Basic Course

Edition: June 2003

Software Rev.
3.5 and 3.6

Training
Manual
Calypso Basic Course

This manual is protected by copyright. No part of its contents may be copied, reproduced,
translated, further processed by electronic means, or passed on without the express consent
of Carl Zeiss Industrielle Meßtechnik GmbH.

We reserve the right to alter the contents of this manual as required.

 Carl Zeiss Industrielle Meßtechnik GmbH. All rights reserved.

Software Revision: 3.5 and 3.6

Edition: 06/2003

Printed in Germany
th
9 edition, June 2001

Carl Zeiss Industrielle Meßtechnik GmbH

73446 Oberkochen
www.zeiss.de

e-mail address of Training Center

[email protected]

Special information on this edition:

The text and graphics contained in this training manual lay no claim to completeness or
correctness.

Please notify your instructor of any flaws or insufficiencies you may discover in the following
sections.

Your cooperation will help us improve Calypso training for future course participants.

Since the software described here is constantly being revised, deviations from the
procedures described here may occur at a later point in time.

Please take this point into consideration when working with Calypso in the future.

Calypso Basic Course

The way to becoming a Calypso Specialist

Calypso Basic Course

Calypso Basic Course

Carl Zeiss
Customer Training IMT

Calypso Basic Course

Item no. 600033-9701-000 Name: Company:

Prerequisites: This Training:

Knowledge of Geometric Dimensioning & Tolerancing Covers the Calypso basic functions
Ability to read drawings with tolerances Is a 5 day training
Basic knowledge of metrology Is recommended to be taken at a Training
Basic knowledge of PC and Windows 2000/NT Center
Input fields Is preparation for Calypso Advanced Training
Using the mouse: left/right button, Starts at 8:30 a.m., ends at 4:00 p.m
select, move, copy, paste ...File structure: File, Folder, Drives,....
Windows: open, close, change, ... Offers practical sessions without trainer after
Functionality of Windows Explorer 4:00 p.m.
Reading the Introduction book, a metrology primer Provides handouts where necessary, you
should bring your own copy of the Calypso
User Manual.

Day 1 Comprehension ↓ Comprehension ↓

Introduction ☺ Starting Calypso ☺
Introduction and training schedule Homing the CMM
Student introductions User interface, Status window ...
Coordinate measuring machines (CMM) in the course Preparation-Feature-Characteristic
Carl Zeiss IMT products
Concepts ☺
Hardware ☺ Result based measurement plans
CMM Automatic recognition of features
Probe head: RDS, ST, VAST, probe rack Pull down menu/Toolbox
Controller Calypso help function/Error report
Joystick and control panel Opening a new measurement plan
Storing measurement plans
Computer ☺
System requirements First features and characteristics ☺
Windows NT User Interface Checking a diameter
Windows Explorer, file structure
Probe qualification ☺
Coordinate Systems ☺ Calibration sphere
Cartesian coordinate systems Master probe
Machine coordinate systems Probe and stylus
Basic system Standard and manual qualification
Manual / automatic probe change

Calypso Basic Course

Day 2 Comprehension ↓ Comprehension ↓
Base alignment and clearance planes ☺ Strategy ☺
Primary, secondary & tertiary axis Point list
Manual and automatic alignments Auto circle path
Clearance planes Intermediate positions
Definition of travel paths Sub clearance plane
Settings Space point
Temperature compensation

Features ☺ Characteristics ☺
Circle, Line, Plane, Diameter
Cylinder, Cone, XYZ-Values
Sphere, Ellipse, Cartesian distance
Select features for Characteristics Angle
Nominals True Position
Tolerances Automatic runs ☺
Exercises Actual selection
All characteristics
Navigation
Speed
Custom / default printouts

Day 3 Comprehension ↓ Comprehension ↓

Constructed Features ☺ Special Alignment ☺
Recall Rotate
Intersection Rotate Distance
Symmetry Displacement
Perpendicular, Projection New Coordinate System
3D-Line
True Position / Form Scanning ☺
Step Width
Exercises Polyline
Settings

Day 4 Comprehension ↓ Comprehension ↓

CAD models ☺ Workroom ☺
Loading the CAD model Setting up new user
CAD window controls Password
CMM configuration
Extracting Features Measurement Units
Defining probe points
Alignment to the CAD model Documentation ☺
Setting default strategies Custom printout
Printout editor
Printer output
Interpreting the Default Printout

Exercises

Calypso Basic Course

Calypso Basic Course

Day 5 Comprehension ↓
Administration ☺ Analysis
Data structure Teacher evaluates class
Backup using Windows Explorer Students evaluate class
Installing Software
Preview
Courses following on from the Basic Course

Calypso Basic Course

Contents
Section 1:

Subsection 1: Calibration

Information
1.1: Why Calibrate Probes 1 – 12
1.2: Spatial Arrangement and Radius of the Probe Tip 1 – 12
1.3: Types of Probe Head 1 – 13
1.4: Calibration Sphere for Probe Head Calibration 1 – 15
1.5: Probing Strategy 1 – 16
1.6: Explanation of the Information in the Probe Data List 1 – 17
1.7: Recalibration 1 – 18
1.8: Checking the Calibration 1 – 19
1.9: General Procedure for Probe Calibration 1 – 20

Subsection 2: Measuring the Workpiece

2.1: Generating Measuring Results 2–1

2.2: General Measuring Procedure 2–2
2.3: Automatic Feature Recognition 2–3
2.4: Types of Control Console 2–4
2.5: Geometric Elements 2–5
2.5.1: Ideal and Actual Form / Substitute Element 2–5
2.5.2: Minimum Number of Probings 2–6
2.5.3: Reduction of Measuring Uncertainty through 2–6
Favorable Probing
2.5.4: Reduction of Measuring Uncertainty through 2–7
More Probings

Subsection 3 : Part Features

3.1: Part Feature: Circle 3–1

3.2: Part Feature: Cylinder 3–2
3.3: Part Feature: Plane 3–4
3.4: Part Feature: Line (straight) 3–8
3.5: Part Feature: Cone 3 – 10
3.6: Part Feature: Sphere 3 – 12
3.7: Part Feature: Ellipse 3 – 13
3.8: Part Feature: Point 3 – 14
3.9: Combination of Geometric Elements 3 – 16

Calypso Basic Course

Subsection 4: Working with Part Features: Constructions
4.1: Recall 4–2
4.2: Perpendicular 4–3
4.3: Intersection 4–4
4.4: Symmetry 4–6
4.5: Distance 4–7
4.6: Projection 4–9

Subsection 5: Alignment
5.1: Why Alignment? 5–1
5.2: Mathematical Alignment 5–1
5.3: Selecting Suitable Elements for Alignment 5–2
5.4: Alignment Procedure 5–2
5.5: Primary and Secondary Reference Elements 5–3
5.6: General Sequence 5–4
5.7: Multiple Coordinate Systems 5–5

Subsection 6: Interpreting Results

6.1: Feature Coordinate System 6–1

6.2: Default Printout 6–4
6.3: Custom Printout 6–6

Calypso Basic Course

Section 2:

Worksheets

Worksheet 1: Probes.

1: Vast / St Probe Head 1–1

1.1: Preparing the Probe 1–1
1.2: Automatic Probe Change 1–8
1.2.1: Making Entries in the “Workroom” Window 1–9
1.2.2: Probe Change Menu 1 – 10
1.2.3: Defining the Position of Storage Locations 1 – 11
1.2.3.1: Determining the Length of the Master Probe 1 – 11
1.2.3.2: Entering Holders 1 – 11
1.2.3.3: Position Definition 1 – 12
1.2.3.4: Assigning Probes to Holders 1 – 12
1.2.3.5: Storing the Probe 1 – 13
1.2.4: Practical application 1 – 13

2: RDS/RST – Probe Head 1 – 14

2.1: Preparing the Probe 1 – 14
2.2: Automatic Probe Change 1 – 20
2.2.1: Making Entries in the “Workroom” Window 1 – 21
2.2.2: Defining the RDS Geometry 1 – 22
2.2.3: Automatic Probe Change Functions 1 – 23
2.2.4: Entering Holders 1 – 24
2.2.5: Position Definition 1 – 24
2.2.6: Assigning Probes to Holders 1 – 25
2.2.7: Storing the Probe 1 – 25
2.2.8: Practical Application 1 – 25
2.3: Managing Stylus Data 1 – 26

Worksheet 2: Base Alignment

2.1: Alignment with three planes 2–1

: Safety Cube 2–5
2.2: Aligning a Connecting Rod 2–7
2.3: Aligning a Gearbox 2–9
2.4: Aligning a Gearbox Flange or Support 2 – 13
2.4.1: ...with Rotation and Offset 2 – 13
2.4.2: ...with Rotation by a Specified Distance 2 – 16
2.5: Redefining the Base Alignment 2 – 19
2.6: Aligning a Shaft 2 – 21
2.7: Generating a Second Alignment 2 – 23

Calypso Basic Course

Worksheet 3: Measuring Strategy

3.1: Editing the Clearance Data 3–1

3.2: Creating Circular Sections 3–4
3.3: Automatic Generation of Travel Paths 3–7
3.4: Generating Part Features by Specifying the 3–9
Nominal
3.5: Default Strategies 3 – 13
3.5.1: Default Strategies for Cylinder 3 – 13
3.5.2: Default Strategies for Circle 3 – 16
3.6: Multiple Clearance Planes 3 – 18
3.7: Defining a Sub Clearance Planes 3 – 20
3.8: Probing a Space Point 3 – 22
3.9: Part Features - Editor 3 – 25
3.10: Plane Measurement with Polyline 3 – 26

Worksheet 4: Characteristics

4.1: X-value, Y-Value, Z-Value 4–1

4.2: Circle and Diameter 4–4
4.3: Plane and Angle 4–8
4.4: Line and Angle 4 – 10
4.5: Cylinder and Diameter 4 – 13
4.6: Cone and Cone Angle 4 – 15
4.7: Cone and Cone Addition Diameter 4 – 17
4.8: Distance 4 – 19

Worksheet 5: Measuring Tasks

5.1: Pitch/Bolt Circle Diameter 5–1

5.2: 3D Line / DIN Parallelism 5–4
5.3: Construction, Intersection 5–7
5.4: Construction, Intersection 5–9
5.5: Construction, Intersection and Wall Section 5 – 11
5.6: Placing New Origin in Center of Cone 5 – 14
5.7: Construction, Symmetry 5 – 17
5.8: Cartesian Distance / Bore plate 5 – 19
5.9: Distance between Parallel Surfaces and Angle 5 – 22
5.9.1: ...with Cartesian Distance 5 – 22
5.9.2: ...with Axis Distance / Perpendicular Length 5 – 25
5.10: True Position 5 – 27
5.11: Polar Angle and Distance in a New Base 5 – 29
Alignment
5.12: Form and Position Evaluations 5 – 31
5.13: Flatness Characteristic 5 – 33
5.14: Base Alignment with 3D Line 5 – 35

Calypso Basic Course

Worksheet 6 : CNC Programming

6.1: CNC Probe Calibration 6–1

6.2: Programming on the CAD Model 6–3
6.3: Programming on CAD Model II 6–9

Worksheet 7: CNC Program and Measurement Plan Documentation

7.1: General Information on CNC Programs 7–1

7.2: Cataloging and Storing Measurement Plans 7–4
7.4: Probe Plan 7–6
7.5: Base Alignment Plan 7–7
7.6: Custom Printout 7–8
7.7: Default Printout 7–9
7.8: List of Characteristics 7 – 10
7.9: List of Part Features 7 – 11
7.10: File for Export to Spreadsheet Program 7 – 12
7.11: Changing the Header 7 - 11

Appendix:
Drawings

Calypso Basic Course

Preparation: Starting the machine

Preparation: Starting the measuring machine

Start computer and Windows NT / 2000

Operating system
Calypso runs under Windows NT and Windows 2000.
Knowledge of these operating systems is very helpful in order to profit from this course.

This training course cannot replace Windows experience, as only a few specific administrative
functions are included.

Start computer
• Switch on computer.
After the operating system has booted you will see the login window.
• The computer is shipped with the defaults:
user name: administrator;
password: <enter>

Your network administrator may have changed or may need to change these settings. Contact
them in case of problems.

The desktop
The monitor screen with various icons is known as the desktop. Here you
will find a “Calypso” icon with which you can start Calypso.

Another option is to use the Start button:

Start - Programs - Zeiss - Calypso

All further Windows functions are available to you from the

desktop.

Folders and paths

Double click on My Computer, and you will see the
computer structure with hard drives and network drives, if
present.

You can obtain another overview with Explorer. Access it

with a right mouse click on My Computer.

Calypso is stored in several different folders.

Please note that a standard installation is described here.

Here are some typical paths:

Measurement plans
C:\Programs\Zeiss\Calypso\home\om\workarea\inspections

Measurement results collected in data files

C:\Programs\Zeiss\Calypso\home\om\workarea\results

Calypso Basic Course 1-1

Preparation: Starting the machine

CAD files
C:\Programs\Zeiss\Calypso\opt\om\cad

User information
C:\Programs\Zeiss\Calypso\opt\om\pictures\userinfo

Protocol formats
C:\Programs\Zeiss\Calypso\opt\om\protform

Calypso Key file

C:\Programs\Zeiss\Calypso\home\om\calypso.key

Error messages
C:\Programs\Zeiss\Calypso\var\opt\om\hotline

Further information is available in the online User Manual

Starting the controller

The controller is located either in a separate cabinet
next to the machine or is integrated in the machine
table.

The operating controls are similar in both cases.

The figures show

Eclipse
Contura
Prismo

A main switch turns on the power supply for the entire machine.
This often also turns off the power to the computer.

o Turn on the main switch

o Start the computer
o Start the controller with:

⇒ key-switch to “man” or “auto”.

⇒ power line control to “On”: the
control lamp is lit.

Wait until the LED’s on the

operating console stop flashing.

Flashing indicates the controller starting phase

⇒ The drives can only now be switched on with the “Drives” rocker switch

The machine is now operational.

CAUTION:
Follow the safety instructions in the
machine’s User Manual under all
circumstances!

Calypso Basic Course 1-2

Preparation: Starting the machine

Note:
The measuring machine computer is operable without the measuring machine. As soon as
Calypso is called up, the computer searches for a network connection.

If this is not found, an error message appears and Calypso only works offline.

Similarly, the machine can be switched on without the computer and is operable with the
control levers.

You should not use this option, as any undefined status errors may render the entire system
unusable.

Standard operating console

Rotary switch for speed

The switch directly affects the controller and allows the traverse speed to be regulated at all
times.

Emergency Stop
Immediately switches off the drives and has to be pressed or pulled out to reset.

Invert button
Switches to the X and Y control levers, so it is possible to work from the rear of the machine
with normal control lever deflection.

Slow button
Reduces the traverse speed for the
control levers down to a maximum of
the probing speed.

Return
Can often be used in the same way as
the computer Enter key.

Stylus selection
Allows the selection of styli 1-5.
Pay attention to the direction of the styli,
which is not necessarily the same as
that shown in the illustration.

Control lever
Serves to drive the CMM. The left lever
controls the Z axis and the right lever
controls the X and Y axes.

The button in the left lever must be pressed in order to rotate the rotary table (if installed).

Calypso Basic Course 1-3

Preparation: Starting the machine

The button in the right control lever sends the CMM position to the Calypso
computer (intermediate position, safety cube).

Some additional operating console functions:

Shift - Return - F2
Manual stylus ejection: The stylus falls out of the measuring probe immediately,
there is no 5 sec. waiting time!
In the case of this type of stylus change, Calypso is not informed of a new
stylus!!

Shift - Return - F3
Manual stylus fitting: The stylus is only fitted, not calibrated!
Calypso is not informed of a new stylus!!!

Shift - Return – F1
Manual calibration:

Shift - Return - F12

Manual reference point traverse.
Pay attention to all consequences, which may arise from a reference point
traverse!

Problems starting?
Computer cannot be switched on?
• There is a main switch for the computer at the rear of some models via the
power line connection. This must be set to “I”.
• For some types of installation, the power supply is interrupted via the main
switch on the measuring machine.
• Are the power cables firmly connected?
• Fuse?

Controller cannot be turned on?

• Emergency Stop still engaged?
• Air pressure too low, drives cannot be switched on!
• Key switch on “0”?
• Rotary speed control set below minimum speed
• CMM sitting on end stop

Calypso Basic Course 1-4

Preparation: Starting the machine

“Safety control lever” function

In accordance with standard EN 60204-1/1998, all newly delivered CMMs from 1.7.2001 must be
fitted with a “safety control stick” function.
Any hazard arising for the operator as a result of an inadvertent traverse of the machine is
avoided by touching the control lever.

This function blocks the control levers if they have not been moved for more than 60 sec.

Circumvention of this safety function invalidates the EC Declaration of

Conformity and the approval for the GS mark.

Functions on the different operating consoles:

Control stick Control stick

Operating console
deactivated with: activated with:
Standard operating probe LED flashes / acoustic
console brief press of the SHIFT key (long
signal on deflection of the
608426-9930-000 press activates the RDS function)
control lever
Firmware status 3.0
Standard operating
console probe LED flashes / acoustic
1004-277 brief press of the SHIFT key (long
signal on deflection of the
with power ON press activates the RDS function)
control lever
drives ON
Firmware status 3.0
Dynalog P
brief press of the SHIFT key (long
currently no display possible
1158-561 press activates the RDS function)
Firmware status 3.0
Dynalog P
1158-501
with power ON brief press of the SHIFT key (long
currently no display possible
drives ON press activates the RDS function)
Firmware status 3.0

Dynalog II indicator at bottom / left of

press softkey bottom / left next to
display, acoustic signal on
indicator
1075-186 deflection of the control lever

Calypso Basic Course 1-5

Information: Calibration

Traffic light window

The traffic light window serves both as a status display and as

a means of controlling the run.

It is always displayed when you have started a measurement.

It controls the communication between the controller and the

Calypso computer.

It is also the interface, through which you can intervene during

a run.

⇒ The traffic light window must not be closed, as Calypso

would then lose contact with the CMM. You can however
minimize it at all times or hide it behind other windows.

⇒ If the traffic light window is closed, the window can be

reopened via the pull-down menu with the following path:

Extras -> Workroom -> CMM -> Connect

Some important functions will now be introduced:

1. Change Views
2. Install measuring machine
3. “Decouple” machine
4. Traffic lights exercise

1. Change Views

Select the various options under “View”.

Move the various fields with the “hand”:

Click on the hand, then click on the field to be moved and move
vertically with the left mouse key pressed.

1-6 Calypso Basic Course

Information: Calibration

The different View options:

Traffic lights
• Normally set to green.
• Clicking on red stops a CNC run.
• Clicking on yellow interrupts a CNC run.
• Jumps to red after a collision.

Base system:
• Information on the current base system

Control stick: Drive to…

• Normally traverse is along the machine
axes.
• May be switched to other alignments or
plane directions.
• Useful, e.g. for narrow oblique bores.

Stylus
• Stylus information. No adjustment
possible

Coordinate display
• In machine co-ordinates. or
• In base system

Probing On/Off
• Switches point acquisition of Calypso
computer on/off

Status bar
• CMM status Information

Calypso Basic Course 1-7

Information: Calibration

2. Initializing the measuring machine

If it is necessary to reinitialize the measuring machine, this is most easily

achieved with

⇒ “Connection – New”,
⇒ “Create Connection” button.

When do you have to initialize the

measuring machine?

If you discover that there is no

communication between the Calypso
computer and the controller. This is normally
an internal network problem.

⇒ Probing points are not acquired.

⇒ Message: No connection to
measuring machine

When do you not have to initialize the

measuring machine?

⇒ CMM cannot be driven:

o Key switch set to “0”

o Potentiometer at left limit stop
o Control lever locked (safety control stick, see page V)
o Drives off

⇒ Calypso software “freezes”:

o screen no longer displays properly

o mouse clicks are ignored

1-8 Calypso Basic Course

Information: Calibration

3. Simulation Mode

This concept represents an interesting possibility of temporarily working only with Calypso
without the measuring machine.

