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8-7

System T

roubleshooting

& Questions

System Troubleshooting and Questions

Global User Manual

Frequently Asked Questions

Is this manual available on the Internet?

All Global service documentation will be online including this document
the Site Preparation Manual and the Service/Maintenance Manual. They
are located at:

http://manuals.brownandsharpe.com

Where can I obtain additional information about Brown and Sharpe
or upcoming training classes?

http://www.brownandsharpe.com

Who do I contact to comment about the manuals or to suggest a
correction?

Contact Brown and Sharpe at 1.800.343.7933 (9a-5p EST)

Will updates be made to these manuals?

Any modifications or revisions necessary will be updated online at the
web site mentioned above.

How do I get any “CMM operation” questions answered?

Contact Brown and Sharpe at 1.800.343.7933 (9a-5p EST)

Summary of Contents for Global 121510

Page 1: ...l includes site preparation information for the following machines Global 9128 Global 122210 Global 9158 Global 121510 Global 9208 Global 123010 62 90103 English shaping the future of measurement 2000 Brown Sharpe Manufacturing Company ...

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Page 3: ...INE 1 7 SYSTEM SPECIFICATIONS 1 8 Global 9XX8 Specifications 1 8 Global 12XX10 Specifications 1 9 Global 9XX8 12XX10 Capacity View 1 10 2 SYSTEM SET UP 2 1 OPERATING TIPS 2 3 START UP CHECKLIST 2 3 STARTING THE GC 2 CONTROLLER 2 7 STARTING THE GC 1 CONTROLLER 2 8 MOUNTING PARTS 2 9 PROBE INSTALLATION 2 11 3 ELECTRICAL SYSTEM 3 1 SYSTEM POWER UP 3 3 SYSTEM SCHEMATICS 3 3 SYSTEM OVERVIEW 3 3 SYSTEM ...

Page 4: ...C T I V 6 4 PROBES 6 5 TP20 Probe 6 5 TP200 Probe 6 5 TRAX Probe Head 6 6 SP600 Probe 6 6 PROBE COMPENSATION AND QUALIFICATION 6 7 MEASURING WITH AN ELECTRONIC PROBE 6 9 TOUCH TRIGGER PROBE REPEATABILITY 6 10 PLANNING THE MEASUREMENT 6 13 7 CONTROLS 7 1 CONTROLLER INFORMATION 7 3 GC 2 CONTROLLER 7 3 GC 1 CONTROLLER 7 6 HOMING SEQUENCE 7 9 JOG BOX 7 12 8 SYSTEM TROUBLESHOOTING AND QUESTIONS 8 1 SYS...

Page 5: ... Maintenance Checklist 9 5 Daily 9 5 10 INTRODUCTION TO CMM 10 1 The Coordinate System 10 3 The Machine Coordinate System 10 6 The Part Coordinate System 10 7 An Explanation of Alignment 10 8 An Explanation of Datum 10 9 An Explanation of Translation 10 11 An Explanation of Rotation 10 13 Measured and Constructed Features 10 15 Volumetric Compensation 10 17 Qualifying Probe Tips 10 19 Projections ...

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Page 7: ...al 1 4 Additional Information 1 4 Feedback about this document 1 5 Machine Safety 1 5 General Safety 1 6 Electrical Safety 1 6 Pneumatic Safety 1 7 The Brown Sharpe Global Coordinate Measuring System 1 8 System Specifications 1 8 Global 9xx8 Specifications 1 9 Global 12xx10 Specifications 1 10 Global 9xx8 12xx10 Capacity View ...

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Page 9: ...and quality of the product If at any time your personnel believe that there are discrepancies in the information contained in this document particularly when related to safety issues it is recom mended that you contact Brown Sharpe for assistance before proceeding Any unauthorized modifications to the machine will immediately void the warranty and may result in system damage or personal injury Sin...

Page 10: ...ddress http www brownandsharpe com This manual is also available on the Internet at the following address http manuals brownandsharpe com Feedback about this Document Comments or suggestions about this manual should be directed to 1 800 343 7933 9a 5p EST Controller References Throughout the Global documentation The B3C LC controller will be reffered to as GC 2 The FBPC controller will be reffered...

Page 11: ...oved General Safety Always wear safety glasses when operating this machine Additionally wear any relative safety equipment as dictated by the working environment A 2 bright yellow caution stripe should be painted 16 outside the machine area When the machine is active stay outside of this safety zone Do not attempt to operate the machine until you have read the Site Preparation and User s Operation...

Page 12: ...oper grounding and shielding Ensure that all shields are properly connected after any repairs Any unauthorized modifications to ma chine wiring will immediately void the warranty and may result in damage or personal injury Pneumatic Safety System pressure must be completely drained and the system locked out before any repairs are made Do not used compressed air to clean the machine Com pressed air...

Page 13: ...y is recognized around the world By purchasing the Brown Sharpe Global CMM you have joined an elite family of individuals not unlike yourself who share your desire to provide their customers efficient accurate services You will want to locate the newly designed Global CMM in a prominent area of your facility to display your commitment to accuracy and repeatability The Brown Sharpe Global CMM has u...

Page 14: ...Global General Information Global User Manual 1 8 System Specifications Floor Plan Global 9xx8 Right Side View GC 2 Controller Opt Controller GC 1 Global 750x230x468 ...

