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Calypso Advanced Training

Calypso 4.8

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100% found this document useful (8 votes)

7K views182 pages

Calypso Advanced Training

Calypso 4.8

Uploaded by

Anonymous yCFSresrfT

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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Carl Zeiss 3D Metrology Services GmbH

Training manual

®
Calypso 4.8 Advanced
Software Revision: 4.8 Training

We make it visible.
© Carl Zeiss
3D Metrology Services

This manual is copyrighted. No part of this documentation may be copied, reproduced, translated
or processed, multiplied or transfered by means of electronic devices without the expressive appro-
val by Carl Zeiss 3D Metrology Services GmbH. Non-compliance will be prosecuted.

All documents in this manual are compiled in concordance with the respective copyrights. If there
are parts of this manual that indicate foreign copyrights, please inform Zeiss accordingly at info@
zeiss3d.de.

This manual is subject to modifications.

Carl Zeiss 3D Metrology Services GmbH will not be held liable for this manual, including the implied
warranty for commercial quality and suitability for a certain purpose.

Carl Zeiss 3D Metrology Services GmbH will not be held liable in any case for errors, accidental
damages or subsequent damages arising from the provision, function or use of this manual.

All product names are registered trademarks or trademarks of the respective proprietors.

© Carl Zeiss 3D Metrology Services GmbH.

Heinrich-Rieger-Str. 1
73430 Aalen

Software revision: Calypso 4.8

14th Edition, January 2009

Calypso Advanced Training

Customer Training

Calypso Advanced Training

Calypso Rev. 4.8

Subject no. 000000-1135-608

Prerequisites: This class:

- Calypso Basic Lesson - Covers additional Calypso functions

- lasts 5 days
- is recommended in one of our training centers
- starts at 8 am and ends at 4 pm,
- Self-made exercises without a coach possible after 4 pm
- provides class-relevant documentation

Understanding Understanding
Review Offline programming with
• Questions from the basic class CAD functions   
• Questions from the practical use • - Calypso Basic Lesson
• Simulation on the CMM or the offline PC
• Optimized programming with resources
• Strategy settings
• Styli
• Programming with CAD model
• CAD import and resources

Coordinate systems    Measurement methods, Part 1   

• Alignment with offset plane • Gauß, Minimum, Tangential elements•
• 3 Aalen, Germany • Filter and outliers
• RPS best fit method • Form test
• Creating a base alignment as per DIN ISO 5459 • Different scanning procedures
• Start system • Editing methods
• RPS best fit method
•
Calculations, operations and evaluations   
• Recalls
• Special calculations
• Introduction to form and position

Calypso Advanced Training

Understanding Understanding
Expanded programming functions    Automation interface   
• Patterns • Pallet measurement, serial measurement
• Linear pattern
• Circular pitch Printout setup  
• True position on circular pitch • Graphic illustration - plotting
• Pattern measurement as per DIN 3960 • Settings with form plot
• Result element • Printouts
• Formulas • Modifying the printout header
• Result element • User-defined printout
• Relatively positioned probings

Stylus systems and accuracy    Measuring methods, part 2   

• Automatic qualification • Scanning with unknown contour
• Special styli • Scanning with 2 styli
• Styli monitoring • Point masking in open scanning paths
• Holder position functions • Self-centering probing
• Analyzing measurement inaccuracies • Safety Cube
• Park position
• Missing bore

Exercises    Review
• How the trainer evaluates the class
• How the participants evaluate the class

Special training or workshops are offered to teach more Ca- For example:
lypso program options. Training option curve, 3 days
Training option PCM, 3 days
Training planner / simulation
Workshop Auto-Run
Workshop Form and Location

Calypso Advanced Training

Content
Offline Programming with CAD Functions.............................. 8
1.1 Calypso Configuration............................................................................................. 9
1.1.1 Simulation on the CMM PC...............................................................................................9
1.1.2 Simulation on the offline PC...........................................................................................10

1.2 Optimized programming with resources........................................................... 11

1.2.1 Filter and outlier resources . ...........................................................................................12
1.2.2 Strategy resources..........................................................................................................12
1.2.3 Preassigning the stylus system for measurement plan.....................................................13
1.2.4 Copying the format: Changing the coordinate system with the "paintbrush"..................14
1.2.5 Coordinate system preassignment..................................................................................15

1.3 Programming with CAD model ........................................................................... 16

1.3.1 Working on the model . .................................................................................................17
1.3.2 CAD import and resources .............................................................................................23
1.3.3 Additional functions.......................................................................................................27

2: Coordinate system........................................................... 28
2.1. Alignment with offset plane.............................................................................. 30
2.2 3D best fit method on the exercise cube........................................................... 33
2.3 RPS best fit method on the exercise cube......................................................... 35
2.4 Creating the base alignment as per DIN ISO 5459............................................. 36
2.5 Start System ..................................................................................................... 38
2.6 Maintaining the feature position....................................................................... 40
2.7 RPS best fit method........................................................................................... 41

3: Measuring methods, Part 1.............................................. 42

3.1 Gauß, Minimum, Tangential elements .............................................................. 43
3.2 Filter and outlier basics..................................................................................... 44
3.3 Form test on the roundness example................................................................ 50
3.4 Automatic calculation of the scanning parameters............................................ 51
3.5 Self-made changes to the scanning and evaluation parameters........................ 53
3.6 Editor................................................................................................................ 55

Calypso Advanced Training

4: Calculations, operations and evaluations......................... 56

4.1 Recall.................................................................................................................... 57
4.1.1 Point recall from polyline................................................................................................57
4.1.2 Point recall from the circles.............................................................................................60
4.1.3 Point recall from cylinders...............................................................................................61
4.1.4 Point recall from curve....................................................................................................64
4.1.5 Point recall from a file.....................................................................................................65

4.2 Special calculations............................................................................................... 66

4.2.1 Measuring features.........................................................................................................66
4.2.2 Limiting freedom degrees...............................................................................................69
4.2.3 Changing the tolerance mode.........................................................................................71
4.2.4 Tangents........................................................................................................................74

4.3 Introduction to form and position......................................................................................75

4.3.1 Flatness, cylinder form....................................................................................................75
4.3.2 DIN position of two bores...............................................................................................77

5: Expanded programming functions................................... 78

5.1 Pattern.................................................................................................................. 79
5.1.1 Linear Pattern.................................................................................................................80
5.1.2 Polar pattern offset.......................................................................................................83

5.2 True position on circular pitch........................................................................... 88

5.2.1 Coordinate system from bore pattern best fit method...................................................91

5.3 Pattern measurement as per DIN 3960............................................................. 93

5.3.1 Circular pitch..................................................................................................................93
5.3.2 Linear pattern.................................................................................................................97

5.4 Formula............................................................................................................. 98
5.4.1 Result Element..............................................................................................................98
5.4.2 Probing a sheet metal.................................................................................................100
5.4.3 Probing positions relative to a feature.........................................................................101
5.4.4 Alignment with offset plane via formula......................................................................102

5.5: Automation interface...................................................................................... 105

5.5.1 Pallet measurement: . .................................................................................................105
5.5.2 Serial measurement: . .................................................................................................105

6: Result display - printout design...................................... 108

6.1 Graphic display - plotting.................................................................................... 109
6.1.1 Flatness and graphic display..........................................................................................109
6.1.2 Settings of form plot.....................................................................................................114
6.1.3 Plot output only if tolerance range is exceded...............................................................115

Calypso Advanced Training

6.2 Printout............................................................................................................... 116

6.2.1 Modifying the printout header......................................................................................117
6.2.2 Changing the printout header for plots.........................................................................119
6.2.3 Changing compact printout header..............................................................................119
6.2.4 Total result...................................................................................................................120
6.2.5 One-line custom printout..............................................................................................121
6.2.6 User-defined printout...................................................................................................125
6.2.7 Attaching a comment to the characteristic ..................................................................128
6.2.8 Inserting a text element................................................................................................129
6.2.9 Groups in the custom printout......................................................................................130
6.2.10 Saving printouts..........................................................................................................131
6.2.11 Changing the INI file for printout header data.............................................................133
6.2.12 Inserting a variable into the printout...........................................................................136

7: Stylus systems and accuracy.......................................... 138

7.1 Automatically qualify stylus system afterwards.................................................. 139
7.2 Special styli......................................................................................................... 142
7.3 Stylus monitoring................................................................................................ 146
7.4 Rack preassignment ........................................................................................... 148
7.5 Qualify the stylus change rack into the CNC....................................................... 149

7.6 Avoid measurement inaccuracies........................................................................ 150

7.6.1 Temperature compensation..........................................................................................150
7.6.2 Behavior in case of collisions.........................................................................................152
7.6.3 Clamping Workpieces for Measurement.......................................................................153
7.6.4 Stylus Systems..............................................................................................................155
7.6.5 Inaccuracy with a CMM................................................................................................158
7.6.6 Inaccuracy Analysis.......................................................................................................159

8: Measuring methods, part 2............................................ 161

8.1 Scanning with unknown contour..................................................................... 162
8.2 Scanning with 2 styli....................................................................................... 163
8.3 Point masking in open scanning paths............................................................ 165
8.4 Self-centering probing..................................................................................... 166
8.5 Safety cube...................................................................................................... 168
8.6 Park position................................................................................................... 171
8.7 Missing bore.................................................................................................... 172

Calypso Advanced Training

Offline Programming with CAD Functions

1.1 Calypso Configuration............................................................................................. 9

1.1.1 Simulation on the CMM PC...............................................................................................9

1.1.2 Simulation on the offline PC...........................................................................................10

1.2 Optimized programming with resources........................................................... 11

1.2.1 Filter and outlier resources . ...........................................................................................12

1.2.2 Strategy resources..........................................................................................................12

1.2.3 Preassigning the stylus system for measurement plan.....................................................13

1.2.4 Copying the format: Changing the coordinate system with the "paintbrush"..................14

1.2.5 Coordinate system preassignment..................................................................................15

1.3 Programming with CAD model ........................................................................... 16

1.3.1 Working on the model . .................................................................................................17

1.3.2 CAD import and resources .............................................................................................23

1.3.3 Additional functions.......................................................................................................27

Calypso Advanced Training

1.1 Calypso Configuration

This section shows how to easily program with standard Calypso

without the planning and simulation options.

Goal of this section:

• Switching in simulation mode
• - Calypso Basic Lesson
• Safe manual input of features and strategies
• Changing the nominal geometries
• Preparing styli in simulation mode
• Programming on the CAD model
• Simulated CNC runs

1.1.1 Simulation on the CMM PC

Every Calypso PC can be programmed offline.

Two possibilities:

• with an existing connection to the CMM,

by clicking "simulation mode",
bears the risk of collisions at CNC start,
Existing stylus data is used.

• Connection with simulation

is used to be able to also start sequences.
Here, the stylus data must first be crea-
ted.

Switching on simulation mode:

1. Disconnect existing connection: Close
the stoplight window
2. Extras - workroom - control: Simulati-
on: create connection.

Caution:
Check all simulation settings to match
the machine settings.
Make sure that you are working in
simulation mode!

If you are not in simulation mode you will

change the stylus data and there is a risk
of collision!

Calypso Advanced Training

1.1.2 Simulation on the offline PC

The programming station is a stand-alone Calypso PC, where

remote machine measurement plans are created. The installation
of Calypso on the PC was performed as a "simulation".

The workroom houses the measuring device used later, although

no control is connected to it.
But the stoplight window is present, because measurement plans
can be started.

Caution:
Check all settings of the simulation so that they conform to
the online device settings.

10 Calypso Advanced Training

1.2 Optimized programming with resources

This section describes the possible settings for quick program-

ming with default values and system settings.

1. Filter and outlier resources

2. Strategy settings

3. Preassigning the stylus system for measurement plan

4. Preassignment of coordinate system

5. Copying the format: Changing the coordinate system
with the "paintbrush"

The table represents possibilities for resources , not changes for individual features/characteristics/
runs

Resource Change with

Measurement
Probing path Extras - workroom - measurement
Clearance Extras - workroom - measurement
Clearance plane Can be edited by means of editor or feature
Rounding locations Extras - workroom - measurement - nominal value
Preassignment of coordinate Extras - workroom - measurement - nominal value
system
Tolerance mode Extras - workroom - measurement - nominal value
Filter / outlier Prepare - resources
Strategy settings Prepare - resources
Styli Preparing - styli
Coordinate System Prepare - preassignment for new features
Printout
Print output Resources - define printout
Print output - files Resources - results to file
File name for output file Resources - names for output file
Feature evaluation Resources - presentation of features
Feature - naming Extras - workroom - work environment- IndicationNames
CNC
CNC CNC - preassign CNC start values

Calypso Advanced Training 11

1.2.1 Filter and outlier resources

1.2.2 Strategy resources

These resources can be used to quickly extract already finis-

hed features with settings from the CAD model.

The following possibilities exist:

• Defining and saving filter and outlier settings
• Defining and saving strategy settings
• Saving both types of settings together

A data file is created for each of the mentioned cases.

This can be found at

. . . \Zeiss\Calypso\home\om\config\
rules\ . . .
Calypso will always access this path auto-
matically.

Task:

• Define the filter and outlier resources as

shown.
Save these under the name
"AufbauSchulung_Filter" (AdvancedTrai-
ning_Filter)

• Define the strategy resources and save

these under the name
"AufbauSchulung_Strategie" (Advanced-

The following applies to the filters/outliers:

The setting of the current measurement
plan is changed.

The following applies to the strategy:

The default setting for new features is
changed for every measurement plan.
With an update from former Calypso ver-
sions, this equals existing functions.

12 Calypso Advanced Training

• Click on "General" and save both under

the name "AufbauSchulung_Alle"
(AdvancedTraining_All)

• Open a new measurement plan, load the

model
"Scanmax.sat"
and program the following task.

Goal:

Program the sequence CNC with as few

mouse clicks as possible.

1.2.3 Preassigning the stylus system for measure-

ment plan

Use this very convenient function with

your programming:

If geometries are extracted from the CAD

model, you need not worry about styli.

They can be assigned automatically later

by:
Resources -> Stylus System -> Preassign
the stylus system for measurement plan
autom.

Calypso Advanced Training 13

1.2.4 Copying the format: Changing the coordinate system with the
"paintbrush"

The "paintbrush" changes the properties

of objects, the assignment of a coordinate
system is one of the properties.

Task:

Create a 2nd coordinate system in the center bore.

Assign a new coordinate system to the circles (1-6) without ope-

ning the features.

Assign the new coordinate system to the first of the circles.

Select the
"Paintbrush - transfer format"
.

Only select "coordinate system“.

Now select the five other circles, which are also to be transferred
to the coordinate system (circles 5 - 7).

Close by clicking OK.

14 Calypso Advanced Training

1.2.5 Coordinate system preassignment

This function can be used to determine which coordinate

system the subsequent measuring features are to be calcula-
ted in.

Retrieval:

Resources - preassignment for new features

Select the desired coordinate system.

Do NOT close this window.

The assignment is only made for the features that are mea-
sured or determined while the window is open.

Preassignment for the projection plane

The function can also be used for projection planes.

Calypso Advanced Training 15

1.3 Programming with CAD model

Depending on the respective CAD program, the CAD files are
written in a specific format.
There is a difference between
• manufacturer-specific data sets such as ProE
• system-neutral data sets such as STEP.

Furthermore, there must be a differentiation between

2D and 3D data:

• 2D data is based on vector-oriented drawing programs and it

produces two-dimensional data.
This data can be used for programming in Calypso.

• 3D data sets deliver geometry data for a volume model.

Wire models, surface models and volume moduls are the basis
for programming with Calypso.
The decisive factor is often the quality of the delivered data.
Incomplete or faulty constructions of surfaces in the model
complicate the programming of the measuring run.

Therefore, controlling the model is always the first step when

working with CAD files.

16 Calypso Advanced Training

1.3.1 Working on the model

Note:
A larger version of this drawing can be found in the Appendix.

Calypso Advanced Training 17

Loading and controlling the model

The exercise workpiece is loaded as an Acis model and rendered

to check for completeness.

The position of the basic system stems from the design phase.
If the position does not meet the requirements for measurement,
the model must be moved.E

Adapting the origin and the axis directions

Here, the Calypso offers two possibilities:

• Manually transforming the model
• Directly creating the base alignment

In this example, the model is first manually transformed and the

coordinate system is created afterwards.

Manually transforming the model

Moving the model by 180 mm

Rotating the model by -90°

Base alignment in desired position

18 Calypso Advanced Training

Selecting features and defining solid geometry

Defining a solid geometry means: individually extracting

known spatial geometric features from the model.
Here, the dimensions and the name of the feature (for some
formats, as indicated by the designer) are made available for
Calypso.
Furthermore, the creation of circles, straight lines and points is
possible. These, however, are not spatial features and must the-
refore be selected separately.