When could this function be applied?

⇒ To test CNC programs, only for methods of calculation
⇒ Retrospectively changing reporting output
⇒ Offline programming

Particularly the last of the possibilities listed, “offline programming”, is indispensable for
working on the CAD model.

Disengaging the measuring machine:

⇒ “Connection – New”,
⇒ select “Simulation” mode
⇒ Important: click “Create Connection”.

From now on, you can start CNC runs without the machine running. The measurement
characteristics are only calculated with nominal values.

Calypso Basic Course 1-9

Information: Calibration

4. Traffic light exercise

Create a traffic light window as shown.

Move the window to the right edge of the screen and then
click on the disk icon.

⇒ The window will always have this shape and

will be opened at this location.

1-10 Calypso Basic Course

Information: Calibration

Section 1: Information

Fundamentals of Calypso

Calypso is a characteristic oriented program.

What does this mean?

Its whole operating philosophy centers around the
characteristic as the central criterion.

You must check the size, position tolerance etc. specified

in the drawing.

These are your characteristics.

You integrate all characteristics in a measurement plan.

This provides the basis for your CNC run.

What must you probe to create a characteristic?

You probe the part features.

Example:

Look at the bore in the top surface of the cube shown in the
drawing on the right. Let's assume we want to check its
position.

st
1 possibility:
You measure the bore e.g. via 4 probing points. The
bore has thus become the part feature "circle".
Then you create two characteristics, an X value and a
Y value from this circle.

⇒ create a characteristic from a part feature.

nd
2 possibility:
First you remove your characteristics from a toolbox or menu option and insert them in a
measurement plan.
Then you measure the corresponding part features in the characteristics.

⇒ assign a part feature in a characteristic.

Both of these methods are based on the linkage of a characteristic to a part feature and can
be used in combination.

Don't forget:
The characteristic represents the highest step in this hierarchy.
In other words, the part feature is assigned and subordinated to the characteristic.

Calypso Basic Course 1-11

Information: Calibration

1. Calibration

1.1 Why calibrate probes?

During a three-dimensional measurement, a

workpiece is usually probed from different
sides. In order to measure all of the
measuring points required without reclamping
the workpiece, a so-called probe is used.

A probe may comprise any number of styli as

long as a useful geometry is thus obtained.

The individual styli are fastened to the adapter

plate e.g. in a star shaped configuration.
Probe configurations can be assembled using
connecting elements such as extensions or
joints. The stylus support (e.g. plate or cone)
is mounted on the probe head.

In a CNC measuring run, the CMM knows

which probe should be used for probing and
automatically retrieves it from the probe rack.

1.2 Spatial Arrangement and

Radius of the Probe Tip

1-12 Calypso Basic Course

Information: Calibration

In order to obtain the same

measuring results from different
probe styli during any subsequent
measuring runs, the computer
must find out: ·
• the position of the master
stylus, ·
• how the individual styli are
arranged in reference to
the master stylus
(proceeding from the probe
to the master probe),
• the radius of the probe tips.

And that's exactly what happens

during probe calibration.

Following calibration, the

computer knows the distance
from the center point of the
master stylus tip to the center of
every other stylus tip and the
effective diameter of each stylus
tip.

Calypso Basic Course 1-13

Information: Calibration

1.3 Types of Probe Head

Measuring Probe Head

The measuring probe head automatically counterbalances
itself.

The default measuring force setting is

0.2 N.
Other measuring force settings ranging from 0.05 N to 1 N
(1.6 N) can also be selected as required.

Basic rule of thumb:

Use low measuring forces for long, thin probes and elastic
workpiece materials.
Use higher measuring forces for rapid scanning and self-
centering probing.

The permissible stylus weight and extension length should

always be taken from the pertaining CMM operating
instructions.
The standard values (without any guarantee of
correctness) are:

Universal probe head: 600 g and extensions of up to 300

mm

VAST probe head: 300g and extensions of up to 300 mm.

Trigger Probe Head

Probe stylus weight:

Standard: 300 g; 200 g for high-acceleration CMMs.
Once again, please refer to your CMM operating instructions for
the exact values.

The weight of the probe is counterbalanced by turning the

knurled ring after clamping the probe.

When using more than one probe, always perform

counterbalancing with the heaviest probe.

The measuring force is not preselectable for trigger probe

heads. A probing pulse can be triggered by a measuring force of
less than 0.01N.

1-14 Calypso Basic Course

Information: Calibration

RDS
Rotary Dynamic Sensor
Probe head featuring 180° rotation in two axes.
Possible positions: 144x144 equals 20,736.
Step size: 2.5°.

The sensor technology of the RDS is based on

that of the piezoelectric RST, i.e. features double
triggering.

Extensions of up to 300 mm and probe lengths

of up to 90 mm are permissible.

Calypso Basic Course 1-15

Information: Calibration

1.4 Reference Sphere for Probe Head Calibration

A reference sphere or, as it is also called, "calibration sphere" is required
to calibrate the effective diameter and length of the stylus.

A sphere which has as small a form defect as possible (less than 0.2 µm)
is used for this purpose.

The diameter of the sphere is determined in the software. For this reason,
the reference sphere matching the CMM being calibrated, identifiable by
its engraved serial number, must always be used. It is also very important
to make sure that the reference sphere and styli are always kept clean
and free of damage.

Position of Reference Sphere

Due to the mathematical correction of guideway deviations throughout
the entire measuring range, varying correction values are effective. For
this reason, the computer must know the position of the reference
sphere.

The position of the reference sphere must first be defined or calibrated

for this purpose. This is done by screwing it onto the workpiece table in a
more or less freely selectable location. Just make sure that the CMM
can probe the workpiece with all of its styli without reaching an end
position (limit stop) or colliding with a workpiece.
.

The position of the reference sphere must not be changed during

calibration. Exception: collision with the shaft of the reference sphere or
a probe stylus.

In this case the reference sphere must be rotated and then its position
must be redefined.

1-16 Calypso Basic Course

Information: Calibration

1.5 Probing Strategy

We usually select automatic
probe calibration.

The CMM can produce identical

probing runs with respect to
probing behavior and
repeatability only in CNC mode.

After starting the "Calibrate

probe" function, you must probe
in the shaft direction of the
probe stylus being used.

The CMM then travels in a

CNC mode and displays the
values generated in the
window. If the scatter is too
high, a separate message
appears.

The probing strategy for a

manual measurement should
include at least 6 measurements. The position of the probing points is shown in
the drawing on the right.

Calibration taking the bending of the stylus into account (tensor calibration) is
always an automatic process.

Probing direction during stylus calibration

As shown in the following

example, the geometry of the
workpiece to be measured must
be taken into account when
calibrating the stylus.

Example: when measuring this

V8 engine block, we will probe in
the direction of the cylinder bores.
Exactly this direction, i.e. the
direction of the normals towards
the inclined surface, must be
taken into account when
calibrating the probe.

Calypso Basic Course 1-17

Information: Calibration

1.6 Explanation of the Information shown in the Probe Data List

The probe stylus data is listed in the window following calibration.
The complete probe can be viewed in the probe management
window. The data is saved to the hard disk and can be printed out
as required.

This can be done by selecting "Print" from the pull-down menu.

Values in the probe data log:

X center coordinate of probe tip

Y center coordinate of probe tip
Z center coordinate of probe tip
R effective probe tip radius
S standard deviation
Mode designation of calibration method

Master probe (stylus):

The reference for the styli of all probes is
always the master stylus marked with a red
dot. In other words: We imagine a zero point
in the master stylus and all other probe styli
have X,Y and Z coordinates referenced to
this zero point.

This rule applies to all CMMs with CAA

correction.

Reduction of the standard deviation

If standard deviation S, which is output at the
end of each calibration, is too high, the
calibration must be repeated. This deviation
should be less than twice the resolution of
the CMM measuring system (when using a
stylus with an 8 mm probe tip and no
extension).

Expressed in figures:

Resolution of meas. sys.: Permissible

deviation
0.5 µm Less than 1 µm
0.2 µm Less than 0.4 µm

1-18 Calypso Basic Course

Information: Calibration

1.7 Recalibration
It is often necessary to use several
different probes with varying stylus
configurations to measure a
workpiece.

The calibration data of all probes is

automatically saved to the hard disk
and can be recalled to the computer
following manual or automatic probe
change.

Please note that: all of the probes

used to measure a workpiece are
referenced to the common zero point
of the master probe.

The master stylus is the reference for

all other probes.

If the reference sphere is not moved

while calibrating the probes, several
different probes can be calibrated in
succession.

If any stylus of a probe is replaced due to a defect or a new stylus is added to the
probe configuration, recalibration is necessary.

Recalibration procedure:

The position of the reference sphere must be defined with the master probe.
Only after this has been done can the actual calibration procedure be performed.

Following calibration, the program saves the data of the individual probe styli to
the hard disk. If a new probe is inserted during a CNC run, the computer can
recall the corresponding probe stylus data from the hard disk.

When the CMM is switched on, the software will automatically use stylus 1 of the
last probe used.

Calypso Basic Course 1-19

Information: Calibration

1.8 Checking the Calibration

Temperature fluctuations in the environment may have a lasting effect on the probe
calibration. In this case, it is advisable to perform calibration at short time intervals.

Example:
Material: aluminum
Temp. during calibration: 20° C Length: 200 mm
Temp. during measurement: 22° C Expansion: 9.2 µm

Inspection procedure:

Measure the reference sphere as a spherical element with

the master probe (stylus).

We thus obtain the center point coordinates of the sphere.

These center point coordinates are then set to zero.

Now measure the sphere again with all other styli. The
coordinates of each individual stylus may deviate from the
zero point (center point of the master stylus) only within the
measuring uncertainty range of the CMM. The diameter of
all stylus tips must be roughly the same.

1.9 General Procedure for Probe Calibration

• Assemble the probes taking the workpiece

geometry and the planned measuring sequence
into account.

• Probe configurations with extensions must be adapted to room temperature,

especially when made of aluminum.

• Insert master probe in probe head.

• Define (calibrate) position of reference sphere.

• Insert the probe to be calibrated.

• Select the calibration method.

• Start the probe calibration procedure.

• Calibrate the probe.

• Check the result (scatter S) and repeat calibration if necessary.

1-20 Calypso Basic Course

Information: Calibration

Notes:

Calypso Basic Course 1-21

Information: Basics of Metrology

2. Measuring the Workpiece

2.1 Generating Measuring Results

Calypso measuring software basically distinguishes

between part features, characteristics and the reference.

Characteristic:
This is the drawing inscription you want to check.
For example, the position of a bore: in this case you are
interested in two coordinate values.

Part feature:
The element you must probe to check the characteristic.
e.g. in our example a circle must be measured.

Why? Because this circle yields the two required

coordinates and the diameter in the result printed out in
the measurement listing.

Reference:
What is the characteristic referenced to? The two
coordinates obtained in our example are referred to the
zero point in your drawing.

Another example:

This time we want to check the roundness of a bore. We

once again need a circle as the part feature. We also
require many probing points along the circle's
circumference, since we want to check the shape (form)
of the bore as well.
What is the roundness now referenced to? Directly to
the element being checked. The roundness itself is not
dependent on the zero point in the drawing.

So we should always ask the following questions at the

start of each measurement:

• What must I check?

Define the characteristic.

• What are the measurements referenced to?

Define the reference point/value.

• What must I probe to accomplish this?

Define the part feature.

Calypso Basic Course 2-1

Information: Basics of Metrology

2.2 General Measuring Procedure

Provided that we have performed the probe calibration correctly, we are now
ready to try the first measurement.

But first another question:

Must Calypso know the position of the workpiece on the CMM?

Or, to put it differently: Does the workpiece have to be aligned?

A distinction is needed between:

1. Individual manual measurements:

This answer to this question depends on the reference of the characteristic:

• If the characteristic is referenced to the zero point in the drawing:
We must perform an alignment.
• If the characteristic is referenced to another feature or itself:
No alignment is required.

2. CNC runs:

The part must always be aligned for CNC runs.

We don't usually just check a single characteristic on a part, but rather a larger
number of characteristics. If these include features referenced to the WCS
(workpiece coordinate system), alignment is required.

Assuming that an alignment is indeed required, it must be performed prior to

the actual measurement.

However, to do this we must first know all part features, which is not yet the
case.

For this reason, the alignment procedure will first be explained in the following
chapter.

2-2 Calypso Basic Course

Information: Basics of Metrology

2.3 Automatic Feature Recognition

Must Calypso know the part feature before it begins probing?

The part feature does not necessarily have to be specified prior to measurement.
The automatic feature recognition function can calculate the geometry of part features from the
probing points if no element has been specified.

In what order are part features measured?

The order in which the elements are measured results from the characteristics we obtain from the
print.

We define the characteristics to

be checked one after another to
obtain a measurement plan.

The measurement plan

comprises a series of features
which we must check.

These may include e.g. X

values, diameters, etc.

Not all dimensions of a working or an engineering drawing can be measured directly by probing
them, e.g. an intersection line can not be measured in this manner. On the other hand, this is not
really necessary, since the computer can link different features and calculate new ones. This can
be done either with features which have just been measured or, as we will see later on,
constructed from features measured earlier.

Calypso Basic Course 2-3

Information: Basics of Metrology

2.4 Types of Control Console

Your CMM is equipped with one of the following

control consoles:

• Standard control console for trigger probe

head
• Standard control console for measuring
probe head
• Alphanumeric control console
• Dynalog control console

2-4 Calypso Basic Course

Information: Basics of Metrology

2.5 Geometric Elements

A geometric element is described by a

standard geometric form or shape. In contrast
to this, sculptured surfaces have a random
contour.

The illustration on the right gives you an

overview of various geometric elements.

2.5.1 Ideal and Actual Form / Substitute Element

A workpiece is designed by taking its ideal
geometric form as a starting point. i.e. ideally
one would assume that all bores conform to
their specified dimensions and that they are
perfectly round and correctly positioned.
However, an actual workpiece will have
deviations in size, form and position. All of
these deviations can be measured by means
of coordinate metrology.

The amount of these deviations is determined

by probing the corresponding elements (in this
case the bore).
The computer then calculates the substitute
form from the probing points. The substitute
form is comprised of geometrically ideal
substitute elements. Here for example the
substitute element is a circle.

The measuring values supplied by the

computer express the deviations between the
size and position of the substitute element and the size and position values specified in the
drawing. They also indicate how large the form deviation is in reference to the ideal geometric
substitute element.

Calypso Basic Course 2-5

Information: Basics of Metrology

2.5.2 Minimum Number of Probings

A minimum number of probings is

mathematically required to calculate
geometric elements. Knowledge of (and
compliance with) the minimum number of
probings is an important prerequisite for
measurement and automatic feature
recognition.

2.5.3 Reduction of Measuring Uncertainty through Favorable

Probing

As mentioned earlier, actual or real

workpieces never correspond to their
ideal form, i.e. deviations in form always
occur for production-related technical
reasons.

If only the minimum number of probings

is performed and the probing points are
unfavorably distributed, varying
measuring results may occur. For this
reason it is important to probe as
favorably as possible and distribute the
probing points as evenly as possible over
the entire part feature or element
measured.

2-6 Calypso Basic Course

Information: Basics of Metrology

2.5.4 Reduction of Measuring Uncertainty through More Probings

In order to ensure that the ideal

geometric substitute element will be
calculated by the computer, it is often
advisable to probe a higher number of
points than mathematically required. The
computer then evaluates the probings
and calculates the best-fit substitute
element via a compensating calculation.

The following rules generally apply:

The more probings you perform, the
more reliable and repeatable the result
will be.
(However, since you have certain time
limits for performing a measurement, a
compromise must be found). The
computer outputs the measured values
and the absolute deviations from the
substitute element in the listing or default
printout.

It is important to realize that: "More

probings" means more probing points
evenly distributed over the entire part
feature.

Calypso Basic Course 2-7

Information: Basics of Metrology

Notes

2-8 Calypso Basic Course

Information: Part Features

3. Part Features

3.1 Part Feature: Circle

This program can be used to measure bores or bosses
featuring a circular cross section.

The computer automatically differentiates between bores

and bosses, i.e. inner and outer diameters.

The minimum number of probings is 3.

Recommended: At least 4 probings for position definition

and use scanning or a high number of individual points
for form analysis.

Explanation of values in the report

X Center point coordinate

Y Center point coordinate
Z Center point coordinate
of feature zero point

D Diameter
4P Number of probings (here 4)

S/MIN/MAX
Standard deviation or scatter, minimum and
maximum value referenced to best-fit substitute
element (automatically calculated if more than the
minimum number of probings is performed).

Projection:
The circle originally lies at an oblique (slanted) angle in
the base system. A projection is required for further
evaluation:

Automatic: into a base system plane.

Selectable plane: a measured plane.

A reference is thus generated e.g. for the diameter of the

circle.

Calypso Basic Course 3-1

Information: Part Features

3.2 Part Feature: Cylinder

The part feature "cylinder" is used to determine the
diameter, axial direction and position of circular bosses
and bores. The computer automatically distinguishes
between inner and outer diameters, i.e. between bores
and bosses. The minimum number of probings is 5.

Probing strategy:
Recommended number of probings: 8.
Probing procedure: distribute the probing points as
evenly as possible, i.e. placing them on (the periphery
of) a "circular section".

You must either probe a large number of individual

points or use the scanning mode for form evaluation.

Probing on surface lines could also be performed here.

Definition of the element (feature) reference point FRP:

Most negative value of all probing points projected onto the axis.

Explanation of values in the report

X, Y, Z
Coordinates of FRP on cylinder axis

D Diameter of cylinder

X/Z A1 or Y/Z A2
Angle between reference axis Z and projection of
cylinder axis.

8P Number of probings (here: 8)

S/MIN/MAX
Standard deviation (scatter), minimum and
maximum value referenced to the best-fit
substitute element (automatically calculated if
more than the minimum number of probings is
performed – here more than 5).

3-2 Calypso Basic Course

Information: Part Features

3D Display of Projection Angles

The inclination of the cylinder axis is clearly described
by 2 angles listed in the printout. How are these
angles be interpreted?

If we could view the axis in a glass cube, the

projection angle would appear as shown in the figure
on the right.

Projection Angle A1

When looking towards the Y axis and at the X/Z plane,

you will see angle A1 between reference axis Z and
the projection of the cylinder axis in this plane.

Projection Angle A2

If you face the X axis and look directly at the Y/Z

plane, you will see angle A2 between reference axis Z
and the projection of the cylinder axis in this plane.

Calypso Basic Course 3-3

Information: Part Features

3.3 Part Feature: Plane

The part feature "plane" is used to determine the
position and inclination of planes. Although the
probing direction is freely selectable, it is not
adviseable to mix directions in one plane.

The minimum number of probings is 3.

Probing Strategy
Recommended number of probings: 4
Probing procedure: as perpendicular to the surface
as possible.

Recommended: at least 4 probings for position

definition, use scanning or a large number of
individual points for form analysis.

Explanation of the values in the report

X
Y
Z Coordinates of feature reference point

X/Z A1 Angle between reference

axis Z and
Y/Z A2 the "shadow" (=projection) of the normals in the X/Z or Y/Z plane.

5P Number of probings (here: 5)

S/MIN/MAX
Standard deviation (scatter), minimum and maximum value referenced to the best-fit
substitute element (automatically calculated if more than the minimum number of
probings is performed – here more than 3 probings).

Length 1, length 2:
Length and width of plane extending over the actual probings.

3-4 Calypso Basic Course

Information: Part Features

Reference or Space Axis, Normal and

Element Reference

The plane of the workpiece to be

determined is inclined. Its degree of
inclination can be expressed in different
terms. Here it is expressed based on the
inclination of the surface normals in
reference to the coordinate – i.e. reference
– axis.

FRP (feature reference point):

The FRP can also be called the origin of a
local coordinate system (or, for prismatic
workpieces, the local element coordinate
system).

Definition for planes:

Bottom left when viewed from:
the +X / -Y / +Z perspective
Bottom right when viewed from:
the -X / +Y / -Z perspective

Calypso Basic Course 3-5

Information: Part Features

3D Display of Projection Angles

The inclination of the plane is uniquely described
by specifying 2 angles in the measurement report.

