VSA Operational Manual
Contents
1. F including vapor ppm Vol at 100 psig mg cubic meter 1 0 1 94 0 3 0 01 2 1 0 40 16 0 1 3 5 0 4 128 1 0 4 15 37 4 940 5 0 5 40 44 6 1240 25 6 50 1500 Note OPTEK Recommends air quality of Class 3 or better 29 Care of Guide ways Keep guide way amp bearing surfaces clean of debris amp dust Contamination with oil coolant or other fluids is to be avoided Clean guide ways and bearing surfaces when needed with air pressure applied Use ISOPROPYL ALCOHOL ONLY Do not clean bearings or guide surfaces with keytones Clean by applying alcohol to a clean dry cloth and wiping surfaces thoroughly Allow guide surfaces to dry completely before passing bearings over cleansed area Caution A qualified service technician must perform all maintenance Cleaning the Exterior Surfaces Clean the painted surfaces of the equipment with a damp cloth Use an all purpose cleaning solution If necessary a protective wax may be used on the painted surfaces The granite should be cleaned with a dry cloth Use Granite Surface Plate Cleaner Z 212 or a compatible cleaner This can be ordered from The Calibration Solution 9865 N Alpine Road Machesney Park IL 61115 Phone 815 877 0880 FAX 815 877 2062 www thecalibrationsolution com Cleaning Optics Since most solvents used to clean optics are harmful to human touch gloves are recommended for the cleaning process Gloves will also protect the optics f2. OPTEK VideoMic workstation 10 Chapter 2 Getting Started OPTEK VideoMic VSA Power On Procedure Ensure compressed air is being provided at the back of the VideoMic VSA At the console Ensure the X and Y axis are positioned in the center of travel Ensure the Emergency Stop button is in the up position Press the Power On button If necessary turn on the monitor Use the individual power button for this If the PC is not on turn on the PC and follow the on screen instructions Ensure the HGP is lowered and no objects are in the light interrupt path Ensure all Control Panel LED s are off Fine position amp Z axis toggle Move the transport by hand in all directions It should move freely Start IK5000 software using the icon The VideoMic VSA will automatically proceed through a homing sequence When completed the transport should be positioned with the camera lens near the center of the glass platen 10 Conduct a test of the Operator s controls joystick trackball interlocks etc o0 NOg gt O N Caution Note The transport cannot move with the HGP open Be certain the HGP is closed while setting Machine Zero Homing Sequence IK5000 Once IK5000 is started a window will appear asking if you make sure that the Motors are tumed on would like to begin the automatic homing sequence Do you want to begin the automatic homing sequence If Yes Select Yes and observe the dialog b
3. camera so Light to Dark the dot can be seen on the Video monitor taking up more than half of the video screen Dark to Light Adjust the light settings as low as possible maintaining a clear image in the Video First Edge window DEZE Position the dot as close as possible to the center of the Video monitor Tool Config Go to Probe Probe library Click the magnification of interest and choose the An Resolution tab Light Control Select Teach to edit the calibration Focus Enter the size of the calibration dot The actual size of the dot is found on the back of the calibration slide case Arrange the calibration probe to cover the dot and double click to cause the probe to shoot from dark to light Check the feature view to determine if the dot diameter matches the slides given diameter When you do a pixel calibration this dialog box will come up to prompt ou to enter the size of the artifact you are using to calibrate with The usually comes from the VED Pie slide Sied with the system Yed Artifact Size x If you select continue the system will prompt you to measure the New Calibration Edit Calibration v Default Calibration specified artifact If you say cancel it will return you to the Probe Library Artifact Size 1 000 window After the appropriate information has been placed in the Standard Size area select the circle tool twice This will center the tool in the Video window Using the digital position
4. iaaiiai eiea 28 LED lighting uni replacement neuere ertet tenetur ee 28 LED Profile Light Replac amp ment u R ee nee 28 LED Top Light Replacemeni u En ee 29 Lubricating the rail system Z AXIS un ee ee 29 Standard Steel Rails Z AXIS i 2 9 ete 0er 29 Care or Air Bearings eiin D hai cy decret A decere das uae V dece ue aie ve ae eda uaa vu ede e ep b aede e p Ghats 29 G re of Guide ways a eoe E N u uuu diel a eve e deed Gel din re tu cnet ve aep a edades ede ha e Ee di 30 Cleaning thhe Ext rior S rfae6 oe ea einer 30 Gleaning Oplcs 4 a 30 EE a AiE a E NN 30 OPTEK SERVIGE tentes lenken eater et epe bea teca eraa ev pr araa a eaaet pe be Eaa 30 Chapter 7 Warranty nee tee pte dede as pr tede teca eee tee ev vo qaa usq derart be irn 31 lauri E A 32 EIABIEITYSOE WARRANTY er 2 tere te repete e rate tecto edel este o est at o edet avt eto vere becas 32 Service amp General Gare c t ett e ende ep be tea pelo o ev p ebat a rnv eee br e Pueden 32 M interiance Schedul 5 2 lese cta eterne rete toc ev pel ester rv bleekrh endlosen 33 Chapter 1 An Overview The VideoMic VSA System Overview In response to the ever increasing demands placed on industry to improve the quality decrease the size and increase the density of a given product the OPTEK systems have evolved The VideoMic VSA systems are the latest respo