Page 15: ...Global General Information Global User Manuall 1 9 General Info Floor Plan Global 12XX10 Right Side View GC 2 Controller Opt Controller GC 1 Global 750x230x468 ...

Page 16: ...Global General Information Global User Manual 1 10 Floor Plan Global 9XX8 Front View ...

Page 17: ...p Global User Manual 2 1 System Set Up SECTION 2 System Set Up 2 3 Operating Tips 2 4 Start Up Checklist 2 6 Starting the GC 1 Controller 2 7 Starting the GC 2 Controller 2 8 Mounting Parts 2 10 Probe Installation ...

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Page 19: ...played by the computer Be sure that the main air line is always securely attached to the system DO NOT attempt to move the bridge carriage or Z rail while air pressure is below the value noted in the pneu matic section of this manual Serious damage to the machine will result Before mounting parts or fixtures clean away any chips or debris using a brush or vacuum Do not use com pressed air to clean...

Page 20: ...ed and inspected Air supply has been properly connected and inspected Air supply is set to the correct pressure as defined in the Pneu matic section of this manual The computer system software is installed and all interfaces have been properly installed Safety The pre operation checklist must be performed and followed specifically to ensure a safe and continuous operation of the CMM Follow all rec...

Page 21: ...ll obstruct ma chine travel With the power strip turned Off connect the power strip to the facility supplied electrical power source Stop and Start Contingencies If power loss occurs the procedure for restarting is the same as described in the Electrical Power Up procedure You must clear all errors based upon which Operating System you are using If the measurement session is to be stopped overnigh...

Page 22: ...onsid ered a hard stop and is fatal to the program s execution The program may have to be reloaded when the machine fault is cleared If the E Stop is used refer to the Controls section of this manual for restart procedures It is recommended that the power switch be left on between shifts paused but the machine should be shutdown at the end of the day E Stop Button Power Switch ...

Page 23: ...cles which could pro duce a collision 5 This system requires a duplex outlet One for the GC 2 and the the other for the workstation power strip Connect the controller and workstation accordingly 6 Turn the system ON 7 Unlatch all emergency stop buttons GC 2 Control Panel Jog Box Options by rotating counter clockwise 8 Power up the GC 2 controller 8 1 Rotate the disconnect switch to the ON position...

Page 24: ...e is not correct adjust it as outlined in the Pneumatic section of this manual 4 Verify that there are no obstacles which could pro duce a collision 5 Plug the workstation into a protected power strip 6 Turn the power strip ON 7 Turn the GC 1 control power switch to the ON position 8 Power up the computer and log on if necessary 9 Start the measuring software if it had not started automatically 10...

Page 25: ...measuring operation The more accessible and stable the workpiece the more accurate the results Remove all obstructions from the worktable s surface Clean the worktable surface with alcohol Ensure the workpiece to be measured does not exceed the workpiece capacity Ensure the sections to be measured are within the measuring range of the probe Locate the workpiece as close as possible to the operator...

Page 26: ...m the worktable The maximum allowable torque is 15 ft lbs If using a clamp or bracket locate the workpiece as close as possible to the operator using the closest insert Place the clamp or bracket on the workpiece without it interfering with the travel of the probe probe head and Z ram Clamp Kit Worktable Insert Mounting Parts Mounting Parts ...

Page 27: ...e Global CMM is assembled with a standard Renishaw PH10MQ Probe Head with Autojoint and equipped with a single standard Probe refer to the following table A Renishaw Hand Control Unit HCU1 controls the movement of the PH10MQ probe head in the A and B axis of rotation The probe and if required the PAA1 Adapter is attached to the probe head and the probe head is installed in the Z ram quill Model St...

Page 28: ...0 Renishaw SP600M Removal of the Probe TP20 200 and adapter Using the hand key rotate the locking unlocking screw clockwise a 1 6 of a turn screw groove goes to horizontal releasing the adapter from the probe head TP 20 200 to adapter Use C clamp tools from Renishaw Stylus Change ...

Page 29: ...System Set Up Global User Manual 2 13 System Set Up Locking unlocking Screw Hand Key Locking Unlocking Screw Counter Clockwise Removal Screw Groove Releasing the Probe ...

Page 30: ...tools from Renishaw Stylus Change Always remove module from probe sensor Use appropriate Renishaw tools 1 Slowly engage the threads of the probe into the adapter by rotating the probe clockwise Continue rotating until the probe is flush against the adapter 2 Install the adapter against the probe head s stem with the alignment dots facing forward and vertically inline Note If you are installing a T...

Page 31: ...System Set Up Global User Manual 2 15 System Set Up Alignment Dots ...

Page 32: ...head and remove the four 4 screws securing the probe head to the Z ram quill 4 Separate the probe head from the Z ram quill 5 CAREFULLY disconnect the electrical cables between the probe head and the Z ram quill and remove the probe head Caution Electrical and pneumatic power to the CMM must be turned off prior to removing the probe head Probe Head Electrical Cables Probe Head Connectors ...

Page 33: ...to the Z ram quill making sure the alignment dot is facing forward Caution Ensure electrical and pneumatic power to the CMM is turned off prior to installing the probe head Use caution to avoid pinching the electrical cables between the probe head and ram 3 Tighten the four 4 screws securing the probe head to the Z ram quill 4 Install the probe to the probe head Probe Head Alignment ...