How can the specified angles be interpreted?

If we viewed the normals of the inclined plane in a

glass cube, we would see the projection angles as
shown in the picture on the right.

Projection Angle A1
If we face the Y axis and look at the X/Z plane,
we see the inclination of the surface projected
into this plane.

Together with the Z reference axis, the

projection (=shadow) of the normals in the X/Z
plane forms projection angle A1.

Projection Angle A2
Here's how it looks in the Y/Z plane.
Together with the Z reference axis, the
projection (=shadow) of the normals in the Y/Z
plane forms projection angle A2.

The computer always selects the reference axis

so that angles of less than 45° result.

3-6 Calypso Basic Course

Information: Part Features

Projection Planes for Z Reference Axis

The projection planes and corresponding reference axes

are specified for the projection angles in the printout.

The coordinate axis with which the projected normal

forms the specified projection angle is the reference axis.

It is selected so that a projection angle of less than 45°

results. The reference axis shown here is the Z axis.

For this reason, the projection planes are the X/Z and Y/Z
planes.

For the preceding sign of A1/A2, see the illustration on

the right.

Calypso Basic Course 3-7

Information: Part Features

3.4 Part Feature: Line

A basic distinction is made between 2D
and 3D lines:

2D line:
− Measurable via probings
− Main application: inspection of angles
and constructions (links)
− "Exceptional plane", conceivable as a
plane having the length "0" in one
direction.

3D line:
− Can only be calculated
− Definable via recall e.g. from 2 spatial
(3D) points
− Main application: measurement of
angles and constructions (links).

2D line:
Minimum number of probings: 2.

Probing strategy for 2D line:

Recommended number of probings: 3.
Probing procedure: Distribute probing points as evenly as possible.
Note: All of these points should lie on "a single line" since the automatic feature recognition
might otherwise offer a plane.

Explanation of the values in the report

X
Y Coordinates of feature reference points for
Z lines
Y/X A1 Projection angles between reference axis X
Z/X A2 and projections of lines

3P Number of probings (here: 3)

S/MIN/MAX
Standard deviation (scatter), minimum and maximum value referenced to the best-fit
substitute element (automatically calculated if more than the minimum number of
probings is performed – here more than 2 probings).

Definition of FRP:
Projection of the first probing point onto the line.

3-8 Calypso Basic Course

Information: Part Features

3D Display of Projection Angles

When viewed three-dimensionally, the projection

angles appear as shown on the right.

The definition of the projection angles is the

same as for a cylinder or a plane.

3D line:

In the stricter sense the 3D line represents a link (construction), or more specifically, a recall
from two known spatial points.

The way in which you generate these points is up to you. The center points or intersecting
points of circles are often used for the calculation (see "Calculations").

Two probing points also make sense if they are defined as space points.

Calypso Basic Course 3-9

Information: Part Features

3.5 Part Feature: Cone

The part feature "cone" is used to determine the
following parameters of a cone or cone stump:
The position and direction of the cone axis, the cone
diameter on the FRP (perpendicular to the axis
direction) and the aperture angle of the cone.

The computer automatically distinguishes between

inner and outer diameters, i.e. conical bores or plugs.

Minimum number of probings: 6.

Probing strategy:
For single-point probing, 12 points are required for
reliable measurement.

Probing procedure: Distribute the probing points

among the sections as well as possible, i.e. 4 points
per "circular section".

Cone surface lines can also be probed for form evaluation.

Definition of the FRP:

The center of the circle with the smallest diameter.
The direction of the axis is always from the small to the large diameter.

Explantion of the values in the report

X, Y, Z
Coordinates of FRP on cone axis

D Diameter of cone at FRP

X/Z A1 or
Y/Z A2
Angle formed by projection of cone axis
and Z reference axis

Cone Angle Aperture angle of cone

12P Number of probings (here: 12)

S/MIN/MAX
Standard deviation (scatter), minimum and
maximum value referred to best-fit substitute
element.

Diameter at other intersection heights:

Via an additional step, you can calculate either
the diameter at a defined height or the height at a defined diameter.

3-10 Calypso Basic Course

Information: Part Features

3D Display of Projection Angles

A 3D view of the projection angles yields the picture

shown on the right.

Projection Angle A1

When facing the Y axis and viewing the X/Z plane, angle
A1 can be seen between the Z reference axis and the
projection of the cone axis in this plane.

Projection Angle A2

When facing the X axis and viewing the Y/Z plane, angle
A2 can be seen between the Z reference axis and the
projection of the cone axis in this plane.

Calypso Basic Course 3-11

Information: Part Features

3.6 Part Feature: Sphere

The part feature "sphere" is used to measure the
center coordinates and the diameter of spheres or
spherical zones.

Min. number of probings: 4.

Probing strategy:
Recommended no. of probings: 6.

Probing procedure: two points near the pole, four

more points equally distributed around the equator.

Explanation of values in the report

X, Y, Z
Coordinates of sphere center point
D Sphere diameter
6P Number of probings (here: 6)

S/MIN/MAX
Standard deviation (scatter), minimum and
maximum value referenced to best-fit substitute
element (automatically calculated if more than
the minimum number of probings is performed –
here more than 4 probings).

3-12 Calypso Basic Course

Information: Part Features

3.7 Part Feature: Ellipse

The part feature "ellipse" can be used to measure
bores or bosses having a circular cross section
whose axes are not located parallel to the
coordinate axes of the workpiece. It can of course
also be used to measure "real" ellipses.

The computer automatically differentiates between

bores and bosses, i.e. inner and outer diameters.
Min. number of probings: 5.

Probing Strategy
Recommended number of probings: 8.

Probing procedure: All points must be probed in a

rd
single plane i.e. the CMM must not travel in the 3
axis during measurement.

Meaning of Values in Printout

X Center point coordinate

Y Center point coordinate
Z Center point coordinate
of feature zero point

D1 Small diameter
D2 Large diameter
8P No. of probings (here: 8)

S/MIN/MAX
Standard deviation (scatter), minimum and
maximum value referenced to best-fit
substitute element (automatically calculated if
more than the minimum number of probings
is performed).

Projection:
The ellipse was originally "slanted" in the base
system. A projection is required for further
evaluation:

Automatic: into a base system plane

Selectable plane: a measured plane.

A reference is thus created e.g. for the X value of

the ellipse.

Calypso Basic Course 3-13

Information: Part Features

3.8 Part Feature: Point

Point Probing on a Surface Parallel to Coordinate Planes

The part feature "point" is used to determine individual
points on the workpiece, e.g. to measure dimensions.
(of course no compensating calculation is performed
for the "point" part feature.)

The coordinate in the probing direction is important

during probing.

The contact point and the relevant coordinate coincide

only if the surface being probed is parallel to the X/Y,
X/Z or Y/Z plane of the workpiece coordinate system.

Probing Strategy
Number of probings: 1
Note: Probing at angles of less than 45° from the
coordinate axes will result in a maximum measuring
uncertainty due to probe bend.

Point Probing on an Inclined Surface

When probing on a surface which is inclined in

reference to the coordinate planes, the actual
coordinate is not identical with the contact point.

A deviation between the measured value and the

actual point of contact then occurs (cosine error).
This deviation increases proportionate to the
magnitude of the angular deviation.

The individual point can thus be used for

measurements only under certain conditions.

Space Point
The actual value can only be measured via the space
point.

The space point takes the normal direction of the

surface into account.

3-14 Calypso Basic Course

Information: Part Features

Explanation of the values in the report

Following the probing, the computer prints out the

result of the measurement in the measurement
log.

Example:
Probing direction parallel to X axis

X X coordinate of contact point

Supplementary coordinates
Y and Z coordinate of
sphere center point

This also roughly applies to the other probing

directions.

3-15 Calypso Basic Course

Information: Part Features

Summary of Geometric Elements

3-16 Calypso Basic Course

Wissen: Verknüpfungen

Notes.

Calypso Grundkurs 3-17

Information: Constructions

4. Working with Part Features: Constructions

Let's take a look at the toolbox to survey the various

possibilities for making constructions (links).

The constructions are listed as the second item in this

menu.

It is often impossible to perform measurements directly.

For example, the intersecting point of the two bore axes
in the following illustration can not be measured directly.
Such "invisible" or imaginary elements can however be
calculated by linking and reconstructing part features.

Most Important Constructions

⇒ Recall
⇒ Perpendicular
⇒ Intersection
⇒ Symmetry
⇒ Projection

⇒ (Distance)

Calypso Basic Course 4-1

Information: Constructions

4.1 Recall
Recall of Multiple Part Features to Generate a New Element

It is possible to link several different elements

located in a common coordinate system to form a
new element.

Example: Circles 1, 2 and 3 have been measured.

Then the bolt circle on which they all lie can be
determined via recall.

Drag a circle out of the toolbox or from the Feature

menu and open it.

Start the recall function by clicking on the nominal

input button. Select ’’Recall“ from the list of options.
All appropriate part features are then offered and a
corresponding selection must be made.

The recall function will be dealt with in connection

with constructions in the following section.

4-2 Calypso Basic Course

Information: Constructions

4.2 Perpendicular
Linking 2 Elements via a Perpendicular

The perpendicular line having the shortest distance

between two geometric elements in space can be
determined with "Perpendicular".

This routine always links the two elements specified

in the feature.

One of the two elements must be spatially defined,

e.g. must be a line, plane, cylinder axis or cone axis.
And since the perpendicular is located at 90° angles
to this element, the direction of the perpendicular is
thus obtained.

However, the perpendicular can not be uniquely

defined by means of its direction alone. A point on
the perpendicular is also required for this purpose.
This point is provided by the other element which is
not used to determine the direction, e.g. an element
such as a point, circle, plane, line, cylinder axis or
cone axis.

Easy to remember with:

FROM a spatially defined point PERPENDICULAR TO the second element.

The perpendicular is output as a straight line. The part feature "line" comprises two coordinates of the
FRP and two projected angles. The length of the perpendicular is also specified for the perpendicular.

Calypso Basic Course 4-3

Information: Constructions

4.3 Intersection
Construction (Linking) of 2 Elements via Intersection

It is not always possible to probe all of the required

geometric elements, e.g. lines resulting from the
intersection of two planes. We can link planes via the
Intersection function and obtain the intersection line as
the result.

Important: For cylinders and cones, the Intersection

function links only their axes (this also applies to the
functions "Symmetry", "Perpendicular", etc.); the
surface lines are of no importance.

For this reason, we simply refer to intersections of

cylinder axes, cone axes
and lines as intersections of axes.

4-4 Calypso Basic Course

Information: Constructions

Circle/Axis or Circle/Circle Intersection

The intersecting point which results if two

elements are projected onto a common plane is
calculated via this function.

If 2 intersecting points result, one of them can be

selected at the computer. Exception: Distance D
between the center point of the circle and the axis
is equal to the radius of the circle. If no
intersecting point results, this will be noted in the
measurement report.

A circle/circle intersection may result in 2

intersecting points. In this case you must select
the intersection which should be applied in the
window.

Axis/Plane or Plane/Plane Intersection

With an axis/plane intersection, the three

coordinates of the axis piercing point are calculated
via the plane.

With an intersection of two planes, an intersection

line results as a spatially defined element.

Calypso Basic Course 4-5

Information: Constructions

4.4 Symmetry
Linking of 2 Elements via Symmetry

Like Intersection elements, symmetry elements,

e.g. the symmetry or mid point of two bore center
points, can not be probed. We can, however, link
these two bores via the Symmetry function and
thus obtain the symmetry point as a result.

The calculated Symmetry element can be freely

linked with other elements as required.

4-6 Calypso Basic Course

Information: Constructions

4.5 Distance
Distance of 2 Elements via Cartesian Distance

Until now, all measuring results for geometric elements

were referred to the origin or zero point of the
workpiece coordinate system. As a result, the distance
between the elements could not be measured directly.

Via the Cartesian Distance function you can measure

the distance between two geometric elements and
output this value in rectangular (Cartesian) coordinates.

The Cartesian Distance function always links the two

part features specified in the characteristic.

Two references must be specified:

• The first reference defines the plane in which the measurement will be taken, i.e. the spatial
alignment.
• The second reference defines the direction in which the distance should be calculated, i.e. the plane
alignment.

The evaluation of the Cartesian distance therefore also includes the alignment!

A positive (±) sign is always output for the calculated "coordinates".

One exception here is the calculation of the distance between two planes.

The distance between two almost parallel planes can be inspected if both of them are entered in the
Cartesian distance.

Important: Do NOT enter any references!

Calypso Basic Course 4-7

Information: Constructions

Distance between Two Elements via Polar Distance

The function Distance, Polar 2d can be used to

calculate polar distances.

Distance, Polar 2d determines the direct distance

between two elements projected onto a plane. As with
the Cartesian distance, a "spatial alignment" is
required.

Spatial distances can be calculated via the function

Distance, Polar 3d.

Two spatially defined points are required for this

purpose.

4-8 Calypso Basic Course

Information: Constructions

4.6 Projection
Projecting one Element onto Another One

Figuratively speaking, one might say that a projection

casts the shadow of one element onto another one.

A line projected onto a plane will result in a line in that

plane.

As with the perpendicular, a defined point can be

projected onto a plane. This is the "foot of the
perpendicular", i.e. the point impinged on (i.e. struck) by
an imaginary perpendicular.

This is important for angular observations, e.g. of a bore

pattern.

Calypso Basic Course 4-9

Information: Constructions

Notes:

4-10 Calypso Basic Course

Information: Alignment

5. Alignment

5.1 Why Alignment?

Let's assume that the workpiece is lying on the
machine table "aligned" only by the eye.

Until it has been aligned, e.g. directly after system

switch-on, all coordinate values will be referenced to
the machine coordinate system.

The measuring results can not be directly compared

with the dimensions in the working or engineering
drawing if they are referenced to the machine
coordinate system (MCS).

On the other hand, it is quite possible to check

characteristics which are not dependent on the WCS,
e.g. roundness, flatness etc.

5.2 Mathematical Alignment

When a part is clamped to the CMM table, the workpiece planes always assume a more or less oblique
position in the CMM coordinate system.

This situation can be corrected either by physically aligning the workpiece to the CMM coordinate
system or by generating a coordinate system which is referenced to the workpiece. This second
possibility is exactly what happens during mathematical alignment: using workpiece features, a separate
coordinate system is generated – the workpiece coordinate system.

What is really important here: mathematical alignment is both faster and much more precise than
mechanical alignment.

Calypso Basic Course 5-1

Information: Alignment

5.3 Selecting Suitable Elements for Alignment

The working drawing clearly shows which
elements of the workpiece determine the
coordinate axes. The fact is, however, that you
often have to take a very close look at the
drawing, since these elements can often be
determined only based on the function of the
workpiece. Workpieces of this sort include e.g.
cylinder axes for a gear train, reference circles for
a flange or, as shown here, planes situated
perpendicular to one another.

For our example, we have selected two

perpendicular workpiece planes, planes 1 and 2.

5.4 Alignment Procedure

What do we need to generate a workpiece coordinate system?
Answer: 3 axes and a spatially defined zero point.
These requirements result in the following alignment procedure:
st
Probe first feature 1 workpiece axis = space axis
and zero point
nd
Probe second feature 2 workpiece axis
and zero point

Probe all other features Remaining zero points

If you start from the coordinate planes, the first axis yields the first coordinate plane. According to
the DIN (= Deutsche Industrienorm) standard, this plane is referred to as the principal or primary
reference. The second axis yields the second coordinate plane, i.e. the secondary reference. The
zero point in the third axis is the tertiary reference.

The software automatically recognizes the purposes for which the probed part features can be used.
Our example depicts the first part feature for the spatial direction and the first zero point. If the first
element were a cylinder, the cylinder axis would be defined as the spatial direction and the zero
point would be fixed in two coordinates.

5-2 Calypso Basic Course

Information: Alignment

5.5 Primary and Secondary Reference Elements

Of course other reference elements can also be
used as the planes displayed for Spatial rotation
and Planar rotation. However, in this case,
please note:
• that Spatial rotation requires reference
elements with which two projection angles
are defined while Planar rotation requires
only one projection angle and
• that Spatial rotation must always be
performed prior to Planar rotation.

Possible Part Features for Primary

Reference

− Plane
(also calculated e.g. from 3 spheres)

− Cylinder

− Sphere

− 3D line e.g. from.:

Sphere/Sphere
Circle/Circle
....

Possible Part Features for Secondary Reference

− Plane

− 2D line

− Cylinder

− Cone

− 3D line from e.g.:

Sphere/Sphere
Circle/Circle
Space Point/Space Point
....

Calypso Basic Course 5-3

Information: Alignment

5.6 General Sequence

If we probe part features which should be located in a single coordinate plane with Spatial
roation and Planar rotation, the zero point will be set automatically. For more information, please
refer to the following exercises. This results in a general alignment sequence.

• If necessary, select a new coordinate system from the toolbox.

• Select (at least 2) part features which make sense from a measurement standpoint

• Probe 1 part feature (e.g. plane 1)

• The primary reference and first (or second) zero point is then calibrated

• Probe part feature 2 (e.g. plane 2, which is perpendicular to plane 1)

• The secondary reference and further zero point(s) are measured

• Probe any further part features (e.g. plane 3) for remaining zero points

5-4 Calypso Basic Course

Information: Alignment

5.7 Multiple Coordinate Systems

In most cases, the dimensions in working or
engineering drawings are referenced to different
features. e.g. most of the dimensions of our
workpiece are referenced to planes 1, 2 and 3;
however, some features are also referenced to the
large bore.

In order to obtain useful measuring results from

these elements, it is advisable to change the
position of the workpiece coordinate system.

You can individually select the coordinate system in

which each part feature is created and/or saved.

Important:

The coordinate system is saved in (along with) the

part feature!

Calypso Basic Course 5-5

Information: Alignment

Notes

5-6 Calypso Basic Course

Information: Interpreting Results

6. Interpreting Results

6.1 Feature Coordinate System

Each part feature has its own coordinate system with the following characteristics:
• Clockwise rotation
• A zero point, the FRP or feature reference point
• The axis designations U, V, W

The overview below shows the respective position of the zero point:

Circle:
In the center at the actual measured height.

Not projected into a plane of the coordinate system.

Ellipse:
In the center.

Not projected into a plane of the coordinate system.

Calypso Basic Course 6-1

Information: Interpreting Results

Plane:
At bottom left when viewed from:
+X / -Y / +Z

At bottom right when viewed from:

-X / +Y / -Z

Cylinder:
Most negative value of all probings projected onto the
cylinder axis

Standard direction of axis: positive direction of largest

components.

This can, however, be changed.

Calypso Basic Course 6-2

Information: Interpreting Results

Cone:
In the center of the circle with the smallest
diameter.

Direction of axis: always from smaller to larger

circle.

Calypso Basic Course 6-3

Information: Interpreting Results

6.2 Default Printout

• The default printout is available for every measurement plan.

• It appears following the first action which yields a result.
• All actions, e.g. measurements and calculations, can be followed
• It is usually displayed hidden behind the user desk or minimized (iconized) in the
footer.
• It can be brought to the foreground of the display (unhidden) by clicking on it.
• It can be printed by clicking on the printer icon.
•
• Example no. 1:

Circle 1(diameter of circle 1) Name of part feature, here a circle

The circle is used for the "diameter" characteristic
Gaussian circle Circle calculated according to the Gaussian best-fit
#P (4) Number of probing points
Inner element Automatic recognition of inner/outer elements
X -39.836 -39.800 X value of circle FRP in base system
Act. and nom. value, possibly offered as rounded act. value
Y 32.339 32.300 Y value of circle FRP in base system
Z -1.344 -1.300 Z value of circle FRP in base system
D 30.052 30.100 Diameter, actual and nominal values
S 0.0040 Sigma, standard deviation. Indicates accuracy of
form and quality of probings.
High S may indicate a probing error
Min (2) -0.003 The minimum probing point here is probing 2
Max (3) 0.002 The maximum probing point here is probing 3
Form 0.005 Form calculated as difference between min. and max.

