CALYPSO

Option 8
RDS CAA

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.: 61212-2780502
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.

61212-2780502 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 61212-2780502 Operating Instructions

Contents
Chapter 1 Qualifying the RDS with CAA
Principles of the RC-CAA qualification . . . . . . . . . . . . . . . . 1-2

Qualification of the RDS fitting position in the CMM . . . 1-4

Establishing the prerequisites for the fitting position qualification of the
RDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Performing the fitting position qualification . . . . . . . . . . . . . . . . . 1-5

Qualifying the stylus system with RDS-CAA . . . . . . . . . . . 1-7

General information about qualification . . . . . . . . . . . . . . . . . . . . 1-7
Qualifying stylus systems and styli . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
How to define a new stylus system for RDS-CAA . . . . . . . . . . . 1-8
How to add further styli to a stylus system . . . . . . . . . . . . . . . . 1-9
Qualifying stylus systems and styli with RDS-CAA . . . . . . . . . . . . 1-10
How to qualify the first stylus with RDS-CAA . . . . . . . . . . . . . 1-11
How to qualify additional styli with RDS-CAA. . . . . . . . . . . . . 1-13

61212-2780502 Operating Instructions Contents 1

Contents 2 61212-2780502 Operating Instructions
 Chapter

1 Qualifying the RDS with CAA

.................................................................................................................................
If you have the RDS CAA option (Computer Aided Accuracy), you can
determine the stylus data for all angular positions of an RDS in a sin-
gle operation, using no more than a small number of probing actions.
Only a few angular settings are actually qualified physically. The data
for the other positions is derived using a mathematical model (calcula-
ted qualification).
As a consequence, the qualification procedure is completed much
more quickly and all physically possible angular positions of the RDS
are subsequently available for probing the workpiece. Subsequent re-
qualification, too, is faster.

NOTE The probe types RST, TP2, TP20, TP200 and XXT-TL3 can be used on
hss
the RDS. The “CAA qualification module PS” option is additionally
required in order to use the XXT-TL3 probe.

The RDS CAA option is available for both CALYPSO and CMM-OS.
The procedure for both programs is described in this document.

This chapter contains:

Principles of the RC-CAA qualification . . . . . . . . . . . . . . . . . . . . . 1-2

Qualification of the RDS fitting position in the CMM . . . . . . . . . . 1-4
Qualifying the stylus system with RDS-CAA . . . . . . . . . . . . . . . . . 1-7

61212-2780502 CALYPSO Operating Instructions 1- 1

 Qualifying the RDS with CAA

Principles of the RC-CAA qualification

Given the stepping adjustment of 2.5 degrees, a stylus on the RDS
can, in theory, adopt 20,736 positions, but, depending on the device
geometry, not all of them are physically possible. Without RDS-CAA,
each position is considered as an individual stylus that must also be
qualified.
Conventional qualification has generally been restricted to qualifying
a subset of the RDS positions. CALYPSO/CMM-OS supports this pro-
cedure with the styli list for RDS in which each of the required positi-
ons is entered as a stylus with its own name.
Advantage of RDS-CAA If you use the RDS CAA option, however, you can determine the sty-
lus data for all possible angular positions of an RDS with just a small
number of probing actions. Only a few angular settings are actually
qualified physically; the values for the other positions are computed
using a mathematical model.
As a consequence, the qualification procedure is completed much
more quickly and all angular positions of the RDS are subsequently
available for probing the workpiece. Subsequent re-qualification, too,
is faster.

NOTE The probe types RST, TP2, TP20, TP200 and XXT-TL3 can be used on
hss the RDS. The “CAA qualification module PS” option is additionally
required in order to use the XXT-TL3 probe.
Even if the XXT-TL3 is only used as master stylus, you need the “CAA
qualification module PS” option in order to perform the RDS-CAA
qualification.

Three or four-step pro- Qualification is a three or four-step procedure:

cedure
– Qualification of the RDS by Zeiss (factory qualification)
Factory qualification involves generating correction files for each
individual RDS: these files are a prerequisite for subsequent, com-
puted qualification. The correction files are installed on your sys-
tem together with the RDS CAA option.
– Qualification of the RDS position on the CMM
Once the RDS has been mounted to the CMM, this fitting position
qualification process determines and saves the position of the RDS
within the CMM alignment.