Modifying the model

Clicking the cone:

Here, you can see that only one half has be stored.

This means, that a model revision would make sense.

After the reworking, here "merge faces with same geometry",

the cone and all other features can be extracted correctly.

Calypso Advanced Training 19

Measuring on the CAD model

Features for the base alignment:

The base alignment is to be created from three planes.
These planes are extracted as solids.
After that, the planes are equipped with strategy (probing points)
and entered into the base alignment.

The safety cube is defined with the function "safety cube of

CAD model".
The edge distance of 10 mm is sufficient.

20 Calypso Advanced Training

Strategy Defaults:
This procedure defines the measuring strategy of the transfer or
creation of measuring features when extracting from the CAD
model.

Example: Plane with multi polyline

Strategy defaults can be set for every feature

on this list.
Here, for example, the multi polyline is set
for a plane and the top plane is re-extracted.

Based on these settings, this plane features

a scanning path along every border.

This plane can now be used for characteristics that require the
form of this surface, e.g. the perpendicularity to the side surface.

Calypso Advanced Training 21

Additional menus and settings

"View' menu
This menu can be used to make settings and save some data.

Note:
Details regarding these functions can be taken from the ope-
rating instructions.

"Display" menu (CAD model control)

This function can be used to alter the display in the ACIS window.

Modifying CAD features

This menu point covers a multitude of functions, only some of
which are presented here.

• Deleting features and rendering them invisible

• Creating features from the wire model
• Positioning the model
• Cutting the model

Example: Creating elements from the wire model

Principle:
• Switch on the wire model
• Click on a contour
• Click the respective button
• Clicking a circle creates a circle, clicking two circles creates a
cylinder
• Offset to move the generated feature
• Curves with preset point numbers
• Spatial points at preset position.

Note:
These functions and many more are the subject of the
training seminar "Planner and Simulation"

22 Calypso Advanced Training

1.3.2 CAD import and resources

Data transfer of CAD programs to Calypso

Calypso works with the ACIS format of the Spatial company,

which uses data with the extension *.sat or *.sab.
In order to preserve this format, different methods can be ap-
plied:

1. Calypso imports the respective original data format via an

import filter. (=direct import)
2. Calypso imports a conversion format such as STEP.
For this, the CAD system exports into this format from its
original format (e.g. STEP).
3. The CAD program exports the ACIS format for Calypso direct-
ly.

Neutral data formats:

VDAFS: Developed by the "Verband deutscher Automobilbau-
er" (Association of German Automobile Manufacturers), a very
important format in the past.
IGES:works with 2D and 3D data, when imported into Calypso,
there can be problems due to the inaccuracies in the original.
STEP: Modern, internationally used format, which converts
volume models with nearly zero losses and which can contain
additional information such as mass.
This format is the preferred choice.

Important:
CAD programs often allow different export settings.Here, one
must experiment with the correct export setting to achieve opti-
mized results in Calypso.

CAD model file formats

Currently, Calypso supports the following file types:

ACIS files .sat or .sab

CATIA files *.exp, .model
CATIA V files *.CATPart
Drawing interchange format *.dxf
STEP files *.stp
IGES files *.igs
VDAFS files *.vda
Unigraphics *.ug
ProE *.prt
Parasolid *.x_t
Inventor *.ipt
Solidworks *.sldprt, .sldasm
IDEAS *.idi

What is important during the import is that the file extension is

correct, as Calypso recognizes the file type via its extension.

Calypso Advanced Training 23

Importing a model

The CAD model can be located on any file path.

You can access the respective directory via <CAD file
- load...>.

You can always import *.sat files with "file type".

Additionally, one or more import filters can be relea-
sed.
The respective files are only shown if you switch to
the respective file type.

In this example, the always included ACIS model of

the exercise cube is loaded.

Problems while loading?

Problems during the loading process are multi-facetted and can

be difficult to eliminate.

• Type of data set correct? A file extension does not necessari-

ly have to be correct, there could have been retroactive
changes. Be careful with unknown file formats.
• Does the data set version match the Calypso converter?
• Check the interface. Is the correct interface unlocked in Calyp-
so?
• Is the data set really a volume model, not just a drawing
saved as a model?
• If the model is visible, but features additional auxiliary lines,
these can be deleted.
• If the CAD model does not appear on the screen, the window
Scheme ACIS Interface Driver extension in the taskbar
might contain additional information.
Also, a log file with the model name will be created. This
file contains additional information and possibly a list of
errors.

24 Calypso Advanced Training

Examples for faulty loaded models:

Automatic healing

The model can be adapted in four steps by means of the <CAD

file - model revision" function.
Revising the models allows the correction of slightly faulty mo-
dels.
Especially older model files may be faulty.
Generally you should strive to make a revision redundant.

Note:
This procedures does not have to be successful! With very "bad"
data sets, a usable model may be created after the procedure.
You also must take into consideration the large calculation effort,
which may take several hours depending on the model and the
computer.

This resources process consists of several steps:

• Simplification
• Stitching
• Build geometry
• Correct boundary curves

Calypso Advanced Training 25

General procedure
The function "correct boundary curves" should always be perfor-
med.

"Creating geometry" includes the "simplification" and "stitching".

The procedure is time-consuming, but cannot be avoided with
some models.

The functions in detail:

Simplification

The healing process starts with the simplification.

The first step is the "cleaning" of a model. Inaccuracies, and
edges with the length zero, are deleted.
Delivered models often feature geometries that are not mathe-
matically described. Here, in this step, the analytical geometry
(arc, cylinder, cone, lane) are approached.
This calculation requires a tolerance to be able to obtain a limit
value for the simplification.
Properties are added to this geometry to easily identify them
during the procedure.

Stitching

This function "sews together" a group of surfaces to achieve one

single surface or a geometry.
Here, a solid model is created.

Build a geometry

Defining a geometry "heals" inaccuracies of the model. A sequen-

ce of calculations improves the accuracy.
The entire model will be revised.
The function includes the two former ones and can take some
time with larger models.

Correct boundary curves

Corrects the boundary curves of the model.
Cuts that cannot be created point to unclean boundaries.

26 Calypso Advanced Training

1.3.3 Additional functions

CAD -> modification -> delete free lines and points

This function is intended to clean a CAD model of points and

lines, which were only intended to be a help for the designer and
which do not have any meaning for the Calypso user.
Careful, if the designer wanted to mark by free points, where the
metrology technician was to probe the model; if these free points
were relevant for measuring needs. In this case, you will lose this
information.

CAD -> modification -> merge faces with same geometry

Independent of the topology, surfaces with the same geometry

are merged.
An example for this is a cylinder consisting of two semi-bowls
which is merged into a complete cylinder by this function.

CAD -> modification -> combine CAD features

The following two cubes are two spatially separated objects.

Thus, there is no visible connection between the two.

Nothing has changed visually after this command was entered

(the bodies are not "stuck together"). Their position in the space
remains the same. However, Calypso treats them as one body.

A typical use is the addition of a clamping device to the model to

be measured.
If the measured object and the device are considered one unit,
they are tested as one compared to the stylus, also with collision
measurements.
Another case, where this command is very useful is if the CAD
object is present as a surface model. Depending on the graphic
card, this command can lead to the model being much quicker to
handle (rotate, move…)

Calypso Advanced Training 27

2: Coordinate system

2.1. Alignment with offset plane.............................................................................. 30

2.2 3D best fit method on the exercise cube........................................................... 33

2.3 RPS best fit method on the exercise cube......................................................... 35

2.4 Creating the base alignment as per DIN ISO 5459............................................. 36

2.5 Start System ..................................................................................................... 38

2.6 Maintaining the feature position....................................................................... 40

2.7 RPS best fit method........................................................................................... 41

28 Calypso Advanced Training

Overview of the best fit method methods:

Procedure Number of points Application

3D best fit method Arbitrary number of Gauß best fit method of all actual points to the
points or geometry nominal points
elements
Selection of points according to the function of the
workpiece. Prefered use with free forms with regu-
lated geometric elements for positioning.

RPS 3 -6 3-2-1
A coordinate is determined three times (must be
on one plane), the second one two times, the third
one once.
Usual procedure of chassis metrology, the points
are indicated in the respective drawing.
P6 3 1. Point is origin.
1st and 2nd point is spatial direction
1st and 3rd point is additional direction

Application example: Special procedure for the

automobile industry, tubular bodies
Perforated template Arbitrary Optimized best fit method of bore patterns
best fit method bores

Procedure with 3 Raw cast parts

offset plane for plane

• All processes should be conducted with loops as an iteration.

• If you select the option Best fit method to the CAD model, the actual points are initially
aligned with the nominal points (as per Gauß); after that, the perpendicular foot points of
the aligned actual points from the CAD model are calculated. Finally, the actual points are
aligned with the perpendicular foot points (as per Gauß).

Calypso Advanced Training 29

2.1. Alignment with offset plane

This exercise uses a theoretical plane 50 mm above the workpi-

ece as a primary reference of the alignment.
This plane cannot be probed directly, but should be captured
with 3 points on the cube, whose height must be corrected.

This offset plane is a feature in Calypso and must be probed with

exactly 3 points.

Take an Offset plane (measuring - special features) into the

measurement plan and open it.

Probe three points for the plane on the exercise cube.

• Point 1 at the rear of the cover surface

• Point 2 in the circular slot
• Point 3 in the front slot

Do NOT complete the feature with OK.

These points must be corrected immediately, so that a plane

is created 50 mm above the cube.For this, click on "Evaluation
- modify points“.
The correction values are (as per drawing):
• 1: -50
• 2: -58 mm ( -60 if using offline training)
• 3: -60
Correction direction:
(+) in the direction of the vector
(-) against the direction of the vector
The prefix originates in the desired offset height and shows what
measurement value is used to correct the individual point.

Close offset plane.

Select further sensible features for the alignment and probe

them.
Here, a circle in the top bore 30 and a 2D line on the front sur-
face.

Enter the features into the base alignment.

Special:
Enter an offset in Z by -50 mm so that the base alignment
comes to rest on the workpiece.

30 Calypso Advanced Training

Define the safety cube

Edit the clearance and the probing path.

Take into consideration that every point on the offset plane will
be probed with a standard probing path (5 mm), just like in a
normal plane. However, this is not possible with the points in the
slot.

Note: Later during the exercise, the cube will be tilted slightly.
Please take this into consideration with the probing points
and probing paths of all features.

Start the run once to ensure a flawless process.

Insert the loop

Only the loop allows an approach calculation.

Why this is necessary will be described on the following pages.

Here, you can practice entering a break condition:

baseSystem().valueA<0.005

This break condition stops the loop (not the run!), if the condition
is met.
This will be explained in further detail later.

Slightly tilt the workpiece on the measuring table and

restart the run.
(Not possible during offline training).

The base alignment will be run five times. Here, the cal-
culation will approach more and more, an iteration will
be conducted.

View the default printout:

What is interesting here, is the "delta value", a calcula-

tion of the moving, rotating and tilting values.
The "delta value" indicates by how much the coordinate
system has changed since the last alignment.
You can hence call this value a best fit method value.

In a later exercise, this value is queried via a break condi-

tion.

Calypso Advanced Training 31

Thoughts about correcting the probing points

With this alignment, the "incorrect" correction during the first run
will yield an offset plane with an error in the device coordinates.

If the alignment is repeated and the plane direction of the first

run is accessed, the result will improve considerably. In a third run
- with the correction direction of the second alignment - the error
will approach zero.

This principle of approaching is similar with other alignments.

The entered loop is worked off, here, an improvement is determi-

ned via the base alignment of the previous run.

In a later section, the alignment with offset plane will be rerun.

Here, the probing points will be calculated on a theoretical plane

via formula functions.

32 Calypso Advanced Training

2.2 3D best fit method on the exercise cube

This procedure can be used for the calculated alignment of work-

pieces, for which no unique reference features were defined.
With the 3D best fit method, a arbitrary number of points can be
adapted as best as possible to their nominal geometry.

In our example, we would like to adapt four intersections of

cylinders with planes using the above mentioned procedure, until
the sum of all error squares between nominal and actual points
becomes minimal (best fit method as per Gauß).

Probe the required features on the exercise cube.

• Plane_top
• Plane_top
• Plane_top
• Cylinder_30_front
• Cylinder_15_front
• Cylinder_30_top
• Cylinder_12_top

Open the toolbox and place the operation "Intersection" into

the measurement plan four times.

Intersection:
• Intersection 1: Plane_front - cylinder_30_front
• Intersection 2: Plane_front - cylinder_15_front
• Intersection 3: Plane_top - cylinder_30_top`
• Intersection 4: Plane_right - cylinder_12_right_center

These four intersections are used as best fit method points.

Select the
Resources - measurement plan - base alignment

At the prompt "New base alignment“, select the

"3D best fit method".

Calypso Advanced Training 33

Select the intersections by selecting "Select features“.

The nominal values of the intersections refer to the coordina-

te origin in the front top left.

Here, every arbitrary origin can be used, the nominal values

must be adapted accordingly.

Best fit method to the CAD model:

The best fit method takes place in three steps:
• Gauß best fit method of the actual points to the assigned
nominal points
• Calculation of the perpendicular leg points of the thus adap-
ted actual points on the CAD model.
• Gauß best fit method of the actual points to the assigned
perpendicular leg points.

Start the program. 1 , -50 , 0 , -34

The run will conduct 3 loop cycles and calculate a base align- 2 , -75 , 0 , -47
ment every time. 3 , -40.2 , 0 , 32
Every run takes the previous base alignment and "improves" 4 , 30 , 0 , -34
it. This change of the previous run can be seen as the "delta
value" in the default printout.
If the delta value is only slightly changed, the base alignment
is well adapted.

Note:
The delta value does not necessarily need to approach zero.
This is only the case in the base alignment.
If a 3D best fit method is used as a second or later coordinate
system, the delta value changes toward a arbitrary numeric
value.

Entering a break condition

baseSystem().valueA<0.01
Note:
As this procedure requires knowledge about conditions, this
exercise can also take place after the respective sections have
been worked on.
However, if the formula is transfered flawlessly at this point,
this example will run smoothly.

34 Calypso Advanced Training

2.3 RPS best fit method on the exercise cube

This exercise will give you an introduction to the RPS alignment.

RPS is the abbreviation for reference point system.
The RPS alignment is based on the 1-2-3 rule.The features point,
spatial point and intersection are permitted.

RPS alignments are suitable for prismatic workpieces; here, the

"RPS 321" must be selected.When working on sheet metal pi-
eces, which are evaluated with the option "free form", you must
click on "RPS free form.

Probe six individual points on the exercise cube.

Three points on top of the workpiece.

Two points in the front.

One point on the right.

Retrieve the base alignment and select the RPS method.

Select the features for the alignment: all six points. Preassign the
coordinates of the points and the axis direction to which they
apply.

Click on "Loop" and enter the number of runs. Reassign a break

condition.

Measure a circle and create the feature "Diameter".

Start the run.

Note:
The use of the RPS free form is described in the respective
training.

Calypso Advanced Training 35

2.4 Creating the base alignment as per DIN ISO

Calculating the base alignment without use DIN ISO 5459

The standard calculation is the determination of the intersec-

tion of three measured planes (presetting Gauß).

The planes are intersected together to derive the origin of

the reference system. The primary reference determines the
spatial direction and the secondary reference determines the
plane direction of the reference system (perpendicular to the
drawing plane in these examples and therefore invisible).

Calculating a base alignment as per DIN ISO 5459

The standard DIN ISO 5459 describes how a reference system

must be created from several references.
An instruction from this standard defines how the reference
elements must be arranged relative to each other:

The secondary reference must be perpendicular or parallel

to the primary reference and the tertiary reference must be
perpendicular or parallel to the primary and secondary refe-
rences.

This results in the following:

If references are interchanged, there will be different results
with positioning tolerances.

Retrieval:

Setting for all references:

References must be created as per standard with tangential

features.
This means external or internal features for circles.

In order to enter the references as tan-

gential features from the start, you can
select this in the input mask.

36 Calypso Advanced Training

Exercise:
Create a base alignment on the exercise workpiece and
compare the results of the distance measurement.

Check the measurement of this bore first using the "usual" me-
thod and afterwards after the setting as per ISO 5459.

Evaluation with X, Y values.

Compare the results and interpret them.

Calypso Advanced Training 37

2.5 Start System

A start system is used if the base alignment is difficult to qualify

manually. For example, with several stylus systems and complex
operations.

Here, a start system may be an advantage.

