Qualify Tutorial

Inspection Example – Sheet Metal Part
Objective: Generate an inspection report for a sheet metal part. Learn how to register scan data to the CAD model using a set of features, analyze the resulting deviations, create dimensions, and prepare views for a report in HTML or PDF format \…\Geomagic Qualify 5\TutorialData\sheet-metal-inspection.wrp

Files:

1. Open file sheet-metal-inspection.wrp. This file contains a CAD model of a sheet metal part, imported as IGES from a CAD package, representing the as-designed condition. The file also contains the scan data of the physical part. 2. The first step in inspecting a part is to register, or align, the point cloud to the CAD model so that we can perform a deviation analysis and compare the as-built condition (Test model) to the as-designed condition (Reference model). NOTE: Upon import, the CAD model is given the designation of REF, or Reference, in the Model Manager and the point cloud is designated as TEST. This designation occurs automatically and assists the software in some automated functions downstream. 3. In the Model Manager tree on the left-hand side of the screen, click on the REF object (the CAD model) to make it the active object, if it is not already. The point cloud will disappear and you should have just the CAD model visible on screen. Use Ctrl+D to fit the model to the screen 4. Change your view to the Front view. 5. From the Tools Features menu, select Create Features. This function allows the user to specify a set of features to be used for registering, or aligning, two objects. There are a variety of feature types, including holes, slots, rectangles and lines. Besides being used for alignment, they can also be analyzed and compared against one another. We will create 7-8 features that we can use for both alignment and analysis.

9. This is to be used as our first alignment feature. In the Parameters section of the dialog. Change Feature Type back to Hole. Under Feature Type. Click on the slot indicated by the green arrow below. Click once near the edge of the hole indicated by the green arrow below. Change the Feature Type to Slot. select Hole.6. the Length and Width of the slot are given (12 mm x 6 mm). Click the Next button towards the bottom of the dialog box to create another feature. the Diameter of the hole is given (12 mm). In the Parameters section of the dialog. Click Next. This will be the third and final alignment feature. representing Hole 1. . Click the hole indicated below. 10. representing Slot 1. Leave the default settings for Fitting Method (Best Fit) and Selection (CAD Boundary). 7. 8. A green circle is fit to the boundary. This will be the second alignment feature. A green slot is fit to the boundary.

11. you should have eight features. When complete. 13. 12. We will create some additional features. We now have enough features defined to align the parts. though. to use for analysis. Click OK to dismiss the dialog. Create each of the five additional features shown below using the image as a guide. Click Next. .

Now that the features are defined on the CAD model. Experiment with this function by querying some of the other features. 17. for alignment. 20. click OK. and the scan data as the “Floating” object in the upper right. extracted from the scan data. but these are the eight we will use for alignment and analysis. These are the eight that will now be automatically generated on the point cloud. Toggle off the Use Feature Plane and Use Feature Axis checkboxes. saving the user the time and effort of doing it manually. indicating that we are going to use features. 22. Select Datum/Feature Alignment from the Tools Alignment menu. 19. “OK” next to all eight in the dialog box. toggle on the Features option. in the upper left. Select Feature Info from the Tools Features menu. Highlight the point cloud object in the Model Manager to make it the active object. Click on Slot 1. As each feature is created. Select Auto Create Datums/Features from the Tools menu. but that is not the case here. Now we will align the two models using one of several alignment methods available in Qualify. we must define the same set of features on the scan data to be able to perform our alignment and analysis. Click Done to dismiss the dialog. 23. it should say. Under the Datum/Feature Inputs section of the dialog. if it is not already. 21. Show all features using the hotkey Alt+4. 16. When finished. you are presented with the actual measured values for that slot. we can extract some basic information about the features we just created. Even before we do an alignment.You can certainly create more if you like. When complete. You will see a list of the eight features we created on the CAD model. Make sure the Fine Adjustments Only checkbox is unchecked. 14. For this we will use an innovative function that can automatically detect and create features in a point cloud or polygon mesh. Placing a check in this box would save time if the models were previously aligned. 18. the dialog box lists its progress. rather than datums. 15. A list of features should appear in the two boxes below that. . In the dialog box. The screen is reconfigured to show the CAD model as the “Fixed” object. Click Apply to initiate the function.