5. principles User Programmability over movement focus magnification lighting data acquisition tools and reporting Automating these tasks eliminates operator error and speeds throughput Accurate Positioning of samples obtained from high acceleration linear motors and high accuracy scales to determine position Path optimization may improve throughput Non Linear Error Correction NLEC This software feature allows any errors detected in the measurement system to be corrected automatically The entire measurement area is mapped and compensated for inherent mechanical errors Video Edge Detection VED A user programmable feature which allows the choice of how the software sees a feature Setting the threshold strength and the VED method provides great flexibility in the types of features which can be measured Control over the image from the camera and frame grabber The IK5000 software and lighting may be used to manipulate the image to enhance weak features and image processing software library functions for the frame grabber take advantage of the video enhancement capabilities These five main concepts combined with other principals make the OPTEK VideoMic a teachable automatic and accurate measuring device Caution Operation of this equipment assumes some basic knowledge of computers and MS Windows software If you are not familiar with these computer terms please read this manual completely before you power up the
6. the extreme rear and right of its travel Note the Units Inches or MM and sign or of the numbers to verify your initial settings Note If fast moves are needed turn off fine positioning in the tools CNC mode menu 12 Machine Zero Machine zero is critical as it is the reference for the calibration system The IK5000 will go through a homing process immediately on startup see Homing Sequence or using the mouse choose the Set Machine Zero from the Datum menu This position for X Y and Z is the machine zero position After this process it is possible to have non zero numbers in the display This is OK Digital Positioner Move the Digital Positioner trackball This allows for fine movement Watch the Digital Read Out DRO on the monitor to ensure the trackball is moving one of the axes If the numbers move in the DRO relative to the axis being moved the trackball is functioning correctly Note also the display resolution This should match the resolution of the encoder scales Tooling Fixtures or Hinged Glass Platen Check to see if any tooling fixtures are mounted and secure If a pneumatic system is used actuate this through its cycle and back System Cooling Verify that the fan is working on the system The fan is located on the back near the power switches on the electrical bay side of the unit The fan will turn on immediately when the green Power switch is depressed There are one or more fans in
7. Allows for more precise positioning of the transport or Z axis focus The Keyboard Supplies input to the dialogue boxes which the software provides Note Selecting the Z axis toggle Run or Fine positioning switches will engage that function for both the joystick and trackball Joystick Trackball Emergency Stop Z Axis Toggle User Programmable Fine Positioning Power requirements 120 VAC 60 Hz or 220 VAC 50 HZ 5 0 Amp single phase Since OPTEK machines are sent world wide connectors for your machine for power requirements are not supplied See a qualified electrician for hookup according to local safety codes Air Requirements Clean dry compressed air 3 CFM 85 Liters min at 110 120 PSI 7 8 25 bar regulator adjusted to 80 PSI The OPTEK VideoMic VSA should be mounted level within about 005 foot for best performance Caution For power installation see a qualified service technician to obtain a power connection and approved hardware Caution The unit must be positioned so it is easy to operate the Main Disconnect Caution The unit must be plugged in to an outlet with a protective grounding terminal Caution A qualified service technician must perform any required maintenance Back View Machine Cover Cooling Fan 100psi air input Input power 115VAC or 220VAC Leveling foot Circuit breaker and Lockout switch Operating Principles The use of the VideoMic depends on five main