Sequence:
First create the base alignment, then the start system.

Example on the exercise cube:

As it is not necessary to work with a start system on the

exercise cube, a case has been constructed to show the the
principle :

The base alignment is placed in the middle of the top bore, a

start system on the front right edge of the cube.

The CNC program should be started by means of the start

system.

Notes:
Create the start system as a complete coordinate system, not
only by means of 3 points for the zero position.

The start system can only be created if the base alignment

exists already.

Exercise:

Creating the base alignment in the center of the bore

Plane with 4 points

Circle with scanning strategy
Straight line with 2 points

38 Calypso Advanced Training

The start system can be prepared via

Resources - base alignment - start alignment

Measuring the features and creating the start system

Click "OK":
The offset values of the base alignment to the start system are
displayed.

Create arbitrary characteristics to permit a sensible CNC start.

Test the start system with the possible options "manual align-
ment", etc.

Calypso Advanced Training 39

2.6 Maintaining the feature position

When selecting a coordinate system in the feature, the

position of the feature to the new coordinate system can be
kept.

When the coordinate system is changed, the numeric values

of the nominal values do not change.

The position of the feature practically "wanders" into the

new coordinate system.

Application

When programming workpieces with identical assemblies

(e.g. V motor), we like to program one side, then set a new
coordinate system in order to copy the features here.

This only makes sense if they change positions.

In this case, this option is used.

Application with "Paintbrush function"

When using the "Paintbrush function", this option can be

selected.

40 Calypso Advanced Training

2.7 RPS best fit method

With geometry best fit method, several features, especially pla-

nes, can be adapted to their respective nominal geometries.

The best fit method calculates as per Gauß.

Freedom degrees with the best fit method calculation can be
arbitraryly limited.

The result is a coordinate system that can be used for subse-

quent evaluations.
The printout is the same as with the 3D best fit method.

Example:

A geometry best fit method is to be conducted on two slanted

surfaces.

Every side is measured as a plane.

Retrieving the geometry best fit method:

Resources - utilities - geometry best fit
Selecting the two surfaces.

If necessary, limit the freedom degrees; here they are all open.

Calypso calculates a best fit method of all points to the nominal

geometry of the two planes.
This results in a new coordinate system.

Here, you can position a theoretical plane, which is located in the

center between the two planes.

Application example:
Aligning dovetail guide.

Calypso Advanced Training 41

3: Measuring methods, Part 1

3.1 Gauß, Minimum, Tangential elements .............................................................. 43

3.2 Filter and outlier basics..................................................................................... 44

3.3 Form test on the roundness example................................................................ 50

3.4 Automatic calculation of the scanning parameters............................................ 51

3.5 Self-made changes to the scanning and evaluation parameters........................ 53

3.6 Editor................................................................................................................ 55

42 Calypso Advanced Training

3. Measurement methods, Part 1

3.1 Gauß, Minimum, Tangential elements

Calypso initially calculates features as per the Gauß process: Mi-

nimizing the error squares or method of the smallest error square
sum.
Surface portions go into the material and away from it from the
ideally calculated Gauß circle.

As soon as a geometric feature is to be merged with another

feature, the evaluation as per Gauß should be considered.

In this example, a bolt must fit into a bore.

If both features are evaluated as per Gauß, no statement can be
made regarding the best fit method.
Here, the bolt must be evaluated as a external feature and
the bore must be evaluated as a internal feature.

As outliers affect the surface considerably, you must filter and

activate the outlier elimination.

Calypso Advanced Training 43

3.2 Filter and outlier basics

What does "filter" mean?

Every surface of a body varies from its ideal geometry.

This is called shape variance.

Shape variance can be subdivided into

• Dimensional variance
• Form variance
• Position variance
• Surface variance

Filtering separates the form variance of different orders

from each other, but is also used to balance arbitrary mea-
suring variances.

Goal:
The geometry deviations relevant to the functions must be
captured and presented as a measurement result.
For most of the measuring results, surface roughness does not
play a role, but are included in the measurement result.
These temporary structures are eliminated by filtering.
Here, you need a low-pass filter.

How does a surface look?

From a technical viewpoint, a surface is the overlapping of many

undulations with different undulation lengths (with different
amplitude peaks and phase responses).

This illustration shows undulations of different undulation lengths

that were "added together" and make up the surface structure.
Here, the amplitude peak is drawn the same to simplify the view.

With a plane from the bowed form to the invisible roughness.

With a cylinder, from the oval form to the roughness.

What does "filter" mean?

only take into consideration short or long undulations during an
evaluation.

44 Calypso Advanced Training

Functionality of the Gauß filter

On all measured points, their average value with the surrounding

points is calculated.

The surrounding points are weighted, therefore they will only

contribute a smaller portion. The weighting is not linear but cal-
culated with the Gauß bell curve.

The width of the bell determines with the extent of the captured
points.
The wider the bell, the "stronger" the filtering.

With the straight measurement, they refer to the limit undulati-

on length (lc), which is defined in millimeters. Here, the length of
the undulation is important.

If a roundness measurement is considered during the filte-

ring, they refer to a limit undulation number, which is defined as
undulations per revolution.

Conversion:

Limit undulation length lc = D x 3.14 / limit undulation number

Limit undulation length = D x 3.14 / limit undulation number

Recommended setting:
Straightness measurement: Limit undulation lengths 8.0, 2.5,
0.8, 0.25 mm
Roundness measurement: Limit undulation numbers 15, 50,
150, 500 W/U

Minimum number of points for filtering:

Number of undulations per revolution x 7 points = minimum
number of points

Points per undulation: 7.

Calculation: Length*points per undulation / limit undulation
length

Example:
length= 113
Limit undulation length 0.25 0.8 2.5 8.0 mm
> Min. number of points = 3164 988 316 99

Calypso Advanced Training 45

Limit undulation length

If you enter the undulation length to the amplitude into diagram,

this will create the limit of which the "cut" is made once a certain
undulation length is reached.
This is called the limit undulation length.

With roundness, the undulations/revolution (U/r) to the ampli-

tude are recorded.
With planes, the undulation length l to the amplitude is consi-
dered.

Filter types

2RC (ISO 4291, no longer commonly used)

(R = resistance; C = capacitor)
The 2RC filter is a mathematical replication of a real RC filter.
The transfer during the limit undulation length is 75%. The
amplitude of the limit undulation length is also dampened by
a fourth.

Gauß (ISO 11562)

The standard filter and commonly used in metrology.

The transfer during the limit undulation length is 50%.

The amplitude of the limit undulation length is thus dam-
pened by a half.

Spline
Newer filter with better functionality on open contours.
Quicker calculation and more stable performance with outliers
than Gauß.
This filter is not normed.

46 Calypso Advanced Training

Types of filters:

Low-pass filter

Low frequencies (minor W/U) pass through the filter, high

ones are filtered out.
Surface roughness is filtered out.

Low-pass filter

High frequencies (high W/U) pass through the filter, low ones
are filtered out.
Form deviations are filtered out.
Examining roughness.

Band-pass filter

A certain frequency band passes the filter.

Certain form portions and rough areas are filtered.
Examining ripples.

The limit undulation lengths are described in more detail in the

applicable standard.

Note:
This subject is covered in detail in the
form and position deviation training.

Calypso Advanced Training 47

Recommendations

Filter settings are not normed.

Tests have yielded experience results, which have lead to the
following recommendations, among others in AUKOM:

Roundness measurement: Filtering and measuring points

Form only Form and ripples, form Ripples only

Standard form measure- including grid marks periodic profile portions
ment z e.g. size of grid marks
e.g. wear / coupling
Limit Measuring Limit Measuring Limit Measuring
Workpiece undulation points per undulation points per undulation points per
diameter number circum- number circum- number circum-
[ mm ] [ U/r ] ference [ U/r ] ference [ U/r ] ference
8 15 105 50 350 15 – 150 1050
8 25
80 50 > 350 150 1050 50 - 500 > 3500
> 80 to 250 150 1050 500 3500

Straightness measurement: Filtering and measuring points

Limit undulation length Measuring points per Step width

mm
lc[ mm ] [ mm ]
.,25 28 0,0357
0,80 > 8.75 0,1143
2,5 > 2.8 0,357
8 > 0.875 1,143
25 0,28 3,570

48 Calypso Advanced Training

Outliers

A measuring point is considered an outlier, if its distance to the

calculated Gauß feature exceeds a fixed threshold value*.

Threshold value = factor standard deviation

Outliers within workpiece: Cavity in the material

Outliers outside workpiece: Bulge in the material

Recommended setting:
The setting depends on the specific workpiece and its machining.
An outlier elimination of 3*S can be used in many cases without
problems.
Make sure that no more than 5% of the measuring points are
deleted as outliers.

Switching on filters and outliers

1. Global

Switching on via:
Resources - save/load defaults
Valid for all subsequently measured elements.

2. Feature-related

Valid for the feature, is taken into consideration with every

evaluation of the feature.

3. Evaluation-related

During the selection of the feature in the characteristic. Only

applies to this evaluation.

Calypso Advanced Training 49

3.3 Form test on the roundness example

In this section, you will learn:

• how to define scanning paths,
• how to have the optimal parameters of Calypso set automatically,
• how the scanning speed affects the result,
• what effect filtering has,
• how to handle outliers,
• how to use tangential and minimum features,
• how to use strategy presets.

Resourcess for the exercise

1. Measure a circle in the cylinder at the front side.

2. Place the strategy "Circle section" into this feature.

Bores in another workpiece can also be used for this exercise.

3. Run this feature once more.

Do not change to the settings in the circle section yet!

4. Open the default printout to constantly monitor the results

50 Calypso Advanced Training

3.4 Automatic calculation of the scanning parameters

Click on strategy step distance.

Click on calculation.
Now, there will be a query regarding the use of the feature.
As there has not yet been an allocation of the circle to an evalua-
tion, e.g. diameter, Calypso requires this information to calculate
the speed and the number of points.

Click on Calculate and then choose between location, size and

form. Observe the changes in speed and the step width.

Click basic settings. You will reach the

familiar page in system settings.

Changes on this page will result in modifica-

tions of the basic parameters.

Please keep in mind that changes to the

operation of the measuring device can nega-
tively impact the scanning process.

Calypso Advanced Training 51

In the next section, three characteristics will be linked to this

circle.Use this circle
• for a position: Z value
• for a measurement: diameter
• for a form: Roundness.

In the Roundness, a graphic evaluation is possible.

Select the circle in the list of features and open "Use..." with the
right (center) mouse key.
You will see where the feature is used.

The button "Use" in the strategy offers

additional information about tolerances and
evaluation procedures.

Changes to the characteristic and the fea-

tures are possible.

Note:
This subject is covered in detail in the
form and position deviation training.

52 Calypso Advanced Training

3.5 Self-made changes to the scanning and eva-

luation parameters

In the following steps you will manually change the scanning

settings step by step and you can create a printout each time for
comparison.

1. Calculation:
Speed 12

Roundness
0,0239

2. Speed increase
Speed 80

Roundness
0,0220

3. Speed reduction
Speed 2

Roundness
0,0174

4. Use of a filter
Speed 12
Filter 150 W/U

Roundness
Filtering not possible! 0,0239

Calypso Advanced Training 53

5. Use of a filter
Speed 12
Filter 50 W/U

Roundness
0,0093

6. Use of a filter and an outlier feature

Speed 12
Filter 50 W/U
Outlier 2xS

Roundness
0,0035

7. Use of a filter and an outlier feature

Speed 12
Filter 50 W/U
Outlier 2xS + neighbor

Roundness
0,0027

8. Minimum circumscribed element

Speed 12
Filter 50 W/U
Internal feature

Roundness
0,0099

54 Calypso Advanced Training

3.6 Editor

In addition to the presets for e.g. filters and outliers that were
already presented in a different section, these assignments can
easily be changed using the Editor:

Opening the Editor:

Resources - characteristics - settings editor

Calypso Advanced Training 55

4: Calculations, operations and evaluations

4.1 Recall.................................................................................................................... 57

4.1.1 Point recall from polyline................................................................................................57

4.1.2 Point recall from the circles.............................................................................................60

4.1.3 Point recall from cylinders...............................................................................................61

4.1.4 Point recall from curve....................................................................................................64

4.1.5 Point recall from a file.....................................................................................................65

4.2 Special calculations............................................................................................... 66

4.2.1 Measuring features.........................................................................................................66

4.2.2 Limiting freedom degrees...............................................................................................69

4.2.3 Changing the tolerance mode.........................................................................................71

4.2.4 Tangents........................................................................................................................74

4.3 Introduction to form and position......................................................................................75

4.3.1 Flatness, cylinder form....................................................................................................75

4.3.2 DIN position of two bores...............................................................................................77

56 Calypso Advanced Training

4.1 Recall

4.1.1 Point recall from polyline

The term "recall" bears the possibility to perform further calculati-

ons from earlier features using already measured values.

Task:

Measure a plane with one or more polylines and recall the mea-
sured points into the feature "Line" to perform an evaluation of
True straightness.

This exercise is done on the CAD model.

Create the base alignment and safety cube as usual.

Take a plane from the toolbox and place it onto the right side of
the cube with three lines.

Take the feature

"3D line" into the measurement plan twice.

Open a line and define the nominal value definition with "point
recall".

Select the plane, watch for the buttons that will now appear in
the top bar:

Calypso Advanced Training 57

First click on the left button; the actual points will be displayed as
Xs in the feature.The right button allows a new selection.

The actual points (!!) are shown as red Xs.

Select the left scanning path using the "lasso".

Further possibilities regarding the point selection are shown

These points are taken over and calculated as a 3D line.

When using the buttons like the example, a "box" is manually

created in the CAD window. Calypso calls this a "box". This box is
defined via the corner points, similar to the safety cube.

In addition, there is the "path" (currently not selected).

This describes the entire scanning path.

In the sequence of the buttons, you have the following means of

recalls:

1. Point
2. Point range
3. Box
4. Circle Path
5. Angle area
6. Cylinder

Observe the reference to the coordinate system with "box"!

58 Calypso Advanced Training

Create a second 3D line with a different scanning path.

Evaluate one straightness from the 3D lines.

Plot the result.

Interpret the plot!

Calypso Advanced Training 59

4.1.2 Point recall from the circles

Task:
Measure three circles in a bore and recall the measured points
into the measurement feature "cylinder".

Take a cylinder from the toolbox.

Select "nominal value definition - point recall".

Select three circles and use the known buttons in the header bar
to display the actual points and select them.

Here, the box is shown for each of the two captured circles.

Naturally, "path" can be selected for both circles, as all points in

the circle section are to be used for the recall.

You can now put a box around the circles and select the actual
points using the "lasso".

This will calculate the desired cylinder and is available as a calcu-

lated feature.

The selection of individual points is also possible by clicking on

the CAD graphic.

60 Calypso Advanced Training

4.1.3 Point recall from cylinders

Task:

The surface lines of a cylinder should be checked for straightness.

Define a strategy that makes sense for the CMM to check the
form of the cylinder; here, this would be 2 circle sections and 4
surface lines.

For a straightness evalulation, 2D line or 3D line could be used.

The 2D line is calculated on the surface of the workpiece, the 3D
line is calculated from the stylus sphere center points.

Think about how usable these results are for your measuring
task.

Take a 2D line and select "Recall feature points".

Select the measured cylinder.

You can select the individual strategies of the cylinder.

The main interest here is a surface line.

Path (3) is the first of the surface lines.
This path is selected.

Calypso Advanced Training 61

You will get the desired 2D line and can insert it into the True
straightness.

The graphic evaluation of the form plot gives you a visual impres-
sion of the cylinder surface.

Caution:
The evaluated scanning path was driven in the direction of the
nominal value cylinder (!).

Therefore, the evaluation cannot be used here, look at the gra-

phic as well.
The following thought is the base:
In the nominal value cylinder, the angles A1, A2 are rounded to
"0".
The surface lines are therefore sanned in the axle direction of the
nominal geometry and not in the direction of the "true" cylinder.
Here, a "pre-alignment" is necessary to measure in the aligned
coordinate system.
A typical evaluation could be the parallelism of two opposite
lines.
A statement about, for example, a possibly cone-shaped figure is
therefore possible.

Begin a new exercise by measuring a cylinder, here this cylinder

consists of 2 circles with point recall.

Create a new coordinate system with the spatial direction of the

first cylinder.

62 Calypso Advanced Training

In this coordinate system, you will measure

the actual cylinder.

As before, recall two opposite surface lines as a 2D line.

These lines can be examined for parallelism, as they were cap-

tured along the actual direction.

Calypso Advanced Training 63

4.1.4 Point recall from curve

Note:
This evaluation can only be performed if the option "curve" is
available.