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Page 35: ...Global Electrical System Global User Manual 3 1 Electrical System SECTION 3 E l e c t r i c a l System 3 3 System Power Up 3 3 System Schematics 3 3 System Overview 3 3 System Requirements ...

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Page 37: ... The Global CMM will require a dedicated protected circuit to operate correctly There are two available controllers which are explained in greater detail in the controller section of this manual System Requirements The Global CMM will require a dedicated grounded circuit to operate correctly GC 2 GC 1 Global Input Voltage 10 115 230 VAC 50 60Hz 115 230 VAC 60Hz Full Load Current 12 6 Amps 2 Amps P...

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Page 39: ...Global Pneumatic System Global User Manual 4 1 Pneumatic System SECTION 4 Pneumatic System 4 3 System Power Up 4 3 System Schematics 4 5 System Overview 4 9 System Requirements ...

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Page 41: ...the right rear corner of the CMM This unit includes a 5 micron particulate pre filter to remove large solid contamination and liquids This is fol lowed by a 01 micron coalescing filter which removes sub micron particulate matter and oil aerosols down to the 01 micron level Both filter assemblies have automatic drains which expel collected liquids as triggered by a float operated valve at the botto...

Page 42: ...In cases such as this additional filtration and an air drier may be necessary To ensure a successful installation it is recommended that the user follow the start up instructions in the Site Prep Manual for customer piping After installation monitor system operation of the machine to determine if the air prep package is performing adequately Pay particular attention to the automatic drains The flo...

Page 43: ... the recommendation is to replace both filter elements If the elements are becoming clogged more than one time per year it may be necessary to install additional filtration in the facility compressed air system The Bridge The bridge is a rigid aluminum alloy assembly comprised of an X rail supported by two 2 legs a right leg drive leg and a left leg The aluminum alloy construction provides greater...

Page 44: ...wing the bridge and carriage to move freely along the X Y and Z axis Note These air bearings are adjusted during manufacturing and should only be re adjusted after replacement and by Brown Sharpe representatives Typical Air Bearing The Counter balance Cylinder and Regulator The Z axis is counterbalanced through the application of regu lated pressure to neutralize the combined weight of the z rail ...

Page 45: ...R egulato r Counter balance Cylinder Regulator Note The counter balance cylinder system pressure should be adjusted after every probe head exchange The Pressure Switches This CMM utilizes 2 pressure switches one to protect the air bearing system the other to protect the counterbalance system The switches are located on the base above the air prep unit and are designated as de scribed here Counter ...

Page 46: ...es sure If supply air were reduced to 53 psi 5 psi below normal operating pressure of 58 psi the PAP switch would send a signal to the controller to shut the machine down The PCC switch works the same way If the counterbalance pressure is changed to accommodate a probing system change the pressure switch should be adjusted accordingly Air Pressure Switches Air Solenoid Valve Safety Lockout Valve P...

Page 47: ... installed probe before you apply air to the filter regulator assembly Automatic Drains Pressure Gage If the system air pressure gage does not indicate 58 psi adjust the regulator to 58 psi Activate the controller and electrical system to power up the pneumatic system applies system pressure to the air bear ings Note The pressure switch will open the solenoid shutoff valve allowing system air pres...

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Page 49: ...obal User Manual 5 1 Major Components SECTION 5 Major Components 5 3 Granite Pedestals 5 3 The Bridge 5 6 Pneumatic System 5 10 Pneumatic System Air Pressure Adjustment 5 12 Counterbalance Cylinder Air Pressure Adjustment ...

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Page 51: ...he granite is supported by five 5 adjustable pedestals of which three 3 are equipped with anti vibration pads and actually support the machine The remaining two 2 do not touch the granite and are for safety only anti tip The pedestals are adjusted at installation to provide a level worksurface to ensure accurate workpiece measurement There are four 4 lift points for the granite worktable two 2 lif...

Page 52: ...l User Manual 5 4 Pedestal Placement A nti T ip Ped estals Sup p ort Ped estals The underside of the granite is marked to ensure proper placement of the support pedestals The anti tip pedestals should be distributed as shown ...

Page 53: ...ed in staggered rows and spaced approximately 8 5 and 12 inches apart Caution Do not overtorque the clamp bolts Overtorquing may cause the worktable insert to come loose from the worktable The maximum allowable torque is 15 lbs Inserts The y axis Cable Track and the Air Filter Regulator Assembly are mounted on the lower right hand side of the granite work table Air Filter Regulator Assembly Cable ...

Page 54: ...ith six 6 air bearings Three 3 in the front and three 3 in the rear The two 2 inner air bearings are preloaded and lock the bridge in place when the CMM is not in opera tion Left Leg X Rail Drive Leg Y Rail Prelo aded Air Bearing The drive leg provides a channeled conduit which encloses and protects pneumatic tubing and an electrical harness During CMM operation the drive leg is moved along the y ...

Page 55: ...een 15 air bearings Six 6 X and and nine 9 Z bearings Of the two upper back air bearings the rear air bearing is preloaded and will lock the carriage in place when the CMM is not in operation During CMM operation the X Z carriage is moved along the x axis by a drive belt attached to a motor The tower is mounted atop the X Z carriage and houses the Z Ram X Z Carriage Drive Belt X D rive M otor Belt...