Diameter Circle 1 Diameter Insp. Feature Diameter for Part Feature "Circle 1"
Circle 1 0.100
30.048 30.100 -0.100 -0.052 --
Act. value Nom. value Upper and Deviation from Upward utilization of
lower tol. tol. center tol. to max. 50%

6-4 Calypso Basic Course

Information: Interpreting Results

• Example 2:

Plane 1(angle 1 plane 1) Name of part feature, here a plane

The plane is used for the "angle" characteristic
Gaussian plane Plane calculated according to Gaussian best-fit
#P (4) Number of probing points
Outer element Automatic recognition of inner/outer elements or features
Z -16.930 -16.900 Z value of plane FRP in base system
Act. and nom. value, possibly offered as rounded act. value
X -87.120 -87.100 X value of plane FRP in base system
Y 4.639 4.600 Y value of plane FRP in base system
A1 X/Z -40.113 -40.100 Angle between plane normals and Z axis of base system,
here projected in the X/Z plane
A2 Y/Z 0.333 0.300 Angle between plane normals and Z axis of base system,
here projected in the Y/Z plane
S 0.002 Sigma, standard deviation. Indicates accuracy of form
and quality of probings.
High S may indicate a probing error
Min (1) -0.002 The min. probing point here is probing no. 1
Max (2) 0.002 The max. probing point here is probing no. 2
Form 0.004 Form calculated as difference between min. and max.

Calypso Basic Course 6-5

Information: Interpreting Results

6.3 Custom Printout

• The custom printout is used for "publishing" your measurements

• It is not automatically displayed, but can be started in the CNC Start window
• Its appearance can be defined in the "Resources" pull-down menu
• As a rule, only the characteristics are displayed here
• A printout can be activated in the CNC Start (Run) window
• A specific printout header can be explicitly assigned to the workpiece

Display without printout header:

6-6 Calypso Basic Course

Worksheet 1: Probes Vast / ST Probe Head

Worksheet 1: Probes

1.1: Preparing the Probe

Job:
Prepare (assemble) a star-shaped probe configuration with 5 styli
for the following measurements.

The calibration procedure must always be performed in the following order:

1. Define position of reference sphere: Ref. Sphere Position

The master probe should only be used for “defining” the reference sphere. In
more recent Calypso revisions, it is no longer possible to calibrate this probe,
so that the function of the master probe is limited to defining the reference
sphere.

Imagine a probe coordinate system whose origin lies in the center of the sphere
of the master probe. From this origin, all other probes have coordinate values,
or offsets, in X, Y, Z.

This position definition sets the coordinate system to zero, so to speak. This is
prerequisite for every calibration, i.e. this step must be carried out before every
calibration.

This step is called:

2. Calibrate the measuring probe stylus: Stylus qualification

In the second step, the measuring probe styli will be qualified establishing their
individual offsets from the master probe and their “effective” measuring
diameter.

The “calibration” must be made for every stylus.

This step is called:

Calypso Basic Course 1-1

Worksheet 1: Probes Vast / ST Probe Head

Job Action Procedure

Begin new Enter name of Enter a sensible name. For the probe calibration,
measurement measurement plan Calypso requires that a measurement plan be open.
plan

Call up probe Click on Prerequisites

functions The screen for the probe functions is displayed. See
Click on Probes next page.

Is the master probe in the probe head?

Yes: Carry out the “Ref. Sphere Position”.

No: First carry out a manual probe change.

1-2 Calypso Basic Course

Worksheet 1: Probes Vast / ST Probe Head

Job Action Procedure

Proceed as shown in the

diagrams

Call up the manual

probe change function.

To release or insert the

probe, you have to click
on the symbol, e.g. on
the arrow.

Please note:

With a trigger probe

head, you have to
deflect the probe after 5
secs. The magnetic
holder is opened only
after the mechanical
contact has been
disengaged.

With a measuring
probe head, the probe
is released after 5 secs.
i.e. it falls out. You must
catch the probe.

Calypso Basic Course 1-3

Worksheet 1: Probes Vast / ST Probe Head

Job Action Procedure

Insert master Proceed as shown in the

probe diagrams

You can insert the probe

in the empty probe head.
Usually the force of the
permanent magnet is
sufficient to hold the
probe.

The probe is only pulled

into its holder when you
click on the “Insert”
symbol and after you have
answered Yes to the
question “Insert probe?”

You will hear a “click”.

Here select the Master

Probe as you have to
define the position of the
reference sphere with this
probe.

Then select Stylus

Number 1.

This is the end of the manual probe change.

1-4 Calypso Basic Course

Worksheet 1: Probes Vast / ST Probe Head

Job Action Procedure

Define the
position of the The actual definition starts here:
reference You are first asked for the angle of the
sphere Reference Sphere shaft.

This input must be made so that the probe can

navigate around the sphere!

With standard positions, you can click on one of

the icons and the values are displayed in the
windows.

If another position is necessary, then you must

enter the values.

Probe in direction of stylus shaft.

The actual measurement is performed

automatically and the result is displayed in the
window.
Watch out for a standard deviation near 0.001
mm.
Note: For more information, refer to the
“Information” section of Chap. 1.

Probe head:
ST: “6 points” calibration mode
MT: “6 points” calibration mode

The position definition is performed in the 6

points mode.

The stylus calibration which follows, can use

various modes.

This is the end of the position definition.

Calypso Basic Course 1-5

Worksheet 1: Probes Vast / ST Probe Head

Job Action Procedure

Releasing the Release the master probe and

master probe insert the measuring probe After the position of the reference sphere has
and inserting the been established, the master probe must be
measuring removed and the probe to be calibrated
probe inserted.

Click on the up arrow and then

select “OK”.

Click on “New”.

Enter a name for the probe and

the stylus.

Now click on “OK”.

Click on “Qualify stylus”.

1-6 Calypso Basic Course

Worksheet 1: Probes Vast / ST Probe Head

Job Action Procedure

Calibrate stylus
Select the mode Probe head:
ST: “6 points” calibration mode
MT: “Tensor” calibration mode
RDS: “6 points” calibration mode

“6 points” for trigger probe heads

“Tensor” for measuring probe heads to take the
Click on bending parameters into account.
<Qualify Stylus >

The calibration procedure is performed

Probe in the direction of the
automatically and the result is displayed in the
stylus shaft
window.
Watch out for a standard deviation near 0.001
mm.

The first stylus of the first probe has now been calibrated.

Calibrate Click on the “Create New Stylus no. 2 will be automatically displayed.
remaining styli Stylus” button. Rename this stylus to “rear”.

Click on
<Qualify Stylus >
Now calibrate all remaining styli in the same
manner as the first one.

Calypso Basic Course 1-7

Worksheet 1: Probes VAST / ST Probe Head

1.2 Worksheet: Automatic Probe Change for ST 3 and for

Vast Probe Head
Configuring and handling the automatic probe changer

Probes can be changed conveniently and easily with the automatic probe changer.
This is performed automatically during a CNC run.

The probe used to measure a given part feature is always stored directly in the feature.
When a specific part feature is due to be measured, the matching probe is
automatically requested. If the required probe is already inserted in the probe head, the
measuring run will be continued.
If any other probe is inserted in the probe head, the program then checks whether the
required probe is located in one of the probe holders.
If this is the case, Calypso will automatically change probes.
If not, the operator will be prompted to perform a manual probe change.

It thus follows that the best way to avoid frequent changing of probes during a
measuring run is:
− to sort part features according to the probe required to measure them and
− to select the option: Order "By Part Feature List" when starting the CNC run.

The following description deals with setup and operation of the probe changer in
connection with the trigger probe head.

Practical exercise :
1. Configuration in the “Workroom” window
2. Operating the probe changer

1. Making Entries in the “Workroom” Window

The automatic probe changer can be registered and activated in the “Workroom”.

− Activation: Checkbox in front of “Probe Changer Exists” checked

− Select “Construction” to match the given CMM type

You are now finished with the Workroom definition.

In order for the probe changer to function properly, its holders must be defined
prior to operation.

This is performed within a measurement plan.

1-8 Calypso Basic Course

Worksheet 1: Probes VAST / ST Probe Head

2. Probe Change Menu

Open a measurement plan:
Resources
Automatic Probe Change

The probe changer rack is displayed here. Each holder can be clicked on. The one
currently selected appears green.
Important: The current status of the individual holders (empty/occupied) will be
displayed correctly only after all holder positions have been defined and the first
probe change has been performed.

3 functional groups:

Adding and deleting storage locations

− Important: Up to 15 holders are possible here. Please keep to the designations
A, B, C, D etc.

Changer options for position definition and probe assignment:

− Approach In direction: changes approach direction e.g. to +X (rack located to
the right)
− Define position of holders: define holder locations with master probe
− Store/Insert Probe: executes travel movements
− Assign Probe to Selected Holder: assigns a probe to a specific storage
position, does not execute a movement
− Approach parameters: Defines the way in which the probe will approach the
individual bays. Entering a value of “999” for “Position over holder” will cause
the probe to travel to the end of the Z axis stroke before moving to the holder.

Define length of master probe

Calypso Basic Course 1-9

Worksheet 1: Probes VAST / ST Probe Head

3. Defining the Position of Storage Locations

3.1 Determine the length of the master probe. This is done only once, since
the length normally remains the same.

3.2 Entering holders

Edit
Add Holder

Enter name:
A
B
etc.

The holders are assigned uppercase letters.

A maximum of 15 holders is possible.

1 - 10 Calypso Basic Course

Worksheet 1: Probes VAST / ST Probe Head

3.3 Position Definition:

Click on first holder
Changer
Set active holder...A
Define holder position

ST: position stylus in center of

circle:

VAST: position stylus above

cone:

The CMM executes

movements.

Repeat this procedure for all positions.

3.4 Assigning Probes to Holders:

Click on first holder, selected holder turns green

Changer
Assign
probe to
selected
holder
Select “master
probe”

Repeat
procedure for all
other probes

If a long Y probe
is used or the
rack is located to
one side, the
Approach In
direction and
positions must be
determined.

Click on holder
Changer
Approach Parameters

Set Approach Direction

Enter positions before and after

holder.

Calypso Basic Course 1 - 11

Worksheet 1: Probes VAST / ST Probe Head

3.5 Storing the Probe:

To ensure that the probes are in the correct orientation for loading into their
assigned locations, it is good policy to initially use the manual probe change
option. This ensures that the probe plate is mounted in the probe head correctly
and that Calypso knows which probe is currently loaded.

After the probe has been loaded manually return to the automatic probe change
option:

Click on the applicable holder

Changer
Store Probe

Repeat the procedure for the remaining probes.

Calypso will update the display to show each probes status i.e. if it is currently
loaded in the head or docked in its changer bay.

4. Practical Application
If there are enough holders for routine daily work, a fixed allocation can be
generated and saved.

If the number of probes required is greater than the number of holders available,
the rack must be "re-equipped" or refilled with different probes prior to each
individual run. In this case, suitable information and documentation must be
supplied.

Calypso's "User information" function enables you to prepare such information by

showing a video sequence.

For more information on this function, please refer to your operating instructions.

1 - 12 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

Worksheet: Probe

2.1: Preparing the Probe

Job:
Prepare (assemble) a probe with position in 5 directions for the
following measurements.

The calibration procedure must always be performed in the following order:

1. Define position of reference sphere: Ref. Sphere Position

2. Calibrate the measuring probe stylus: Qualify Stylus

Calypso Basic Course 1 - 13

Worksheet 1: Probes RDS/RST Probe Head

Job Action Procedure

Position of Click on The Resources menu box opens.

reference sphere "Resources"
button

The probe calibration functions are now

accessible. (Graphics: see previous page)
Probes -> Define position of ref. sphere
-> Administration
-> Stylus qualification (calibration)

Call up probe
functions

If the master Manual The master probe must be inserted for position
probe is not Probe Change definition.
inserted in the Change probes manually if necessary.
probe head:

Manual Probe
Change Important:
To release the probe, the button on the side of
the plate must be pressed, and the stylus
deflected at the same time.

Release probe

Note:
Define position of ref. sphere
YES or NO?

⇒ Has the control been switched off since the

last calibration? -> YES.
⇒ Has the ref. sphere been unscrewed and
screwed back in since the last calibration? ->
YES.
⇒ Are there any temperature fluctuations ?
⇒ Are you sure about these points? -> YES.
⇒ The control hasn't been off and the ref.
sphere hasn't been unscrewed; the temp. is
stable: ->NO.

1 - 14 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

Job Action Procedure

Manual probe
change:

Insert master
probe

The actual measuring probe is now inserted.

The master probe should not be used for
normal measuring purposes. If it becomes
damaged, you may no longer be able to
accurately define the position of the reference
sphere.

The probe should be in position 0/0, each axis

in 0°, The stylus points in –Z.

The list displays the probes currently available

in Calypso.
If you select the master probe,“1” is then
displayed as existing stylus.

If there are several styli, then they are all

offered. The stylus selected is then the one
which is activated.

Calypso Basic Course 1 - 15

Worksheet 1: Probes RDS/RST Probe Head

Job Action Procedure

Define position of
reference sphere The actual position definition starts here:
You are first asked for the angle of the
reference sphere shaft (post).

This input is required so that the probe can

navigate around the sphere.

With standard positions, you can click on one of

the icons and the values are displayed in the
windows.

With other positions, you have to enter the

values.

Probe in direction of stylus shaft.

The position definition is performed automatically

and the result is displayed in the window.
Watch out for a standard deviation near 0.001
mm.
Note: For more information, refer to the
“Information” section of Chap. 1.

RDS probe head:

“6 points” calibration mode

The Position Definition is performed in the 6
point mode.

The calibration which now follows also uses the

6 points mode.

1 - 16 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

Job Action Procedure

Following the position definition, the master

probe must be removed and the probe to be
calibrated inserted.
Insert Manual Probe Change
measuring (arrow pointing
probe down)

Insert measuring probe.

Allocate name Manual Probe Change

for probe and (arrow pointing up)
stylus The probe is first given the name “new”.

Stylus 1.

Stylus name “unknown” (temporarily)

Using the right mouse button, click on

Probe “new” probe, select “new”

Probe name “Star1”

Change stylus name:

Stylus name e.g. 0/0 for both angle

positions 0°.

Calypso Basic Course 1 - 17

Worksheet 1: Probes RDS/RST Probe Head

Job Action Procedure

Calibrate stylus Select the Mode RDS probe head:

“6 points” calibration mode

“6 points” for trigger probe heads,

”tensor” for measuring probe heads to take the
bending parameters into account
Click on

The calibration procedure is performed

automatically and the result is displayed in the
window.
Probe in the direction of the Watch out for a standard deviation near 0.001
stylus shaft mm.

The first stylus of the first probe has now been calibrated.

Calibrate Click on
remaining styli
Enter the values you see in the diagram for the
axes. The probe swivels to the new position.

New Stylus Direction Stylus no. 2 is displayed automatically. Allocate

the stylus the name "-90/90".

Now calibrate all remaining styli in the same

manner as the first one.
Click on

1 - 18 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

2.2 Worksheet: Automatic Probe Change for RDS

Configuring and Handling The Automatic Probe Changer

Probes can be changed conveniently and easily with the automatic probe changer.
This is performed automatically during a CNC run.

The probe used to measure a given part feature is always stored directly in the
feature. When a specific part feature is due to be measured, the matching probe is
automatically requested. If the required probe is already inserted in the probe head,
the measuring run will be continued.

If any other probe is inserted in the probe head, the program then checks whether
the required probe is located in one of the probe rack storage positions (holders).
If this is the case, Calypso will automatically change probes.
If not, the operator will be prompted to perform a manual probe change.

It thus follows that the best way to avoid frequent changing of probes during a
measuring run is:
− to sort part features according to the probe required to measure them and
− to select the option: Order "By Part Feature List" when starting the CNC run.

The following description deals with setup and operation of the probe changer in
connection with the bi-axial indexing joint with the RDS probe head.

Practical exercise :
1. Configuration in the "Workroom" window
2. Operating the probe changer

Calypso Basic Course 1 - 19

Worksheet 1: Probes RDS/RST Probe Head

1. Making Entries in the "Workroom" Window

The automatic probe changer can be registered and activated in the
"Workroom”.

Extras
Workroom
CMM
Probe Changer

− Activation: Checkbox in front of "Probe Changer Exists" checked

− Select RDS under Construction

1 - 20 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

2. Defining the RDS Geometry

Resources
Automatic Probe Change

Calypso requires the distance of

the slot on the probe plate to the
A axis of the RDS.

A 180° reversal measurement is

performed for this.

Perform the steps

in the order shown
in the diagram (see
Op.Instr.)

Calypso Basic Course 1 - 21

Worksheet 1: Probes RDS/RST Probe Head

The following calibration of the styli is performed after clicking on <OK>

1. Move RDS aligned along the reference plane, accept position 1

2. Rotate RDS about 180°
3. Move RDS aligned along the
reference plane, accept position
2
4. The slot distance is approx. 38
mm

5. Calibrate styli

The probe menu is opened

automatically and you have to
calibrate the styli in the positions requested.

The objective of this procedure is to

check the correct angle position of the
RDS.

If the deviations which occur are too

large, an error message is later
displayed (see Section 3: Position
definition of holders).

3. Automatic Probe Change Functions

Resources
Automatic Probe Change

The probe changer rack is displayed here. Each holder can be clicked on. The
one currently selected appears green.
Important: The current status of the individual holders (empty/occupied) will be
displayed correctly only after all holder positions have been defined and the
first probe change has been performed.

The functional groups:

Adding and deleting holders

Changing operations for position definition and probe assignment:

− Approach In direction: changes approach direction e.g. to +X (rack located
to the right)
− Define position of holders: Define holder locations with master probe
− Store/Insert Probe: executes travel movements
− Assign Probe to Selected Holder: assigns a probe to a specific storage
position, does not execute a movement
− Approach Parameters: alternative method to clicking on a holder.
Sometimes required separately.

1 - 22 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

4. Entering Holders
Edit
Add Holder

Enter name:
A
B
....

Note:
The corresponding probe can already be named here for each holder.
However this is not necessary and in our case will be done later.

5. Position Definition:
Click on holder A

Changer
Define Holder Location

The three holder surfaces are probed.

Repeat this procedure for every holder.

Calypso Basic Course 1 - 23

Worksheet 1: Probes RDS/RST Probe Head

6. Assigning Probes to Holders:

Click on first holder (selected holder turns green)

Changer
Assign Probe to Selected Holder
Select "master probe"

Repeat procedure for all other probes

If the rack is located to one side, the Approach In direction and positions must
be determined.

Click on holder
Changer
Approach Parameters
Enter positions before and after holder.

1 - 24 Calypso Basic Course

Worksheet 1: Probes RDS/RST Probe Head

7. Storing the Probe:

Click on holder A

Changer
Store Probe

Insert new probe manually

Repeat "Store Probe" procedure

8. Practical Application
If there are enough holders for routine daily work, a fixed allocation can be
generated and saved.

If the number of probes required is greater than the number of holders

available, the rack must be "re-equipped" or refilled with different probes prior
to each individual run. In this case, suitable information and documentation
must be supplied.

Calypso's "User information" function enables you to prepare such information

by creating a video sequence.

For more information on this function, please refer to your operating

instructions.

Calypso Basic Course 1 - 25

Worksheet 1: Probes - General

Worksheet 2.3 : Managing stylus data

Print stylus data
The function is initiated in probe administration under the print function.

The following screens appear:

The format of the data can be selected from the selection list, which then appears in
the printout. The selected data is stored and is available as default settings for the
next occasion.

Click on Ok to print out the data.

1 - 26 Calypso Basic Course

Worksheet 2.1: Alignment with 3 Planes

Worksheet 2.1: Base Alignment

Alignment with three planes

Part features: plane 1, plane 2, plane 3

Practical exercise :
The workpiece alignment is placed in the upper front left-hand corner.

It is aligned via three planes with automatic feature recognition.

The order of alignment is plane 1 - 2 - 3

Note:
The entire alignment procedure can be followed in the CAD window. Here you can
also observe the tilting and rotation of the base alignment during individual steps by
deliberately inclining the workpiece to the machine alignment.

