TubeScan

Operator’s Manual
TubeScan – Version 1.0

Table of Contents

Section 1: Introduction ...................................................................1

Section 2: TubeScan Main Window ...............................................4

Section 3: System Setup.................................................................7

Section 4: Recipe Setup..................................................................9

Section 5: Security ........................................................................10

Section 6: Configure COM Ports..................................................11

Section 7: Test Relays ..................................................................13

Section 8: Header Setup ...............................................................14

Section 9: SPC Summary Reports ...............................................16

Section 10: LaserMike Configuration ..........................................17

Section 11: Stack Calibration .......................................................18

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TubeScan – Version 1.0

Section 1 Introduction

Introduction
The TubeScan measurement system consists of a PC running Windows XP Professional (or
Windows Vista), an external relay module, an optional printer, PC software described herein, a
LaserMike Model 192-20 processor, two LaserMike Model 179 scanners, one LaserMike Model
501 scanner, and a specialized scanner mounting fixture.

Installation
To install the TubeScan software, create a directory on the C: drive named C:\TubeScan and copy
the file named TubeScan.exe to that directory.

To run TubeScan, click Run on the Windows Start Menu and select C:\TubeScan\TubeScan.exe,
double click C:\TubeScan\TubeScan.exe from within Windows Explorer, or create and use a
shortcut on the Windows desktop.

Running TubeScan for the First Time

The first time TubeScan is run, the communication parameters of the PC are defaulted to COM 1,
2400 baud, no parity, 8 data bits, and 1 stop bit for LaserMike communications. Communications
with the relay module are defaulted to OFF.

Be sure to match the serial port configuration of Libraries 1 – 3 of the LaserMike 192-20 (refer to
the 192-20 Operator’s Manual) to the communications settings of TubeScan.

Any changes made to the COM Port Settings will be saved to disk and retrieved the next time
TubeScan is run.

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Registration

The TubeScan software must be registered for use on each computer on which it is installed.
Until registration is complete and the unlock code has been entered, the registration form will be
displayed each time TubeScan is run. Additionally, although navigation through all setup and
data display screens is possible, no data will be displayed until the unlock code has been entered.

To register, complete the form and click OK. A file named TubeScan.rgs will be created in the
TubeScan directory. Attach the TubeScan.rgs file to an e-mail message and send to
register@badgerware.net. An e-mail response containing the unlock code (for that particular
computer) will be sent within 24 hours. The actual response time will usually be much less than
24 hours depending on what time of day (Eastern Time) the registration is received.

Click Cancel to postpone registration and close the form without creating the TubeScan.rgs file.

To redisplay the form without having to restart the program, click Registration on the TubeScan
Menu.

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To display the Unlock window, click Unlock on the TubeScan Menu. To unlock the software,
enter the unlock code received in the registration e-mail response and click OK.

Click cancel to close the window without attempting to unlock.

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Section 2 TubeScan Main Window

Menu
To access the TubeScan Menu, click Menu in the upper left hand corner of the Main Window.

System Setup Click System Setup to display the System Setup window.

Report Folder Click Report Folder to specify the folder where report files will be saved.

Security Click Security to enable or disable security. The current level of security is
displayed in parentheses to the right of the Security label on the Menu.

COM Ports Click COM Ports to display the Configure COM Ports window.

Stack Cal Click Stack Calibration to display the Stack Calibration window.

Exit Click Exit to exit from TubeScan.

About Click About to display the TubeScan version information.

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Diameter Display
Recipe Label The currently selected recipe is displayed above the diameter measurement.
Cick the label to display the Recipe Selection and Setup window.

Run/Stop Click Run to instruct the LaserMike to start automatic measurements. A

window will be displayed instructing the operator to move the scanner
mounting fixture to the proper position based on the Nominal value entered
in the selected recipe. Diameter values will be updated on the screen as they
are performed by the LaserMike.

Click Stop to stop the measurements.

The diameter measurement is displayed at the top of the window. Diameters within limits are
displayed in green. Diameters outside the reject limits are displayed in red. When a reject
condition occurs, Relay 2 on the relay module will be triggered.

If a communication error occurs, a purple error box describing the error will be displayed at the
bottom the window.

If a scanner error or a loss of communications occurs, when Run has been clicked and data is
being displayed, a purple error box describing the error will be displayed at the bottom of the
window. Also, Relay 3 will be triggered.

SPC Data
Samples The number of samples collected is displayed.

Average The average diameter of all samples collected is displayed.

Maximum The maximum diameter of all samples collected is displayed.

Minimum The minimum diameter of all samples collected is displayed.

Range The difference between the Maximum and Minimum is displayed.

Std. Dev. The standard deviation of all samples collected is displayed.

CpK The CpK of all samples collected is displayed.

Cpk = the smaller of:

(Upper Limit – Average) / (3 * Std Dev) or
(Average – Lower Limit) / (3 * Std Dev)

Cp The Cp of all samples collected is displayed.