1-2 61212-2780502 CALYPSO Operating Instructions

 Principles of the RC-CAA qualification

– Stylus qualification in twelve positions per main stylus (this is the

stylus in the direction of the ram).
Finally, the required stylus system and its stylus are inserted into
the RDS and qualified in few positions. CALYPSO/CMM-OS then
calculates the correction values for all of the remaining positions.
If the stylus system has only one stylus, this completes qualification
of the RDS.
– Qualification of remaining styli on the stylus system (star styli)
If a stylus system carries multiple styli (star styli), each of the remai-
ning styli is then qualified in four positions.
CALYPSO/CMM-OS calculates the correction values for all positions
of the remaining styli, and this completes qualification of the RDS.

61212-2780502 CALYPSO Operating Instructions 1-3

 Qualifying the RDS with CAA

Qualification of the RDS fitting position in

the CMM
Once the RDS has been mounted to the CMM, the fitting position
qualification is performed to determine the RDS position in the
machine alignment. This is a prerequisite for qualifying the stylus sys-
tems and styli on the RDS.
This fitting position qualification must only be made once for the RDS.
The stylus systems and styli used on the RDS can then each be quali-
fied without re-qualifying the fitting position of the RDS every time.

Establishing the prerequisites for the fitting

position qualification of the RDS
Your RDS has been qualified at the factory. In this case, the requisite
correction files for the RDS are available.
Reference sphere A further prerequisite is that the reference sphere has been defined.
has been defined Make sure that CALYPSO/CMM-OS knows the position of the refe-
rence sphere and that the shaft of the sphere points in the direction
of 45/45 angular position of the RDS.
– For a bridge CMM, this is the position with a 135° angle of inclina-
tion and a 315° angle of rotation.
– For a horizontal-arm CMM, it is the position with a 135° angle of
inclination and a 45° angle of rotation for column 1 and the posi-
tion with a 135° angle of inclination and a 315° angle of rotation
for column 2.
If one of the conditions is not met (if the reference sphere's shaft
points in a different direction or its position is not known), you must
re-qualify the reference sphere (see in the Basic Operating Instructions
under “Qualifying the reference sphere”).

! Important!
Never position the shaft of the reference sphere to 45°/45°. This
would involve a risk of collision in case of automatic determination.

The master stylus has Fitting position qualification must be performed using the master sty-
been lus. Only use the master stylus intended for this machine!
inserted
CALYPSO determines the necessary parameters by means of a reversal
measurement; you can view it under Extras → Workroom → CMM
on the Master Stylus index card.

1-4 61212-2780502 CALYPSO Operating Instructions

 Qualification of the RDS fitting position in the CMM

The procedure for installing the CMM's master stylus in the RDS is
described in the Basic Operating Instructions under “Inserting the sty-
lus system”.

Performing the fitting position qualification

You must open a measurement plan before you start fitting position
qualification in CALYPSO.
To perform fitting position qualification:
1 In CALYPSO, click the Stylus System button in the list of prerequi-
sites.
- or -
In CMM-OS, select Stylus → Stylus Qualification.
The Probing system qualification window is opened. You will
find detailed information on this dialog box in Probing system
qualification in the Calypso Online Help.
2 If it is not already displayed, select the name of the master stylus
from the Stylus System selection list.
The name and number of the stylus (the master stylus system has
only one stylus) will now appear in the Stylus name / no. selec-
tion list. Under Taper Angle, 180° is selected.
3 From the Mode selection list, select RC-CAA.

61212-2780502 CALYPSO Operating Instructions 1-5

Qualifying the RDS with CAA

4 Click the Fitting position button.

The label on this button changes, depending on the situation: the
default label is Qualify stylus.
5 After you are prompted, move the stylus towards the reference
sphere and probe the sphere in the stylus direction. (Your stylus
must be oriented to the rotation/tilting angle 0/0. Now move in
ram direction towards the sphere and probe once. In case of a
bridge CMM, probe the north pole; in case of a horizontal-arm
machine, probe the equator.)
In accordance with the selected mode, CALYPSO/CMM-OS auto-
matically proceeds with qualification, performing probing opera-
tions in 12 positions to determine the fitted position of the RDS to
a high degree of precision, which it then saves.
The results are shown in the R (radius), S (sigma) and X, Y, Z (sty-
lus geometry) fields.
6 Click OK to return to the work area.
The position of the RDS has now been successfully determined, and
you can begin with qualification of the individual styli.

1-6 61212-2780502 CALYPSO Operating Instructions

 Qualifying the stylus system with RDS-CAA

Qualifying the stylus system with RDS-CAA

Even with the RDS CAA option, the basic procedure for using stylus
systems remains the same: When you create a measurement plan, you
must always make sure that you have installed the correct stylus sys-
tem and that it has been qualified.
When qualifying a stylus, you first specify the stylus you use and then
initiate measurement of the reference sphere for this stylus. (In
CALYPSO, the Stylus System button turns green if this has already
been performed for the displayed stylus system.)
Only a few angular settings are actually qualified physically with RDS-
CAA. All further positions will then be computed, thus being available
for measurements.