8. OPERATIONS TECHNOLOGY INC VideoMic VSA Operation Manual IK5000 VIDEO MEASUREMENT AND INSPECTION WORKSTATION For S N Model VSA Version G December 2011 Operations Technology Inc P O Box 408 Blairstown NJ 07825 www optek net Phone 908 362 6200 Fax 908 362 5966 VIDEO MEASUREMENT AND INSPECTION WORKSTATION L n n n 1 Chapter T AIR OVerVieW u un A A A vty etl A pne deve ua deeds 4 System OVerVIieW a uuu ELEM 5 System Description RI PII ccc 5 Camera Head Assembly 5 5 iat ee eve en u Ad e eu p edv e den EA ad 6 XV SpIIIEAXIS Transport xc 6 Table Assembly Qranite uyu us ee en u nl 6 El amp ctr nics Area ee ee ee IUA NE ee ee ee ed ed 6 Contra PA pc innen waaka Sth edie 6 A 6 O e T 7 inp EEUU 7 Documentation for the OPTEK VideoMiic ener inttr sn terret rns n nnn sites internen rris sinere ns 7 The oontrol Panel sr ug a muna m e OM EPIRI REGIE tee e tiem ic ayauya esee neu ende 8 BaCk VIEW Cc 9 Operating PriNCIpIES gu u Deer c nie 10 Ghapter 2 Getting Started aer A ado bi 11 OPTEK VideoMic VSA Power On Procedure nc conocer 12 Homing Sequence IK5000 ai Ir re ae qaa ua ka a u hap a aaa Ohad 12 Operational Checkout IA aa g Maya y ete elu ae aa aa tied 12 Check system safety and integrity 0n4ernnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn
9. and parcentricity first Mechanical squareness and camera rotation adjustments follow and then software adjustments to the imaging system using the probe library Movement The transport movement is then determined and incorporated into the calibration using NLEC Non Linear Error Correction Adjustments to the Camera System Camera Rotation A mechanical adjustment Pixel calibration Software compensation Camera Rotation Calibration Software compensation Camera Offset For multiple Magnification Systems Calibration Procedure Do squareness or camera rotation first Pixel cal can be approximate at this point Adjusting the Camera Squareness A Mechanical Rotation which is only required if the machine or camera system is moved The next step in the alignment process is to ensure the camera is square to the X axis travel With a large crosshair on the video monitor place a sharp image all the way to the left side of the screen just touching the horizontal line of the crosshair Move the image to the right side of the screen with the joystick The object should follow the line If the does not follow the crosshair line loosen the two camera mount set screws Also used in adjusting Parfocality and rotate the camera until the image stays on the line from left to right Tighten the setscrews when the image touches the line from left to right Camera Rotation Correction Software Alignment Position a dot resting tangential to the
10. brary on the left Double Click the Probes Group if no sub categories are shown Unload Probe Tips 1 Gotothe Probe Menu gt Click Probe Library 2 Select ContactProbes gt Group_1 gt Tip_1 gt Unload Button above OK 3 Repeat step 2 for all remaining probes Calibration Sphere Size OPTEK initially calibrates all Touch Probe systems with a 1 calibration sphere if the artifact is 1 skip the next section and proceed to the Calibration 1 Goto the Tools Menu gt Options gt Probes Tab gt Change Sphere diameter to the correct size Touch Probe Calibration In Probe Library if Probes is the only option shows double click to expand it 1 Goto the Probe Menu gt Probe Library gt ContactProbes gt Group_1 gt Tip_1 gt Size Ofs Tab gt Hit Teach 2 Measure Four Points around the equator of the sphere and one on the top gt Hit OK 3 Repeat steps 18 2 for all remaining probes Skip to Probe Rack Port Teach if the rack does not need to be re taught Probe Rack Teach Remove all Probe tips from the Probe Rack and manually load the desired tip Open the program OPTEK ProbeRack Teach in C QC 5000 ProbeRack and ensure the Part View matches the Probe Rack layout Follow the instructions given by the program Once successfully completed continue below Probe Rack Port Teach Open Probe Library Probe Menu gt Probe Library 1 Remove all Probe tips from the rack gt Manually load the tip for the desired Port 2 P
11. crosshair tool horizontal centerline on the Video window at the left side of the field of view From the CNC toolbar choose Axis Lock Tools General Password Enter the security code Choose Probe Probe library Select VED from the left side window and Camera from the right side Select the Orientation tab to adjust Camera Skew Click the Teach button A calibration circle tool will appear on the Video monitor An instruction box will appear on the right Follow these instructions to complete the Camera Rotation Correction This completes the Camera Rotation Correction Exit this window by pressing OK 17 Pixel Calibration Assuring that the feature measures at the correct size All measurements are performed by calculating pixels These pixels have a set value that is determined through a simple calibration process If the pixels are not calibrated any measurements made will be incorrect The pixel calibration is based upon the Calibration Slide The standard Calibration Slide shipped with the system is for reference only This is not a traceable item If a traceable Calibration Slide is needed please contact your OPTEK representative or contact Operations Technology Incorporated for more information Ri WED Windows View f 25 eO v Auto Focus E e p Set the IK5000 to metric units Crosshair a T To perform a calibration the light New Tool levels must be set correctly Tools u Position the slide under the