Cp = (Upper Limit – Lower Limit) / (6 * Std Dev)

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Start/Stop Click Start/Stop to start or stop SPC data collection.

Clear Click Clear to clear SPC data.

Header Click Header to display the Header Setup window.

Print Click Print to print and/or save an SPC summary report.

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Section 3 System Setup

Click System Setup on the Menu to display the System Setup window.

Security Level

Security Level specifies the level of security when the software is locked.

1. System Setup The user can view but not modify the System setup, Report Folder
selection, COM Port setup, and Stack Calibration.

2. Recipe Setup The user can view but not modify the System setup, Report Folder
selection, COM Port setup, and Stack Calibration. The user can view
and change recipes but not modify recipe settings.

3. Recipe Selection The user can view but not modify the System setup, Report Folder
selection, COM Port setup, and Stack Calibration. The user can view
but not change or modify recipe settings.

Measurement Units

Measurement Units specifies the units of the measurement values. The choices are inches and
millimeters. The setting of this parameter is transmitted to the LaserMike. The specified units are
displayed at the bottom of the Main Window.

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Resolution

Resolution specifies the resolution of the measurement values. The choices are x.1, x.12, x.123,
x.1234, and x.12345. The setting of this parameter is transmitted to the LaserMike.

SPC Sample Interval

SPC Sample Interval specifies the amount of time (in seconds) between SPC samples when SPC
is active. Note: When set to 0, every measurement will be collected.

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Section 4 Recipe Setup

Click on the recipe label to display the Recipe Setup window.

Recipe Select the recipe to load or modify.

Nominal Enter the Nominal diameter.

Reject Enter the Reject Tolerance. The Reject Tolerance is added to and subtracted
from the Nominal to determine the Upper and Lower Reject Limits.

Offset Enter an optional diameter offset. The Offset is added to the diameter
measurement before it is displayed.

Name Enter an optional name for the recipe.

OK Click OK to save any changes and load the selected recipe.

Save Click Save to save any changes to the selected recipe.

Cancel Click Cancel to discard any changes to the selected recipe.

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Section 5 Security

The TubeScan software has three levels of security. The security level is specified on the System
Setup window.

Security status is saved to disk and retrieved each time TubeScan is run.

Enabling Security

When Security is disabled, click Security on the Menu to display the Lock prompt.

To enable Security, enter a password (up to 8 alphanumeric characters), verify the password, and
click OK.

To exit from the Lock prompt without enabling Security, click Cancel.

Disabling Security

When Security is enabled, click Security on the Menu to display the Unlock prompt.

To disable Security, enter the same password used to enable Security and click OK.

To exit from the Lock prompt without disabling Security, click Cancel.

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Section 6 Configure COM Ports

Click COM Ports on the Menu to display the Configure COM Ports window. COM Port settings
are configurable for communication with the LaserMike and the relay module.

LaserMike
Click the LaserMike tab to display the settings for communications with the LaserMike. These
settings must match those of the LaserMike.

COM Port Specifies the COM Port of the PC to which the LaserMike is connected.

Baud Rate Specifies the baud rate of the serial communication between the PC and the
LaserMike (1200, 2400, 4800, 9600, or 19200).

Parity Specifies the parity for the serial communication between the PC and the
LaserMike (none, odd, or even).

Data Bits Specifies the number of data bits for the serial communication between the
PC and the LaserMike (7 or 8).

Stop Bits Specifies the number of stop bits for the serial communication between the
PC and the LaserMike (1 or 2).

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Relay Module
Click the Relay Module tab to display the settings for communications with the relay module.

COM Port Specifies the COM Port of the PC to which the relay module is connected.

Baud Rate Specifies the baud rate of the serial communication between the PC and the
relay module (fixed at 9600).

Parity Specifies the parity for the serial communication between the PC and the
relay module (fixed at none).

Data Bits Specifies the number of data bits for the serial communication between the
PC and the relay module (fixed at 8).

Stop Bits Specifies the number of stop bits for the serial communication between the
PC and the relay module (fixed at 1).

OK Click OK to accept changes.

Cancel Click Cancel to discard changes.

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Section 7 Test Relays

When the Relay Module tab is selected on the Configure COM Ports window, click Test to
display the Test Relays window.

Buttons are provided to manually turn the relays on and off.

Note: The Relay 1 buttons can be used during calibration of the LaserMike to manually select
the scanner connected to LM2.

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Section 8 Header Setup

Click the Header button to display the Header Setup window.

Print Manufacturer Check Print Manufacturer to print the manufacturer name on the
SPC summary report.

Print Customer Check Print Customer to print the customer name on the SPC
summary report.

Print Lot Number Check Print Lot Number to print the lot number on the SPC
summary report.

Print Operator Check Print Operator to print the operator name or number on
the SPC summary report.