As this subject is dealt with in the training "Curve measurement",

more detailed information is not required at this point.

The recall from curve points was mentioned here to be thorough

and because of its interesting uses.

The example in curve training is the following:

Task: Points are extracted from a curve and calculated into a

geometric element.
Here, the curve is measured on the top side of the cube. After
that, approx. 10 points in the curve are calculated into a circle.

64 Calypso Advanced Training

4.1.5 Point recall from a file

The files must be saved as text files, with the file extension ".txt".

Example of a data file:

x y z u v w r
0.0000 -41.1667 19.9998 0.0000 -0.8233 0.5676 2.5
26.4592 -31.5372 20.0002 0.5292 -0.6307 0.5676 2.5
40.5402 -7.1540 20.0001 0.8108 -0.1431 0.5676 2.5
35.6550 20.5770 20.0000 0.7131 0.4115 0.5676 2.5
14.0901 38.6802 20.0001 0.2818 0.7736 0.5676 2.5
-14.0681 38.6882 20.0001 -0.2814 0.7738 0.5676 2.5
-35.6437 20.5968 19.9998 -0.7129 0.4119 0.5676 2.5
-40.5442 -7.1310 20.0001 -0.8109 -0.1426 0.5676 2.5
-26.4771 -31.5221 20.0001 -0.5295 -0.6304 0.5676 2.5
-0.0230 -41.1667 19.9998 -0.0005 -0.8233 0.5676 2.5

Here:
• x, y, z: coordinates of the point
• Limit undulation number [ W / U ] Directional vector
• r: Probe sphere radius
• Separating character: Tab
• The header is not necessary.
• When "r" is entered, the correction is in vector direction by
the radius.

The data files can also be created via PCM or exported from
curves.

If features are selected in the list in addition to the "Point recall

from a file", there will be a measurement prior to the recall. This
can be helpul if the files for the point recall are not created until
they are in the selected features.

If the features cannot be measured or if there are errors during

the measurement, the point recall cannot be performed.

Calypso Advanced Training 65

4.2 Special calculations

4.2.1 Measuring features

Slot

Note:
For this exercise, we will use another workpiece. Here, there is a
slot as well as a rectangle.

Define a base alignment on the exercise workpiece.

Define a safety cube.

Measure the slot with one of the shown probing strategies.

The automatic feature recognition can capture the feature.

Create the characteristics length, width and feature angle to

check the dimensions and the angle position of the feature.

Rectangle

Measure a rectangle, minimum number of points: 5, better than

2 points on each side, distributed evenly.

Scanning with unknown contour

Both elements can be extracted with a single point or with scan-

ning probe heads with the mode "unknown contour".
For details, read the section "Scanning unknown contour".

66 Calypso Advanced Training

Cone, circle on cone

When extracting a circle on a cone surface from the CAD mo-

del, the feature "circle of cone" is set automatically.

With manual probing, the circle on cone can first be opened

(from measuring - special features) in order to probe points di-
rectly or it can be adjusted afterwards.

In both cases, the cone angle is required for the probing

direction.
In the first case, this comes directly from the CAD model,
with manual probing, it must be entered.
If the respective cone is already present as a feature, you
can access the actual value directly via "formula".

Special features "Circle on cone":

"Circle on cone" corrects the probing points in normal direc-
tion of the set cone angle.
During the measurement, Calypso switches on a scanning
routine which allows stable driving on the inclined cone
surface.

Changing the nominal geometry of the cone and the circle to

cone

When the cut height in the circle is changed to cone (nominal

values in X, Y, Z), the cone diameter is not recalculated and
adapted.

So, if the cone is moved along the Z axis in this example, the Z
nominal value is changed - the diameter will not change!

Only with the use of the respective button can the diameter be
corrected by a movement.

Here, you can change:

• Feature reference point or
• relative height.
Only the respective spatial direction is released.
Then, all components are recalculated.

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Radius, sphere and angle point

With the features radius, sphere and angle point, you can select
the respective radius correction with single point measurements
in different situations in order to correctly define the contact
point.

Regarding the radius point:

A radius point is not automatically detected by CALYPSO.
Insert the feature "Radius point" from the measurement menu
- special features into the measurement plan, define the cen-
ter point and then conduct the probing.

Sphere point:

With the sphere point, the measured value is corrected into the
direction of the connecting line between the probing sphere
center point and the indicated center point.

68 Calypso Advanced Training

4.2.2 Limiting freedom degrees

Task:
A frequently occurring measuring problem is the measurement of
a small circle section.
Here, the center point of the circle to be measured is often deter-
mined. I.e., the coordinates are defined with X value and Y value.
The probing points are calculated for a circle, whose diameter is
a characteristic.

Or the radius is predetermined and the center point coordinates

must be determined.

Both methods are shown here.

The exercise can be conducted on any workpiece; this example
shows the carrier.

Probe 4 probings on the circle to be measured.

Enter the nominal values properly.

Define the characteristics X, Y, D as well as the radius measure-

ment.

Calypso Advanced Training 69

Let the sequence run while creating a com-

pact printout.

In the following, you will change the evalu-

ation and create one compact printout each
to compare to. It is recommended saving
these printouts.

Compact printout of the "normal" Gauß

circle.

Constrain the evaluation.

Evaluation - evaluation constraints.

The function "evaluation constraints" allows defining vectors for

X, Y, Z with the circle or the radius.

Conduct the different evaluations and observe the compact

printout.

X, Y value constrained

Radius constrained

70 Calypso Advanced Training

4.2.3 Changing the tolerance mode

1. Principle:

Depending on the mode, deviations are output in different ways.

The two possibilities are the number vector or amount mode.

Standard mode = number vector mode

Number vector mode:

The formula for the deviation in Calypso is:
Deviation = actual value - nominal value

Number vector mode:

E.g. in chassis manufacturing and other applications, deviations
are shown in a different way:
actual
Deviation = (actual value - nominal value) x
actual

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2. Retrieval:

Extras - workroom - measurement - nominal

There are two possibilities of switching:

1. For the entire system: In the system settings of the

workroom.

2. For the loaded measurement plan: Resources - cha-

racteristics settings editor - tolerance mode

Only applies to the most recently loaded measure-

ment plan

Notes:

1. The deviations are shown in the printout.

2. If the amount mode is set for the current measurement plan
(or system), a "<->" will be displayed in the printout header of
work and compact printout after the column header "Dev.".
The printout header of the custom printout cannot (does not
need to) be changed.

3. You can also access the deviation via the PCM formula.
z
getActual(„DIN Rundlauf1“).deviation

4. The prefix of the recall value is the same as the setting in the
measurement plan or the control panel.

5. In the table file, an additional printout header field is used.

The name of the field is "deviation mode". The value of the
field is "number vector" or "amount", translated into the
respective current set language.

72 Calypso Advanced Training

3. Example

Both of these default printouts show the difference between

number vector mode and amount mode.

The mode can be displayed in the printout

header. For this, the respective variable must
be inserted.

Example of a printout header:

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4.2.4 Tangents

The function "Tangent" is a construction.

In principle, the function offers two calculations:

• given are 2 circles, calculation of the tangents or
• given are 2 lines, calculation of the tangential circles.

Here, you can use more than circles and lines.

The alternatives and additional possibilities can be found in the

Operating Instructions.

Task:

1. Measure two circles, e.g. on the exercise cube and link them
via the tangent function (see illustration).

2. Measure two lines and determine the tangential circles while

specifying the diameter.

74 Calypso Advanced Training

4.3 Introduction to form and position

4.3.1 Flatness, cylinder form

Flatness

Measuring feature:
Plane with scanning paths

Tolerance zone
2 parallel planes with distance t

Test length:
Size of the surface

Calculation:
The plane is evaluated as a minimum feature
Procedure: All measured points are transfered to an assigned
plane as per the minimum feature.
The distance between the highest and lowest point, with
reference to this plane, is the form deviation.

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Cylinder form

Characteristic:
Outside cylinder

Strategy settings
• Radial cutting method: Circle sections, here e.g. 4 circles with
the same distance or
• surface line method: 4 surface lines or
• screw line method: Helix path.

Tolerance zone
2 coaxial cylinder, distance t

Calculation:
Evaluation of all measuring points as a minimum cylinder.
Calculated deviation = minimum - maximum

Cylindridcity includes the following deviations:

• Roundness of every cross section,
• straightness of the axis,
• straightness of the surface line,
• parallelism of the surface line.
Each of these individual deviations cannot be greater than the
cylinder form.

Components of the cylinder form deviation:

• Parallelism compared to surface lines,
• Roundness
• straightness.

Cylinder form deviations without roundness deviations

• ball-shaped => drum form;
• double-concave => saddle form;
• crooked;
• cone-shaped.
Only with a crooked cylinder, the axis is also crooked.
Here, the captured axis is not the same as the assigned axis.

For the cylinder form, this does not matter, as only the outer
contour is tested.
This is different for other evaluations, such as parallelism.

Cylinder form4 Flatness, cylinder form4

Cylinder form241th
Minimum cylinder Point recall outside
------------------------------------------------------------
X -0.01880 0.00000 S 0.01331
Y 0.00397 0.00000 Min (477) -0.02851
Z 3.00000 3.00000 Max (500) 0.02851
D 31.97045 32.00000 Form 0.05703

Cylinder form_241 DIN cylinder form

---------------------------------------------------------------
Cylinder form_241 0.05000 0.05703 0.00703

76 Calypso Advanced Training

4.3.2 DIN position of two bores

In this example, the distance between two bores is to be

determined.
Test features are the 2 bores on the front side of the cube.

This initially classic distance calculation via the "distance" func-

tions is intended to lead to the use of a DIN position.

• The first drawing shows a classic distance value with tole-

rances.
• The second drawing shows a DIN position with only one
reference.
• The third drawing also shows a true position, but with com-
plete reference to the outside surfaces.

Task:
Observe the drawing information and discuss the advantages
and disadvantages of the different dimensioning.

Pay special attention to:

• the creation of the reference system,
• the calculation of the test features (Gauß, minimum, ...),
• the form of the features,
• the measuring strategy,
• a possible best fit method.

Here you can see the input window for the third drawing.

Note regarding references:

Calypso initially offers the base alignment as a reference.
If this is the same as the required references, the base align-
ment must have been calculated with the tangential features
of the planes!

If Gauß features are used here,

there will be different results for the position!

Basically, the question remains for other evaluations:

whether the base alignment has been captured with the cor-
rect features in the proper mode.

Note:
The use of form and position tolerances and
their deviation calculations are the subjects of
a different training session.

Calypso Advanced Training 77

5: Expanded programming functions

5.2 True position on circular pitch........................................................................... 88

5.2.1 Coordinate system from bore pattern best fit method...................................................91

5.3 Pattern measurement as per DIN 3960............................................................. 93

5.5: Automation interface...................................................................................... 105

78 Calypso Advanced Training

5.1 Pattern

With patterns, there are distinctions between:

• patterns in the measuring feature

• characteristic "circular pitch"

Patterns in the measuring feature:

Patterns are first understood as regularly arranged features

of the same geometry. These should be combined and mea-
sured.

In Calypso, a measuring features receives a pattern and multi-

plies either linear or rotary.

In addition, patterns can also be irregular.

Then, a "position list" will specify the positions.

Characteristics from features with pattern automatically recei-

ve a loop.

Characteristic "circular pitch":

A similar term is the feature "circular pitch".

This either requires

• a measuring feature with pattern or
• several measuring features without pattern.

The circular p also evaluates individual and sum pattern errors.

The characterstic does not form a loop.

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5.1.1 Linear Pattern

A workpiece with linear pattern is programmed offline.

The bores are to be measured with the measuring feature circle.

This circle will only appear once in the measurement plan and will
be multiplied via the loop function.

Here, there are two practical possibilities:

1. Pattern function in the measurement feature (this exercise)

2. Pattern via formula function (section "circular pitch").

This exercise is programmed offline!

1D linear pattern

Open a new measurement plan and pull three planes and a circle
into the list of measuring features.

Enter the nominal mass of the workpiece

into the three planes.

Define a base alignment from the three planes and apply the
safety cube.

80 Calypso Advanced Training

Enter the coordinates of the circle:

X= -37.5
Y = 12.5
Y=0
Y = 12.5

Define a pattern in the circle.

First, select a 1D linear pattern; here, a new pattern will be crea-

ted.

Calculating the nominal geometry:

As you are not working with formulas here, do not change
this setting.

Enter these values:

These bores are displayed in the graphic.

Calypso Advanced Training 81

Create the characteristics from the circle.

x, y, z:

Keep in mind, that Calypso recognizes an automatic loop creation

here.

Start the CNC program in the "simulation" mode.

In the custom printout, you will recognize the projected nominal

values of every single circle.

2D Linear pattern

With a 2D pattern, you can measure an offset in 2 coordinate

direction.

Copy the most recently created circle and define a new 2D pat-
tern.

Enter the characteristics and start the CNC run.

Reuse the simulation.

Set up via "Exclude indexes" that the following bores are not to
be measured:5, 7, 9, 11

Switch on the simulation mode.

Planner - simulation stylus system

Start the run.

82 Calypso Advanced Training

5.1.2 Polar pattern offset

Task:
Measuring 6 bores as a polar pattern offset.
By specifying a polar pattern offset, the
measurement run for a circle is expanded to
all 6 circles of the pattern.

Sequence:

Loading the CAD model

The undulation must be loaded as usual. The alignment should be

created with sensible features.

Features for the alignment:

Example:
Primary: Cylinder 32 mm diameter
Secondary plane on diameter 60
Origins on cylinder axis, on top of the plane

Calypso Advanced Training 83

Define the safety cube

Cut:

The shown bore as a cylinder.

The plane on top of the surface with 6 bores.

Create a pattern in the cylinder.

Select the polar pattern offset.

The pattern angular pitch orients itself to the applicable rules of

the sense of rotation.

CAD view:

Set the coordinates for the cylinder to radius, angle, height.

84 Calypso Advanced Training

Select the characteristics radius and angle in the cylinder.

The two characteristics contain one loop each, based on the

pattern in the cylinder feature.

For the printout this means that first, all radii and then all angles
will be printed.

It makes more sense to print out the radius and angle of each
bore.

Creating a group
Delete all the loops in the characteristic.

Create a new loop in the group.

Creating several loops

In this example, you would merely measure the bores:

1, 2, 4, 5.

Without the function "Excluding indexes", this could be solved

with loops.

Calypso Advanced Training 85

Pattern and formula

Setup the circle with pattern.

In this circle, refer the nominal values to the outer circle.

Here:
First run the formula, then the pattern.

Respond to the message with "NO".

This counters the suggestion.

Only this way will all the circles be measured.

Otherwise, only the first circle will be measured six times.

86 Calypso Advanced Training

Meaning:

First formulas, then pattern:

Only the first pattern feature is calculated using the formula.
All others are run with this value.

First pattern, then formula:

Every pattern feature is calculated using the formula.
This makes sense with a LOOP or changing nominal values.

Example: With every run, a new nominal value is calculated from

actual values (getActual).
Or the nominal value is changed via "LOOP".

If the feature does not contain formulas, this selection will be

ineffective.

Short version:

Does the nominal value change during pattern measurements?

YES:
First pattern, then formula

NO:
First formula, then pattern

Note:

The use of formulas and parameters will be handled during an

advanced training.

Calypso Advanced Training 87

5.2 True position on circular pitch

Task:

The 6 bores are dimensioned from angles and radii.

Here, the most favorable position tolerance, as an alternative to
the previous exercise is explained via True position - bore pattern.

Sequence:

Insert a True POS into the measurement plan, open it, click on
best fit bore pattern.

Keep the sequence of the entries!

References:
Here, the base alignment can be used as a direct reference.

Indicate the tolerance 0.1. mm.

Click on on the bore pattern

Click: Select the features.

Click "Polar view", the nominal values can now be

accessed in a polar way!

88 Calypso Advanced Training

Select the 6 cylinders of the pattern.

Cancel the pattern.

The pattern is not canceled, if the number of features is to be
variable via parameter input (PCM).

The cylinders are displayed, the tolerance

can be changed if necessary.

Different evaluation possibilities can be

selected. The calculation takes place after
you click "Run".

More information regarding this subject can

be found in the Operating Instructions.

Display as a plot:

Calypso Advanced Training 89

Best fit method methods and their calculation

Gauß best fit method (L2 best fit method): With this method,
outliers affect the result only slightly. Limitations due to refe- ∑f
i
i
2
= Min
rences are not taken into consideration.

L1 best fit method: With this method, outliers have even less of
an effect than with the Gauß best fit method. Limitations due to ∑f
i
i = Min
references are not taken into consideration.