General information about qualification

The stylus system must be qualified:
– If you have installed a new stylus system that has not been quali-
fied yet.
– If you want to re-qualify a stylus system, for example after a colli-
sion or due to thermal changes.
To qualify a stylus, instruct CALYPSO/CMM-OS to use this stylus to
probe the reference sphere, mounted on the measuring table, in a
special manner. With RDS-CAA, the stylus data will be determined
automatically for all angular positions of the RDS.

Qualifying stylus systems and styli

In CALYPSO/CMM-OS, each stylus system and stylus is given its own
name. Styli are also assigned numbers. CALYPSO/CMM-OS uses the
names and numbers to identify the stylus system and styli and for
saving their data.
Consequently, each stylus has to be defined. You cannot qualify the
angular positions of a stylus with RDS-CAA until the stylus has been
defined.
In most cases, a stylus system has only one stylus. Star styli, as the
name suggests, have more than one stylus.

61212-2780502 CALYPSO Operating Instructions 1-7

Qualifying the RDS with CAA

How to define a new stylus system for RDS-CAA

To define a stylus system:
1 In CALYPSO, click the Stylus System button in the list of prerequi-
sites.
- or -
In CMM-OS, select Stylus → Stylus Qualification.
The Probing system qualification window is opened. You will
find detailed information on this dialog box in Probing system
qualification in the Calypso Online Help.
2 Click the Insert new stylus system button.
The Create New Stylus System window appears on the screen.

3 Enter the names for the new stylus system and the first stylus. Do
not use any control characters in the name.
CALYPSO does not distinguish between uppercase and lowercase
characters. Points at the end of a stylus or stylus system name are
not accepted.
4 Tick the RDSCAA check box.
5 Click OK to close the window.
The names of the stylus system and the first stylus are displayed in the
Stylus System and Stylus name / no. selection lists.

1-8 61212-2780502 CALYPSO Operating Instructions

 Qualifying the stylus system with RDS-CAA

If the stylus system has other styli, you now have to add them in
CALYPSO (see ➤“How to add further styli to a stylus system” on
page 1-9).

How to add further styli to a stylus system

If a stylus system has more than one stylus, CALYPSO/CMM-OS must
be informed of the other styli. Therefore, after defining a new stylus
system or modifying an existing stylus system, you must add the addi-
tional styli, if any, and qualify them.
To add further styli:
1 In CALYPSO, click the Stylus System button in the list of prerequi-
sites.
- or -
In CMM-OS, select Stylus → Stylus Qualification.
The Probing system qualification window is opened. You will
find detailed information on this dialog box in Probing system
qualification in the Calypso Online Help.
2 Click the Insert new stylus button.
3 In the Create new stylus window, enter the name and number to
be used for referencing the stylus.
With respect to the name, CALYPSO/CMM-OS does not distinguish
between uppercase and lowercase characters.
The number must be unique within the stylus system. Therefore,
you can only choose among the free stylus numbers or enter a
higher number than the last one of the selection list.

4 If you wish to add further styli, repeat steps 2 through 3.

The name of the stylus will now appear in the Stylus Name / No.
selection list.
Next steps The next step is to qualify each main stylus in turn (see ➤“Qualifying
stylus systems and styli with RDS-CAA” on page 1-10). On the basis of
the data determined during qualification of the main styli, you then
start qualifying the other styli (star stylus).
Deleting a stylus or In the Stylus Data Management, you can delete styli created incor-
changing the name/no. rectly or edit the names and numbers of the styli.

61212-2780502 CALYPSO Operating Instructions 1-9

 Qualifying the RDS with CAA

– To delete, select the stylus in question in the navigation area and

select Delete from the context menu.
– The edit the name and number of a stylus, select in the navigation
area the Geometry branch of the respective stylus system and
click the corresponding cell in the table.

Qualifying stylus systems and styli with RDS-

CAA
Qualification of a stylus system's first stylus is not the same as qualifi-
cation of the stylus system's other styli, if any.
– The first (and possibly the only) stylus is qualified in 12 physical
angular positions.

NOTE The direction of this stylus must match the direction of the ram.
hss

– Each additional stylus for this stylus system is qualified in four phy-
sical angular positions.

NOTE For the qualification of XXT styli with RDS-CAA, different angular
hss positions than those required for the qualification with trigger measu-
ring systems are needed. The reason for this is that scanning parame-
ters are determined in addition to the RC and the stylus bending
qualification.
Additional angular positions are particularly required for the qualifica-
tion of lateral styli.