Page 56: ...ched to the motor through a series of pulleys and a pulley belt The counter balance cylinder which provides a force to offset the weight of the Z ram probe head and probe is counter balanced within the Z ram The probe head is mounted on the lower end of the Z ram and supports the probe Z Ram Counter balance Cylinder Counter balance Cylinder Z Ram Tower Probe Head Pulleys Belt Motor ...

Page 57: ...hine The CMM has three 3 separate scales one for each axis of travel x y and z and each with their own separate scanning head sends a signal to the controller indicating a position along the scale Each scanning head is adjusted to maintain a close tolerance to the scale during axis travel The y axis scale is mounted on the outer side of the Y rail along the travel of the drive leg and the y axis s...

Page 58: ...e The z axis scale is mounted vertically on the right hand side of the Z ram and travels with the Z ram through the X Z carriage The z axis scanning head is located on the X Z carriage between the Z ram s right hand side air bearings Scale Scanning Head z axis Scale Scanning Head x axis Scanning Head Scale Scanning Head Scale Adjustments Alignments Detailed adjustment information can be found in t...

Page 59: ... the gage indicates 55 psi proceed to step 6 Adjustment Knob 5 Turn the pressure switch s adjustment screw clockwise or counter clockwise until the computer program indicates Air Pressure Low The system air pressure switch is now set to 55 psi 4 If the pressure gage does not indicate 55 psi pull the adjustment knob down releases the snap lock of the knob on the Air Regulator and turn the knob cloc...

Page 60: ...p to snap lock the knob back in place The system air pressure is now set to 58 psi 7 Check the CMM for proper operation before beginning any workpiece measurement Counterbalance Cylinder Air Pressure Adjustment 1 Verify that all pneumatic system components are installed and functioning properly 2 Verify that the probe is removed from the probe head 3 Turn ON the controller computer and apply facil...

Page 61: ...emains stable the forces are likely equal 6 If the forces are not equal loosen the locking nut on the regulator stem and adjust the counter balance cylinder regulator knob until the exerting forces that extend and retract the Z Ram are equal Refer to the following table Clockwise Knob Rotation Cylinder Pressure To Balance Turn the Knob The Z Ram Clockwise Counterclockwise Counterclockwise increase...

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Page 63: ...3 Manual Temperature Compensation 6 3 Linear Temperature Compensation 6 4 A C T I V 6 4 Probes 6 5 TP20 Probe 6 5 TP200 Probe 6 6 TRAX Probe Head 6 6 SP 600 Probe 6 7 Probe Compensation And Qualification 6 9 Measuring With An Electronic Probe 6 10 Touch Trigger Probe Repeatability 6 13 Planning the Measurement ...

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Page 65: ...values are determined based on the temperature entered This type of system is highly subjective due to the undetermined method of measuring the room tem perature Temperature compensation will only be as accurate as the room temperature entered into the system If 70 F is entered into the computer when in reality the temperature is 68 F the resulting compensation will be inaccurate based on the inco...

Page 66: ...tors which change value based on temperature The higher the temperature the lower the resistance and conversely the lower the tempera ture the higher the resistance Thermistors are used in a wide variety of applications in industry today The most common use is as part of complex Engine Management Systems used on virtually every engine manufactured today Using a sophisti cated parametric compensati...

Page 67: ... the probe is attached to is still the determining factor in overall accuracy There are many other factors which affect system accuracy including the experience of the machine operator Each Global CMM model is supplied with a standard probe as detailed below TP20 Probe The TP20 Probe is a 5 way kinematic touch trigger probe It incorporates a 2 piece design which includes a Probe Body and a detacha...

Page 68: ...ace plane can be deflected independently from the other surface planes SP600 Probe High repeatability and 3D form measurement is achieved by using a novel type strain gauge structure to detect small displace ments of the stylus tip The strain gauge output is processed and converted into a Renishaw 2 wire system format using an ASIC electronic chip and hybrid micorcircuit technology The stylus modu...

Page 69: ... to the features surface as possible When a point is measured with a probe the point recorder is at the center of the probe not on the surface of the probe Probe compensation is the process of calculations that correct the measured feature for the probe radius error The approach vector for the first point of a feature is used in these calculations and is thus of critical importance The SP600 Probe...

Page 70: ...All probes must be qualified before accurate measurements can be made There are two reasons for this To calculate tip diameter To learn the location of the center of the probe tip in the measuring volume This is important to obtain properly compensated data when the positional feedback is filtered through the error map Before qualifying a probe Verify that the proper probe type is selected in the ...

Page 71: ...nsion the larger the pre travel error and the more residual error is left after probe qualification Also longer probes tend to be not as stiff as shorter probes The more a stylus flexes or deflects the lower the accuracy Therefore probing with very long stylus extension combinations should be avoided Probe hits also known as points should be taken perpendicu lar to the part surface wherever possib...

Page 72: ...ong the axis of stylus give results that are not as repeatable as those taken perpendicular to the axis Probe hits neither perpendicular nor parallel to the probe body give results that are less repeatable than those taken parallel to the probe body Probe hits taken parallel to the stylus axis but are at an angle to the probe body are not repeatable and should be avoided if possible Probe configur...

Page 73: ...System Options Global User Manual 6 11 System Options ...