Minimum feature (Tschebyscheff). With this method, the

result is strongly influenced by outliers. Limitations due to refe- Max (fi )= Min
rences are not taken into consideration.

Tolerance best fit method. Here, there is an iterative attempt

to get all values into the tolerance range. The possible movement Min(fi)= Max
and rotation area can be limited by the reference features. This
equals a "go/no go" statement of a mechanical gauge with addti-
onal mention of all deviations.

Tangential features

External, internal
r0 = Min unf fi <= 0

fi are the deviations of the contact points from the balancing r0 = Min unf fi <= 0
feature
r0 is radius of the circle, e.g. i = [1, N]

90 Calypso Advanced Training

5.2.1 Coordinate system from bore pattern best

fit method

Translating and rotating movements from the actual bore pattern

to the nominal bore pattern are calculated by means of a bore
pattern best fit method. This result can be represented in a coor-
dinate system.
1. Create a bore pattern on the right side of the cube.

2. Open the True position and select "bore pattern best fit me-
thod".

3. Change the name of the bore pattern.This will be the name of

the new coordinate system.

4. Measure a new circle, i.e. in the center of the circle section.

Set this circle to the adapted coordinate system "Bore pat-
tern_right“.

Calypso Advanced Training 91

Notes:

• Caution: The name of the bore pattern not identical to the bore pattern of the True position.

• The coordinate system of the best fit method is now available for additional features and
operations.
An exception is the mutual dependency. The selection menus in the features or operations are
limited accordingly.

The problem with the calculation of coordinate systems is the mutual dependency of the system
and the geometry, which can be created if the geometry is indicated in a reference system while
the reference system requires the same geometry for the calculation. The coordinate systems
always calculate their reference features back into the base alignment. The reference feature
requires the coordinate system for the backward calculation.
In this case, the Calypso would terminate the calculation with an error message.)

• Displaying a coordinate system in the graphic window.

If a measuring feature or characteristic is selected in Calypso, all relevant features are highligh-
ted in the graphic window (if "Show selected features" is activated in the CAD settings). If the
bore pattern best fit method should be displayed, a coordinate system is drawn, but also the
references of the True position which calculates the bore pattern.

• Calculation procedures
A nominal coordinate system is calculated from the references of the True position by means of
the nominal values.
The result of the bore pattern best fit method is added to this coordinate system.
If the True position does not have any references, the result of the bore pattern best fit method
is added to the reference system of the bore pattern best fit method.

92 Calypso Advanced Training

5.3 Pattern measurement as per DIN 3960

5.3.1 Circular pitch

This example explains pattern measurement on a drill template.

The circular pitch is a characteristic and should not be mista-

ken for the polar pattern which is added to a feature via "Nomi-
nal value definition - Pattern".

For the characteristic "circular pitch", either a feature with polar

pattern offset or more individual features.
This selection must take place at the beginning during the circular
pitch.

General procedure
1. Measuring feature(s)
2. Possibly a pattern within - create polar pattern
3. Insert characteristic circular pitch
4. Assigning feature(s)

The pattern measurement is possible with almost all feature

types.

Contrary to the best fit bore pattern, you will not work with an
automatically generated loop.

Pattern parameters:

p: Pitch angle
Angle or arc length between the two features of a pitch step.
The arc length is calculated from the distance of the first nominal
geometry to the center point of the pitch center.

pk: Total pattern angle

Angles or arc length between the first feature of the pattern
measurement and the second feature of the respective pitch step.
The arc length is calculated with the distance of the first nominal
geometry to the center point of the pitch.

Calypso Advanced Training 93

Calculated deviations:

fp: Individual pitch error

Difference between actual and preset
distance between two adjacent features.

The result is an angle or a arc length.The

arc length is calculated with the distance
of the first nominal geometry to the
center point of the pitch.
The nth result of this evaluation cha-
racteristic is the pitch error between the
last (the nth) and the first feature.

fp: Cumulative pitch error

Sum of the pattern individual deviations. Difference between
actual and nominal distances of a feature from the first fea-
ture of the pattern measurement.
The result is an angle or a arc length. The arc length is calcu-
lated with the distance of the first nominal geometry to the
center point of the pattern.
The nth results of this evaluation characteristic is always 0°
(the angle from the first feature to itself).

fu: Pattern jump

Difference between the actual and the previous pattern indivi-
dual deviation.
The result is an angle or a arc length.
The arc length is calculated with the distance of the first no-
minal geometry to the center point of the pattern.
The first result is always 0.

Fr: Concentricity
Radial deviation of a feature to the par-
tial circle radius of the pitch. The center
point of the partial circle represents the
center of the pitch. The radius is the
distance between the center of the first
actual feature of the pattern.

Fre: Roundness

Radial deviation of a feature to the partial

circle radius of the pattern.
The partial circle is calculated as per
Gauß, the center point is calculated from
the actual features of the pattern.
The radius is the distance between the
calculated partial circle center point and
the first actual feature of the pattern.

94 Calypso Advanced Training

Sequence:

Individual feature with pattern

• Create an alignment and measure the circles as a polar pat-

tern offset.

• The bores are named circle1(6).

• Take a circular pitch as a characteristic.

• Select "individual measuring feature with pattern"

• Enter Circle1 as a test feature.

• The evaluation methods are determined by selection and

deselection.

Different test features

• Create an alignment and measure different circles.

• Take a circular pitch as a characteristic.

• Select "different test features"

• Enter the test features into the subsequent input window.

This page appears to show the features:

Here, the features are entered and can be moved in the given
sequence.

As no feature with pattern is used, the center of the pattern

as well as the angle and projection must be entered here.

Calypso Advanced Training 95

Print output

In the "normal" compact and custom prin-

tout, the minimum and maximum values are
indicated.

All values only appear if "Expanded pattern

output" is selected!

Example of a compact prin-

tout:

Here, only the extremes are

shown; the table offers a detai-
led listing of the values.

96 Calypso Advanced Training

5.3.2 Linear pattern

Analog to the circular pitch, a linear pattern can be evaluated.

Here, the same system applies as for the previously described
circular pitch.

p:
Distance between the two features of a pattern step.

Total pattern distance pk

Distance between the first feature of the pattern measure-
ment and the second feature of the respective pattern step.

Pattern individual deviation fp

Difference between actual and preset distance between two
adjacent features.

Divsion total deviation Fp

Sum of the pattern individual deviations.
Difference between the actual and nominal distance
of a feature from the first feature of the
pattern measurement.

Pattern jump
Difference between the actual and the previous pattern indivi-
dual deviation.
The first value is "0".

Task:
Create a linear pattern on the workpiece and evaluate the pat-
tern.

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5.4 Formula

5.4.1 Result Element

Task:
A section width is determined from the difference in diameters of
two circles.

Note:
In Calypso, many calculations can be performed via "construc-
tion".
Of course, you can use other methods to handle the shown
problems.
Therefore, the following example should be seen as an intro-
duction into the subject of "Use of formulas".

Sequence:

The measurement to be found is the difference between the two

radii.

• Create two circle arcs (measure them or extract them from

the CAD).

• For the formula: take a "Result element" from

"Size - move - result element"

• For formula-based calculations, press the right mouse button

and enter the formula:

getActual("Circle1").radius - getActual("Circle2").radius

98 Calypso Advanced Training

• Rename the characteristic accordingly.

• Enter the nominal value.

In the CNC run, this characteristic is treated and evaluated like a

normal characteristic.

Calypso Advanced Training 99

5.4.2 Probing a sheet metal

Sheet metal measurements are often critical due to the easy de-
formation of the materials. So, if you want to measure a bore in a
piece of sheet metal, the exact probing height is important.
This height varies up to several tenths of millimeters.
(Shown higher in this illustration.)

Note:
In sheet metal measuring, "Relative measuring" with the Calypso
option "Free form" is often used.

Here, this problem is handled with a formula.

Task:
First, the surrounding sheet metal (1) must be probed to roughly
get on the actual measuring height (2).
The actual height of the probing can be determined and used via
the "formula".

Sequence:

1. Probe the bore as a circle

2. Probe an individual point on the surrounding surface of the

bore.

3. Open the Z value (nominal value) in the circle with a formula.

4. Enter the actual value of the point into this formula and sub-
tract half of the sheet metal thickness.

Example: with a sheet metal thickness of 1 mm:

getActual("Point1“).z - 0.5

Caution: NEVER use the comma as a decimal point in formulas,

only a period!

5. Check the function by changing the point probing with a coin.

100 Calypso Advanced Training

5.4.3 Probing positions relative to a feature

Task:
Measure the bore and refer other probings to the center point

• Measure bore 3 as the center point of the bore pattern.

• The probings in bores 4 - 7 must be defined relative to bore 3.
For example, if bore 1 was offset by 0.5 mm, the probings in the
other bores should also be offset by 0.5 mm.

Sequence:

1. Measuring the center bore will yield circle 3.

2. Insert another circle from the toolbox into the list:

3. Open circle 4 and apply formulas to the nominal values as
shown:

4. Assign a circle section with 4 probings to the circle in the
strategy.

5. Copy the circle and change the formula three times as per the
nominal values of the other bores.

6. Create the features diameter and start the sequence.

Calypso Advanced Training 101

5.4.4 Alignment with offset plane via formula

Note:
Only perform this exercise after you have worked through the
formula functions in this training session.

Task:

This exercise has an offset plane that is created differently from

the exercise previously shown - via the formula functions.
This leads to more of a variety, as a arbitrary number of measu-
ring points can be available for the offset plane.

A workpiece is resting on three points that are at different

heights.You must use these three points to determine a plane
which will be declared the primary reference in the base align-
ment.
This is the classic calculation of an offset plane.
However, an offset plane from the toolbox always consists of
exactly three probings, whose height can be corrected.

This new WKS should be run at least twice to create the correc-
tion of the offset probings in the correct coordinate system.

Sequence:

Load the CAD model of the exercise cube

Click on 3 points in the CAD window:

1. Point (P1) on the cover surface
2. Point (P2) in the front slot
3. Point (P2) in the rear slot

Add 2 more points (P4, P5) from the toolbox into the list.

Open the first of these points (P4),

Recall one feature: P6
Edit the Z value with the formula:
"getAcutal["Point2"].z+10"

Open the second point (P5), recall P3, correction by 8 mm.

102 Calypso Advanced Training

Take one plane from the toolbox and define it via recall of P1, 4,
5.This plane 1 is situated analog to the cover surface.

Form the first symmetry point from 2 probings (P6, 7): front right
- front left.

Form the second symmetry point from 2 probings (P6, 9): rear
right - rear left.

Create a 3D line from these 2 symmetry points.

Set point 10 on the front surface to Y=0.

Create a base alignment:

Plane 1 for primary

3D line for secondary
3D line for origin in X
Point 10 for origin in Y
Plane 1 for origin in Z

Place a loop over the base alignment.

Start the run and interpret the result.

Calypso Advanced Training 103

104 Calypso Advanced Training

5.5: Automation interface

In this section, we will give you brief introduction to this subject.

You should participate in special training if you desire to do so.

The function "Autorun" generally permits two different run versi-

ons:

5.5.1 Pallet measurement:

Several identical parts are to be measured consecutively -
clamped on a pallet.

This requires an accurate clamping device, as the same mea-

surement plan is offset by the X, Y values of the clamping
locations.

5.5.2 Serial measurement:

Several different parts are to be measured consecutively and
automatically.

Different measurement plans are run subsequently.

Autorun works with a special user interface, which has the actual
Calypso run in the background.
This interface is intended for users that are basically only suppo-
sed to start programs.
In autorun mode, the user rights must be adjusted specifically for
each user and they do not affect the user rights in Calypso.

Calypso Advanced Training 105

Example for a serial measurement:

Example for a pallet measurement:

More specific information about this subject can be found in the

Operating Instructions or a special training session.

106 Calypso Advanced Training

Place your own images into the autorun inter-

face.

Example for a designed interface:

Here, there is a special image for every CNC run.
In addition, a background image can be defined.

These functions can only be activated by clicking the right mouse

button on the background or the run.

The images must be in .bmp, .jpg or *:gif format.

See the Operating Instructions for more detailed descriptions.

Calypso Advanced Training 107

6: Result display - printout design

6.1 Graphic display - plotting.................................................................................... 109

6.1.1 Flatness and graphic display..........................................................................................109
6.1.2 Settings of form plot.....................................................................................................114
6.1.3 Plot output only if tolerance range is exceded...............................................................115

6.2 Printout............................................................................................................... 116

108 Calypso Advanced Training

6.1 Graphic display - plotting

6.1.1 Flatness and graphic display

Exercise sequence

In this exercise, you must measure a surface of the exercise cube

as a plane and evaluate this with the different functions of the
Flatness:

1. Flatness and preset path

2. Flatness as processing
3. Flatness as CAD plot
4. Output via the function "Graphic feature“

Calypso Advanced Training 109

First, measure the front side of the exercise cube with a polyline.

Take a flatness into the measurement plan.

Evaluate as usual.

1. Flatness and standard plot

This display is offered as a standard by Calypso.

The plot can be adapted in its display via "Edit".

Here, you can change the display of the points.

110 Calypso Advanced Training

2. Flatness as processing

The "processing" is the more rare display and not

usually used for the evaluation of a polyline.
Here, the flatness of linear segments is displayed.

3. Flatness as a CAD plot

In order to get the view pictured here as a plot, pro-

ceed as follows:

Load the CAD model

• open the plane
• click on the ACIS window with the right mouse
button,
• select "display actual points"
• close the plane
• open the Flatness
• CAD - view - save view
• Enter name, here: Ebenheit1 (flatness1)
• click on "Graphic"
• select "CAD view" in the top menu
• select characteristics "Flatness 1",
• click on the "Plot"

Calypso Advanced Training 111

4. Output via the function "Graphic element“

For already existing graphic evaluations, such as roundness, flat-

ness, an alternative display can be retrieved with the additional
function "Graphic element".

Note:
This functionality can only be used if the "Zeiss reporting module"
is loaded.

Sequence:

Take a graphics element from the auxiliary means (Resources

- utilities).

In this menu, you can select one or more plots, which are output
with templates that can also be selected.

This menu also allows you to change the templates.

Example of a roundness plot.

Adjustment options and information mode.

112 Calypso Advanced Training

Example for a multiple plot

Calypso Advanced Training 113

6.1.2 Settings of form plot

With two-dimensional form plots, the outliers in the

respective plot can be made visible and marked speci-
fically.

In the properties window of the form plot, the follow-

ing page can be retrieved.

Limit deviations to

Entering the limits for the deviations in the form plot.

You can enter a arbitrary (positive) number. This will determine

that outlier points, which are above the entered numeric value
(e.g.: whose value is more than twice as much as the max. per-
missible tolerance) are transformed to the range limits (alas, here:
to twice the max. permissible tolerance).

Display range limits for outliers

By activating this box, the areas containing one or more outliers

are marked by lines in the form plot. The lines begin at the X co-
ordinate (all non-round plots) or the angle (all roundness plots) of
the first outlier point and they end at the last outlier belonging to
the same range. If the "range" consists of one single outlier, only
this line is drawn directly to this outlier.

Form plot: Surface lines with cylinder scanning

With the form plot "Cylinder form", a surface linear

plot can be displayed.

114 Calypso Advanced Training

6.1.3 Plot output only if tolerance range is exceded

During a CNC run, the form plots can only be displayed if at least
one of the following two conditions is fulfilled:

1. The standard deviation of the feature to be displayed exceeds

a preset value.
2. The percent of tolerance usage of the feature to be displayed
exceeds a preset value.

The respective values are entered into the measurement plan

editor "Characteristics" (Resources Menu). In additional to pure
numeric values, you can also enter formulas (PCM).

Minimum standard deviation for form plot:

This determines the input of the values for the minimum stan-
dard deviation, as of which a form plot is to be displayed in
the automatic run (CNC run). The input is form plot related.
The dimension of the standard deviation is always a length.

Min. tolerance deviation in % for the

form plot:

This determines the input of the values

for the minimum tolerance deviation, as
of which a form plot is to be displayed in
the automatic run (CNC run). The input is
in percent values.

Formula input instead of fixed value:

The menu is activated by pressing the right mouse button.

The selection of the menu item "Formula" opens the formula
editor window, where the formula (or the parameters) are
defined. When clicking different characteristics in the list, the
background color of the input field turns white accordingly
(input value) or yellow (formula).

With the bore pattern plot, a plot is output as soon as a value

exceeds the limit values.

Calypso Advanced Training 115

6.2 Printout

Define printout:

Retrieval:
Resources - define printout.

This page controls the printout for all prin-

touts. The functionality is very versatile and
often self-explanatory.