Calypso Basic Course 2-1

Worksheet 2.1: Alignment with 3 Planes

Job Action Procedure

Begin new Select [File]

measurement [New] The CMM alignment is activated, i.e. no other
plan alignments from other measurement plans are
activated.
Enter name

Select [Base Alignment]

Begin alignment Selection page (not shown):

Click on <Create new base
alignment>

The following screen page is

then displayed ⇒

2-2 Calypso Basic Course

Worksheet 2.1: Alignment with 3 Planes

Job Action Procedure

Define position of Select Stylus 1 No preselection of the part feature is required

workpiece with automatic feature recognition.
primary plane Probe four points on plane 1
with stylus 1.
The spatial rotation of the workpiece is
generated here.
Define first axis Confirm with <OK>.
of workpiece The space angle between the machine axis, in
alignment this case Z, and the normals of plane 1 are
determined.

The workpiece alignment is tilted by this angle so

that the new Z axis, or spatial axis, is parallel to
the normals of plane 1.
Define first
origin in The software recognizes which references this
(performed automatically)
workpiece part feature is useful for.
alignment
Both the spatial rotation and the origin in Z are
defined here (the latter automatically).

The Z axis of the workpiece alignment, and

Define therefore the X/Y coordinate plane (parallel to
secondary plane 1) are defined. The alignment must still be
datum of Select stylus 2 rotated (around the space axis) and displaced
workpiece (in X and Y)

No pre-selection of the part feature is required

with automatic feature recognition.
Define second Probe four points on plane 2
and third axis of with stylus 2.
workpiece
alignment Confirm with <OK>. The planar rotation of the workpiece is defined
with the normals of plane 2.

The workpiece alignment is rotated around the

Define second space axis Z so that the new Y direction
origin of (performed automatically) coincides with the direction of the plane normals
workpiece for the plane just measured.
alignment

Calypso automatically enters this “Y plane” as

planar rotation, and also as new origin in Y.
Define third Select stylus 3
origin of
workpiece Probe four points of plane 3 The plane supplies the new origin in X for the
alignment with stylus 3. base alignment.

Confirm with <OK>.

Calypso Basic Course 2-3

Worksheet 2.1: Alignment with 3 Planes

Job Action
− The workpiece alignment is thus completely defined: the Z axis is perpendicular to and the X/Y plane is
parallel to plane 1.
− The Z origin lies on plane 1.
− The Y axis is perpendicular to and the X/Z plane is parallel to plane 2.
− The Y origin lies on plane 2.
− The X axis is perpendicular only to the Z or Y axis.
− The origin lies on plane 3.

Confirm with <OK>

Since the origin of the base alignment is located

in this plane, its Z value must be zero.

The same applies in Y or X for the other part

features.

Check
Switch to <Features>.
alignment
Open plane 1

Open the other elements

2-4 Calypso Basic Course

Worksheet 2.1: Alignment Safety Cube

Worksheet : Safety Cube

Practical Exercise :
A safety cube must be created as a prerequisite for a CNC run.

The most convenient way to do this is to travel to the corner positions of the cube
and enter them by pressing the button on top of the right-hand joystick.

Another alternative is to manually enter a numeric value or to perform combined

inputs and probings.

Important:

In the following exercises you should always perform alignment by means of the
Clearance Planes (safety cube) work step. If necessary, use this model when
doing so.

Calypso Basic Course 2-5

Worksheet 2.1: Alignment Safety Cube

.
Job Action Procedure

Select Safety Select Resources

Cube Clearance Planes

Run current probe stylus to a The stylus must travel to the position
location which is approx. 10 -15 corresponding to the most positive X, Y and Z
mm to the right of, above and value.
behind the workpiece

Press the button on the right-

The values are then applied and can
hand joystick 3 times
subsequently be read off referenced to the base
alignment and checked for plausibility.

Run current probe stylus to a

location which is about 10 – 15 The stylus must travel to the position
mm to the left of, in front of and corresponding to the most negative X, Y and Z
below the workpiece value.

Press the button on the right- The values are then applied and can
hand joystick 3 times subsequently be read off referenced to the base
alignment and checked for plausibility.

2-6 Calypso Basic Course

Worksheet 2.2: Aligning a Connecting Rod

Worksheet 2.2: Base alignment

Aligning a Connecting Rod

Part features: cylinder, circle, plane

Practical exercise :
Place the workpiece alignment in the center of the 55 mm Ø bore. The plane serves
as the origin in the Z axis.

Note:
Primary datum: Ø 55 bore, -> cylinder
Secondary datum: Axis through 55 mm Ø bore -> 3D line
and 22 mm Ø bore,
X origin: 55 mm Ø bore, -> cylinder
Y origin: 55 mm Ø bore, -> cylinder
Z origin: Plane -> plane

Measure the 55 mm Ø bore as a cylinder and the 22 mm Ø bore initially as a circle.

These measuring results will be required later on as cylinders for evaluating the
parallelism of the bores.

Calypso Basic Course 2-7

Worksheet 2.2: Aligning a Connecting Rod

Job Action Procedure

Open new File The machine alignment is activated, i.e. all

measurement New alignments of other measurement plans are
plan Enter name: inactive.
...................
Enter a name for the measurement plan.

Begin alignment Select Base Alignment.

< Create or Change >

Select stylus 1
Measure
cylinder It is not necessary to preselect the part feature
Measure 8 points in large bore
with automatic feature recognition.
with stylus 1

The primary workpiece reference is created

Place the here.
primary datum
and origin in the The space angle is determined by the machine
cylinder axis axis, in this case Z, and the cylinder axis.
The workpiece alignment is tilted around this
angle so that the new Z axis, the space axis, is
parallel to the cylinder axis.

The software recognizes which references this

part feature is useful for.
Both the primary datum and the X and Y origins
have been automatically determined here.

The Z axis of the workpiece alignment and hence the Y/X coordinate plane (parallel to plane 1) have
thus been defined. The alignment still must be rotated (around the space axis) and displaced (in the Z
axis).

Define position of Measure 4 points on surface This plane is required for the new position of the
third origin with stylus 1 origin in Z. This yields plane 1.

Create Measure 4 points in the small

The temporary coordinate axis 'Z' is rotated
secondary bore with stylus 1
around the origin in the 55 mm ∅ bore until it
datum passes through the center of the 22 mm ∅ bore.
This results in circle 1.

2-8 Calypso Basic Course

Worksheet 2.3: Aligning a Transmission Case

Worksheet 2.3: Base Alignment

Aligning a Gearbox (Transmission) Case

Part features: cone, cylinder

Calculated part features: perpendicular, projection

Practical exercise:

In this example, we imagine a gearbox case with two axes located at 90° angles to
each another.

The first axis (= spatial rotation) should be the cone axis on our practice workpiece
and the second axis (= planar rotation) is provided by the 30 mm ∅ bore.

The origin lies on the cone axis on the upper top surface.

Note:

Automatic alignment recognition should not be used in this example. Instead, the
part features are first measured and then manually assigned.

Continued on next page.

Calypso Basic Course 2-9

Worksheet 2.3: Aligning a Transmission Case

Job Action Procedure

Begin new File The CMM alignment is activated, i.e. all

measurement New alignments from other measurement plans are
plan Enter name inactive.
....................
Enter name for measurement plan.

Switch to part features.

Select part
Toolbox
features The required part features must first be
Measurement
transferred from the toolbox to the list of part
Cone
features.
Plane
Cylinder
These include a cone, a plane and a cylinder.
Open cone

Perform Measure cone with stylus 1. The selected part features are now measured
probings for part Probe points according to one after the other.
features probing strategy. The automatic feature recognition is bypassed
Confirm with <OK. when probing a feature that is already defined.

Open cylinder

Measure cylinder with stylus 2.

Confirm with <OK>.

Open plane

Measure plane with stylus 1. The three features now appear in the list
Confirm with <OK>. highlighted in green to show that corresponding
measured values exist.

2 - 10 Calypso Basic Course

Worksheet 2.3: Aligning a Transmission Case

Job Action Procedure

Assign Select Base Alignment

measured part <Create new base alignment>
features to the
alignment The primary datum of the workpiece is created
Click on Spatial rotation here.

Determine first Select Cone 1 from the list The space angle between the machine axis, in
axis of this case the Z axis, and the cone axis is
workpiece determined.
alignment The workpiece alignment is tilted around this
angle so that the new Z axis, which is identical to
the space axis, is parallel to the cone axis.

Determine the
Click on Planar rotation
second and 2D angle between the temporary coordinate
third axis of the axis, in this case Y, and the projection of the
Select Cylinder 1 from the list
workpiece cylinder axis into the X/Y coordinate plane. The
alignment workpiece alignment is rotated until the Y axis is
parallel to the projection of the cylinder axis.
Place origin in
cone axis

All axis directions of the workpiece alignment have thus been determined, since the X axis must be
perpendicular to the Y axis. The workpiece alignment lies in the cone axis and is partly parallel to the
cylinder axis. It only has to be shifted to the corresponding surface in Z.

Click on X-Origin The three origins in X, Y and Z have now been

assigned.
Select Cone 1 from the list You can watch the origin in the CAD window as
it moves from the origin of the machine
alignment to the base alignment.
Click on Y-Origin

Create position Select Cone 1 from the list

of third origin

Click on Z-Origin

Select Plane 1 from the list

The workpiece alignment has been completely defined:

− Space axis Z is on the cone axis, which is perpendicular to the X/Y plane.
− The X and Y origin lie in the cone axis.
− The Y axis is parallel to the cylinder axis, the X/Z plane is parallel in this direction.
− The X axis is now perpendicular to the Z and Y axis.
− The Z origin is located on surface 1.

Calypso Basic Course 2 - 11

Worksheet 2.3: Aligning a Gearbox Case

Job Action
The alignment procedure is now finished.
The following calculation of the perpendicular and the projection can be performed.

Evaluate the Toolbox

shortest Construction
distance Perpendicular
between the two
axes

Opening the perpendicular:

Marking the tolerance for length

Result analysis

End of practical exercise.

2 - 12 Calypso Basic Course

Worksheet 2.4: Aligning Flange with Rotation and Offset

Worksheet 2.4: Base Alignment

2.4.1: Aligning a Gearbox Flange or Support
with Rotation and Offset

Part features: circles, surface

Practical exercise:
This exercise is to show how an alignment is rotated around a predetermined angle
and an offset is performed in Cartesian coordinates.

Note:
Primary datum: front surface of cube -> plane
Secondary datum: axis through Ø 15 bore -> theoretical line
and Ø 12 bore and Add Rotation
X origin: Ø 15 bore -> circle and offset
Y origin: plane -> plane
Z origin: Ø 15 bore -> circle and offset
Offset/rotate: values as per drawing
st
1 step:
Base alignment acc. to primary datum
and X, Y, Z origin.
Without secondary datum.
nd
2 step:
Secondary datum = enter 12 mm Ø
circle
rd
3 step:
Add rotation by an angle around the Y
axis.
th
4 step:
Offset of alignment in X and Z.

Calypso Basic Course 2 - 13

Worksheet 2.4: Aligning Flange with Rotation and Offset

Job Action Procedure

Open new File The machine alignment is activated, i.e. all

measurement New alignments of other measurement plans are
plan Enter name inactive.

Call up
Begin alignment Base Alignment.
It is not necessary to preselect the part feature, if
you use automatic feature recognition.

Define primary Measure four points on surface

2 with stylus 2. The primary workpiece datum is created here.
datum of
workpiece The space angle between the CMM axis, in this
case Y, and the normals of plane 2 are
determined.
The workpiece alignment is tilted around this
angle so that the new Y axis, which is identical
with the space axis, is parallel to the normals of
plane 2.

Both the primary datum and the origin in Y have

automatically been determined here.
Place origin in Measure four points of bore 15
bore 15 with stylus 2. The center of this bore becomes the X and Z
origin.
Create Measure four points of bore 12
with stylus 2. The preliminary Y coordinate axis is rotated
secondary
around the origin in the 15 mm ∅ bore until it
datum
passes through the center of the 12 mm ∅ bore.

2 - 14 Calypso Basic Course

Worksheet 2.4: Aligning Flange with Rotation and Offset

Job Action Procedure

Rotate the Click on Special The alignment is rotated back by an angle

alignment back calculated according to drawing dimensions.
Click on This angle can be determined via the tangent
Rotate by an angle function.
Rotate Around Y-axis The alignment is now still located in the 15 mm
Enter 29.25° bore and must be moved to the center of both
bores.

Click on Offset
Shift the The offset results from the values in the drawing.
alignment
Input X=25
and Z=14

The alignment procedure is now finished.

One of the bores can now be viewed to check the alignment. For example, if we open the 15 mm bore the displayed
coordinate values of this part feature must be located near the default values X = -25 and Z = -14. The Y value defines
the measured depth.
End of practical exercise.

Calypso Basic Course 2 - 15

Worksheet 2.4: Aligning with Rotation by a Specified Distance

Worksheet 2.4: Base Alignment

2.4.2: Aligning a Gearbox Flange or Support
with Rotation by a Specified Distance

Part features: circles, surface

Practical exercise:
This exercise is similar to the previous one. In this case the X axis should be
positioned so that it lies exactly 2 mm "above" the 20 mm ∅ bore.

Note:
Primary datum: surface 2 -> plane 1
Secondary datum: Ø 20 bore -> circle 1 and Rotate Distance

X origin: Ø 15 bore -> circle 2

Y origin: plane -> plane
Z origin: Ø 15 bore -> circle 2

2 - 16 Calypso Basic Course

Worksheet 2.4: Aligning with Rotation by a Specified Distance

Job Action Procedure

Open new File The machine alignment is activated, i.e. all

measurement New alignments from other measurement plans are
plan Enter name inactive.

Measure the following features:

Measure
features Probe four points on
surface 2 with stylus 2.

Probe four points in 15 mm

bore with stylus 2.

Probe four points in 20 mm

bore with stylus 2.

Begin base Resources

alignment Base Alignment

Enter the features as shown on

the right

Click on this button (at top of

window):

Calypso Basic Course 2 - 17

Worksheet 2.4: Aligning with Rotation by a Specified Distance

Job Action Procedure

Rotate by Enter the value -2 mm

distance

Confirm with <OK>

The base alignment is now rotated until circle 2 has

exactly the Z value of -2 mm. You can check this by
opening the circle.

Open circle 2

Check alignment

The Z value of this bore is -2

mm

2 - 18 Calypso Basic Course

Worksheet 2.5: Redefining the Base Alignment

Worksheet 2.5: Redefining the Base Alignment

Aligning a Displaced Workpiece

Practical exercise:
If a workpiece is moved on the machine table or the part must be re-measured after
a long period of time, the base alignment must be redefined.

This must be done manually.

Calypso Basic Course 2 - 19

Worksheet 2.5: Redefining the Base Alignment

Action Procedure
Job
Open the base alignment From "Resources" select "Base alignment".
Redefine Select “Change active base alignment”
the base
alignme
nt
Select the
"Execute Manual Run Now" function

Manual probing of

Plane 1

With "star probe..."

With Stylus Number. 1

With 4 points (in this case another two

probings must be performed)

The display automatically moves on to the

next feature; do NOT click on <OK>.

The base alignment menu appears on

completion

It is always necessary to change the current

alignment if the position of the workpiece has
been altered to a point where the alignment
can no longer be performed in a CNC run.

2 - 20 Calypso Basic Course

Worksheet 2.6: Aligning a shaft

Worksheet 2.6: Base Alignment

Aligning a Shaft

Practical exercise:
Perform an effective alignment which also permits you to check the hole circle
afterwards.

Use:
Primary datum: cylinder A
Secondary datum: symmetry plane from the side surfaces (distance: 53mm)
Origins: cylinder center, on hole circle plane

Important:
Save this measurement plan as this will be used as the basis for later labs.

Calypso Basic Course 2 - 21

Worksheet 2.6: Aligning a Shaft

Job Action Procedure

Primary datum Measure datum A as cylinder The 32 mm ∅ cylinder is marked as datum A in the
drawing.
The cylinder should be used as the spatial.
The first axis of the alignment is now the cylinder axis.

The second and third axis of the alignment are

Secondary Measure right plane
determined.
datum Measure left plane
This is initially done by calculating a symmetry plane
which is then used as the planar datum in the base
Constructions
alignment.
Symmetry

Allocate right and left planes

The origins should be located on the cylinder axis.

Origin 1 and 2 Allocate cylinder

The exact position of the origins on the axis depends

on the probing point selected.
Origin 3 Probe point in direction of This decision should be made by the operator, since
cylinder axis he knows exactly how the part functions.
The position is of no significance to the evaluations.

2 - 22 Calypso Basic Course

Worksheet 2.7: Generating a second alignment

Worksheet 2.7: Generating a Second Alignment

Job: Placing a new origin in the cone center

Practical exercise:

A second alignment is to be placed in the cone center, i.e. on the cone axis.

Function:
Resources
Utilities \ Alignment

Calypso Basic Course 2 - 23

Worksheet 2.7: Generating a second alignment

Job Action Procedure

Measure cone Measure cone as usual Several sections each with at least 3 probings.

Toolbox
Resources
Utilities
Base alignment Alignment
characteristic
Open the alignment and fill in
the boxes as shown on the right

Origin in X and Y is cone

Allocate origins

Rename
Cone center

CAD drawing

2 - 24 Calypso Basic Course

Worksheet 3.1: Measuring Strategy, Editing the Clearance Data

Worksheet 3.1: Measuring Strategy

Editing the Clearance Data

Job: measuring the groove on the top surface of the cube

Practical exercise:

Measure groove with three planes, optimize probe travel paths.

Calypso Basic Course 3-1

Worksheet 3.1: Measuring Strategy, Editing the Clearance Data

Job Action Procedure

Define base Proceed in the usual manner to Create a base alignment or use the currently
alignment locate the base alignment at valid one and place the safety cube around the
the front left-hand corner. workpiece in the usual manner.

Define safety cube (Clearance

Planes)

Measure left Select stylus 1

groove side
Probe 4 points on
Probe four points on left side of groove surface
left side of groove
with stylus no. 1.
The part features should be renamed
Comment
immediately after they are created.
Rename:
"Groove_left" Overwrite the displayed feature name.
Confirm with <OK> Make sure you assign a meaningful name.

Measure right Probe 4 points on right side of

side of groove groove Probe 4 points on right side of groove surface
with stylus no. 1.
Comment
Rename:
"Groove_right"
Confirm with <OK>

Measure bottom Probe 4 points on bottom side Probe four points on bottom surface of groove
side of groove of groove with stylus no. 1.
Comment
Rename:
"Groove_bottom"
Confirm with <OK>

Select 3 planes
CNC run of 3
planes The three part features must appear gray.
CNC In the Feature list, click on the top element. Then
Run press the <SHIFT> key and hold it down while
CNC run clicking on the bottom element.

Features list
Current selection Fill out the page as instructed and the run will
begin.
Clear existing results: <YES> First the base alignment is realigned and the
Confirm with <OK> probe travels up to a location just in front of the
first part feature.
Reduce speed! At this point we expect a collision.

3-2 Calypso Basic Course

Worksheet 3.1: Measuring Strategy, Editing the Clearance Data

Job Action Procedure

Reduction of Open "groove_left"

clearance
distance Strategy
Clearance Data

Remove checkmark from

<Clearance Distance>

Enter "2"

Close plane and edit

"groove_right" in the same way

The run can now be restarted and successfully

completed with the corrected values.
Start CNC run CNC run button
(see above) Following each part feature, the CMM travels to
the clearance plane in +Z.

This should now be changed so that the CMM no

longer travels to CP+Z between part features.

Calypso Basic Course 3-3

Worksheet 3.2: Measuring Strategy, Generating Circular Sections

Worksheet 3.2: Measuring Strategy

Creating Circular Sections

Job: measuring the cylinder on the front surface of the cube

Practical exercise:

The 30 mm ∅ cylinder is measured by probing 8 points on its front side. Then

circular sections are generated and all other points are probed automatically.