Page 74: ...ct of surface finish of the component being inspected however the the largest ball which can be used is limited by the smallest hole to be mea sured Another possible cause of error is shanking when the probe contacts the part with the shank of the stylus and not the tip The measuring system will assume the hit was taken with the tip and large errors will occur Increasing the diameter stylus ball i...

Page 75: ...evant dimensions are indeed verified Clamping is a crucial aspect of planning a measuring strategy yet it is often overlooked Incorrect clamping practices can lead to part deformation and use up a significant portion of the part tolerance This problem can be magnified with temperature variation during the measurement period Since each part is different in size and shape there are no generic means ...

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Page 77: ...Global Controls Global User Manual 7 1 Controls SECTION 7 Controls 7 3 Controller Information 7 3 GC 2 Controller 7 6 GC 1 Controller 7 9 Homing Sequence 7 12 Jog Box ...

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Page 79: ...larger machines and machines that incorporate the use of Temperature Compensation packages The GC 1 controller is incorporated as part of the workstation Both controllers require dedicated protected AC power sources to ensure proper operation The controller distributes the power to the CMM electrically operated components Communication between the controller and the workstation is accomplished via...

Page 80: ... grates one on the front and one on the back of the unit The jogbox is connected to the controller which allows the machine to be manually controlled The jogbox has buttons for system control including a machine start function and an emergency stop switch The control panel is located on the front of the cabinet There are four main controls 1 CONTROL OFF ON Leftmost Switch 2 MODE MANUAL AUTO Direct...

Page 81: ...his system requires a duplex outlet One for the GC 2 and the the other for the workstation power strip Con nect the controller and workstation accordingly 6 Turn the system ON 7 Unlatch all emergency stop buttons GC 2 Control Panel Jog Box Options by rotating counter clockwise 8 Power up the GC 2 controller 8 1 Rotate the disconnect switch to the ON position 8 2 Turn the keyswitch labeled Control ...

Page 82: ...nits The GC 1 control consists of a metal box assembled on the rear of the computer table It contains n An inner control box including the circuits for coordi nating handling and driving the three axes of the measuring machine and interfacing the measuring machine signals probe limit switches brakes and I O s n A power unit that powers the motors and logics in the control system n A power on off s...

Page 83: ...Global Controls Global User Manual 7 7 Controls GC 1 Global Controller and Workstation GC 1 ...

Page 84: ...ply to the CMM and verify that the pressure gauge reads 58 psi If the pressure is not correct adjust it as outlined in the Pneumatic section of this manual 4 Verify that there are no obstacles which could produce a collision 5 Plug the workstation into a protected power strip GC 1 Global Controller and Workstation GC 1 Global Controller 6 Turn the power strip ON 7 Turn the GC 1 control power switc...

Page 85: ...oming is a several step process The Z rail moves to its highest point then moves to a lower position locking on the 0 mark on the Z axis scale This is done as a precaution to clear any parts or fixtures left on the worktable The Z rail should not move throughout the rest of the homing sequence The ZX carriage then moves simultaneously in the X and Y direction to a point in the front left corner of...

Page 86: ...isable the system Manual Motion The Jogbox can move the machine in one two or all three axes simultaneously The manual Joystick motion of the probe using the Jogbox portable station can work in one of three ways 1 Along any direction in space selecting the three ma chine axes and combining joystick movements 2 Along a machine reference plane selecting two machine axes and combining the joystick de...

Page 87: ... Adjust the speed percentage by pressing the arrows of the speed button Powering the system down Exit from the measuring software Power off the control system using the switch on the side of the cabinet If the system configuration includes a PH10 PH10MQ probe head switch off the PHC10 2 control If the system includes other devices switch off the cooresponding controls Power off the CMM Switch off ...

Page 88: ... This button is used to select one of three types of movement FIXED RATE This mode restricts movement to a constant velocity STEP This mode allows the machine to be moved incrementally by joystick control In this mode if the jogbox is deflected beyond a certain point the machine will move the set distance To operate in the Slow Incremental Jog mode both STEP and SLOW must be active To operate in t...

Page 89: ...Probe A axis the up down arrow button selects the Probe B axis and the Circular arrow button selects the W axis PROBE ENABLED Used to inform the operator of the following conditions NOT ILLUMINATED Probe is enabled but controller will not report hits ILLUMINATED Probe is enabled and the host computer is ready to accept a point location FLASHING Temporarily disables the probe This feature is useful...

Page 90: ...ed To unlatch the pushbutton rotate it clockwise 1 4 turn The program may need to be re started after the cause of the ESTOP is corrected HOLD RUN This button is a two function button The HOLD function is accessed by pressing the HOLD button WITHOUT activating SHIFT The RUN function is accessed by ACTIVATING shift illuminating the SHIFT LED then pressing RUN When RUN is active the RUN LED will be ...

Page 91: ... is held down the axis LEDs will indicate which if any axes are locked see the UNLOCK key When the SHIFT LED is on pressing the Z Axis key will enable the W axis and disable the Z axis the function of the X and Y axis will be the same whether or not the SHIFT LED is on or off PRINT This button is used to interface with software commands prompts This button is used to learn positional moves enter p...

Page 92: ...ust be pressed and held while deflecting the joystick to allow the machine to move This prevents accidental movement of the machine This button has no function in DCC mode 3 AXIS JOYSTICK The joystick control provides the operator with an independent means of moving the machine s axes at variable speeds A connection to the three servo motors within the controller allows independent axis selection ...