as shown in the close-up at right. Select Hole 2 in each list and click Create Pair. In this dialog box. For this example. 0 of 3 rotational Degrees of Freedom (DOF) are constrained and 3 of 3 translational DOF are constrained. we will perform a series of analyses to determine the deviations between the as-designed and the as-built conditions 28. This function will create a colored 3D model showing the deviation between CAD and point cloud. flip directions.24. click on “Slot 1” in both the Fixed and Floating lists. Click OK to complete the alignment process. Now. All that remains is one rotational DOF. Do not set any tolerance values and click Apply. Quick Tip: The icons next to the Datum/Feature Pairs box allow you to reorder the alignment pairs. The software calculates the average and maximum deviations and uses these values to generate a default color map. This second pairing constrained 2 rotational DOF. called a Result model. The Statistics section of the dialog box tells us that as a result of this first alignment. 29. using a saved set of tolerances or letting the software determine average tolerance values. For this example. 25. in the dialog box. The CAD model and scan data should be aligned. 27. and delete unwanted pairings. A second feature pair is created. Now that the models are aligned. we have the option of setting our own tolerance values. Make sure Hole 1 is highlighted in both the Fixed list and the Floating list and click Create Pair and the two holes will be aligned in the bottom window of the screen. The alignment is complete. The pairing also appears in the Datum Pairs section near the bottom of the dialog box. The bottom window of the screen is updated as well as the statistics section of the dialog box. The parts are fully constrained. 26. Select 3D Compare from the Analysis menu. That . we will align the two Hole 1 features first. Then click Create Pair. we’ll start by using some calculated average values.

With the parts now aligned. Quick Tip: The Display Resolution and Color Detail slide bars should be set to Coarse unless a high level of detail in the Result model is required. If desired. This helps visualize where some of the deviations may be occurring. More importantly. which tells you some basic information about the deviation between CAD and scan data. type in 5. Quick Tip: There are many available options for editing the display of the Result object. In the Max. Positive field. Notice the Statistics section of the dialog box. The Result model will turn gray with its large. In the Min. green line. below. 33. You can also toggle between Color Reference and Color Test to see either the CAD model or scan data with colors applied. Your model should appear like the image above. Click the Apply button to initiate the calculation. select Compare Boundary. type in 1. The Edit Spectrum option under the Analysis menu also allows the user to change the color scale in many different ways. 31. Upon completion. Positive field. . Now. 32. 35. at right. right-clicking your mouse over the spectrum bar brings up a menu that controls some of the display options for the spectrum. the colored point information is retained in memory.0 mm and hit Enter. we will change these values to some known tolerances. 30. For example. it will always select the largest boundary first. a longer dialog box appears to control the display of the boundary comparison. outer boundary highlighted by a thick. If you toggle on Keep Result Points. From the Analysis menu.0 mm). we can compare their boundaries to check for problems such as springback or trim error. Change the number of Color Segments to 17. Negative field to -5. Now click Apply to update the color map. The Result model now appears in the Model Manager tree as a separate object.image appears at left. Click OK to dismiss the dialog and complete the creation of the Result model. you can toggle on the Test Object in the dialog box to show the point cloud overlaid with the CAD model. 34. By default.0 mm and hit the Enter key (hitting Enter automatically updates the Max.

Hence. Fit the view to screen (Ctrl+D) or use the hotkey Ctrl+R to reset the view. simply zoom in on a region before hitting OK. it is easier to see what we are dimensioning.there is now a whisker plot on the Result model showing the magnitude of deviation between the outer boundaries of the CAD model and scan data. which shows the true direction of the deviation at every location around the perimeter. For this example. instead of having to dimension both. select the 3D Deviation option. Try toggling through each of these three to see the updated result. 36. Textual). The default option is Normal Deviation. 39. and Tangent Deviation. There are many options for 3D Dimensioning. There are two other options under the Measurement section of the dialog: 3D Deviation. Highlight the Reference object (CAD model) in the tree. Radial. Parallel. The orientation the view is in when leaving the dialog is the orientation that will show up on our report. Boundary 1. and then transfer those same dimensions to the Test object (point cloud). 40. The user then chooses one of the five dimensions types (Linear. Now we will create some dimensions on the model using the features we created earlier. We can create dimensions on the CAD model. which shows only deviation tangent to the CAD face. Click OK to exit the function. With the CAD model active. 38. 37. Angular. if you want to create a close-up for your report. click 3D Dimensioning from the Analysis menu. This saves time and because the CAD model has surfaces. the user defines a work plane. Zoom in on a section to see the result. By default. . You now have a Boundaries folder under the result model in the Model Manager containing this view. Here is a brief explanation of how the function works: First. which shows only deviation normal to the CAD face. It can also be used as the drawing and measurement plane as described for the Work Plane dimension type below. This plane is primarily used when picking the annotation point in 3D space. it is the same as the current view but can be changed to any orientation.