The compact printout as well as the custom

printout can be changed regarding their
extent and sequence.

The settings made here apply to the respec-

tively open measurement plan.

116 Calypso Advanced Training

6.2.1 Modifying the printout header

Task:
The standard printout header should be
changed.

Modified printout header.

Find the path for the printout header formats:

C:\Zeiss\Calypso\opt\om\protform\default

Copy the folder "Default" and rename it to "Training"

Note:
The folder "Default" is reassigned for every new measurement
plan for the design of the printout. If its contents are changed or
destroyed, the printouts may no longer function properly.
For this reason you work in a copy, here "Training". A retroactive
renaming of "Training" into "Default" or to "Backup_Default" is
not a problem.

This is only one of the possible variants - creating a backup first

and then working in "Default" is also possible.

Assign the printout header "Training" to

the measurement plan.

Resources - define printout

Output format "Training"

Calypso Advanced Training 117

Opening the graphic program to change

printouts:

Resources - design custom printout - printout

Open the file "vphead.gra"

This printout header has been prepared with

some fields, which can automatically be com-
pleted by the system or the user when starting
the program.

The workpiece name can be the name of the

measurement plan.

Time and CMM are not used as commonly and

can be removed if applicable.

Inserting "Case number" and "Comment".

These fields must be selected from the list on
the left.

Change the title.

Delete the Zeiss logo.

Insert a new graphic, e.g. an image of the

workpiece or a company logo.

Save the file as "Training".

The file is overwritten.

CNC run with the modified printout header:

118 Calypso Advanced Training

6.2.2 Changing the printout header for plots

Task:
The header of the graphic plots should be changed.

Resources - design custom printout - printout

Open file:

Conduct the changes analog to the printout header.

Important:
Changes affect ALL plots!!

6.2.3 Changing compact printout header

Retrieval:

Resources - design custom printout - printout

Notes:
• Just like with the custom printout, different formats can be
defined.
• The file is called "cphead.gra".
• A special printout header is selected via the data structure to-
gether with the custom printout. (This file is located in the
same directory as the files for the pres.printout formats).
• Differences from the Pres.printout, as compact printout is
ASCII:
• Positioning the fields within the columns / lines grid
• Fixed font size
• No graphic
• A different format can be used for each measurement plan.

Calypso Advanced Training 119

6.2.4 Total result

In the custom printout, the total result can be shown first.

Hence, you can tell right away, whether one or more characteri-
stics are out of tolerance and whether the whole part should be
evaluated as "good" or "bad".

Switching on the total result:

Printout

120 Calypso Advanced Training

6.2.5 One-line custom printout

Task:
The standard custom printout consists of a section with a symbol
and several lines.
For extensive measurement plans, this creates printouts with
multiple pages. Here, reducing every characteristic to one line
makes sense.

Note:
The change of the printout is facilitated by
knowledge in common graphic programs as
well as understanding the assignment of the
printout header and the characteristics list.

Sequence:

Opening the Calypso drawing program:

Prepare
Design custom printout
Characteristic

Click on symbol "Load" (=open folder)

Note:
All printout formats (header, characteristic,
feature...) are located in one directory under
the path
C:\Zeiss\Calypso\opt\om\protform\default
When this drawing program is loaded, the
file "
C:\Zeiss\Calypso\opt\om\protform\default
is always loaded first.
If this file is changed in the "default" folder,
the supplied version is destroyed.
For this reason, you must save it under a
different name!

Copy the "default" folder. It will automatically be named "Copy

of default".

This is your backup copy!

Calypso Advanced Training 121

Open the printout editor.

Edit the characteristics display as follows:

Delete the icon, move the entries, add
vertical lines.

By moving the position of nominal and actual values, etc., the

Printout header must be edited:
Load the drawing program for the printout header:
Resources
Design custom printout
Printout header

When you open the drawing program, the file

„...Zeiss\Calypso\opt\om\protform\default\vphead.gra“ will
always be loaded.
Here, you must also immediately save in the "single line" folder.

Edit according to the desired appearance of

the characteristic.
The headline and the numeric values must
be on top of each other.

Note:
Control the appearance via a new printout
on the printer! If the headlines should not
match during the first attempt, continue
until the desired results are reached.

Also edit the Printout header for subsequent pages:

Resources
Design custom printout
Header lines

When you open the drawing program, the file „...Zeiss\Calypso\

opt\om\protform\default\vphead.gra“ will always be loaded.
This is the printout header for the subsequent pages starting with
page 2.

122 Calypso Advanced Training

Assign this new printout header to a measurement plan:

Prepare
Resources - define printout - output format: default com-
pressed

You will receive the shown printout as a

result.

The printout header is changed in a similar

manner. Here, you must load the file
vphead.gra and edit it.

Calypso Advanced Training 123

Overview of the printout header variables

The printout header data (reference)

SYS
CMM no. dmesn
Time time
from nrpgs
Date date
Measurement plan name planid
Software revision:
Department: vda_departm
Software dmeswi
Phone: vda_departm
No. vda_number
Control type Controller
Sheet actpgnr
CMM type dmeid
Tester operid
Run measRun

EDIT
Clamping means no. clmpsn
Remark: vda_departm
Clamping means clmpid
Name partid
Previous operation prevop
Ser. no. Workpiece partsn
Comment measurement
plan partcomment
Subject no.: vda_departm
Fixture no. fixtsn
Name: Name:
Version: Version:
Fixture fixtid
Rev. Workpiece partsn
Test report no. vda_auditno
Drawing no. drawingno

START
Comment at start startcomment
Remark: vda_departm
Name:
Test ID lotid
Lot ID partnbLong
Subject no. vda_subjno
Name: Name:
Process plan mfgdev
Order order
Part number, incremental partnbinc
Version: Version:
Test report no.: Version:
Tool tooldf
Signature: Version:

OTHER
Modified by changeoper
Software rev creation creationswi
Change date changedate
Compiled by produceoper
Creation date creationdate
CMM type creation creationdme

124 Calypso Advanced Training

6.2.6 User-defined printout

Task:
The standard custom printout is to be re-
placed by a printout showing a graphic of
the workpiece. The characteristics should
be listed on the side and reference the
respective features in the illustration.

Note:
The change of the printout requires know-
ledge in common graphic programs as well
as understanding of the assignment of the
printout header and the characteristics list.

Sequence:

Create a measurement plan with characte-

ristics.

Opening the Calypso drawing program:

Prepare
Resources - design custom printout -
user-defined printout

Calypso Advanced Training 125

Note:
The printout header formats of the column
"User defined" are located in the measure-
ment plan folder (inspection).

Insert the "captured" image from the

screen.

Observe the list of available characteristics.

You insert the characteristics into the form and align them to the
side.

Format the page so that it fits into the print area of your printer.
File - format

126 Calypso Advanced Training

Use arrows to point from the characteristic to the graphic.

Now, the printout header itself is missing yet.

You can generate a new header; here, to simplify matters, the
header of a standard printout has been added.

Now the task must be modified for the opened measurement

plan:

Prepare
Resources - define printout

Here, the list output is deactivated and the user-defined printout

is activated.
If this step is not performed, the printer will output both prin-
touts.

Start the run and check the result.

Calypso Advanced Training 127

6.2.7 Attaching a comment to the characteristic

Task:
Attaching a comment to the characteristic

Create a measurement plan with usable characteristics and view

the presentation as well as the compact printout.

Shown here, without a comment,

the characteristic "Diameter" should get a comment.

Select the diameter and click the right mouse button to rename
the characteristic.

Enter a comment text; this should contain at

least two lines for this example.

The display of the printouts after a second

run:

Make sure that the length of the characteristic becomes longer in

the custom printout if the comment covers several lines.

Formula in the comment field

In the comment, the deviation of the respective characteristic

should be output.
Click into the comment field on the right and select "Sigma" as
shown in the attributes.
The output will now yield the deviation in the comment.

This can be improved significantly with a few PCM commands:

128 Calypso Advanced Training

6.2.8 Inserting a text element

Select the text element from the toolbox and insert it into a sensi-
ble location in the measurement plan.

Important: The appearance of the text is subject to the common

rules of the characteristic-oriented run. The appearance of the
printout can influence the text element because of selective CNC
runs or switching programs.

Start the CNC run with all characteristics.

The printouts will have the following ap-
pearance:

Calypso Advanced Training 129

6.2.9 Groups in the custom printout

In the custom printout, the group names will be highlighted.

A unique format can be defined for characteristic groups (file

name "‚grpcf.gra").
(Open pulldown menu > Resources > characteristics settings
editor - group in custom printout)

Example with a larger font for group names:

Note:
Here, the display of groups in the printout must be set to "ON".

Measurement plan editor - characteristics

Groups in the custom printout: ON

130 Calypso Advanced Training

6.2.10 Saving printouts

The saving process will be explained using the example of the

compact printout:

Resource
The compact printout is saved as a text file.
Name of the text file:"cprotokoll.txt" in the measurement plan
directory: ...calypso\opt\om\workarea\inspections\<measurement
plan name>

Printouts can be saved in any desired way via the following func-
tion:

Selecting the name assignment.

Indication of the path and the name con-

vention:

The file name and the path can be com-

bined from the fields of the printout header,
syntax as per PCM convention.
If the file name does not contain a path, the
standard path is used, otherwise, the path
from the defined name.

Possible output files

1. Default printout
2. Compact Printout
3. 3 table files (hdr,chr,fet)
4. pdf files (graphic, text)
5. DMIS
6. QDAS

Calypso Advanced Training 131

Output of ASCII files with the extension *.txt:

The compact printout and the default printout can be output
using this method.

Output in PDF format with the extension *.pdf:

PDF file graphic: puts out the custom printout

PDF file text: puts out the compact printout

Exercise:

Define the output of the compact printout and the custom prin-
tout as a *.pdf file to the "Temp" directory.
Keep in mind, that different names will be assigned.

The name should be composed as follows:

Measurement plan name + date + part number

PDF file graphic:

"C:\TEMP\"+getRecordHead("planid")+getRecordHead("date")+"_Teil_"+getRecordHead("
partnbinc")+"praes.pdf"

PDF file text:

"C:\TEMP\"+getRecordHead("planid")+getRecordHead("date")+"_Teil_"+getRecordHead("
partnbinc")+"praes.pdf"
Note:
The option PDF must be set to "ON' in the menu "Resources
- results on file".

PDF must be activated in the CNC start window to output PDFs!

132 Calypso Advanced Training

6.2.11 Changing the INI file for printout header

data

If a file "userfields.ini" is present, Calypso will take from this file

which data will be queried in the dialog box "input parameters"
and which values can be captured for the individual printout
header parameters.

The settings in this file overwrite the settings of the possibly pre-
sent file userfields.txt.

The file "zzz_userfields.ini" was included in the initial install (this

file contains an example for user-defined printout header fields).
You activate the delivered file "zzz_userfields.ini“ by renaming it
to "userfields.ini".

The further description of the *.ini file can be taken from the
operating instructions.

In this section , there will be an example for a change:

Create a arbitrary formatted printout header with the following

new fields:

• Month
• Day of the week
• Edited by
• Editing machine

These fields should be completed as pulldown menues during the

start of the program.

The next two pages show a "userfields.ini" file with explanations.

Calypso Advanced Training 133

REM this is an example for the "userfields.ini" file.

[Field names] ;
REM userfield names must always begin with "u_".!!
REM e.g. u_hallo_1, u_protocol, u_test

REM *****************************************************
REM **nach REM und ; Texte und Meldungen **
REM ** werden vom Programm nicht benötigt **
REM *****************************************************

u_field_1
u_field_2
u_field_3
u_field_4
u_field_5

; Definierung des ersten userfields mit dem Namen „u_field_1“

[u_field_1]
name=Monat ;; ifBezeichnung / Name des
this field is confirmed inputfield/list
with "true", it will appear with the
editMode=true ;; edit
Wirdparameters.
dieses Feld mit „true“ bestätigt,erscheint es bei den
;; ifEdit
thisParametern.
field is confirmed with "true", it will not appear with the
runMode=true ;; start
Wirdparameters
dieses Feld mit „false“ bestätigt,erscheint es nicht
;; This
bei den
list isStart Parametern
either a pulldown menu or a
selectiveList=true :; box
Diese Liste ist entweder ein Pull down menue oder eine
;; The
combo box. parameters for this list can be found in the
selected
selectiveListValues=u_field1_valueList ;; profiles
Die selektier
with theParameter für diese Liste findet man in den
name "u_field1_valueList"
;; Ifprofilen
this field mitis dem namen
labeled „u_field1_valueList“
"false", there is no input possible in the
editable=true ;; created
Ist dieses Feld mit
combo „false“
box. With benannt
"true", theist keine Eingabe in der
;; editable
entstehenden combocombo box
box will bemöglich.
created. mit „true“ entsteht die
;; The
editierbare
value that combo box.in the created field first, is the
appears
defaultValue=1 ;; value
Der Wertwithder theim erzeugten
option name Feld"1" zunächst erscheint ist der
; Weet mit dem optionsname „1“

REM Hier wird die Eingabeliste für das Userfeld ( Pulldown menue ) mit dem Namen „Part“ definiert.
[u_field1_valueList]

REM Nach dem = sind beliebige Namen möglich.

1=Januar Ebenfalls
; You ein Standartwert
will also zu erkennen
detect a standard option
value option defaultValue
default value
; Defined
Definiertby
durch u_field_1
u_field_1
2=Februar
3=März
4=April
5=Mai
6=Juni
7=Juli
8=August
9=September
10=Oktober
11=November
12=Dezember

134 Calypso Advanced Training

REM Definition of the second user field with the name "u_field_2"

[u_field_3]
name=Bearbeiter
editMode=false ; if; Wird dieses
this field Feld mit „false“
is confirmed bestätigt,erscheint
with "false", es nictwith
it will not appear bei the
; Editparameters.
; edit Parametern.
runMode=true ; if; Wird dieses
this field Feld mit „true“
is confirmed bestätigt,erscheint
with "true", it will appeareswith
bei den
the
; Startparameters
; start Parametern
selectiveList=false ; Keine
; No Liste ( Pullmenu)
list (pulldown down menue)
editable=false ; keine(combo
; none ( combo box )
box)
defaultValue=Meier ; Dieser
;This valueWert erscheint
will appear in so
thelange
inputim Eingabefeld
field bist er
until it is changed.
; geaendert wird.

[u_field_2]
name=Wochentag
editMode=true
runMode=true
selectiveList=true
selectiveListValues=u_field2_valueList
editable=false
defaultValue=3

[u_field2_valueList]
1=Montag
2=Dienstag
3=Mittwoch
4=Donnerstag
5=Freitag
6=Samstag
7=Sonntag

[u_field_3]
name=Bearbeiter
editMode=false ; if; Wird
this field is confirmed
dieses with "false",
Feld mit „false“ it will not appear
bestätigt,erscheint es nictwith
bei the
; edit
; Editparameters.
Parametern.
runMode=true ; if; Wird
this field is confirmed
dieses with "true",
Feld mit „true“ it will appeareswith
bestätigt,erscheint the
bei den
; start
; Startparameters
Parametern
selectiveList=false ; No list (pulldown
; Keine Liste ( Pullmenu)
down menue)
editable=false ; none
; keine(combo
( combo box)
box )
defaultValue=Meier ; This
; Dieservalue willerscheint
Wert appear insothe inputimfield
lange until it is bist er
Eingabefeld

[u_field_4]
name=Bearbeitungsmaschine
editMode=true
runMode=true
selectiveList=true
selectiveListValues=u_field4_valueList
editable=true
defaultValue=D12

[u_field4_valueList]
1=D12
2=D13
3=D14
4=D15

[u_field_5]
name=Currency
editMode=true
runMode=true
selectiveList=true
selectiveListValues=u_field5_valueList
editable=true
defaultValue=Euro

Calypso Advanced Training 135

6.2.12 Inserting a variable into the printout

This task can only be performed with the PCM option.

The exercise consists of selecting the "part number incremen-

tal" from the variables of the printout header, which are known
from previous exercises and to insert them as a comment into a
characteristic.

Keep in mind that this example is only intended to give you an

idea of the complex operation possibilities of variables by means
of formulas.
Think of your own applications to deepen the subjects.

Sequence:

Take another diameter from the previous example, open it and

delete the comment.
Click into the comment field on the right and select "Formula".

Enter into the formula field:

The function "getRecordHead()" reads a variable from the list of

the printout header variables, here the variable "partnbinc". This
is the part number incremental.

The printout now puts out the part number in the comment.

136 Calypso Advanced Training

CAD file -> Convert CAD entities

With this function, CAD files can be converted into *.sab files in
the background.