Print Machine Number Check Print Machine Number to print the machine number on
the SPC summary report.

Print Date and Time Check Print Date and Time to print the date and time on the SPC
summary report.

Manufacturer Enter the manufacturer name.

Customer Enter the customer name.

Lot Number Enter the lot number.

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Operator Enter the operator name or number.

Machine Number Enter the machine number.

OK Click OK to accept changes.

Cancel Click Cancel to discard changes.

Set Header Label

The Lot Number, Operator, and Machine Number labels are user configurable. On the Header
Setup window, click the text of the label to be changed to display the Set Header Label window.

Old Label The current label is displayed.

New Label Enter the new label.

OK Click OK to accept the new label.

Cancel Click Cancel to discard changes and maintain the current label.

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Section 9 SPC Summary Reports

SPC summary reports can be printed to paper or saved to disk as a text file. Report files are saved
to the folder specified by the Select Folder for Report Files window. Report Files are named per
the customer, lot number, operator, and machine number entries (if selected) and the date and
time.

The Header settings determine the format of the header printed at the top of the report.

The general format of the report is:

SPC Summary Report

ABC Corp.
Customer: XYZ International
Lot Number: 18623
Operator: Smith
Machine Number: 278
Printed: 09/16/2008 5:30:35 PM

Upper Spec: 6.100

Lower Spec: 5.900

Samples: 2596
Average: 6.0000
Maximum: 6.0002
Minimum: 5.9842
Range: 0.0160
Std Dev: 0.0005
CpK: 68.76
Cp: 68.79

Units: mm
Sample Interval: 5 seconds

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Section 10 LaserMike Configuration

The TubeScan software is designed to interface to a LaserMike 192-20 processor connected to

three scanners (two Model 179s and one Model 501) mounted on a specialized scanner mounting
fixture. Connect the Model 179 scanner labeled “Scanner 1” to the Scanner 1 (or LM1) connector
on the back of the 192-20. Connect the Model 501 scanner labeled “Scanner 2” and the second
Model 179 scanner labeled “Scanner 3” via the remotely switchable junction box to the Scanner 2
(or LM2) connector on the back of the 192-20. Connect Scanners 2 and 3 to the junction box such
that Scanner 2 will be connected when Relay 1 on the relay module is open and Scanner 3 will be
connected when Relay 1 on the relay module is closed.

Three measurement ranges can be measured via three libraries configured on the 192-20. The
TubeScan software will automatically switch libraries based on the Nominal value entered for the
selected recipe when Run is clicked. In order for measurements to be performed correctly,
libraries 1 through 3 must be properly configured and calibrated on the 192-20:

Library 1 (0 – 5”)

HOT SIZE DIAMETER

COLD SIZE -- off –
SERIAL OUTPUT HOT SIZE

To calibrate Library 1, set HOT SIZE to DIAMETER and calibrate Scanner 1 connected
to LM #1. After calibration, revert to the settings listed above.

Library 2 (5” – 9”)

HOT SIZE EDGE

COLD SIZE EDGE
SERIAL OUTPUT HOT, COLD SIZE

To calibrate Library 2, set HOT SIZE and COLD SIZE to DIAMETER and calibrate
Scanner 1 connected to LM #1 and Scanner 2 connected to LM #2. After calibration,
revert to the settings listed above.

Library 3 (9” – 19”)

HOT SIZE EDGE

COLD SIZE EDGE
SERIAL OUTPUT HOT, COLD SIZE

To calibrate Library 3, set HOT SIZE and COLD SIZE to DIAMETER, manually turn on
Relay 1 via the Test Relays window within TubeScan, and calibrate Scanner 1 connected
to LM #1 and Scanner 3 connected to LM #2. After calibration, revert to the settings
listed above.

In addition to the settings listed above, be sure to match the Baud Rate, Word Length, Stop Bits,
and Parity of each library to those of the TubeScan software.

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Section 11 Stack Calibration

Measurements in the 0 – 5” range via Library 1 are performed in diameter mode by Scanner 1.
Measurements in the 5” – 9” range via Library 2 are performed in edge mode by Scanners 1 and
2. Measurements in the 9” – 19” range via Library 3 are performed in edge mode by Scanners 1
and 3. In order for the two edge mode measurements to generate the correct diameter
measurements, the separation distance between the scanners must be known. These distances are
determined via the Stack Calibration feature.

Click Stack Calibration on the Menu to display the Stack Calibration window.

Known Size Enter the known size of the calibration standard positioned between either
Scanners 1 and 2 or Scanner 1 and 3.

Units Enter the measurement units of the known size.

Cal Click Cal to perform the stack calibration. Relay 1 is automatically triggered
to select Scanner 3 when the known size is greater than 9 inches.

Be sure to perform stack calibration for both the range 5” – 9” and the range 9” to 19”. The
separation distances are stored to disk and retrieved each time TubeScan is run.

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