3-4 Calypso Basic Course

Worksheet 3.2: Measuring Strategy, Generating Circular Sections

Job Action Procedure

Determine base Proceed in the usual manner, Create a base alignment or use the currently
alignment placing the base alignment in valid one and place the safety cube around the
the front left corner. workpiece in the usual manner.

Define Clearance Planes

(safety cube)

Select stylus 2 Probe 8 points on cylinder with stylus no. 2. The

first four points must be probed on the first
Measure cylinder Probe 8 points on cylinder (do section and the last four on the second section.
not close) The automatic feature recognition usually
displays the correct element, e.g. here the
Comment cylinder. If this is not the case, e.g. with short
Rename: cylinders, you must select the cylinder in the
”Cylinder 30_front” "Geometry" field.
Confirm with <OK>

Add circle Open Cylinder30_front Closing and reopening ensures correct

sections recognition and storage of elements

Click on <Strategy>

Edit circle
sections Click on the icon with the two
red circles to create two circle
sections (Circle Auto Path)

The aim is to measure the two circle sections

only.
The individual probings should be deleted.

However, the two circle sections must be

correctly defined first.

Calypso Basic Course 3-5

Worksheet 3.2: Measuring Strategy, Generating Circular Sections

Job Action Procedure

Definition of Select 1st Circle Auto Path

circular Change number of points to
sections 20
Change measuring height to
2 mm

nd
Select 2 Circle Auto Path
Change Number of Points to
20
Change Measuring Height to
10 mm

This display then appears in the

CAD window

Delete single
points
The cylinder was measured with 2x4 points and
then extended by 2 circle segments via the
Strategy.
First the 8 points are measured in the CNC run,
then the two circular sections are measured.
If it is no longer necessary to measure the first 8
points, they can be deleted by selecting them
and then clicking on them with the right mouse
button. The menu which then appears contains
the <Cut> command.
Once all the single points have been deleted, the
Start CNC run cylinder is measured with the selected number of
points (circle auto paths).

Now the run can be started in the usual manner

and completed correctly using the corrected
values.

3-6 Calypso Basic Course

Worksheet 3.3: Measuring Strategy, Automatic Generation of Travel Paths

Worksheet 3.3: Measuring Strategy

Automatic Generation of Travel Paths

Job: measuring a cylinder on the front surface of the cube

Practical exercise:

In contrast to the previous exercise, the cylinder is probed with single points;
Calypso then uses these to automatically calculate circular sections.

There should be no single points in the travel path list, but only Circle Auto Paths.

The 30 mm ∅ cylinder on the front side is measured with 8 points from which the
Circle Auto Paths are created.

You can also measure the 15 mm ∅ cylinder.

Calypso Basic Course 3-7

Worksheet 3.3: Measuring Strategy, Automatic Generation of Travel Paths

Job Action Procedure

Define base Proceed in the usual manner to Create a base alignment or use the one which is
alignment place the base alignment in the currently valid and place the safety cube around the
front left corner. workpiece in the usual manner.

Define Clearance Planes

(safety cube)
Probe points on cylinder with stylus no. 2. If the
Measure Select stylus no. 2
number of points is <9, the first 3 points should all
cylinder
be on a single segment.
Measure 15 dia. Cylinder with
8 points at the front

Comment
Rename:
"Cylinder15_front"

Click on Strategy

Click on icon
Changes to:

Close Strategy
Close Cylinder
You can now see the single points in the list.

Convert points in Open cylinder again There are now no single points in the travel path
Strategy list. Instead, Calypso has converted the single
Click on points to 2 circle auto paths which you can change
Strategy as required.

Edit Circle Auto Edit values as required

Paths

Start CNC run in usual manner

CNC run

3-8 Calypso Basic Course

Worksheet 3.4: Measuring Strategy, Generating by Specifying Nominal Value

Worksheet 3.4: Measuring Strategy

Generating Part Features by Specifying the Nominal Value

Job: measuring a cylinder on the top surface of the cube

Practical exercise:

The 30 mm cylinder on top of the cube is created by specifying a nominal value. Then
the circular sections are created by automatically probing the probing points.

In this case the center coordinates, height and diameter of the cylinder to the base
alignment must be known.

You can watch the cylinder while it is being generated in the CAD window.

Calypso Basic Course 3-9

Worksheet 3.4: Measuring Strategy, Generating by Specifying Nominal Value

Job Action Procedure

Determine base Proceed in the usual manner to Create a new base alignment or use the one
alignment locate the base alignment in the which is currently valid and place the safety cube
front left-hand corner. around the workpiece in the usual manner.

Create a safety cube

(Clearance Planes)

Retrieve cylinder from toolbox

and open

Comment
Rename:
"Cylinder30 _top"

Enter nominal geometry ⇒

Do not yet close the feature

with <OK>

Display in CAD window:

3 - 10 Calypso Basic Course

Worksheet 3.4: Measuring Strategy, Generating by Specifying Nominal Value

Job Action Procedure

Click on Strategy

Click on icon with two red

circles

Add Circle Auto

Paths

Open Circle Auto Paths

Enter values for

st
Edit Circle Auto 1 Auto Circle Path:
Paths Measuring height 1 mm
nd
2 Auto Circle Path:
Measuring height 6 mm

View of Circle Auto Paths in

CAD window ⇒

CNC run Start CNC run in usual manner

Calypso Basic Course 3 - 11

Worksheet 3.4: Measuring Strategy, Generating by Specifying Nominal Value

Notes

3 - 12 Calypso Basic Course

Worksheet 3.5: Measuring Strategy, Default Measuring Strategy

Worksheet 3.5: Measuring Strategy

3.5.1 Default measurement strategy for Cylinder

Job: Defining a default measurement strategy for all cylinders

Practical exercise:

By changing the settings, you should specify that each cylinder is to be measured
with 2 circle auto paths for the cylinder part feature.

Note:
When programming a workpiece, we recommend, from experience, that you work
with Default Measuring Strategies.
The advantage this brings is easier editing and universal use.

This default should not be used if you want to work with probings which are to be
positioned exactly.

Calypso Basic Course 3 - 13

Worksheet 3.5: Measuring Strategy, Set Default Measurement Strategy

Job Action Procedure

Determine base Generate base alignment and Create a new base alignment or use the one
alignment safety cube which is currently valid and place the safety cube
around the workpiece in the usual manner.

Resources
Set Default
Measurement Strategy

Select parameters for cylinder

Click on Circle Auto Path 1

Set Number to 2

Close with OK and then open

again

Use the Strategy in the usual

manner for a cylinder

With this setting, 2 circle auto paths are

generated for every cylinder.

3 - 14 Calypso Basic Course

Worksheet 3.5: Measuring Strategy, Default Measurement Strategy

Starting angle
and angle Difference between start angle and angle range
range

Both angle specifications must be set in the Feature

definition screen and the Strategy screen.

The geometry of the cylinder can only be set in the

Feature definition screen.

The CMM movement is controlled by the start angle

in the Feature definition screen. The strategy
defines the path that the CMM will take to measure
the feature relative to the feature definition.

Example
If the element begins at a starting angle of 310 deg.,
the circle path can start at 2 deg or 3 deg so as not
to start directly at the edge.

It is imperative to take into account the reference

axis in the respective planes!

XY ⇒ X
YZ ⇒ Y
ZX ⇒ Z

Later, when programming on the CAD model, the

elements will be extracted with their true angles.

This is also the reason for the existence of the input

fields. The true geometry is always given in the
Feature definition accordingly; the strategy is based
on this data and defines the associated strategy.

Calypso Basic Course 3 - 15

Worksheet 3.5: Measuring Strategy, Set Default Measurement Strategy

Worksheet 3.5: Measuring Strategy

3.5.2 Default Measurement Strategy for Circle

Job: defining a circle section using 3 probings

Practical exercise:

The Default Measurement Strategy is also set to Circle Auto Path for the circle.

A Circle Auto Path is to be defined with 3 probings.

Calypso will calculate a scanning path from the first probing point to the last probing
point with exactly 3 probings.

This function works with 3 probing points. With 4 probings, a complete circle is
calculated.

3 - 16 Calypso Basic Course

Worksheet 3.5: Measuring Strategy, Default Measurement Strategy

Job Action Procedure

Define Default Define the Default

Strategy Measurement Strategy for the
circle in the usual manner,
here 1 Circle Auto Path

Measure circle Perform 3 probings in the

circular groove, see previous
page

Calypso calculates a circle

Create Strategy Close the circle and open

again,
check the strategy:

As expected, a Circle Auto

Path is found as the
measurement strategy.

Interpret result Open the Circle Auto Path and

make a diagnosis of the
resulting values.

Here notice in particular the

Start Angle and the Angle
Range.

Calypso Basic Course 3 - 17

Worksheet 3.6: Measuring Strategy, Creating Multiple Clearance Planes

Worksheet 3.6: Measuring strategy

Creating multiple Clearance Planes

Job: measuring the surface on the bottom of the cube

Practical exercise:

The bottom surface of the block should be measured by four points probed with
different styli. The probing direction is –Z.

The probing route around the workpiece may prove difficult here. The CMM must
"search for a path" around the workpiece after the first two probing points.

You should watch out for the additional confirmation query on creating multiple
clearance planes which appears in the part feature after selecting <OK>.

3 - 18 Calypso Basic Course

Worksheet 3.6: Measuring Strategy, Creating Multiple Clearance Planes

Job Action Procedure

Determine base Proceed in the usual manner, Create a new base alignment or use the one
alignment placing the base alignment in which is currently valid.
the front left-hand corner.

Remove plane from toolbox

The automatic feature recognition is also
and open it
possible here.
Prepare plane
<Comment>
Rename:
“Plane_bottom“

Select stylus no. 3

Create multiple Probe 2 points at bottom left

clearance
planes?
Select stylus no. 5

Probe 2 points at bottom right

Confirm with <OK>

Answer query on Create

multiple clearance planes
with YES

Reopen plane
Open strategy ⇒

A separate clearance data line has now been

generated for each probing point. Subsequent
editing of this data is possible if required.

If subsequent changes have been made, the

query on “Create multiple clearance planes”
must be answered with CANCEL. Otherwise the
manual changes will be overwritten.

Calypso Basic Course 3 - 19

Worksheet 3.7: Measuring Strategy, Define Sub Clearance Plane

Worksheet 3.7: Measuring Strategy

Defining a Sub Clearance Plane

Job: measure groove on top side of cube with improved travel

paths

Practical exercise:

While measuring the three planes in the groove the probe should not
travel to the +Z clearance plane, but rather, remain in the groove
instead.

An additional sub clearance plane must be defined here.

3 - 20 Calypso Basic Course

Worksheet 3.7: Measuring Strategy, Define Sub Clearance Plane

Job Action Procedure

Define a new Clearance Plane

Plan
Navigation
Sub clearance plane

Click on <New>
e.g. enter “CP_groove”
Define a new
clearance plane Check Parent Group, here
CP+Z

Close with OK

Assign this Clearance Plane

“CP_groove” to the 3 surfaces
of the groove

Open groove_left

Select the new clearance plane

Assign the by selecting it from the
Clearance Plane <Clearance Plane> list.

Now the machine will no longer travel back to the

Select this clearance plane for safety cube but will only use the clearance
groove_bottom and between the planes.
groove_right
If you need to, create new subplanes.

The CMM will stop traveling to the +Z parent

plane only when the clearance plane has been
changed for all elements in this groove

A retract plane with a fixed distance should only

be entered in exceptional circumstances. The
distance refers to the base alignment and is not
updated when the BA is changed. This may lead
to collisions.

Calypso Basic Course 3 - 21

Worksheet 3.8: Measuring Strategy, Probing a Space Point

Worksheet 3.8: Measuring Strategy

Job: Probing a Space Point

Practical exercise:

The inclined surface is probed with a single probing point and the contact point is
redefined to a space point.

3 - 22 Calypso Basic Course

Worksheet 3.8: Measuring Strategy, Probing a Space Point

Job Action Procedure

Probe point Select stylus no. 1 A single probing is performed with stylus no. 1.
Since the inclination of the surface cannot be
recognized by the software, the probe tip radius
Perform probing on 40° inclined is corrected in the workpiece coordinate system.
surface.

Click on Evaluation

Define space Select Space Point

point

Confirm with <OK>.

Determine
Click on
orientation of
Measure Normal Vector Now
normal

The CMM automatically

performs 3 probings

Three probings are executed to determine the

orientation of the normal.

The direction components of the probing are now

apparent in the element.

Calypso Basic Course 3 - 23

Worksheet 3.8: Measuring Strategy, Probe Space Point

Changing the To change the radius at which the points

radius at which used to update the vector are taken, select
sample hits are Feature Settings Editor from the
measured. Resources menu.

Highlight the point to which we are

applying the change in the list. Select
“Radius for space point normal
measurement” from the list of options and
then set the new value from the list
provided.

3 - 24 Calypso Basic Course

Worksheet 3.9 : Measuring Strategy, Editing Clearance Data

Worksheet 3.9: Part Features - Editor

Job: Editing Clearance Data

Practical exercise:

Use the editor to optimize the travel paths for individual features.
Try out the various functions.

Call up with
Resources
Feature Settings Editor

Calypso Basic Course 3 - 25

Worksheet 3.10: Polyline

Worksheet 3.10: Measuring Strategy

Job: Plane Measurement with Polyline

Practical exercise:

To create a polyline strategy to measure the right side plane on the training block.

This strategy is typically used when scanning, but can also be performed with
trigger probe heads.

3 - 26 Calypso Basic Course

Worksheet 3.10: Polyline

Job Action Procedure

Determine base Proceed in the usual manner, Create a new base alignment or use the one which
alignment placing the base alignment in is currently valid.
the front left-hand corner.
A new plane is needed, as this strategy should not
be linked with the alignment plane. Manual
Insert and open Plane alignment would be impossible.
Strategy
Polyline
Open

Select Step Width

Define the polyline by

probings on the workpiece

Calypso Basic Course 3 - 27

Worksheet 3.10: Polyline

Notes:

3 - 28 Calypso Basic Course

Worksheet 4.1: Length, Width and Height Characteristics

Worksheet 4.1: Length, Width and Height

Characteristics

Characteristic: X-Value, Y-Value, Z-Value

Part feature: point

Practical exercise:

Check coordinate values with the POINT part feature.

Default printout:

Calypso Basic Course 4-1

Worksheet 4.1: Length, Width and Height Characteristics

Point feature

Selection of tolerance for X creates X

value characteristic

X value characteristic

4-2 Calypso Basic Course

Worksheet 4.1: Length, Width and Height Characteristics

Job Action Procedure

Define base Proceed in the usual manner,

alignment placing the base alignment in The workpiece coordinate system is now located
the front left-hand corner. in the front upper left-hand corner of the
workpiece.

Select stylus no. 5

The result in the default printout is a point with
Measure length Probe the right side of the cube
the coordinate of the contact point.
with stylus 5.
The result equals the length of the cube.
Click on tolerance for X
Confirm with <OK>
The X value characteristic is automatically added
Create to the measurement plan.
characteristic
The result in the default printout is a point with
Select stylus no. 4 the coordinate of the contact point.
The result equals the width of the cube.
Measure width Probe rear side of cube with
stylus no. 4.
The Y value characteristic is automatically added
Create Click on tolerance for Y to the measurement plan.
characteristic Conclude with <OK>

Select stylus no. 2

The result in the default printout is a point with
the coordinate of the contact point.
Measure height Probe bottom side of cube with
The result equals the height of the cube.
stylus no. 2.

Click on tolerance for Z

Confirm with <OK> The Z value characteristic is automatically added
Create to the measurement plan.
characteristic

Note:
At this point it becomes apparent just how
important it is to assign meaningful names to
part features so that the right feature can easily
be found.

Compare the measuring results You should rename the part feature as soon as
with the engineering drawing. possible, preferably immediately after
measurement.
Result Please practice doing this during the following
comparison exercises.

End of practical exercise

Calypso Basic Course 4-3

Worksheet 4.2: Diameter Characteristic

Worksheet 4.2: Diameter Characteristic

Part feature: circle

Practical exercise:

The large bores on the top and the front side of the cube are measured with the part
feature CIRCLE and checked with the characteristic "Diameter".

4-4 Calypso Basic Course

Worksheet 4.2: Diameter Characteristic

Calypso Basic Course 4-5

Worksheet 4.2: Diameter Characteristic

Job Action Procedure

Measure upper Select stylus no. 1.

bore Move stylus to center of bore All features and further callouts can be followed
and measuring depth. in the default printout. There the circle is
illustrated along with the following icons:

Probe wall of bore in +X,-X, +Y X, Y center point coordinates

and -Y D diameter
S/MIN/MAX standard dev., min. / max.
values

Check diameter Click on tolerance for D The inspection of the "Diameter" characteristic
characteristic Enter values causes an icon to be created in the
Click on <OK>. measurement plan. This icon can also be
renamed to keep better track of things.
Select stylus no. 2. Specification of the nominal value and
Position probe in center of bore tolerances is obligatory.

Measure front Pull a circle out of the toolbox

and into the part features. The next bore is measured via an automatic run:
circle The "4-point macro" performs four single
Open the circle.
probings in the axial directions of the CMM.
Click on Strategy. Then click
on the circle icon with the four Important:
dots in the window. The axial directions are determined based on the
stylus selected.
Selected stylus in center point
of circle? This starts the automatic circle macro.
Click on <YES>.
Close Strategy
The CMM automatically travels in the bore and
then stops at the starting point.
This circle is displayed in the default printout and
can temporarily be inspected.

Check diameter Check the diameter characteristic in the usual

Click on D
characteristic manner

Try to correct the nominal value !

Click on the nominal value,

this is not editable.

4-6 Calypso Basic Course

Worksheet 4.2: Diameter Characteristic

Open diameter

It is possible to generate a measurement

characteristic directly from a calculated
element, but it is based on the nominal value
from just this calculation.

Now open the diameter characteristic and

correct the nominal value to 30.000.

If a correction is not possible because the

measurement characteristic mode is set to
“automatically from nominal geometry”, open
the characteristics editor and change the
setting to “input in characteristic”.

End of practical exercise

Calypso Basic Course 4-7

Worksheet 4.3: Angle Characteristic

Worksheet 4.3: Angle Characteristic

Part feature: plane

Practical exercise:

Use the part feature PLANE to determine the angle of inclination and position of flat
surfaces referenced to the base alignment.
The projected A1 or A2 angle can be used for this.
For the Angle between features, the characteristic of the same name is called up.

In this example we want to change the 40° angle shown above.

4-8 Calypso Basic Course

Worksheet 4.3: Angle Characteristic

Job Action Procedure

Measure plane Use stylus no. 1 to probe the Check the results in the default printout:
four corner points of the
inclined surface. Z Coordinate of FRP*.
X/Z A1 Angle formed by reference axis
Z
Y/Z A2 and the projections of the
plane normals into
Toolbox the X/Z and Y/Z planes.
Features Location
Angle betw. Features * FRP: feature reference point = origin of feature
alignment (U, V, W)

Characteristic Enter the features as

Angle between shown on the right.
Features

Click on the second

box at Select Result

The desired angle can

be defined with Select
Result.

The actual is
displayed for existing
measured values.

The desired 40° angle can be checked here by

two different methods:

1. with the projected angle A1, as the plane is

at 40° to the base alignment
2. with the angle between features, which can
regardless of the base alignment.

End of practical exercise.

Calypso Basic Course 4-9

Worksheet 4.3: Angle Characteristic

Worksheet 4.4: Angle Characteristic

Part feature: line

Practical exercise:

The position and angle are determined with the LINE part feature.

Note:
The line feature can always be used in cases where the workpiece is too thin for a
surface measurement.

4 - 10 Calypso Basic Course

Worksheet 4.3: Angle Characteristic

Job Action Procedure

Measure line Select stylus no. 1. Check the results in the default printout:

Move stylus no. 1 into groove

and probe 3 points on left side Z Coordinate of FRP
wall. X Coordinate of FRP
X/-Y A1 Projected angles between Y axis
Z/-Y A2 and projections of lines in the
Z/Y- and/or X/Y plane.

See illustration below:

Check Click on tolerance for A1 (X/Y)

inclination Click on <OK>.
characteristic

Result Compare measuring results

comparison with values specified in
drawing.