12. ctions at the control panel Teach Joystick Buttons do not work Check tools options buttons settings Uncheck level base if necessary Data Problem Data doesn t seem right Software reports th wrong data Program created from DXF imported in wrong denomination DRO does not give correct data Possible scale errors Reader head loose DRO does not give any data Possible break in connections IK5000 Core Files There are 6 Core Files in the IK5000 Untitled 5US Supervis 5SY Datamaps 5MP Encoder 5ES Settings OEM NLEC txt 1 2 3 4 5 6 A Help Restore Settings Linear motor Tuning issue Scale or reader head misalignment Mechanical part loose worn or misaligned Clean the surface plate Calibrate Joystick Check Acceleration deceleration integral factor Motor and Power Supply are not connected The unit power was turned ON near the machine limits SET Home or Reset Auto Zero SET Home or Reset Auto Zero or limit switches are damaged Joystick Joystick Z Sotware Fence f Ans Mero Home Joystick X Joystick Q Superesor Z Axis Joystick Y Motion Mouse XA Digital Positioner General Configuration Cumerd values Enable Sh 2 v E Share With Preferences Reverse Nom Fine Accel Debounce cms Magnification scale e Iways make back ups This file includes the data from all core files in one file 24 Select the t
13. d constructed to fulfill a specific function utilizing unique variations in mechanics or technologies from our standard products PERIOD OF WARRANTY Operations Technology Incorporated warrants their products to be free of defects in material or workmanship for a period defined below commencing on the shipping date of the items covered Standard Equipment One year Special Equipment Ninety 90 days ITEMS NOT COVERED BY THIS WARRANTY The computer and associated components are covered to the extent of the original equipment manufacturer s warranty LIABILITY OF WARRANTY Operations Technology Incorporated warrants to the original purchaser that the equipment sold under this agreement shall be free from defects in material and workmanship Defective materials will be replaced or repaired at the discretion of Operations Technology Incorporated Liability will be determined by Operations Technology Incorporated All liability is expressly limited to said repair or replacement of defective parts all other damages and warranties statutory or otherwise being expressly waived by the purchaser This warranty is null and void if the equipment failure is due to negligence accident abuse or improper operation It is also nullified by tampering altering or unauthorized repair of subject equipment or components This warranty does not include lamps which are considered consumable items The user shall return allegedly defective material
14. done for each of the other magnifications except High which is the Master Probe in this group 21 Chapter 5 Troubleshooting Startup Troubleshooting Checklist This is a very short list to help if simple oversights occur For extensive troubleshooting consult your supervisor and other documentation provided Problems and possible causes The system does not turn on Is the red emergency stop button in the up position Is the power cord plugged in Is the line voltage correct 115 VSAC or 220 VAC The monitor does not work Is the monitor turned on Does it show an image Is the video cable plugged in The computer does not turn on Is the computer power button pressed in Is the line voltage correct 115 VSAC or 220 VAC Is the power cord plugged in The printer does not work Is the printer plugged in and turned on Is the paper loaded Is the data cable plugged in The stage moves by itself Are the cables in the control panel plugged in Is the DRO operating correctly Computer connections terminated properly The transport does not move in one or two directions Did the Homing sequence complete correctly The digital positioner trackball does not work Is the digital positioner turned on in the software Choose Tools CNC Digital Positioner Make sure the X and the Y Enable boxes are marked The stage will not move beyond a certain point Did the machine zero point get set correctly From
15. e lubrication is essential for linear motion Poor lubrication causes a linear motion system to wear quickly and reach the service life limit prematurely Lubricants are expected to Lubricate the bearings to prevent seizure and minimize wear by reducing friction Protect the metal surface of the z rails by coating the surfaces Lubrication intervals depend on the conditions of use and the environment The rail and bearing manufacturer recommends the system be lubricated every three to six months OPTEK recommends cleaning and re lubricating the rails and bearings monthly with Dupont Krytox Lubricate the linear motion system with the same type of lubricant Do not use or mix different lubricants Standard Steel Rails Z Axis To clean the rails wipe all races with lint free cloth moving the transport to expose all races in both the X and Y axis The lubricant recommended by the bearing and way manufacturer is any high grade slide way lubricant OP TEK recommends Dupont Krytox Use the very minimum 1 8 dab on each race no more Exercise the transport system through its entire travel to ensure even distribution of Krytox Care of Air Bearings Do not operate unless air pressure is applied to bearings Air must be oil free and free of contaminants and moisture A filtered air supply is highly recommended ISO QUALITY CLASSES QUALITY CLASSES DIRT WATER OIL Particle size in microns Pressure Dew point