The selected files are converted in the background and saved

once more under their name with the extension *.sab in the same
directory. The printout of the conversion is saved under the file
name with the extension *.log in the same directory.
A background conversion can diminish the performance of the
applications running in the foreground.

You can select multiple files.

CAD file -> CAD model comparison

Compares models, e.g. after drawing modifications.

This function is to be considered an auxiliary function only, as
CAD programs can better perform this comparison on their own.

Calypso Advanced Training 137

7: Stylus systems and accuracy

7.1 Automatically qualify stylus system afterwards.................................................. 139

7.2 Special styli......................................................................................................... 142

7.3 Stylus monitoring................................................................................................ 146

7.4 Rack preassignment ........................................................................................... 148

7.5 Qualify the stylus change rack into the CNC....................................................... 149

7.6 Avoid measurement inaccuracies........................................................................ 150

138 Calypso Advanced Training

7.1 Automatically qualify stylus system afterwards

Task:
Stylus systems must be qualified beforehand.
Creating a qualification measurement plan

The star stylus must be requalified.

This can take place in two different ways.

Method 1:
With the button:

Here, only the stylus system located in the probe head is qualified
automaticallly.

Method 2:
Via a measurement plan with characteristics for each individual
stylus system.

Functions as a regular measurement plan. Here, the stylus sy-

stems to be qualified can be selected.

Note:
Many stylus functions depend on the probe head and
are not shown here.
Further information can be found in the document "Sen-
sors".

Calypso Advanced Training 139

Method 1:

• The reference sphere must be qualified.

• Only the stylus system located in the probe head is qualified.
• The mode of the original qualification is used.
• Navigation around the sphere are calculated automatically.

The printout shows these values:

Method 2 Retroactive qualification while maintaining the

bending parameters (tensor)

Resource:
The star stylus (and possible additional stylus systems) should be
present and qualified.

Principle:
• First, the master probe automatically qualifys the reference
sphere at the most recently used position.
• Then, the stylus systems are qualified in the order of the plan.
• Single styli can be selected.
• Stylus changes are performed automatically (except when the
stylus is not assigned to any holder).

Open a new measurement plan; and from the toolbox or the

resources menu - utilities, insert as many entries "Stylus system
qualification" as there are stylus systems - including master pro-
be.

Rename the characteristics.

This does not assign the respective stylus! (see below).

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Open each characteristic, here for the master probe:

(1) Assigning the stylus system

(2) Setting up the mode for this requalification
(3) Selection of the stylus for (4)
(4) Adding or removing individual styli for the "requalification“

Set up the adjustments for the master probe

as shown.

Open the star stylus.

Only select individual styli.

Set the mode for each stylus to "Geometry

- Requalification“.

Start the sequence

CNC start window: "Use position points only"

The CMM only runs the "6 point" mode for this "requalification".
The tensor remains intact from the original qualification, the geo-
metry values (sphere center points and diameters) are redetermi-
ned.

Caution:
The mode "Use position points only" remains during the subse-
quent CNC start, even if another program is started!
You must switch back to "use clearance planes", otherwise there
may be severe collisions!

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7.2 Special styli

Disc stylus

Task:
Qualifying the disc stylus and subsequent correction on the ring
gage.

A disc stylus is not a complete sphere but a section of a sphere.

The danger with working with the stylus are probings with the
edge of the disc and not with the sphere section surface.
The problem with qualifying is hitting the probings exactly at
"equator height".

For this reason, the diameter is corrected afterwards on one ring

gage.

Procedure:

1: Qualify the disc stylus on the reference sphere

2: Requalify on the reference sphere or on the ring
gage
3: Manual correction of the stylus data

Re: Step 1:

1. Qualify the reference sphere with master probe

2. Insert the disc stylus and qualify in the "manual" mode with
the "disc" geometry.

3. The first probing must now take place in the direction of the
shaft of the installed disc; from this, Calypso will detect the
shaft direction for this stylus pin.

This probing will not be included in the calculation.

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The following probings must be made on the circumference.

As this method is not sufficient for a very accurate qualification
(bending parameter, point recording only on the circumference),
you should requalify on the ring gage.

Re: Step 2:

1. Clamp the ring gage and align it.

2. Measure the circle in the ring gage.
3. Compare the circle diameter with the nominal diameter of the
ring.
4. The diameter of the disc can only be corrected manually.

Re: Step 3:

1. Output of the diameter in the default printout.

2. The deviation from the actual diameter must now be cor-
rected.
3. Open the stylus data and edit the radius.
4. Measure the ring gage again and check the diameter.
5. Perform another correction if necessary.

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Qualifying a slanted stylus

• Qualifying a slanted stylus as per "eye measure"

• Determining the shaft inclination with the cylinder feature
• Requalifying with the correct vector data

Assemble a slanted stylus.

Use this stylus as a new stylus.
"Improvised" qualification
Qualify the slanted stylus on the reference sphere.
Mode: 6 points for the "improvised" qualification.

Only with the "true" qualification with the then known angles
will you need to work in the "tensor" mode.

"Probing in shaft direction" means: best possible probing as per

eye measure from the shaft direction.
The query for the angles of the shaft is displayed
These are not known yet.
Simply confirm with OK.

The stylus is qualified and measurements are possible.

Close the stylus menu.
Use the shaft of the stylus to probe eight points in two planes on
the reference sphere.(see image)

A cylinder is recognized.
The inclination of the cylinder axis, output via the projected
angles A1 and A2 is determined by the inclination of the stylus
shaft.

The two angles A1 and A2 must be entered when the query

appears with the subsequent "true" qualification (in the tensor
mode).

This process ensures that Calypso uses a "semi sphere" to qualify

under the correct angle, which is a resource for correct probings.

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Qualifying a cylinder stylus

Sequence:
• Qualifying the cylinder stylus in manual mode
• Requalification on the reference sphere
• Manual correction of the stylus data

Assemble a cylinder stylus.

Measure the stylus in the "cylinder" mode, on the equator of the

reference sphere, with three points each in two planes.

After you complete the qualification, you should switch to the

features side.

Measure a circle on the equator of the reference sphere.

Compare the diameter of the circle with the diameter of the

reference sphere.

The deviation from the actual diameter must now be corrected.

Open the stylus data and edit the radius. (See disc stylus sequen-
ce)

Iterate this process if necessary.

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7.3 Stylus monitoring

This function must be divided into two areas:

Monitoring the CNC qualification

Here, you will check for correct geometry, temperature and
deviation (Sigma) during the qualification.

Monitoring the styli during CNC start

Here, you will check which styli are required for the CNC
run, whether the stylus has been qualified, whether a stylus
change position has been assigned to it or whether a manual
stylus change is planned. The mode of the original qualifica-
tion is used.

Depending on the validity status, the run can be terminated or

started or a warning message can be displayed.
If one of these limits is exceeded, the stylus must be set to the
"unqualified" status.

Note:
Further information can be found in the operating in-
structions or the online help.

Monitoring the CNC qualification

Here, there are two possibilities:

1. Using global limit values.
These are set via the workroom.
They apply to every stylus that is qualified in the CNC run.
2. Setting stylus-related limit values.

Here, the stylus-related setting overlays the global one.

In both versions, the shown criteria are monitored.

In the workroom, you can globally preassign the limit values and
the stylus test:

Extras - workroom - CMM - stylus systems

146 Calypso Advanced Training

Checking the styli during CNC start

Switching on the function:

Resources - stylus system - stylus check at CNC start

You can set up the respective function in this self-explanatory

menu.

Task:

Set up the limit value in a measurement plan and test different

termination criteria.

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7.4 Rack preassignment

Here, a rack location assignment can be saved for each measure-

ment plan.
During CNC start, the correct assignment is checked.

Note:
Further information can be found in the operating in-
structions or the online help.

Application

1. Creating and managing rack assignments

The assignments are managed in the menu "Automatic stylus

change" via "Administration".

2. Switch on function
Resources - measurement plan - rack assignment

If the function is activated, there will be check when the mea-

suring run is started whether the saved assignment matches the
assignment in the stylus change rack.
If the assignment does not match, there will be a message as to
which of the used stylus systems should be mounted in which
rack positon.

The displayed assignment includes the holder location name, the

holder location name and the stylus system name.

Caution:
The parameters entered under "approach parameters" are
not saved. This means that those parameters that were active
prior to loading are executed. This can lead to collisions.

Task:
Allocate an assignment to a measurement plan and examine
several application cases.

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7.5 Qualify the stylus change rack into the CNC

This function allows the automatic qualification of the stylus

holders in the CNC.

This function is only required if the stylus change rack changes

positions frequently, e.g. if it is mounted on a pallet, which is
clamped onto different positions within the measurement volu-
me.

Further information pertaining to this unusual case can be

found in the operating instructions or the online help.

Retrieval:

Resources - utilities - qualification of stylus system holders

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7.6 Avoid measurement inaccuracies

7.6.1 Temperature compensation

Calypso calculates the geometry of a workpiece for the material

properties at 20°C.
20°C is the reference temperature for length measurements as
per DIN EN ISO 1.
If the temperature deviates from 20°C, the measured geometry
data must be corrected.
For this, the temperature of the CMM and the workpiece must be
known.
The respective expansion coefficient must always be entered
manually.

Retrieval of the temperature compensation

The temperature compensation must be switched on first.

They distinguish between two cases:

1. The CMM does not have a temperature sensor.

When the temperature compensation is opened, the values
for the workpiece and the ratio are at 20.000 °C .

• Measure the temperature of the workpiece

• Enter the temperature and the workpiece expansion coeffi-
cient.
Corrections are performed automatically during the run.

2. Temperature sensors are connected.

When the temperature compensation is opened, the current
values for the workpiece and/or the ratio are displayed.

• Select the connected sensors. If there are two sensors, the

temperature will be averaged out.
• Enter the workpiece expansion coefficient.
Corrections are performed automatically during the run.

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Monitoring functions

Calypso issues a warning during CNC start and in the printout if

the limit values are exceeded.

You must pay special attention to the temperature when qua-

lifying styli.
First, the temperature is saved along with the stylus data and can
be taken into consideration here..
Furthermore, even temperature differences in the stylus caused
by the heat of your hands must be avoided shortly before the
qualification.

Temperature effect with styli

Expansion of the used materials:

• Aluminum: Length change = 2.3 µm/degree
• Titan: Length change = 0.6 µm/degree
• Carbon fiber / ceramic: Length change = 0.1 µm/degree

Example: Comparison of materials with a temperature difference

of "only" 5°
(Measurement began at 20°,
end of measurement 25°, stylus length L= 200mm)
• Aluminum extensions : Length change = 23 µm !!!
• Titanium extensions : Length change = 6 µm !!!
• Carbon fiber/ceramic extensions : Length change = 1 µm !!!

Remedy:
If you are expecting temperature fluctuations on the measuring
device, use the components listed in the following, if possible
in the listed sequence:
• 1. Carbon fiber
2.
3.
4.
5.

Note:
Temperature compensation cannot be used during stylus
qualification.With temperature differences between the stylus
qualification and the measurements on the workpiece, you
must requalify the styli if necessary!

Display the temperature in the printout header.

The temperature can be displayed with the SYS parameter "tem-

peratureworkpiece".
Alternative, PCM can be used.

The temperature can be compared at the beginning and the end

of a measurement by means of the PCM and a message can be
generated.
More information regarding this subject is included in the PCM

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7.6.2 Behavior in case of collisions

With the characteristic "CMM Check", you can monitor your

coordinate measuring device quickly, safely and as per standard
(DIN EN ISO 10360 and VDI/VDE 2617).

The qualified characteristic "CMM Check" allows a quick and

standardized monitoring of the CMM. The control and evaluation
software allows an expressive evaluation by monitoring factors.

Recommended monitoring cycle:

or:
After a collision

The following components of the CMM are monitored by "CMM Check":

The probe head system (precision sphere, adjustment ring, reinforcement normal):
• the variance of the probe head system, measured in relatively small meauring areas
• the probing behavior of the probe head system, overlayered by the features of the CMM (oscil-
lation, hystereses, dynamic deformations)
• the scanning features of the probe head system.

The CMM Geometry

• the variance in the entire measuring volume of the CMM, caused by the straightness variance of
the guides and their perpendicularity to one another
• the length measuring variance (end dimension 40 mm / end dimension 400 mm)
• the CMM as form measuring device including its filtering functions

The rotary table (2 precision spheres as options)

• the four axle movement for the CMM with rotary table
• the sum of variances from the CMM geometry and component variance of the rotary table.

Literature Reference:
„Genau messen mit Koordinatenmessgeräten,
H.-G. Pressel, expert-verlag

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7.6.3 Clamping Workpieces for Measurement

A manufactured workpiece must be positioned on the coordinate machine for measuring. Usually,
a clamping machine is used to achieve this. The clamping machine is adapted precisely to the work-
piece and fulfills the following functions:

• Defining the Workpiece: Positioning features such as stops, linings, index pins, prisms, are
used to place the workpiece into a certain position on the CMM.
• Clamping the workpiece: Clamping features such as quick clampers, clamping claws, spring
tensioners, hold the workpiece in the desired position during the measuring process.
The determination and tensioning of the workpiece must ensure that the workpiece will not warp
and that it does not move during the measuring procedure. A clamping of this type is called "stati-
cally defined". With "statically underdefined" clamping, the workpiece is still able to move (e. g. the
rotating part of a prism without length stop). With "statically overdefined" clamping, the workpiece
will be deformed/warped (e. g. clamping of a surface on four placement points).

With statically defined clamping, the clamping features should be located as directly as possible
across from the defining features. This will prevent deformations of the workpiece during the clam-
ping process.

Another important advantage of the statically defined clamping is also that the workpiece and the
clamping machine can change with different temperatures, without bending forces influencing the
measurement process. With statically overdefined clampings, where the workpiece is "pulled" into
a forced position, bending forces will be generated with temperature changes, which deform the
workpiece inside its clamping.

The 3-2-1 clamping is a typical, statically defined clamping for prismatic workpieces (lathing
pieces, housing. . . ). Three placements position the workpiece in the space (Z axis). Two stops
prevent the rotation in the placement plane (Y axis) and one stop determines the position along the
Y axis (origin).

Chuck clamping is often used for rotating parts. Here, the prism defines the space axis (Z axis); the
radial stop prevents the rotation around the Z axis and the length stop defines the position along
the Z axis (origin).

Defining features are made of hardened materials. They must allow a continuous repeatedly accu-
rate position of the workpiece and must never close. Damages to the workpiece are avoided by a
high surface quality.

Examples for Defining Features:

• Stops, placements
• Pins
• Prisms
• Centering cones
• three spheres (Bessel points for long parts, example: Portal check)

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Clamping features must provide the necessary tensile force

during the measurement. They must not deform or damage the
workpiece. They must not become loose during the measurement
or during transport of the workpiece

Examples for Clamping Features:

• Claws, tensioning connections
• Quick clampers (knee lever tensioners)
• Screws, also with torque limits
• Puddy, adhesive
• Spring tensioner
• Swivelling clamper
• Magnets
• Vacuum

Example for a Clamping Machine

Handling tips for Clamping Machines

• Clean the surfaces where the workpiece is to be placed (defined) prior to clamping it. Also, you
should keep the defining features of the machine clean.
• After placing the workpiece into the machine, check whether the workpiece is shaking in the
clamping. Dirt, shavings, burs on the workpiece and worn out defining features on the ma-
chine can jeopardize the safe tensioning.
• Make sure that the clamping features are in their intended positions during the measurement.
That way, collisions and damages on the stylus system can be prevented during measure-
ment.
• The workpiece should always be clamped in the optimized measuring range of the CMM, i. e.
not along the edge. This requires a deep knowledge of your CMM.
• With highly accurate measurements, you should avoid using magnets for clamping. The measu-
ring result is falsified by the magnetic affect on the workpiece and the stylus system.
• Use defined spring forces for clamping and defined torques for screwed connections (torque
wrench).

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7.6.4 Stylus Systems

Generally, you should make sure that a visual check is performed before stylus definition
or measurement in order to check the cleanliness and integrity of the stylus features, styli and
extensions.

Extensions/connections/intermediate pieces:
• Watch for cleanliness and damages to the insertion surfaces and possibly loose adhesive con-
nections.

• Tighten the screwed connections correctly and thoroughly (use only the intended tool, other
Extras may cause damages)

• Secure the permanent connections with extensions and intermediate pieces with adhesive.

• Setup with as few individual parts as possible (extensions and intermediate pieces) per stylus.
Prefer a special feature with directional changes and angled pieces !

Assembly configurations:
• Sufficient wait time after the assembly and before the qualification to discharge the heat from
the hands. >> Otherwise: qualification and accuracy errors!!