Note: between features.

Compare the results.
Like all features, the line has both a feature
origin and a "direction" or reference axis. In our
example, this is -Y.
The first probing point defines the origin and the
second one the "direction".
The projected angles A1 and A2 thus depend on
the probing sequence.

In the next section of this exercise, we want to try out the Symmetry function. Both planes (left and right
side of groove) have to be measured and the symmetry plane calculated from both.
Finally the 10° angle is checked, this time with the Angle between Features function.

Calypso Basic Course 4 - 11

Worksheet 4.3: Angle Characteristics

Job Action Procedure

This part of the exercise supplements the “Angle” topic and accesses the constructions.
We will deal with constructions in more detail later on in the course.

You can skip this part of the exercise and do it later.

Measure Measure the two groove planes First the planes are measured, then the
Features and the cylinder symmetry plane for these almost parallel planes
is created. The angle to the front cylinder is
Toolbox checked with this “Symmetry”, which is in actual
Construction fact a plane.
Symmetry

Create Symmetry Enter both planes in the

Symmetry.

Characteristic
Enter and fill in Angle betw.
Features

4 - 12 Calypso Basic Course

Worksheet 4.5: Diameter Characteristic

Worksheet 4.5: Diameter Characteristic

Part feature: cylinder

Practical exercise:

The position deviation, direction and diameter of the large bore on the front side of
the cube is measured with the CYLINDER part feature.

Note:
Avoid probing errors caused by conical bore shapes. Watch out for scatter. Correct
probing points if necessary.

Calypso Basic Course 4 - 13

Worksheet 4.5: Diameter Characteristic

Job Action Procedure

Measure Select stylus no. 2 Check results in default printout:

cylinder Perform 8 probings with stylus
Explanation
Tip: use a measuring strategy
you are already familiar with Z Coordinate of FRP
X Coordinate of FRP
D Diameter
Z/Y A1 Projected angles between Y axis
and projections of cylinder axis
X/Y A2 into the Z/Y and/or X/Y plane.

Check diameter Check "D" in the feature The nominal value input opens. The nominal
characteristic window values and tolerances for the selected
characteristic can now be entered.
Enter tolerances Each selection creates a characteristic in the
measurement plan.
<Click on <OK>

Result Compare measuring results

comparison with values specified in After switching to the measurement plan, check
engineering drawing. the color display to see whether any values are
out-of-tolerance.

4 - 14 Calypso Basic Course

Worksheet 4.6: Cone Angle Characteristics

Worksheet 4.6: Cone Angle Characteristic

Part feature: Cone

Practical exercise:

Use the CONE part feature to determine the center coordinates, size, cone angle
and direction of the cone axis.

Measure the cone angle.

Note:
Observe probing strategy and exclude probing errors.

Calypso Basic Course 4 - 15

Worksheet 4.6: Cone Angle Characteristic

Job Action Procedure

Measure cone Select stylus no. 1. Check results in default printout:

Use stylus no. 1 to measure

cone. Follow recommended X, Y Coordinate of FRP
probing strategy, i.e. probe 3 x D Diameter of cone at this location
4 points on 3 circular sections. X/Z A1 Projected angles between Z axis
and projections of cone axis into
Confirm with <OK>. Y/Z A2 X/Z and/or Y/Z plane.
AC Cone angle

Check cone Drag "cone angle" into Enter nominal value and tolerances.
angle measurement plan from toolbox
characteristic As an alternative, the method used last can be
Open characteristic entered here to create a characteristic.
Characteristic: of measured
cone

Result Compare measuring results

comparison with values from engineering
drawing.

End of practical exercise.

4 - 16 Calypso Basic Course

Worksheet 4.7:Cone Addition Characteristic

Worksheet 4.7: Cone Addition Diameter Characteristic

Part feature: cone

Practical exercise:

Using the CONE ADDITION calculating program, you can either determine the
diameter of a cone at a particular height or its height at a certain diameter.

Calypso Basic Course 4 - 17

Worksheet 4.7:Cone Addition Characteristic

Job Action Procedure

Calculate Drag "Cone Addition"

diameter construction into part
features

Characteristic: cone last

measured

Height: -7 mm, referenced to

base alignment

Inputs as shown in illustration

Result
comparison

Check results in the default printout

D Specified diameter
X,Y,Z Calculated coordinates applicable with
this diameter.
The Z value is the height being
searched for.

Use this construction "the other way around" in the second part of this exercise:
Calculate a point on the cone axis where the (cone) diameter equals exactly 30 mm.

4 - 18 Calypso Basic Course

Worksheet 4.8: Part Features and Characteristics

Worksheet 4.8: Part Features and Characteristics

Distance characteristic

Part feature: circle

Practical exercise:

This “Distance” characteristic is a universal evaluation which does not fit in the
framework we have met until now:
♦ In the input screen, it is possible to select several characteristics.
♦ The characteristics do not appear in the list of characteristics on the screen.
♦ In the customer printout, a display is made using automatic name allocation.
♦ The characteristics created are also available individually as characteristic
under other functions.

Job here:
Measure a circle in the center bore and evaluate the X value and Y value of this
bore.
Compare this with the “Cartesian distance” which is dealt with later in the course.

In the second part, calculate the angle between two bores.

Calypso Basic Course 4 - 19

Worksheet 4.8: Part Features and Characteristics

Job Action Procedure

Measure the bores on the top

of the practice cube as circles

Drag a “Distance” into the

measurement plan:

Toolbox
Size characteristics
Distance

Open Distance and enter the

center circle.

Select X and Y.
If only the first feature is filled in, Calypso
calculates the distance from the origin to this
feature, here the circle center point.

4 - 20 Calypso Basic Course

Worksheet 4.8: Part Features and Characteristics

Job Action Procedure

Angle between Drag another distance into the

2 circles plan and enter two circles from
the top bore pattern.

Select angle “A”.

Enter the nominal value, The angle is 120°, rotated starting from the X
confirm with <OK> axis.

Try out other combinations of If the features are swapped, Calypso calculates
circles in the distance and an angle of 60°.
observe the angle each time.
Feature 2 is the reference. Starting from the
reference, the angle is calculated
counterclockwise to feature 1.
You can try out the existing rule here by
performing different evaluations.

Calypso Basic Course 4 - 21

Worksheet 5.1: Pitch Circle Diameter

Worksheet 5.1: Pitch/Bolt Circle Diameter Characteristic

Diameter of a bore pattern using recall

Part features: bores measured as circles

Practical exercise:

Measure the 55 mm pitch/bolt circle in the top surface.

You will find the required function under
Nominal Definition
Recall

Note:
Open a new measurement plan for this exercise.

Calypso Basic Course 5-1

Worksheet 5.1: Pitch Circle Diameter

Job Action Procedure

Open new File Give the measurement plan a meaningful

measurement New, name so that it can be clearly identified and
plan Name .............. selected from the list later on. We will be using
this measurement plan again for other
examples.
Define base Proceed in the usual
alignment manner
and safety
Place the base alignment in the top front left-
cube
hand corner of the workpiece
Select stylus no. 1

Measure 1
st
Measure circle no. 1 by The preliminary results can be viewed in the
circle probing four points. default printout.
Confirm with <OK>

Measure 2
nd Measure circle no. 2 by
circle probing four points.
Confirm with <OK>

Measure 3
rd Measure circle no. 3 by
circle probing four points. All three circles are now recorded as part
Confirm with <OK> features and can be used in the next step.

Add new circle to

measurement plan and open
Calculate bolt-
circle Comment
Rename: The pitch/bolt circle is determined by adding
"bolt circle _top" another circle. This new circle is defined by
three points: the center points of the three
Nominal Definition previously measured bores.
Recall

Select circle 1,2 3. Select by clicking on feature. Each selected

Confirm with <OK> element will appear gray. The result of this
calculation is handled as a new part feature.

5-2 Calypso Basic Course

Worksheet 5.1: Pitch Circle Diameter

Job Action Procedure

Check diameter Toolbox Check the diameter characteristic in the

characteristic Size elements usual manner.
Diameter

It is possible to create a characteristic from a

Open diameter calculated element directly, e.g. in this case the
diameter.
Characteristic:
An alternative approach here is to drag the
Circle...
diameter characteristic out of the toolbox and
into the measurement plan.

End of exercise.

Calypso Basic Course 5-3

Worksheet 5.2: 3D Line

Worksheet 5.2: 3D Line / DIN Parallelism

Job: calculating a 3D line

Practical exercise:

Measure circles in the bore at the front and rear of the practice cube. The center
points of the circles are available as spatially defined points.
The 3D line is to be calculated through these two points.
A 3D line can only be calculated, it cannot be probed.

This line E-F must be checked with

DIN parallelism against the cylinder
axis.

5-4 Calypso Basic Course

Worksheet 5.2: 3D Line

Job Action Procedure

Measure a circle at the front in The display on the screen should be similar to the
the 30 mm bore, and another illustration.
circle further back in the bore.

Take a 3D line from the toolbox.

The 3D line is a feature which cannot be measured

directly.
Open the 3D line and recall the
two circles.
The recall causes a line to be calculated through the
two circle center points.

This 3D line will be

used for a new
alignment in a later
exercise.

Calypso Basic Course 5-5

Worksheet 5.2: 3D Line

Job Action Procedure

Evaluating a Measure the bore marked The bore has to be measured as a cylinder, a circle
DIN parallelism measurement would not allow a parallelism
evaluation.
Toolbox
Size elements
DIN Parallelism The DIN parallelism is a location element.
More detailed information on location elements, in
Assign the part features particular their relationship to the feature form
deviations, is available in relevant literature.
Here the function is shown in Calypso independent of
the measuring technology.

Make sure you understand the result by asking

yourself the following:

♦ What causes the reference and part feature to be

exchanged?

5-6 Calypso Basic Course

Worksheet 5.3: Intersection Construction

Worksheet 5.3: Construction, Intersection

Characteristic: X value, Y value of an intersection point

Job: calculate point of intersection between circle and line

Practical exercise:
Determining the intersection between the lines and the circle.
The 2D intersection (projection into a coordinate plane) is calculated in the first
part
and the 3D intersection (wall section) is calculated in the second part.

Note:
The base alignment is again located at the front top left.

Calypso Basic Course 5-7

Worksheet 5.3: Intersection Construction

Job Action Procedure

Determine base Proceed in the usual manner, Create a new base alignment or use the one
alignment placing the base alignment in which is currently valid
the front left-hand corner.

The measurement plan from the last example

Toolbox
can be used again.
Constructions
Determine Intersection
intersection
characteristic Open characteristic

Click on feature 1 Here we use the capability of measuring new

features directly from the "Intersection"
Select "New" and click on characteristic.
circle
Select the appropriate feature or reference and
Measure circle 1 by probing measure a new feature instead of an existing
four points one.

Measure 30 Click on feature 2

mm ∅ bore
Click on "New" and line

Measure line by probing three

points

Select front intersecting point

using X or Y size.

Enter nominal values and

tolerances
Measure left The "intersection" of the circle and the line
edge of groove Confirm by clicking on <OK> yields 2 intersecting points (or none).
The intersecting point to be used for viewing
Select the characteristic must be selected in the
intersecting Measure cylinder in hole characteristic.
point

This is the end of the 2D definition of the intersection point.

If the height of the penetration point of the line through the bore is to be defined, a cylinder has to be
measured in the bore.

Create wall Open intersection again, enter

section cylinder instead of circle. The wall intersection outputs coordinates in the
height as well.
Check “Wall”

5-8 Calypso Basic Course

Worksheet 5.3: Intersection Construction

Worksheet 5.4: Construction, Intersection

Characteristic X value

Job: calculate position of an intersection line

Practical exercise:

Determining the distance between the edge and the origin via the
INTERSECTION construction program.

Note:
The base alignment is at the top front left.

Calypso Basic Course 5-9

Worksheet 5.4: Intersection Construction

Job Action Procedure

Determine base Proceed in the usual manner, Create a new base alignment or use the one
alignment locating the base alignment in which is currently valid
the front left-hand corner.

The measurement plan from the last example

Select stylus 1
can be used again.

Probe plane 40° counter-

clockwise from top surface
Measure plane

Toolbox
Constructions
Intersection Intersection
characteristic

1. Open characteristic
2. Click on feature 1
3. Select plane 1
4. Click on feature 2
5. Select plane 4

Specify
tolerances
Click on tolerance for X ⇒

Enter nominal values and

tolerances

Confirm with <OK>

Characteristic: Characteristic created

X value automatically ⇒

Result Compare coordinates of

comparison intersecting point with values in
engineering drawing. Consider which point on the workpiece you
have checked with this intersection!

5 - 10 Calypso Basic Course

Worksheet 5.5: Intersection and Wall Intersection Construction

Worksheet 5.5: Construction, Intersection and Wall

Section

Characteristic: X Value, Y Value from Intersection

Job: piercing point of cone through top plane

Practical exercise:

Calculating the point where the cone axis pierces the top plane (surface) of the
cube.
In the second part the wall intersection is calculated with the same features.

Calypso Basic Course 5 - 11

Worksheet 5.5: Intersection and Wall Intersection Construction

Job Action Procedure

Determine base Proceed in the usual manner to Create a new base alignment or use the one
alignment place the base system in the which is currently valid
front left-hand corner.

Measure cone with stylus 1

Characteristic:
Intersection Toolbox
Constructions
Intersection

Fill out as in figure ⇒

Click on tolerance for X and

Y⇒
Specify
tolerances Enter nominals and
tolerances

Confirm with <OK>

CAD display

Result Compare results with values Two characteristics, the X value and the Y value,
comparison specified in drawing are automatically created.

5 - 12 Calypso Basic Course

Worksheet 5.5: Intersection and Wall Intersection Construction

Job Action Procedure

In the second part, a “wall intersection” is

created from the two features used before.
Here one of the features, the wall, is used for the
intersection calculation.

Click on cone

The result in this case is a circle in the

intersection plane.

The “Wall” option is always offered for

intersections if Calypso can carry out a
calculation.

Calypso Basic Course 5 - 13

Worksheet 5.6: New Alignment

Worksheet 5.6: New alignment

Job: Place New Origin in Center of Cone

Practical exercise:

Placing a second alignment in the center of the cone, i.e. on the cone axis.

Function:
Resources
Utilities
Alignment

5 - 14 Calypso Basic Course

Worksheet 5.6: New Alignment

Job Action Procedure

Measure cone Measure the cone in the usual Measure several sections with at least 3 probings each.
manner.

Toolbox
Resources
Characteristic Alignment
base alignment
Open the alignment and fill in
the fields as shown

The origin in X and Y is a cone

Specify origins

Rename
Cone center

CAD display

Calypso Basic Course 5 - 15

Worksheet 5.6: New Alignment

Job Action Procedure

Reference 12 Open first circle The alignment in which the feature is being viewed is
mm ∅ circles to located in the feature.
new alignment
This means that any given part feature can exist only in
one alignment.

The "circle" part feature is referenced to the new

Selection for alignment: alignment in the cone center.
Cone center The X, Y values change.

Specify The X value and Y value characteristics are generated.

tolerances.

Perform the same settings for the other two circles.

5 - 16 Calypso Basic Course

Worksheet 5.7: Symmetry Construction

Worksheet 5.7: Construction, Symmetry

Characteristic: Symmetry,
Characteristic: Alignment
Characteristic: Y-Value

Job: Y value of a symmetry point

Practical exercise:

Check whether the two 12 mm ∅ bores on the left side of the bore pattern in the
top surface of the cube are symmetrical to the center of the pitch/bolt circle.

The alignment in the cone center should be used for this purpose.

Calypso Basic Course 5 - 17

Worksheet 5.7: Symmetry Construction

Job Action Procedure

Create symmetry Toolbox

point Constructions
Symmetry

Enter circle 1 and circle 2 as

the features.

Note:
Change alignment to
Alignment_Cone_center

Result Tolerance for Y automatically

comparison results in Y value characteristic.

The Y value should be close to the origin, since

the symmetry point should lie on the X axis.

5 - 18 Calypso Basic Course

Worksheet 5.8: : Cartesian Distance

Worksheet 5.8: Characteristic: Cartesian Distance

Part features: circles

Construction: recall

Practical exercise :
The cartesian distance allows the user to measure the distance between features
rather than reporting their location relative to the origin.

Calypso Basic Course 5 - 19

Worksheet 5.8: : Cartesian Distance

Job Action Procedure

Determine Proceed in the usual Create a new base alignment or use the
base manner, placing the base current alignment. Just ensure that the
alignment alignment in the front left- alignment included the top face and front face
hand corner. features as these will be needed later.

Select stylus 2

Measure hole 1 as a circle.

Measure the
four holes in It is not necessary to preselect the part feature
Measure hole 2 as a circle. with automatic feature recognition.
the front face.
Measure hole 3 as a circle.

Measure hole 4 as a circle.

The cartesian distance characteristic is

Calculate the From the Form and Location actually in two different menu’s. It can also be
25mm menu select “Distance” and found in the “Size” menu.
distance then “Cartesian Distance”.
between hole
1 and hole 3 Select hole 1 for feature 1
Select hole 3 for feature 2

Select plane 2 (front) for the Parallel defines this plane to be the plane of
Primary datum. (Parallel) measurement.

Select plane 1 (top) for the Parallel defines the orientation of the
Secondary datum. (Parallel) measurement

5 - 20 Calypso Basic Course

Worksheet 5.8: : Cartesian Distance

Job Action Procedure

Calculate the Bring down another cartesian

2mm distance distance.
between holes
2 and 4 Select hole 2 for feature 1
Select hole 4 for feature 2

Select plane 2 (front) for the Parallel defines the this plane to be the plane of
Primary datum. (Parallel) measurement.

Select plane 2 (top) for the

Perpendicular defines the orientation of the
Secondary datum.
measurement.
(Perpendicular)

Repeat this procedure for the remaining dimensions on the print shown at the beginning of this
exercise.

Calypso Basic Course 5 - 21

Worksheet 5.9: Distance between two Planes

Worksheet 5.9: Distance between Parallel Surfaces,

Angle to Main Axis

5.9.1: Characteristics: Cartesian distance and projected

angle
Part features: planes

Practical exercise

Part 1:

Measuring the groove on the top surface of the cube with two planes, determining
the width and angular position. Note the travel paths of the probe.

Required functions:
Cartesian Distance
Symmetry
Projected Angle

5 - 22 Calypso Basic Course

Worksheet 5.9: Distance between two Planes

Job Action Procedure

Measure planes To measure the planes of the At least the two lateral groove surfaces must be
groove, proceed as outlined in available as planes in the "part features".
section 3.1

Groove width:

Determine Toolbox
characteristic Location characteristics
Cartesian Distance

Open and fill in page

Feature 1 is groove_left

Feature 2 is groove_right

Do NOT enter any datum!

Specify tolerances and

nominal positions!

The application of the Cartesian distance with

two planes is calculated as follows:
From the "center" of the first plane perpendicular
to the second plane. The perpendicular is then
placed here and its length is output.
This technique is a practical solution for
measuring the distance of planes which are
approximately parallel to each other.

Calypso Basic Course 5 - 23

Worksheet 5.9: Distance between two Planes

Job Action Procedure

Either the right or the left side of the groove is
Angular pos. of suitable for checking the 10-degree angular
groove: position if it can be assumed that the planes are
located approximately parallel to each other.
A reference to the center of the groove is
possible by forming the symmetry plane.
Toolbox
This solution is described here.
Production of Construction
symmetry Symmetry

Open and fill in page

Calculate
construction Feature 1 is groove_left

Feature 2 is groove_right

Specify tolerances and

nominal positions!

Determine
feature
The result is a symmetry plane.
The angle projected into the XY plane can be
used here for checking.

Characteristic:
projected angle

5 - 24 Calypso Basic Course

Worksheet 5.9: Distance between two Planes

Worksheet 5.9.2: Characteristic Axis Distance

/Perpendicular Length

Part features: planes

Practical exercise

Part 2:

Drawing a perpendicular from one plane to a second plane.

The result here is a line.
The length of this line can be evaluated as characteristic.