16. e up direction Make sure your Z is counting positive in the up direction Probe Library Resolution Tab Select teach to do your Video Pixel Calibration You MUST calibrate each magnification Notice the size of a pixel at each magnification Remember we do sub pixel edge detection The IK5000 s edge detection is far superior to the QC4000 The edge detection is extremely sensitive in low light settings Camera Calibration Camera SKEW This is the section of Probe Library where you do your Camera Calibration If you click on Teach Probe Library walks you through doing a camera Skew calibration If your camera image is backwards or opposite you can change the Orientation here Remember to make this one of your first calibrations Properties Offset Resolution Auto Foces Mag Offset Orientation General Orientation Camera Skew Teach x 0 001820003329 Optical Axis 7 02856000 Tea Y 0 081844575581 Reverse M Horz M Vert Teach 20 Probe Library Offset Tab This frame shows the offset from magnification MedHigh to the master mag High These offset are also known as parcentricity and parfocality If you click on teach the system will walk you through the calibration You should start this procedure at MedHigh Notice reference is not checked Only the master probe HIGH in the group is checked The same calibration needs to be
17. ecuring samples for viewing e Interlock safety device to stop all motion e Optional Tooling Fences to secure samples to the stage in a reproducible fashion Table Assembly Granite e Bottom light for profile work e X Y Transport Stage Electronics Area Electronics boards Power supplies and amplifiers Fuses Rear power switch circuit breaker Control panel Power switches Emergency off lockout Joystick for X Y and Z Digital Positioner Data entry buttons Computer e Network Card e Frame Grabber Board e X Y and Z Axis board with onboard light I O and programmable zoom controller Front View X axis and camera head Monitor assembly Optional _ Hinged Glass VideoMic 52 J Daten HGP II Standard p N Keyboard IE Mouse Om Control panel Y axis transport assembly Height adjustment Granite table Computer system Electronics bay Software The VideoMic utilizes Microsoft s Windows operating system and Heidenhain IK5000 application programming for measurements Third party software is also available to utilize computer aided design and computer aided manufacturing CAD CAM programs Documentation for the OPTEK VideoMic 1 2 OPTEK VideoMic VSA Operational Manual IK5000 this book The Heidenhain IK5000 User s Guide describes the software features available to users programmers and maintenance professionals IK5000 Software on line hel
18. ed feature s and distribution of measurement points Measure Toolbar Used to measure and construct features Buttons correspond to items on the Measure menu View The view toolbar is used to adjust the part view window Layer control and Toolbars can also be accessed here Buttons correspond to items on the View menu View Rotator Changes the display angle of the part view and feature stamp Tolerance toolbar Used for performing tolerances on selected features Tolerances include run out concentricity parallelism true positions etc Datum This toolbar is used for establishing various Datum Zeroing operations and reference frames Program A toolbar used to access programming functions Buttons correspond to items on the Tools menu Feature List Found as a tab in the Program window this describes the measured features Program List Found as a tab in the Program window this shows the part program listing This is a brief introduction to the software display Amplifying information on each of the above may be found in the IK5000 User s Manual or later in this manual There is an excellent interactive online manual for IK5000 It is highly recommended that all operators spend some time with the CD ROM Light Control Sliders The image quality varies with the type of sample being tested and the options chosen in the light control window Once the OPTEK is turned on and IK5000 is run
