVCMM Measuring uncertainty definition

To activate the OVCMM and select the environmental conditions:

1 Select Extras → Workroom → Measurement and click on the
VCMM tab in the Measurement Methods notebook.
A notebook page opens with the Settings for measuring uncer-
tainty data VCMM.

2 Activate the Measuring uncertainty data active check box.

3 If the work of the OVCMM is to be entered in a log file, activate
the Output trace check box.
This can be useful for tests and checks performed by ZEISS Service.
4 In the Environmental conditions group, activate the Conditions
active check box.
5 In the Conditions selection list, select the relevant specific environ-
mental condition.
6 Save and close with OK.

1-10 61212-2770502 CALYPSO Operating Instructions

 Using the OVCMM

The OVCMM is now active. It will be started automatically after the

next CNC run and will take the selected conditions into account for
the uncertainty calculation.

NOTE Do not forget to deactivate the OVCMM after CNC run and output of
hss the record, as it will otherwise become active again after every CNC
run and will repeat its calculations.

Results of the OVCMM

If the OVCMM has been activated, it will automatically start after
each CNC run.
The entire measurement plan is then repeated 128 times by the
OVCMM, whereby the measuring results are different every time, but
are systematically distorted.
The error analysis includes:
– the results of the highly precise CMM qualification
– the stylus characteristics
– the environmental condition you may have selected
– additional contributions to measuring uncertainty, e.g. due to
ambient influences.
The standard measuring uncertainty is calculated as combined uncer-
tainty of all the influencing variables taken into account.
Then, the record of the CNC run is output with an additional column.
This column shows the uncertainty U of each individual characteristic,
extended by the factor k=2.

hss
! Important!
At present, the base alignment must not be created using a CMM and
the OVCMM Measuring uncertainty definition option. Recommended
procedure:
• At first, measure the data without activating the OVCMM Measu-
ring uncertainty definition option.
• Then perform the simulation in another CNC run without resetting
the results.

61212-2770502 CALYPSO Operating Instructions 1-11

OVCMM Measuring uncertainty definition

1-12 61212-2770502 CALYPSO Operating Instructions

Index
D Stylus characteristics
for OVCMM 1-5
Determining measuring uncertainty 1-1
for virtual CMM 1-5
Symbols Preface-2
M
Measuring results T
uncertainty 1-3
Text conventions Preface-1

O
U
OVCMM 1-1
Uncertainty of measuring results 1-3
activating 1-9
basics 1-2
influencing variables 1-3 V
interaction 1-4 Virtual CMM 1-1
results 1-11 activating 1-9
Stylus characteristics 1-5 configuring 1-5
using 1-9 method 1-2
results 1-11
S stylus characteristics 1-5
using 1-9
Standard definition
stylus characteristics 1-5

61212-2770502 Operating Instructions Index 1

Index 2 61212-2770502 Operating Instructions