46. The 3D option will measure the absolute distance and is independent of the work plane. select the Front View. Since the work plane has been defined we can hide it to make it easier to see the dimensions. From the Predefined Views toolbar on the right side of the screen. 44. Finally. For the measurement method. 48. 42. click this button. This dimension will be measured relative to the work plane. the X. user selects the method of measurement. 41. the selection snaps to the center. 43. For the second pick. you can drag the annotation around until satisfied with its placement. similar to a traditional CAD drawing package. With the dimension still active (pink). select Linear.Next. user selects the features (or datums) to be measured and places the annotation. and Z options are those respective components of the measurement. Any time you want to make the work plane parallel to the current view. select Work Plane (it is the icon directly beneath Linear). 45. Y. User then chooses whether to measure between features or datums (can be combination of the two). . Our dimensions will be projected to this 2D plane. Work Plane (default) will measure the distance between features relative to the 2D work plane. Under Dimension Type. Toggle off the Work Plane checkbox under Display options. Now click somewhere between the two points to place the annotation. Under Pick Method. click on or near Hole 3. select Feature. Again. click on or near Hole 4. Click the Save button at the top of the dialog to “lock” the work plane parallel to the current view orientation. as shown below. For the first pick. Likewise. Begin by establishing the view orientation to use. and independent of the work plane. We will start with a simple point-to-point measurement. 47. The selection automatically snaps to the hole’s center point.

set both the + Tolerance and – Tolerance to . 50. Rotate the model a little bit to see how the dimension is projected onto the work plane (it may help to toggle the work plane on temporarily). Once you type in a tolerance. The default dimension name. choose Parallel. or use the same one for all. Click the feature Line 1 first.25 mm. you can change the name to whatever you like. DWP 1. indicates it was created using the Work Plane method. the nominal dimension value is displayed along with the tolerance for this dimension. 51. However. 52. In the appropriate fields. Leave it the default for now. Click Next to finish this dimension and continue with the next one.49. Quick Tip: Clicking the Reset button near the top of the dialog will reset the view back to the orientation it was in when you last clicked Save. Under Dimension Type. that tolerance is used until you change it. . The user can set a unique tolerance for each dimension. Under the Edit Dimension Information option.

56.53. You will notice that the angle given is the smaller of the two possible angles for this measurement (56. Notice in the Edit Dimension Information section that the Tolerance value is still set to 0. After selecting Hole 3. 58. Click Line 1.2 deg vs. To display the complement of this angle. It is not necessary to enter this every time. 55. click the “c” key on the keyboard. 54. 123. however. 57. Since angular dimensions have different tolerances than distance dimensions. change this to be any point on the line if you were not looking solely for the minimum distance.8 deg). Place your annotation. You could. Now switch back to Parallel dimension. . Now move your dimension into a position similar to image below. 59. indicating the position of minimum distance between the two features. pick Hole 3.5 deg in the respective fields under Edit Dimension Information. For the second feature. Click Next to complete the creation of this dimension. a red dot appears on Line 1.Tolerance of 0. Switch the Dimension Type to Angular. Click Next. Continue to use the Work Plane option.25 mm. and then click Line 2. Place the annotation between the two features. enter a + Tolerance and .

Now pick near the center of Rounded Rectangle 1. Immediately after the second pick (Rounded Rectangle 1). Pick first on Line 2. Expand the folder to see the view we just created. Zoom in close on the corner of the model. The value will reflect the distance in the Y-direction only (41. For more information. refer to the tutorial on 3D Dimensioning. Click OK to exit the function. 63. small gray spheres are visible at several positions around that feature indicating the feature center and the ends of each line segment. Your dimensions will disappear from the model. Carefully select one of the two endpoints of the top line segment. Click Next to move on to the next dimension. 61. Experiment on your own by placing some more dimensions on the view if you like. 66. Place your annotation between the two points and drag it to a desirable location. Change the measurement method to Y direction. called Dimension View 1. By default. Now we will create a dimension that only displays the Y component of the distance. We are going to change that to measure to the top edge of the rectangle. 62. change the option under the Selection area back to Second End. Click on it to see that view again.5 mm). Go to the Dimensions Views folder under the Reference object (CAD) in the Model Manager. as shown below. 64. After picking the rectangle. . the parallel dimension is created using the feature center. 65.60. This is new second end of our dimension. We are going to re-pick the second measurement point now that the spheres are visible.