19. elete removes a magnification Disqualify erases the data in the current calibration Warning do not select load unless the rack has been properly setup Selecting OK exits Probe Library 1341 F add dd O es le di x Prapatan Geni waswe u bae 7 Mine Fi Wwe La J wawa P First Jet 19 Probes New Vad e camera 1 Adminestra Desele VedProbes SEX 1 24 00 Admirestra Zw ContactProbeas 50 1 24 00 Adminstra Set Current genup 27x 1 74 00 Admitestra wow Diaquatiy Line Unisad or Teach ATAN Tesch Y 11 0018445 75501 ref s ter vean Bu A Moss j ContactProbes gt i 2 ee Set Current _Disquatiy um Unas o Properties Oe Resolution Aus Focus Meg Searce onl P c vom j Zum Falten Probe Library VED Probes This is the section of Probe Library where you set up how many points will be taken when you fire a video probe Max scans tell you how many points per firing Edge type indicates dark to light light to dark or first edge algorithm Type describes which algorithm will be used Auto Strongest or Teach performs an edge teach Probe Library Autofocus Tab m This is where you teach the AUTOFOCUS range of each magnification ien You must do a TEACH for each Magnification You can also set a search Distance manually If you teach from here you can use most VED Tools Remember a safe distance is in th
20. er track ball Move the transport system until the dot is as close to the center of the circle tool Continue Cancel as possible Size the circle tool to fit over the dot properly Click the right mouse button The system will measure the dot three times From this the X and Y pixel dimensions will be determined The present pixel value can be seen in the Pixel Size window Continue this procedure until all magnifications have been taught Click OK to exit the Learn VED Pixel Size window Click OK to exit the Edit Calibration window 18 IK5000 Calibration procedure for the Probe Library This operation is for factory representatives who are installing new IK5000 operating system computers to existing machines Setup your Magnifications Assign Zoom Positions Teach Autofocus and Video Edge Detection Pixel Calibration Camera Skew Parcentricity Calibration Go back and check all the calibrations by measuring the appropriate artifacts This is an extremely important part of the IK5000 This is the place to set up your Camera Magnifications VED tools and do all your calibrations Probe Library works a lot like Windows NT explorer Click something on the left it opens up and expands to the right If you turn on AutoFinish it will make calibrating easier Remember anything you want to calibrate must be on the right side NOD OA CN Probe Library Mag Tab Selecting new creates a new magnification Selecting d
21. esting information 32 Maintenance Schedule The OPTEK Video Series requires little preventative maintenance The key to the longevity of this machine is the same as many others cleanliness If a simple preventative maintenance schedule is followed the machine will run effectively However if the system is not cleaned and lubricated binding and eventual accuracy loss may result Frequency Clean exterior surfaces of equipment As needed based on the operating environment Clean and lubricate the rail system Every month Lubricate the ball screws Every six months Clean Pneumatic Filters amp Separators Every month Clean the lens system Prior to calibration or when required Scale Replacement Call OPTEK Scale Removal Call OPTEK Scale Insertion Call OPTEK DANGER ENSURE ALL POWER TO THE SYSTEM IS OFF AND THE POWER CORD IS DISCONNECTED FROM THE ELECTRICAL OUTLET PRIOR TO ANY SERVICE TO AVOID INJURY OR DAMAGE TO THE EQUIPMENT 33 Appendix Programming The Accelus Junis Amplifiers 35 Appendix B Touch Probe Calibration First determine if the Probe Rack needs to be re taught select a new probe tip While changing tips if the machine hits the rack or otherwise goes to an incorrect location the rack will need to be re taught Manually remove all tips from the rack and unload all tips If there is no movement or a message instructing to manually load the tip load the desired tip by hand and continue In Probe Li
22. ime or file you want to OK Cancel Ae inch MM Back up Your System The IK5000 software makes periodic automatic backups GOTO Help Backup Settings Once named the file will be saved into the IK5000 Backups folder Backups qb2 files and any important part files should also be copied to disc or other removable media and retained in a safe location 25 Chapter 6 Maintenance Maintenance Through preventive maintenance the OPTEK VideoMic VSA system will prove a benefit to your company General Care The components used in the OPTEK VSA Series will provide years of service with little maintenance if the following guidelines are followed e Keep the system clean The working environment should be as clean dry and dust free as possible e Donottake things apart e Donotremove any covers or components from the system Leave all screws intact If repair is needed contact your OP TEK representative e Call for help e Call OPTEK at 908 362 6200 or contact your local representative if there are any questions or problems e Keep the system up to date To check for the latest version of software check the Internet at www Heidenhain com For the latest hardware updates check the Internet at www optek net If you do not have access to the Internet fax 908 362 5966 requesting information Maintenance Schedule The OPTEK Video Series requires little preventative maintenance The key to the longe