Page 93: ...g Questions 8 3 System Troubleshooting Machine 8 3 Machine won t turn On 8 3 Machine won t repeat measurement 8 4 Inaccurate Measurements 8 4 Probe does not take hits 8 5 System Troubleshooting Computer Peripherals 8 5 The computer won t turn on 8 5 No Power to Monitor 8 5 Printer does not work 8 7 Frequently Asked Questions ...

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Page 95: ... a protected power strip Is the voltage supply correct as described in the electri cal requirements section of this manual Is the ESTOP button disengaged The button must be unlatched rotate counter clockwise for the system to operate Machine won t repeat measurement Are excessive vibrations occurring in the area of the machine Is the part secure on the table Is the probe tight in the Z rail Is the...

Page 96: ...sphere is moved Is the probe damaged Is the temperature of the part machine and measuring environment stable within the specification Has the probe head been repositioned or readjusted Is it square with the machine Was the artifact secured tightly Probe does not take hits Are the cables correct and properly connected Is the probe inhibit switch activated on the hand control Is the probe interface ...

Page 97: ...ce n Is the monitor switch ON Printer does not work n Is the printer cable plugged into the correct port n Does the printer have enough paper n Is the printer jammed n Is the power cord plugged into the printer and the electrical outlet n Are the printer settings correct n Does the printer have a sufficient supply of ink n Does the printer have the proper cable n Is the printer on line n Reset the...

Page 98: ...cursor appears on the monitor but nothing appears when you press the keyboard keys n Is the cable between the keyboard and the connector on the rear panel properly installed n If the Num Lock Caps Lock or Scroll Lock lights are blinking the keyboard password has been activated Enter the password to unlock the keyboard Axes won t move n Is the machine at the end of travel for one of the axes n Is t...

Page 99: ... http manuals brownandsharpe com Where can I obtain additional information about Brown and Sharpe or upcoming training classes http www brownandsharpe com Who do I contact to comment about the manuals or to suggest a correction Contact Brown and Sharpe at 1 800 343 7933 9a 5p EST Will updates be made to these manuals Any modifications or revisions necessary will be updated online at the web site m...

Page 100: ...s after the CMM has been installed No Retain the shipping brackets in case there is a need to relocate the CMM in the future Should I perform the scheduled daily maintenance every 8 hours if I only intend to use the machine for 4 hours Yes Everyday or before every shift you should perform this scheduled daily inspection even if you do not plan on operating the machine for 8 hours Are there any spe...

Page 101: ...lobal User Manual 9 1 System Maintenance SECTION 9 System Maintenance 9 3 Maintenance Inforamtion 9 4 Safety 9 4 Maintenance Tips 9 4 Scheduled Maintenance Intervals 9 5 Scheduled Maintenance Checklist 9 5 DailyMaintenance ...

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Page 103: ...tervals shown This maintenance schedule must be followed to ensure safe and continuous operation of your machine A maintenance log should be kept for each machine and all work and or replace ments recorded for future reference Failure to follow this schedule could be cause for invalidation of the warranty Any components not functioning properly should be adjusted for proper operation or immediatel...

Page 104: ...ce Tips Always lock out the system before performing any system maintenance Assign specific personnel that are thoroughly familiar with CMM operation and safety devices to perform the scheduled maintenance Keep a maintenance log on each machine and record all work and component replacements for future reference Scheduled Maintenance Intervals The recommended intervals for scheduled preventive main...

Page 105: ... interval 4 hours a day continue to perform the preventative maintenance on a daily once a day a monthly once a month and a quar terly once every three months basis Scheduled Maintenance Checklist Daily ü Inspect the CMM for any loose or damaged covers If necessary secure any loose covers and repair any damaged covers ü Wipe all the exposed surfaces of air bearing travel ways with alcohol and a cl...

Page 106: ...o the Air Filter Regulator Assembly or the supply air line ü Inspect both air filters for contamination If necessary drain the filter bowl or replace the filter element Refer to the Servicing Section in the Service Maintenance Manual SMM ü Inspect the facility supplied air lines for loose connec tions or damaged tubing If necessary secure any loose connections and replace any damaged tubing ...

Page 107: ...te System 10 8 An Explanation of Alignment 10 9 An Explanation of Datum 10 11 An Explanation of Translation 10 13 An Explanation of Rotation 10 15 Measured and Constructed Features 10 17 Volumetric Compensation 10 19 Qualifying Probe Tips 10 20 Projections 10 22 Effective Probe Techniques 10 26 Geometric Dimensioning and Tolerancing 10 27 Geometric Characteristic Symbols ...

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Page 109: ...eatures relative to other features on workpieces A coordinate system is similar to an elevation on map where the combination of a letter along one edge of the map a number along the other and elevations shown throughout specifically describe each location on the map This letter number eleva tion combination is called a coordinate and represents a specific place relative to all others Another examp...

Page 110: ... Map Coordinates A coordinate measuring machine CMM works in much the same way as your finger when it traces map coordinates its three axes form the machine s coordinate system Maple A 1 2 3 4 5 B C D E Birch Chestnut Sycamore Elm Oak Ritz Hotel Restaurant Train Station Museum Figure 1 ...