Configurations/stylus lengths:

• You must read the machine description!!!

• Measuring probe head: Max. weight 600 g

• Switching probe head: Max. weight 200 g !!
Specialty: Symmetric placement of the mass !!

• Note: Always use the stylus only as long as necessary and as stabile (rigid) as possible!

• Probing sphere diameter as small as possible (reason: influence of the accuracy via the surface
of the test object => mechanical filtering effect)

• Use the stylus bending correction feature only with highly accurate measurements and/or long
styli
• We recommend a check on an ring gauge (D) and a form plot (v2)

• Calibrating disc styli

Based on the very small contact segment between the stylus and the sphere normal, we recom-
mend a check on an ring gauge (D) and a form plot (v2)

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Checking the Stylus Data and Configurations

Probing sphere diameter

• We recommend a check on an ring gauge (D) and a form plot (v2)
In case of deviations, perform a manual correction of the sphere radius.

Probing sphere distances / diameters / quality of the stylus features used

• Sphere measuring on sphere normal with the first stylus tip of a configuration. Determined
center coordinates in XYZ are declared origins.
• All other probing spheres are measured in reference to this origin and compared.
• If the sphere normal is always in the same location, this means repetitive measuring.
• If the sphere normal is physically offset, this is used to capture systematic errors on the CMM.
• The creation of an automated run in the style of a measuring program "Stylus Qualification
Check" to check the stylus data is recommended when multiple and/or complex configurations
are used.

Description of the Measuring Program "Stylus Qualification Check":

• The measuring program is used to check the stylus data determined in the course of a qualifi-
cation, manually or via a CNC program, or to check the long-term stability of the used styli in
serial measurement, up until a new qualification of the styli.
• The result of a measuring program run is the representation of the variances in the coordinates
X, Y, Z, of all styli used and configurations of a stylus configuration group to the reference
"ZERO" (origin), determined by means of the master probe or the first stylus of a configuration
(master probe).
• In addition, the sphere normal diameter is put out as a measure for the stylus diameter determi-
ned during the qualification.
• The sigma value is an indicator for the degree of contamination, wear, damage or loosening of
styli and stylus features, within a configuration.
• The output is a measurement printout.
• Changes in the stylus data can be detected by comparing the results of the individual measure-
ment runs (printouts).
• The results can be saved and evaluated via qs STAT (option) if a corresponding qs STAT interface
is available.
• By issuing the respective limit values with the permissible deviations of the individual parame-
ters, the user's decision making process is facilitated.

The size of the deviations and/or sigmas to the reference "Zero" depends on the following parame-
ters:
• Quality of calibration
• Length and stability of the used styli and extensions
• Degree of the temperature deviations and time temperature fluctuations on the CMM
• Degree of contamination, wear, damage of the stylus spheres
Existence of of loosened or damaged stylus and/or extension features.

156 Calypso Advanced Training

Causes of extensive qualification sigma values

• After a hard collision with a stylus, in every case, a complete recalibration/requalification of
the configuration is required.
• Stability of the stylus components is not sufficient (e. g. incorrect shaft materials, faulty
adhesive connections, screw on surfaces contaminated, damaged)
• Stylus components not screwed together tightly enough.
• Three point bearing on the probing head or the changer plate contaminated.
• Stylus feature was mechanically damaged by improper treatment or hard collision.
• Stylus layouts that are too long or too heavy are used (perm. limit values are exceeded).
• Impedance by a magnetic field due to steel components used

Stylus change machine / reproducibility:

• Switching system = 1.0 µm on 200 mm
• Measuring system = 0.25 µm on 200 mm

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7.6.5 Inaccuracy with a CMM

Environmental Conditions

Influential Factors
• Temperature fluctuations / sun radiation / draught air
Example: Only 1 degree of temperature difference in the granite traverse creates a mea-
suring error of 12 (twelve) µm/m, if you measure at a distance of 600 mm from the X
measure,
• i. e. on the table surface of CMM.

Scanning / individual points:

• Basically, the following applies: The more measuring points that are picked up, the safer
and more expressive the result!
• Here, take into consideration the correct use of shaft and outlier filters.

Material – test workpiece:

• The temperature of the test workpiece has a decisive influence on the measuring result.
• The test workpieces must generally be "acclimated" prior to measuring, i. e. they must be stabi-
lized to the ambient temperature of the CMM.
• Bascially, a capturing and calculation of the workpiece temperature must take place by means
of the temperature stylus or the temperature sensors on the CMM in order to achieve a
correct measurement result.
•
Projections
• Avoid short measuring lengths with simultaneous large evaluation length. I. e. projections with
a multiple of the measuring length.
Example Measuring Requirement: Coaxiality of two symmetric cylinders with a measuring length
of 20 mm with an axial distance of 100 mm.

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7.6.6 Inaccuracy Analysis

The contributions to the measuring inaccuracies for a CMM consist mainly of the
following
• the known systematic deviations (21 deviation components including pro-
bing variances), which can basically be corrected
• the arbitrary influences, recognizable in the arbitrary probing variances,
which are caused by interpolation errors, dynamic influences and hysteresis
effects.
• the unknown systematic deviations, e. g. by uncorrected temperature influ-
ences, qualification inaccuracies of the used CMMs, short periodic portions
of the deviation components, simplification of the mathematical models to
overlay the different inaccuracy contributions.
The detected inaccuracy contributions for a coordinate measuring process
are shown in Fig. 1.

Determining the Inaccuracy Influences

Significant inaccuracy contributions of a coordinate measuring process result from

the probing procedure, the machine geometry and the stability of the CMM due to
temperature effects.

To determine the probing inaccuracy (P), a qualified sphere and a qualified gauge
ring (CMM check) are measured.

To determine a length measuring inaccuracy (E) (geometry), a bore pattern (portal

check) is measured in several locations on the CMM.

Measuring the deviation components of a CMM with a bore

pattern

Literature Reference:
"Genau messen mit Koordinatenmessgeräten",
H.-G. Pressel, expert-verlag

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160 Calypso Advanced Training

8: Measuring methods, part 2

8.1 Scanning with unknown contour..................................................................... 162

8.2 Scanning with 2 styli....................................................................................... 163

8.3 Point masking in open scanning paths............................................................ 165

8.4 Self-centering probing..................................................................................... 166

8.5 Safety cube...................................................................................................... 168

8.6 Park position................................................................................................... 171

8.7 Missing bore.................................................................................................... 172

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8.1 Scanning with unknown contour

Features (besides points, 2D line and plane) have the "unknown

contour" strategy.
Here, there will be a starting point and an endpoint, just like with
curve measurement.
The machine tries to measure the shortest path between the
starting point and the endpoint.

A typical example for this scanning method is the slot.

Exercise:

Clamp a workpiece with an slot and align the

workpiece.

Take a new slot from the toolbox and open the strategy.

Click on the unknown contour, open it and probe the starting

point and the endpoint.
These points can be identical.

Set the speed and the step distance to sensible values.

Indicate a space axis, here, the normal direction of the slot.

The end criterion sphere means that the end the contour was
recognized as soon as the stylus "arrives" in a "sphere" with a 5
mm radius.

To run this unknown contour, in the strategy, click on "Execute

now" with the right mouse button

Now, the slot will be scanned.

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8.2 Scanning with 2 styli

If it is not possible to scan a circular path on a workpiece with

just one stylus (e.g. full circle on cam shaft), this function will
allow you to measure partial circle paths with different styli at the
"same" height and to combine them into one circular path.
This will create a correct roundness plot.

Exercise:

Align the exercise cube so it "sits on its head".

Measure two circle section with different styli on the cylinder at

three heights.
Apply correct styli and angle names.

There will be 6 circle sections.

Group two circle sections with the marked group.

Start the run and optimize the drive behaviour so that the end of
a path is located on the same side as the start of the next path.

Create a roundness plot for every path.

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The following conditions must be observed:

1. Applicable to: Cylinder, cone, circle and circle on cone.

2. Strategies besides "circle section" will not be considered.

3. In order dissolve a group, all its elements must be marked.

Actuating the button "Group circle sections" dissolves the
grouping.

4. The summary of the selected circle paths takes place directly

after the measurement and is switched in front of the actual
evaluations.

5. The path angle of the circle paths to be combined is arbitrary.

6. The number of the circle paths to be combined is arbitrary.

7. The respective rotation direction of the circle paths to be

combined is arbitrary. The rotation direction of the combined
circle path is the same as the rotation direction of the first
circle path.

8. The sequence of the circle paths to be combined is arbitrary.

9. The circle paths to be combined can be overlapped or feature

gaps. Overlaps are removed.

A selection of the possibilities is shown in the illustration.

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8.3 Point masking in open scanning paths

This function masks points at the start and the end of the scan-
ning path.
The number of points is controlled via the time factor seconds, as
mainly the oscillations of the measuring system are to be elimina-
ted.

In the measuring feature editor, the activation of the function

for the entire measurement plan and for individual measuring
features can be set up.

• The point masking works for the following scanning paths

(not with individual point measurements):
• Circle cross cut of circles, cylinders, cones, spheres, if the total
angle area is smaller than or equal to 360°
• Circle cross cut of circles, cylinders, cones, spheres, if the total
angle area is smaller than or equal to 360°
• Helix of circles, cylinders, cones
• VAST helix of cylinders
• Grid (lines and meanders) of planes
• Polylines of planes
• Circle on plane of planes, if the total scanned angle area is
smaller than or equal to 360°.
• Line of 2D line
• Unknown contour of circles, cylinders, cones, spheres, el-
lipses, slots, rectangles, 2D and 3D curves
• Curve segments of 2D and 3D curves

Notes about the settings:

Standard: Start 0.25 sec; end 0 sec
Short: Start 0.1 sec; end 0 sec
Long: Start 0.4 sec; end 0,25 sec

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8.4 Self-centering probing

Self-centering recording of an unknown contour, i.e. a slot. The

functionality can be used on points, lines, circle paths (with and
without rotary table), curves (with and without rotary table).

The entries for the measuring force and for the self-centering
probing must be made directly for one feature.
An entry from a superior feature (suggestion) is not permitted.

The self-centering probing can only be adjusted for strategies.

This can take place in several ways.

With
"Resources - self-centering probing" for the recently selected
feature or directly in the feature via "strategy".

The dialog box opens; with circle paths, the field "Force direc-
tion" is displayed in the window as well.
For this, the respective direction must be selected.

Notes:

• In the measuring feature list, features are marked with self-

centering probing/scanning by receiving an orange border.
• Setting possibilities in the element editor (ON, OFF, Edit). The
strategy can be edited with "edit".
• With strategies with vectorial probings, the vectorial probing
must be adapted with circular pitch.

• Probing points can only be measured with individual points.

Lines and circle paths, on the other hand, can be scanned
only and without tangential probing (homing) (VAST Naviga-
tor).

• With circle paths with rotary table (also for curves), the circle
path must be situated rotationally symmetrical to the rotary
table axis.
• In general, self-centering measurements can only take place
within certain limits.Hence, right angles cannot be recorded
self-centering. Curves should feature a rotation direction,
similar to a circle path.

VAST XXT and self-centering:

A self-centering probing is not allowed here, as momentum
created by friction forces leads to inaccurate measurements.

166 Calypso Advanced Training

Exercise:

On the exercise cube, the slot is to be scanned on top in a 60°

area. This can take place via self-centering.

Prepare a plan where the circle section exists as a strategy.

Now set the adjustments for the self-cen-

tering probing in the strategy window as
follows:

Another example for self-centering:

On a toothed wheel, the gaps between the teeth are to be
probed via self-centering and circular pitch.

Note: The force direction orients itself by the feature coordi-

nate system. E.g., with points, the force is only switched in
Fz and against the vector direction.

The measuring force

The measuring force can only be assigned to features.Use all

measuring strategies belonging to the feature when this force is
measured.

In order to assign a measuring force to one or more features, it is

selected and the menu Resources -> measuring force is activated.
The above dialog window is displayed, where you can enter the
desired force.

Calypso Advanced Training 167

8.5 Safety cube

General information

The safety cube can be aligned as per a arbitrary coordinate

system (also machine system MS).

With workpieces, where the base alignment is very slanted, the

safety cube will be slanted as well. If the majority of the features
is not aligned with the base alignment or the MS, this may lead
to problems with the drive paths.

Safety cubes with selectable coordinate system

The safety cube can be selected according to a arbitrary coordi-

nate system from this measurement plan.

Safety cubes with different coordinate systems

Safety cube aligned with base alignment

The drive paths of the stylus run along the safety cube; here, at
an angle to the machine axes.

Safety cube aligned on the device system

The drive paths of the styli run along the machine axes.

Note:
If the base alignment changes, the safety cube is "not taken
along"!

168 Calypso Advanced Training

Exterior safety cube

• During the measurement run, the follow-

ing should be avoided:
• a collision with other workpieces,
• a collision with the stylus change rack,
• driving into the end position.

For this, an exterior safety cube can be helpful. The size can be
the measuring volume of the machine. If it is selected smaller,
other workpieces are outside this cube.

The definition takes place via:

Plan - navigation - outer clearance

Switching on the drive test:

Here, there are more possibilities:

Plan - navigation - correction needed

The drive behavior of the machine changes as follows:

• Style change rack

Automatic consideration including the stylus system in the rack.
The stylus that protrudes furthest into the measuring range of each rack determines a plane on
which the drive path is checked.
The foremost stylus tips of the rack are shown as points.
• Measuring range limits (end positions):
Consideration of the values from the configuration in the workroom.

Drive behavior:
With every generated drive path between the measuring features, there is a test for collision/end
position with all defined obstacles.
If a collision/end position is detected, the next one will be "tried" and so forth.

With long narrow stylus systems, you will drive by the workpiece along its side, with flat wide styli
only on top.

Calypso Advanced Training 169

Block edges

Individual edges of the safety cube can be blocked.

The circled edges refer to the machine table. This can change
depending on the axis position!

Retrieval:
Plan - navigation - block edges

Exercise:

Place the safety cube far to the side on the machine and define
an exterior safety cube.

Test the run while considering:

• End positions
• Exterior safety cube
• Stylus change locations
• Blocked edges

170 Calypso Advanced Training

8.6 Park position

General information

A park position is a defined position of the stylus at the end of

the CNC run.

Retrieving a park position

Plan - navigation - CNC end park position

An icon can be retrieved via the function

"List drive paths" in the same menu.

A path to this position can be programmed into the park positi-

on.

Furthermore, a relative positioning to the master probe and stylus

change is possible.

The following illustrations show a park position after the cylinder

measurement in front 100 mm above the workpiece.

Note:
What often makes sense is the use of a safety position with
the correct safety plane directly before the drive command to
a position.

Note:
Park position will not work with measurement plans that
only contain characteristics of the type "Qualifying the stylus
system".

Calypso Advanced Training 171

8.7 Missing bore

General information

To prevent a CNC run from terminating if a bore is missing from

the workpiece, the function "Missing bore" can ensure continuo-
us operation.

Retrieval:
• Only with circles: via "Projection" in the features window
• Further features: Measuring feature editor

Function:
The bores are driven from a certain height at search
speed.
If there is no bore, the system drives to the next
feature at this height.

This height is the clearance distance:

The clearance distance is the distance from the
circle in the initial start direction.
If the bore is not found, Calypso will drive to the next feature
at this height (here, circle 2).
This means that the search distance must be greater than the
submersion depth of the material.

Note:
If the safety distance is too short to drive free of the workpi-
ece, there is a risk of collision.
If the function is preset in the measuring feature editor, Calyp-
so will check the distance and may issue a collision warning.

Task:
Measure two bores as a circle on a cube. The first bore is to be
missing during the test run.
For the first circle, the function "missing bore" is activated.
The clearance distance is 10 mm; this may be enough to drive
safely above the workpiece to the second bore.

In the CNC run, place a coin over the first bore to test the func-
tion.

172 Calypso Advanced Training

Calypso Advanced Training 173

174 Calypso Advanced Training

Calypso Advanced Training 175

176 Calypso Advanced Training

Calypso Advanced Training 177

178 Calypso Advanced Training

Calypso Advanced Training 179

180 Calypso Advanced Training

Calypso Advanced Training 181

10/2008
Heinrich-Rieger-Str. 1

http://www.zeiss3d.de
73430 Aalen, Germany

e-mail: [email protected]
Fax: +49 (73 61) 5 59-1899
Phone: +49 (73 61) 5 59-1800

Calypso Training Materials Printed in Germany

Subject to modifications of the layout and scope of delivery as well as technical developments
© Carl Zeiss 3D Metrology Services GmbH.
© Concept, text and design: © Carl Zeiss 3D Metrology Services

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