only it uses the features of the Test object. You should have Dimension View 1 available in the Dimension Views folder in the Model Manager under the Test object. Toggle between these two to see how the dimensions differ. When finished. Click on the Test object (scan) to make it active in the Model Manager. Select Auto Create 3D Dimensions from the Analysis menu. Click on it to see the dimensions. 69. 68. click Done to dismiss the function. These dimensions should differ slightly from the values displayed for the Reference object.67. Now click on the Dimension View 1 for the Reference object. In the dialog that appears. . simply click Apply. Now we will automatically create the same dimensions on the scan data. This function creates that we just created manually on the Reference object.

toggle on the first three checkboxes (Name. If desired. The tolerance for this comparison is stored in the Tools Options settings under Comparison.21 mm. Also reported here is the deviation of the two holes’ diameters. select Compare Features. 74. From the Analysis menu. Go/No-Go Indicator and Deviation of Center). Notice that its Deviation of Center is 0. you can click on the line attaching the annotation box to the feature to drag it to a new position. . the red no-go indicator is shown. The center of the Test hole and the center of the Reference hole were placed right on top of one another. The annotation will display. a go/no-go color box and the deviation of the two features’ centers. 71.1 mm. 75. since it was the first alignment point used. toggle on the option to display Form Deviations. The default tolerance for all comparisons is 0. Click another feature to create a new annotation. We would expect to see zero deviation here. Try Hole 1. Since these deviations exceed the default of 0. 76.00 mm. in this case about . 72. click on Slot 1 and drag the annotation towards the top left. 73. Three more lines become visible in the annotation box displaying values for deviation of the two slots’ lengths. Right-click on the Features folder under the Result model and select Show All to display all the features.1 mm. or use the hotkey Alt+4. widths. Now make the Result model the active object.70. With this annotation still active (red). and radii. In the dialog box. as shown at right. Toggle off the last three. In the viewing window. This is sometimes necessary after repositioning an annotation. This allows the user to place an annotation on each feature displaying some comparison values between Reference and Test object features. the name of the feature.

and Deviation Dx. toggle on only the toggles for Name. Ty. Continue creating more feature annotations using some of the other features. 78.77. The annotation reports the annotation name (A2). toggle on the Reference Rx. total deviation at that point (D). We can also create annotations listing the deviation between Reference and Test objects at locations other than the features. indicated at right. as well as a color box indicating the color of the spectrum at that point. Dz. For example. Ry. When finished. Tz checkboxes to display the coordinates of the corresponding points on the Reference and Test Objects. Click a point on the model that you want to query to find the deviation at. 79. the XZY components of the deviation (Dx. click OK to exit the dialog. With the annotation still active (red). 82. 81. Toggle off the remaining two (Reference and Test coordinates). Dy. . 80. Dz). select a point in the red portion of the model. Color Box. You should have a view similar to the one below. Dy. Rz and Test Tx. In the Display section of the dialog box. Select Create/Modify Annotations from the Result menu.

When finished. give the report a unique name. or Qualify Template file. 87. under Introduction. Toggle off the other formats 91.qtmpl file. including Dimension Views. Continue scrolling through the rest of the options to see what they are. do not open any other programs because the software is taking screen shots and other visible windows might affect the images. Quick Tip: Any changes to this menu can be saved as a . click OK to exit the command. Click Customize button. 86. Finally. Here you can enter some information about yourself and the part being evaluated. When finished. a report with the given name will be saved to the directory specified in the dialog. When complete. When prompted to save the changes. click OK and this information is saved. click No. 94. Under Formats. Go to Edit Properties. choose HTML only. Fill in a few of these fields. If desired. The first step is to define some basic information about the user. select Create Report from the Result menu. If desired. give the report a brief explanation. Minimize the Geomagic Qualify window and find the report folder you specified. Create a few more annotations. click OK to generate the report. In . While the report is being generated. but don’t change any others at this time. 84. the annotations disappear. 89. Change the Output Directory to some place on your hard drive where you want the report saved. 88. and experiment with the various display toggles. With the Result model still the active object. You can create some more on the Back view if you like. We have now created several sets of views to be used in our inspection report. After setting all available options. Annotated Views and Boundary Views. Under Conclusion. This is because they are view-dependant. it is time to compile the report. This allows a user to fully customize the report output and save all the changes. This information will appear on the report we are about to generate. such as the Back view. 90. explain a little about the results. If you switch to one of the other pre-defined views. Click OK to return to the main dialog. if you haven’t already. Switch back to the Front view.83. 92. 93. 85.

Open this file to view the results of the report generation. Open that directory and you will find a file called report. Use the navigation links on the left side to browse the various pages of this report.that folder you will find a directory labeled html.html. End of Tutorial .