1-10 61212-2780502 CALYPSO Operating Instructions

 Qualifying the stylus system with RDS-CAA

How to qualify the first stylus with RDS-CAA

We assume that the stylus system to be qualified is mounted and that
all of its styli are known to CALYPSO/CMM-OS.
To qualify the first stylus (the main stylus in the angular positions A =
0°, B = 0°) of a stylus system with RDS-CAA:
1 In CALYPSO, click the Stylus System button in the list of prerequi-
sites.
– or –
In CMM-OS, select Stylus → Stylus Qualification.
The Probing system qualification window is opened. You will
find detailed information on this dialog box in Probing system
qualification in the Calypso Online Help.

2 If it is not already displayed, select the name of the stylus system

from the Stylus System selection list.
3 Select the name of the stylus to be qualified first from the Stylus
name / no. selection list.
In the Mode selection field, the RC-CAA mode is set.
4 If the styli you use are very short, reduce the value for Taper Angle
accordingly.
The smaller the taper angle, the smaller is the section of the sur-
face of the reference sphere which is probed for qualification.

61212-2780502 CALYPSO Operating Instructions 1-11

Qualifying the RDS with CAA

5 Click the Qualify Stylus button.

Stylus qualification now begins using the 12 angular positions set
by RDS-CAA. To start the process, you must perform the first pro-
bing manually.
6 When prompted, move the stylus in the RDS 0 / 0 position over the
north pole of the reference sphere and then probe the sphere in
stylus direction.
CALYPSO checks the position of the reference sphere and the
length of the stylus (roughly). Afterwards the 12 positions are
automatically selected and qualified.
The value entered in “Taper Angle” is taken into account as a
maximum value in the selection of the positions and probing ope-
rations.
The results are shown in the R, S, X, Y and Z fields (see in the Basic
Operating Instructions under “About the results of stylus qualifica-
tion”).
Under the heading Stylus, you will now see the symbol for a success-
ful stylus qualification and below that the identifier “RDS-CAA”.

1-12 61212-2780502 CALYPSO Operating Instructions

 Qualifying the stylus system with RDS-CAA

How to qualify additional styli with RDS-CAA

If you want to qualify other styli for this stylus system (as is the case
with star styli), you can do so immediately after qualifying the main
stylus.
Each additional stylus is measured semiautomatically in four RDS posi-
tions in order to achieve the best possible precision.
Prerequisite: You have opened the Probing system qualification
window and have already qualified the first stylus of the stylus system.
To qualify the other styli of a stylus system with RDS-CAA:
1 Select the name of the stylus you want to qualify from the Stylus
name / no. selection list.
2 Click the Qualify Stylus button.
This is not the main stylus, so the CAA star qualification dialog
box is displayed with the list of positions.

If data has been saved for the stylus system to be qualified, the list
is already filled.
3 Under Position (1 to 4) in the list of positions, select one of two
RDS positions in each case by clicking Alternative.
4 If you want to estimate which position is more suitable:
Click the Show button.
The RDS then rotates to the corresponding position.
5 If necessary, enter additional qualification positions with Add.
Four positions are generally enough; additional positions are
necessary only if the qualification accuracy is insufficient.
6 Under Re-Qual. activate at least two positions in the list that are to
be approached during re-qualification in the CNC run.
7 Click OK to start qualification.
CALYPSO/CMM-OS performs the rest of the procedure.

61212-2780502 CALYPSO Operating Instructions 1-13

 Qualifying the RDS with CAA

8 If necessary, repeat steps 1 through 8 for additional styli.

9 Click OK to confirm your entries and close the CAA-Probing sys-
tem qualification window.

NOTE If you do not confirm by clicking the OK button, all unsaved data
hss
from the stylus qualification is lost.

CALYPSO/CMM-OS returns to the work area. The styli have been suc-
cessfully qualified.
In CALYPSO, the Stylus System button is now green.
Qualification CALYPSO/CMM-OS creates a log file which you can either print out or
log save as an ASCII file.
The stylus system qualified with the RDS and its styli can now be used
by all users and in all RDS positions.

1-14 61212-2780502 CALYPSO Operating Instructions

Index
B fitting position qualification 1-4
procedure 1-2
Basics
qualifying stylus system 1-7
RDS-CAA 1-2

F S
Stylus system
Fitting position qualification
qualifying with RDS-CAA 1-1
RDS-CAA 1-4
Stylus system qualification
RDS-CAA 1-7
R Symbols Preface-2
RDS
qualifying with CAA 1-1 T
RDS-CAA
Text conventions Preface-1
basics 1-2

61212-2780502 Operating Instructions Index 1

Index 2 61212-2780502 Operating Instructions