Page 111: ...inued Instead of a finger the CMM uses a probe to measure points on a workpiece Each point on the workpiece is unique to the machine s coordinate system The CMM combines the measured points to form a feature that can now be related to all other features Figure 10 Workpiece Coordinates ...

Page 112: ...surement The first is called the Machine Coordinate Sys tem Here the X Y and Z axes refer to the machine s motions When viewed from the front of the machine the X axis runs from left to right the Y axis runs from front to back and the Z axis runs up and down vertically perpendicular to the other two Figure 11 Machine Coordinate System ...

Page 113: ...orkpiece Before the introduction of computer software to coordinate measurement parts were physically aligned parallel to the machine s axes so that the Machine and Part Coordinate Systems were parallel to one another This was very time consuming and not very accurate When the part was round or contoured rather than square or rectangular the measurement task was nearly impossible Figure 12 Part Co...

Page 114: ...inate System and mathematically relates it to the Machine Coordinate System The process of relating the two coordinate systems is called alignment With a street map we do this automatically by turning the map so that it is parallel to street datum or to a compass direction i e north When we do this we re actually locating ourselves to the world s coordinate system Figure 13 Alignment ...

Page 115: ...museum and the restaurant Thus by using an origin datum s directions and distances people have all the information they need to get from one location to another For example to get from the train station origin to the restau rant you walk 2 blocks north on Elm Street datum take a right and walk 2 blocks east on Maple datum Figure 14 Map Datums Maple A 1 2 3 4 5 B C D E Birch Chestnut Sycamore Elm O...

Page 116: ...r Manual 10 10 An Explanation of Datum Continued In metrology a datum is a feature on a workpiece such as a hole surface or slot We measure a workpiece to determine the distance from one feature to another Figure 15 Workpiece Datum ...

Page 117: ...oles from a central hole To do this you would first measure the central hole translate the origin to the center of this hole and then measure each of the four surrounding holes Moving the starting point origin of the measurement from its present position to another place on the workpiece is called translation The CMM does this mathemati cally when you request an alignment routine from its geometri...

Page 118: ...to the city you need to find it on the map The hotel now becomes your new starting point or origin By knowing your location you can tell by looking at the map that you will have to travel two blocks west along Maple Street to reach the restaurant Figure 17 Translation Maple A 1 2 3 4 5 B C D E Birch Chestnut Sycamore Elm Oak Ritz Hotel Datum Restaurant Datum Train Station Datum Museum Datum Figure...

Page 119: ...eets the Hotel Restaurant and Train Station is on Thus to determine how far it is from the Hotel to the Museum you have to first translate your key origin to the Hotel and then rotate the key to be parallel to the street on which the Museum is located Now you can easily measure the distance from the Museum to the Hotel Figure 18 Rotation Maple A 1 2 3 4 5 B C D E Birch Chestnut Sycamore Elm Oak Ri...

Page 120: ...workpiece The distance between the two holes on the workpiece can be measured once the original origin is translated to the smaller hole and the part coordinate system is mathematically rotated 45 Now both of the holes lie along the new Y axis and the distance can be calculated automatically Figure 19 Rotation a Origin 45 ...

Page 121: ... feature with a probe the features are referred to as measured features Other features such as distance symmetry intersection angle and projection cannot be measured directly but must be con structed mathematically from measured features before their values can be determined These are called constructed features In the drawing below the centerline circle is constructed from the center points of th...

Page 122: ...eatures to another feature or group of features are critical to manufacturing For example the intersect point between the cylinders on one side of an engine block and those on the other side determines how well mating parts fit This intersect point is constructed from the two measured features the engine cylinders Figure 21 Measured Features ...

Page 123: ...the geometric errors of the CMM are measured called error mapping they can be minimized or even eliminated by powerful algorithms in the CMM s software This technique is called volumetric error compensation by eliminating errors mathematically you lower the cost of manufacturing and provide the customer more performance for their money Volumetric compensation can be best understood in terms of the...

Page 124: ...rth and magnetic north 3 W must be compensated for or a sailor would end up northwest of the intended goal and would run aground before reaching the final destination A coordinate measuring machine does a similar compensation automatically to remove the variations of the machine from the measurement Figure 22 Volumetric Compensation ...

Page 125: ...ior to measuring Since it s the tip s circumference that touches the part the probe s center and radius are determined by measuring a very accurate sphere requalification sphere Once the center and radius of the tip are known when the probe contacts a workpiece the coordinates of the tip are mathemati cally offset by the tip s radius to the tip s actual point of contact The direction of the offset...

Page 126: ...al flat map of the world Mercator projection The flat map is made by projecting a globe of the world sphere onto a cylinder In metrology projections allow you to measure more accurately how mating parts will eventually fit together In automotive cylinder measurements e g engine blocks by projecting a cylinder into the plane of the head face you can accurately determine how the pistons will fit int...

Page 127: ...if those points are not at the same distance from the top of the bore the measured diameter will be shown to be elliptical To overcome this misrepresentation the measurement data is projected onto a plane that is perpendicular to the centerline of the cylinder The result is an accurate deter mination of the real size of this workpiece feature Figure 24 Projections a ...

Page 128: ...nts should be taken perpendicular to the workpiece surface whenever possible Touch trigger probes used on coordinate measuring machines are designed to give optimal results when the probe tip touches the workpiece perpendicular to the probe body Ideally you should take hits within 20 of perpendicular to avoid skidding the probe tip Skidding produces inconsistent non repeatable results Figure 25 Ef...