23. ning you must establish the initial settings for the material you are to measure Note Although we see colors by the nature of the process video boards see a monochrome image consisting of black to white and grays in between All image enhancements are made by making adjustments to the gray scale which affect the image that the camera sees The controls have icons for the following optional lighting variations Ring Light or Z Trac optional source intensity On Axis Lighting source intensity optional gt AS Bottom light source intensity I 4 Elevation of the Z Trac assembly optional Quadrant lighting selection and intensity optional AL 115 00 10 00 93 00 54 00 Quadrant Lighting Quadrant lighting is available as an option The icons provide for the lighting of features from the sides for edge detection on highly variable subjects The quadrants may be turned on or off by clicking on the quadrant position in the icon Q Front Q Left Q Right Q Rear 14 HGP and Lighting The presence of the Hinged Glass Platen above a sample will affect the behavior of light from the sources above the sample Keep this in mind when testing light solutions Chapter 4 Calibration Calibration of the VideoMic VSA in IK5000 Calibration Procedure Overview A Complete calibration consists of both optical calibrations and calibration of the movement system Optical Check parfocality
24. nnnnnnnnnnnnnsnnnnnnnnnnnnnnnnnnnnnnnnnenannnnnnnannnn 12 KAN WARS A 12 Machine Aoc EE 13 Digital Post cc 13 Tooling Fixtures or Hinged Glass Platen l rn 13 ice mm M UE 13 The Computer Display Lu uu M 13 Screen Wi dow and Video WINDOW i ettet a een nike rim 13 Light Gontrol Sliders aom seele iaa 14 Quadrant Lighting opor tp etr Pret ran ea ae sea e be ove a Ehe e re HERR pe eet PRAE 14 HGP and Eighting iet rrt ree etes ite t e ere Re E rte iaa 15 Ghapter 4 1K5000 GallDratiOh ret iret e Gas e t eco Mee e t E Sb ei tO ME Ye eb nee 16 Calibration of the VideoMic VSA in IK5000 sesine aanta artara aaa taeae Ba aa aE Eai da SN Eana taeda iah 17 Calibration Procedure Overview x teet e ptite EE eco Se ra a EE e ci EO M Eni C a rV BEER Hd M Dee DE eut 17 Adjustments to the Camera System reiecit So Pe car Ee EH M ect Pg c nese IEEE He REN CE DIR e kd 17 Galibration Procedre oup i irte Ente 17 Adjusting the Camera Sq areness uero Pee rc she Eo ve En ar Pea ER Ee cH Dv RE ELE PER e ee e E HE RE cet ERE 17 Camera Rotation COITectiorn 2 ied ie decenter rates aaa diay sapa aed prp EE Rada a Rd da Pau d ERU ea doas 17 Pixel Galli reatony ERR 18 IK5000 Calibration procedure for the Probe Library U L n n nsn 19 Probe Library Mag Tapu uie is ie ti pep M e e ie d e Reti ids 19 Probe Library VED PODOS HU ii 19 Pr be Libr fy A
25. nse to industry s move toward more compact products while imposing greater throughput and accuracy requirements These products many not heard of ten years ago must be measured inspected and repaired in a production environment The OPTEK VideoMic VSA offers solutions for these challenging manufacturing problems Like earlier OPTEK video systems which offer the ability to automatically measure objects using programmable optical magnification and lighting changes the OPTEK VideoMic VSA allows for sensitive feature detection in challenging situations Superior performance is accomplished through user directed optimization of contrast video edge detection pixel analysis and accurate transport movement The VideoMic VSA offers advanced features such as Balanced Linear Motors High Resolution Linear Scales Modified Bearings and Support Systems A Hi Resolution LCD Monitor more Powerful Frame Grabber Full size Keyboard Adjustable Operator Station The combined effect of these improvements is smoother more stable and quieter operation higher accuracy more rapid and capable sample processing increased component reliability with decreased maintenance Once optimal test methods are determined they are saved in a measurement program for automatic execution The systems utilize a Pentium computer with a high resolution flat panel color monitor operating in a Windows XP environment The icon driven inspection and measurement process is simple and intui
26. osition the machine in front of the desired Port gt Hit Load 3 The tip should be slid into Port 1 and then removed a If the machine Hit the rack or otherwise went to the wrong location repeat the Probe Rack Teach section 4 Ifthe tip was Loaded and Unloaded smoothly from the correct Port select the next tip and hit Set current a The previous tip should be left in its port manually load the next tip 5 Repeat for all remaining Probe tips 37