Functions required:
Perpendicular
Length of Axis

Calypso Basic Course 5 - 25

Worksheet 5.9: Distance between two Planes

Job Action Procedure

Calculate Toolbox
perpendicular Construction
Perpendicular

Insert Length of Click on Depth By clicking on the length the “Length of Axis”
Axis characteristic is created.
characteristic

5 - 26 Calypso Basic Course

Worksheet 5.10: True Position

Worksheet 5.10: True Position

Characteristic True position

Job:

Practical exercise:

Checking the true (DIN) position of bore according to callout on drawing.

Nominal values of bore:

Y = 30
Z = -33

Calypso Basic Course 5 - 27

Worksheet 5.10: True Position

Job Action Procedure

Determine base Proceed in the usual manner to Create a new base alignment or use the
alignment place the base alignment in the currently valid one
front left-hand corner.

Measure the center bore in the

bore pattern on the right side of The 12mm ∅ bore should be checked according
the cube
to references A and B.
Determine
characteristics
Toolbox
Location elements
True Position

Open and fill in page

Specify feature The feature is circle 1

and datum
Primary datum is base
alignment
This corresponds to the A and
B datum

Specify tolerances and

nominal positions!

The “True Position” function is very varied.

Datum systems can be used, and changes in
the datum systems made using “Special”. This
function is also used as the basis for bore
pattern best fits, which are used for calculating
position tolerances.

5 - 28 Calypso Basic Course

Worksheet 5.11: Polar Angle and Distance in New Alignment

Worksheet 5.11: Polar Angle and Distance in a New

Base Alignment

Job: Angle position and distance of a circle to the origin

Practical exercise :
Checking the bore (circle 3) for its angle (to the X axis) and its distance to the
origin of the new base alignment.

Calypso Basic Course 5 - 29

Worksheet 5.11: Polar Angle and Distance in New Alignment

Job Action Procedure

Use the measurement plan

from the previous exercise Each of the two semi-circles is recorded as
circle.
Measure two circles at each
end of the banana shaped
slot

Toolbox This function calculates the polar distance and

Size Elements the polar angle of a feature to the origin.
Polarposition Angle
Polarposition Radius Ensure that a secondary alignment is set at
the center of the cone. The angle calculated
refers to the current origin origin.

Note:
The new origin is only to be applied to the
circle at 60° not with the 0° circle.

Look at the difference in reported angle and

radius for the two features.

Perform a similar evaluation for bores in the

YZ plane and in the ZX plane.

5 - 30 Calypso Basic Course

Worksheet 5.12: Form and Position Evaluations

Worksheet 5.12: Form and Position Evaluations

Form and Location Characteristics

Job: inspect marked characteristics

Practical exercise:

Create a new measurement plan with a suitable

base alignment and safety cube.
Drag the required characteristics into the
measurement plan and measure the
corresponding part features.

Calypso Basic Course 5 - 31

Worksheet 5.12: Form and Position Evaluations

Notes:

5 - 32 Calypso Basic Course

Worksheet 5.12: Form and Position Evaluations

Worksheet 5.13: Flatness Characteristic

Job: check the DIN flatness of a plane with a form plot

Practical exercise:

Opening the shaft measurement plan (exercises 2.7 and 3.10).

Evaluating a DIN flatness for the plane measured with polyline.

Calypso Basic Course 5 - 33

Worksheet 5.13: Flatness Characteristic

Job Action Procedure

Open the shaft measurement The shaft measurement plan contains a plane which
plan from the previous has been measured with polyline. A large number of
exercises. points is required for evaluating the flatness.

Place a DIN flatness in the

plan.

Open Flatness.

Enter the plane

Click on Graphics
Form plot for flatness is output.

5 - 34 Calypso Basic Course

Worksheet 5.14: Alignment with 3D Line

Worksheet 5.14: Base Alignment with 3D Line

Job: base alignment with 3D line from exercise 5.2

Create a new base alignment using the 3D

line from exercise 5.2.

Calypso Basic Course 5 - 35

Worksheet 5.14: Alignment with 3D Line

Notes:

Ine hohe Punktez

5 - 36 Calypso Basic Course

Worksheet 6.1: CNC Probe Calibration

Worksheet 6: CNC Programming

Worksheet 6.1: CNC Probe Calibration

Job: automatic probe calibration run

⇒ A separate measurement plan must be generated for this purpose.

⇒ The sole content of this measurement plan is calibration.
⇒ The styli must be calibrated once manually beforehand.

Two Possible Procedures

⇒ With base alignment and safety cube
∗ The position of the base alignment must be defined in the center of the
sphere.
∗ The safety cube (clearance planes) must be defined.

⇒ With “Position Points”

♦ Run window: Navigate feature to feature: Use position points only

Practical exercise:
If desired, locate the base alignment in the center of the sphere.
Perform alignment with only three origins. Primary and/or secondary datum are
neither possible nor required.
Travel without generation is preferable, since this saves the necessity of performing
an alignment or creating a safety cube.

Calypso Basic Course 6-1

Worksheet 6.1: CNC Probe Calibration

Job Action Procedure

Create base Proceed in the usual manner The base alignment should be located in the
alignment center of the sphere. Measure a sphere as a part
feature and define this sphere as the origin in the
base alignment in X, Y and Z.

Create the safety Proceed in the usual manner The safety cube is defined as shown on the
cube again previous page.

Insert Probe Open toolbox

Qualification in Utilities
measurement Probe Qualification
plan
Open probe calibration menu The location of the reference sphere must be
Ref. sphere position defined once at the beginning.

Start calibration
Click on CNC run, fill in page The stylus can now be calibrated automatically.
and confirm with OK
Fetch (drag) a separate "probe calibration"
characteristic from the toolbox and proceed
accordingly for each stylus.

Set "during automatic run" to

Calibration will now be performed automatically
No in the base alignment at the location previously defined via "location
definition".
The base alignment requires change only if the
sphere is clamped at an entirely different
location.

6-2 Calypso Basic Course

Worksheet 6.2: Programming on the CAD model

Worksheet 6.2: Programming on the CAD model

Practical exercise:

The CAD model of the practice cube is stored as an ACIS data file (*.sat) in a
directory of the Calypso measuring software.

We will perform the following work steps:

⇒ Import this file to Calypso,

⇒ Define a base alignment with 3 planes,
⇒ Automatically create a safety cube,
⇒ Generate a measuring run for the "diameter" characteristic at the front of the 20
mm ∅ cylinder.

All steps must be performed "remotely" i.e. offline on the computer. The finished
program should be executed on the CMM only after the programming procedure has
been completed.

Calypso Basic Course 6-3

Worksheet 6.2: Programming on the CAD model

Job Action Procedure

Read-in CAD CAD The CAD file can be downloaded from a hard disk
data CAD file drive, a floppy disk or a network drive.
Load

Select the file from the Windows browser dialog

box.

Select the “cadcube2” file

Render the display It is then much easier to click on the geometric

features of the rendered model than in the wire
frame model.
Switch to “"Solid geometry”

In the following operation we will first create three

planes and use them to construct a base alignment.
Then we will set up a safety cube around the model.
Click on top surface
Important!
Click on front surface From now on every click placed on the CAD model
will create a new geometric feature.
Click on right lateral surface
Look at the 3 planes in the illustration. Plane 3 is
selected.

6-4 Calypso Basic Course

Worksheet 6.2: Programming on the CAD model

Job Action Procedure

Part feature: Click on front of 20 mm ∅ Note:

cylinder cylinder Set stylus 2 (rear).

Open cylinder
Strategy
Open and edit
Circle Auto Path (2 lines)

Confirm with <OK>, click on Now you have automatically created a cylinder with
diameter characteristic. two circular sections.
The measuring strategy for the cylinder is already
defined.
Click on the diameter field as usual to create a
characteristic.

Calypso Basic Course 6-5

Worksheet 6.2: Programming on the CAD model

Job Action Procedure

Measuring Open plane 1 Until now we have only defined the measuring
strategy for strategy for the cylinder. The 3 planes have not yet
planes been assigned a strategy.
Switch to "Define points" or We want to preset the probing points on screen:
check to make sure that this Important: Select the appropriate stylus! If the
setting is selected points are selected carefully, all of them can be
probed with stylus 1.

Every mouse-click now sets a probing point on

the surface!!

Click on the plane at 4 different

locations.

Confirm with <OK>

Open plane 2

Click on plane 4 times

Confirm with <OK>

Open plane 3

Click on plane 4 times

Confirm with <OK>

The part features have now been assigned a

probing strategy and can be linked to form a base
alignment in the next step.

6-6 Calypso Basic Course

Worksheet 6.2: Programming on the CAD model

Job Action Procedure

Create a base Resources

alignment Base Alignment
new Base Alignment

Fill out base alignment "as

usual" and as shown on the
right.

Now the base alignment has been defined with the

existing features.

Remember: until now everything has been done on

the Calypso computer without using the measuring
machine.
This is the way "offline" part programming done.

This enables you to edit any workpiece as long as

a suitable CAD model is available.

You now need two things for an effective run:

⇒ A safety cube and
the real position of the part on the CMM.

Calypso Basic Course 6-7

Worksheet 6.2: Programming on the CAD model

Job Action Procedure

Define safety Resources

cube Clearance Planes
Clearance Planes From
CAD Model

Offset=10

This simple option saves you the trouble of

entering parameters in the "Clearance Planes"
menu.

An offset of 10 mm defines a distance of 10 mm

from every contour of the workpiece.
Update Clearance Plane
Settings for Defined
Features?: <YES>

Start CNC run Run

The alignment, safety cube and characteristic are
now defined. The CNC run is ready for testing on
the CMM.

Start with
“Manual run“ The workpiece position on the CMM table is
defined directly via this manual run.This saves you
the trouble of calling the base alignment and
selecting "Execute Manual Run Now".

The CMM now switches to "Manual " mode and

guides you through the alignment procedure.

The remainder of the run is then carried out under

CNC control.

Note:
If you always work with the same version of
Calypso and without a CMM, you can test your
CNC runs via the "Simulation" function.

6-8 Calypso Basic Course

Worksheet 6.3: Programming on the CAD model II

Worksheet 6.3: Programming on CAD Model II

Job: parallelism and perpendicularity of a connecting rod

Practical exercise:
Checking the marked DIN perpendicularity and DIN parallelism.
The work piece data are read-in via CAD.

Calypso Basic Course 6-9

Worksheet 6.3: Programming on the CAD model II

Job Action Procedure

Read-in CAD data CAD Note:

CAD File From now on, if possible, avoid leaving the
Load measurement plan so as to retain the display in
the CAD window.

Set stylus 1.

Switch to drive A:
Select "ConRod.sat".
Select the file from its location on disc using the
Confirm with <Open>.
Windows browser dialog box.
The CAD model then appears.

Select part CAD

features Extract
All features All part features are then selected. The features
are rendered accessible to Calypso via the
"Apply" command.
Pull-down menu:
Edit
Select all

Wait for loading process, then confirm with OK.

Confirm with <OK>.

Display in CAD window

6 - 10 Calypso Basic Course

Worksheet 6.3: Programming on the CAD model II

Job Action Procedure

Edit part features Open cylinder 3 The CAD model is then displayed and its
Strategy geometry can be edited.

Circle Auto Path 1

Acc. to the figure, the important part features are:
Adapt intersection height to Cylinder 3: large bore
probe Cylinder 20: small bore
Plane 3: top contact surface

Open cylinder 20 and edit as

cylinder 3

Open plane 3
Switch to "Define Points"

Click on 4 points on surface

of circle ring

Important:
Each click in the CAD window now generates a
new probing point!

Probing points on plane 3:

Close plane with <OK>

Calypso Basic Course 6 - 11

Worksheet 6.3: Programming on the CAD model II

Job Action Procedure

Toolbox
Location
elements
Parallelism

Perpendicularity

Cylinder 3

and

Cylinder 20

Confirm with <OK>.

Cylinder 3

and

Plane 2

Confirm with <OK>.

6 - 12 Calypso Basic Course

Worksheet 6.3: Programming on the CAD model II

Job Action Procedure

Assign base Resources The measurement plan now has 2 characteristics

alignment Base Alignment and the corresponding part features.
The probing points are defined.

Only the position of the work piece on the CMM

"Execute Manual Run Now" is still required.
The position of the base alignment must be
defined manually.
See exercise 2.5

IMPORTANT:
No circles are generated when loading the CAD
model.
A circle in the 22 mm ∅ bore is required,
however, to define the base alignment, since a
cylinder would result in an incorrect base
alignment.

Generate a circle either by clicking in the model

or by entering the nominal values from the
toolbox.

Calypso Basic Course 6 - 13

Worksheet 6.3: Programming on the CAD model II

Notes:

6 - 14 Calypso Basic Course

7 Measurement Plan Documentation

7. CNC Program and Measurement Plan Documentation

General Information on CNC Programs

In Calypso, every measurement is also a preliminary stage to an automatic run. The

software requires only a safety cube (formed by clearance planes) to calculate the
routes.

The list of characteristics also functions as a "CNC program". In the default

operating mode, Calypso processes the characteristics in their given order. The
corresponding part features are probed as required for calculation.

As soon as a change occurs in the order of the characteristics, the entire CNC run
may take on a different appearance.
If you are used to working with a specific sequence, the program run can be
changed with a single mouse-click.

By selecting: Order of Run: from the feature list you can influence the travel behavior
(routing) in such a way that the CNC run will be processed by order of part feature
instead of by order of characteristic. Thus, e.g. you can measure all of the features
on the right side first, and then all of the features on the left side.

This feature reduces the required measuring time by simplifying travel paths and
preventing unnecessary probe change.

Calypso Basic Course 7-1

7 Measurement Plan Documentation

7.1 CNC Start Window

1. Clear Existing Results

• When checked: The actual values from earlier measurements
(including manual) are deleted. The machine must therefore take
new measurements.

• When unchecked: The actual values from earlier measurements

(including manual) are recalculated.

2. Current Alignment
• The base alignment previously saved is used and the alignment will
not be recreated.

• Application

If the base alignment was previously calculated for the mounted

work piece and has not been moved.

3. List of characteristics
• Current selection: only the highlighted features or characteristics are
measured.

• All characteristics: only refers to characteristics. If there are none

available, it may mean that only the base alignment is measured.

7-2 Calypso Basic Course

Measurement Plan Documentation

4. Run Mode
• Set to Normal: will measure all selected features at the speed
selected.

• Slow through first feature: this is a safe operating mode, where the
first feature is measured at a slower speed.

5. Speed in mm/s
• Speed for the measurement run in mm/sec. Note: If the key switch
to the controller is set to manual then the machine moves in set-up
mode (a maximum of 70mm/sec regardless of what is selected
here).

6. Output
• If PDF file is selected, all protocols selected (custom and/or
compact reports) and plots if present are saved as PDF files.

• The custom report and plots are saved in a single file.

• The compact report is saved in a separate file.

• The filenames are composed of the name of the measurement plan,

the run number and the ending “_gra.pdf” for custom printouts and
plots and “_txt.pdf” for compact reports. Example:
TestBlock_1_gra.pdf.

• The PDF files are stored in the folder home\om\workarea\results.

Calypso Basic Course 7-3

7 Measurement Plan Documentation

Cataloging and Storing Measurement Plans

Suggestions for documenting measurement plans are provided on the following

pages.

In practice, it should be possible for anyone to retrieve and reuse an archived

measurement plan within a reasonably short period of time. In other words, all
important information should be kept within easy reach at all times.
It is advisable to either keep a "hard copy" manual in your file cabinet or simply store
the document as a file in the computer.

The operator should decide which of the above two alternatives is preferable from
his standpoint. The lists and tables which must be included in such documentation
are specified below.

A printed copy of all pertaining documents will be handed out to each course
participant.

An "electronic" example of the most important information is stored on the training

computer in the directory C:\Dokumentation\...
If you wish, you may copy the information contained in this directory to floppy disk.

On the following pages you will find examples for:

1. Cover page
1. Probe plan
2. Base alignment
3. Custom printout
4. List of characteristics
5. List of part features
6. Default printout
7. Excel export file

7-4 Calypso Basic Course

7 Measurement Plan Documentation

Cover page example:

Cover page example

Measurement plan: cube1 Workpiece name: example Date: 10/06/99

Drawing no.: 12-555 Comment: Operator: Müller

Customer: PKW CMM: Eclipse 07 Lab room temperature: 20°
Directory path: Server ZOIMS001\Plaene_Schulung\Würfel1\

Calypso Basic Course 7-5

7 Measurement Plan Documentation

Probe Plan
Measurement plan: housing 12 Workpiece name: example Date: Page: 1 / 1
06.10.99
Drawing no.: 12-555 Comment: Operator: Müller
Customer: PKW CMM: Eclipse 07 Meas. lab temperature: 20°
Base Alignment: housing 12 w. auto probe changer
Equipment
Working cycle: 4-3 A: Master prb. B: Star 01 C: Prb12 D: - E: -
Displayed probe: star 01

Probe Joining elements (∅ in [mm] / ∠ in [ ° ])

Ser.: Cf.: Cb.: No.: Type dk Length Adapter Ext. Joint Cube Swivel
1 2 1 600341-8425 ∅ 20 x
2 2 1 602030-8362 20
3 2 1 1 600342-8022 5 53
4 2 1 2 5
5 2 1 3 600342-8021 3 58
6 2 1 4 5
7 2 1 5 3

7-6 Calypso Basic Course

Measurement Plan Documentation

Base Alignment Plan

Measurement plan: housing Workpiece name: example Date: 06.10.99 Page: 1 / 1
12
Drawing no.: 12-555 Comment: Operator: Müller
Customer: PKW CMM: Eclipse 07 Meas. lab temperature: 20°
Base alignment: housing 12 w. auto probe change
Equipment:
Working cycle: 4-3 A: Master prb. B: Star 01 C: Prb12 D: - E: -

Clamping equipment:
matrix bore

Device no.:

Notes on clamping:

Quill prior to start:

Part Feature Probe Stylus No. of Additional information
Primary Plane 1 Star 01 1 4 Top surface
Secondary Plane 2 Star 01 2 4 Front surface
Tertiary
Plane 3 Star 01 3 4 Left surface
origin in X
Tertiary
Plane 2 Star 01 2 4 Front surface
origin in Y
Tertiary
Plane 1 Star 01 1 4 Top surface
origin in Z

Calypso Basic Course 7-7

7 Measurement Plan Documentation

Custom Printout (Screen Display)

7-8 Calypso Basic Course

Measurement Plan Documentation

Default Printout (Screen Display)

Calypso Basic Course 7-9

7 Measurement Plan Documentation

List of Characteristics

7 - 10 Calypso Basic Course

Measurement Plan Documentation

List of Part Features

Calypso Basic Course 7 - 11

7 Measurement Plan Documentation

File for Export to Spreadsheet Program (MS Excel)

7 - 12 Calypso Basic Course

Worksheet 7.11: Changing the Printout Header

Worksheet 7.11: Changing the Header

Practical exercise:
Customizing a printout header.

Calypso Basic Course 7 - 11

Worksheet 7.11: Changing the Printout Header

1. Open new measurement plan or have plan

open

2. Open Explorer and find file with printout

formats.

3. Copy the “default” file and rename to

"Training_34".

4. Resources
Format Custom
Printout.

5. Select Printout
format
"Training_34"

7 - 12 Calypso Basic Course

Worksheet 7.11: Changing the Printout Header

6. Resources
Report
Header

7. Change:

Insert:
"Subject
Number" and
"Comment"

Save by
clicking on
the floppy disk
icon.

8. You may have

to use “Size”
to align the
fields.

Calypso Basic Course 7 - 13

Worksheet 7.11: Changing the Printout Header

9. If you want you can load a picture from a disk, if you have one.

10. Save the record header.

11. Let the CNC program run with the new header and check the result.

7 - 14 Calypso Basic Course

Drawings

Calypso Basic Course

Drawings

Drawing of a Support

Calypso Basic Course

Drawings

Calypso Basic Course

Drawings

Calypso Basic Course

Drawings

Calypso Basic Course

Drawings

Calypso Basic Course