Page 129: ...ose taken perpendicular to the axis Figure 26 Effective Probe Techniques a Probe hits that are neither perpendicular nor parallel to the probe body produce results that are even less repeatable than those taken parallel to the probe body You should avoid taking probe hits parallel to the stylus and at an angle to the probe body since they will produce large errors Figure 26 Effective Probe Techniq...

Page 130: ...Techniques Continued Shanking is another cause of measurement error When the probe contacts the workpiece with the shank of the stylus and not the tip the measuring system assumes the hit was taken in a normal manner and large errors will occur Figure 27 Shanking ...

Page 131: ... measured However the largest tip that can be used is limited by the size of the smallest holes to be measured Measurement points taken with an electronic probe either are recorded when the stylus is deflected enough to break mechani cal contacts or generate enough force to trigger pressure sensi tive circuitry The physical arrangement of the contacts causes slight errors in accuracy although thes...

Page 132: ...ribe part features in a way they can be accurately manufac tured and inspected GD T is expressed in the feature control frame The feature control frame is like a basic sentence that can be read from left to right For example the feature control frame illustrated would read The 0 196 square shape 1 is controlled with an all around 2 profile tolerance 3 of 0 002 4 in relationship to primary datum A ...

Page 133: ...e features such as two and four lane highways bridges and airports They are like the new international road signs seen more frequently on US highways The purpose of these symbols is to form a common language that everyone can understand Geometric Characteristic Symbols Straightness A condition where all points are in a straight line the tolerance specified by a zone formed by two parallel lines Fl...

Page 134: ... The profile tolerance specifies a uniform boundary along the true profile within which the elements of the surface must lie Angularity The condition of a surface or axis at a specified angle other than 90 from a datum plane or axis The tolerance zone is defined by two parallel planes at the specified basic angle from a datum plane or axis Perpendicularity The condition of a surface or axis at a r...

Page 135: ... whose axis coincides with the datum axis Position A positional tolerance defines a zone in which the center axis or center plane is permitted to vary from true theo retically exact position Basic dimensions establish the true position from datum features and between interrelated features A positional tolerance is the total permissible variation in location of a feature about its exact location Fo...

Page 136: ...ed at right angles to the datum axis it controls circular elements of a plane surface Total Indicated Runout Provides composite control of all surface elements The tolerance applied simultaneously to circular and longitudinal elements as the part is rotated 360 degrees Total runout controls cumulative variation of circularity cylindricity straightness coaxiality angularity taper and profile when i...

Page 137: ...Introduction to CMM Global User Manual 10 31 Intro to CMM ...

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Page 139: ...lignment 10 8 Angularity 10 28 B GC 2 Control Panel 7 3 GC 2 Controller 7 3 Belt and Drive Motor 5 7 Bridge 4 5 5 6 C Cable Track y axis 5 5 Circular Runout 10 30 Common Controller 7 3 Concentricity 10 29 Controller Information 7 3 Controls 7 3 Counter balance Cylinder 5 8 Counterbalance Cylinder Air Pressure Adjustment 5 12 Counter balance Cylinder and Regulator 4 6 Cylindricity 10 28 D Datum 10 ...

Page 140: ...1 4 Flatness 10 27 Frequently Asked Questions 8 7 G General Safety 1 5 Geometric Dimensioning and Tolerancing 10 26 Granite and Pedestals 5 3 Granite Worktable 5 3 H Hand Control Unit 7 12 Hand Probes 6 13 http www brownandsharpe com 1 10 I Inserts 5 5 Installation of the Probe 2 13 Installation of the Probe Head 2 16 Internet Accessible 1 4 Introduction to CMM 10 1 L Linear Temperature Compensati...

Page 141: ... 6 9 Mounting Parts 2 8 O Operating Tips 2 1 P Parallelism 10 29 Pedestal Placement 5 4 Perpendicularity 10 28 Planar and Spherical Probing 6 9 Planning the Measurement 6 13 Pneumatic Requirements 8 6 Pneumatic Safety 1 6 Pneumatic System 4 3 Pneumatic System Air Pressure Adjustment 5 10 Position 10 29 Pre operation checklist 2 3 Pressure Switches 4 9 Probe Compensation and Qualification 6 7 Probe...

Page 142: ...es 5 9 Scheduled Maintenance Checklist 9 5 Scheduled Maintenance Intervals 9 4 SP600 Probe 6 6 Starting the GC 2 System 2 6 7 5 Starting the GC 1 System 7 8 Start up Checklist 2 4 Stop and Start Contingencies 2 5 Straightness 10 27 System Description 1 7 System Maintenance 8 9 System Operation 8 3 System Options 6 1 System Schematics 3 3 System Set Up 2 1 System Specifications 1 8 System Troublesh...

Page 143: ...Machine Coordinate System 10 6 The Part Coordinate System 10 7 Total Runout 10 30 Touch Trigger Probe Repeatability 6 10 TP20 Probe 6 5 TP200 Probe 6 5 Translation 10 11 TRAX Probe Head 6 6 Typical Scale 5 8 V Volumetric Compensation 10 17 X X Z Carriage 5 7 Y Y Rail Air Bearing 41 Z Z Ram and Probe Head 5 8 Z Ram Tower 5 8 ...

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