27. oxes and transport movements as the machine determines where the machine limits are located The Transport will first move to the back finding the back Y axis limit then move to the Y zero point in the center of the movement The transport will then move to the right finding the left X axis limit and move so the Head is in the center machine Zero position Last of all the Z axis will move up to find the top Z limit and then to the center zero position When complete the NLEC ON will be showing in the status bar if activated By selecting No a series of boxes will appear guiding you through manual homing The boxes will automatically disappear once the required transport moves are successfully completed If the homing sequence is not performed correctly or canceled the NLEC error correction will be disabled and the machine will be inaccurate for measurements When homing is done please complete the Installation Quality Check for your machine Operational Checkout Please perform this checkout upon start up to ensure the correct functioning of the machine Check system safety and integrity Check the light beam interrupts or HGP interlocks to ensure they are functioning properly X and Y Axis Once the boot process is completed click the X and Y boxes in the DRO to Zero the display Move the stage slowly using the joystick located on the control panel If the system seems to be traveling properly move the stage to
28. p and dialogue boxes This information becomes available in IK5000 when you expand a dialogue box resizing it with the mouse OPTEK and Heidenhain Power Point presentations See your OPTEK representative Windows on line help Accessed through the Windows Graphical User Interface GUI The OPTEK VSA IK5000 Operation Manual binder includes schematics optional utilities and advanced hardware and software maintenance procedures Note If the equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired The Control Panel Power button This supplies power to the OPTEK The unit is turned on and off using this button Emergency Stop Button All OPTEK units are equipped with an Emergency Stop Switch in case of an Emergency Please make all operators aware of its location and purpose Mouse Provides Input to both the computer and the video interface When used on the computer monitor it controls all Microsoft Windows functions and all Heidenhain IK5000 functions OK button Press this to preview the data points gathered Enter button Press this to accept the data points gathered for a feature Trackball This control allows the user to fine position the sample Joystick Moves the transport into position in the X and Y axes and when focusing Z Axis Toggle Switches the function of the Joystick from X Y movement to Z Axis movement Fine positioning
29. perator station cover by removing four thumbscrews Disconnect the LED lighting module at the mini CPC connector beneath the granite table center Remove the LED lighting module by removing four Allen head cap screws Install the new lighting module feeding the connector wire through the hole in the granite first Replace the four mounting screws 8 Connect the electrical feed at the mini CPC connector 9 Restore power to the unit and test the lighting module 10 Replace the back operator s station cover plate 11 Remove power from the unit and reinstall the transport cover plate HGP and any other tooling 12 Restore the unit to operating condition and test No calibrations are required N BRD c 28 LED Top Light Replacement Remove turn off power to the unit Remove the VideoMic VSA cover from the unit Disconnect the LED lighting module at the mini CPC connector beneath the granite table center Remove the LED lighting module by removing two Allen head cap screws Install and fasten the new lighting module Connect the electrical feed at the mini CPC connector near the lighting module Restore power to the unit and test the lighting module Replace the VideoMic VSA cover Restore the unit to operating condition and test No calibrations are required O 0o 73 O OT ds GO IN Lubricating the rail system Z Axis The VideoMic VSA uses rails linear roller bearings and lead screws in the Z axis Proper and adequat
30. r right hand corner of the computer bay Check the regulator bowls for dirt and moisture and clean as required Ensure the air source is turned OFF and residual air pressure relieved prior to bowl removal 2 Check both the table and cantilever for dirt and debris Clean as required using Granite Polish TCS Granite surface plate cleaner or equivalent 3 Lubricate the Z axis and Z trac lead screw using Dow Corning Lubricant 33 extreme low temp bearing grease medium consistency or equivalent 4 Lubricate the Z axis linear bearings using Dupont Krytox or equivalent Removal of the Hinged Glass Platen For removal of the Hinged Glass Platen ensure the transport is positioned near the front center of the table Remove the four Allen head cap screws holding the HGP pivot brackets to the transport Lift the HGP off of the transport at the outside mounting brackets near where the gas spring cylinders attach LED lighting unit replacement The VideoMic VSA uses a uses LED top and profile lighting Individual LED s are not replaceable Contact Operations Technology for a replacement lighting module DANGER ENSURE ALL POWER TO THE SYSTEM IS OFF AND THE POWER CORD IS DISCONNECTED FROM THE ELECTRICAL OUTLET TO AVOID ANY INJURIES LED Profile Light Replacement Remove turn off power to the unit Remove the HGP and any tooling on the transport Remove the transport glass top plate by removing 16 recessed Allen head cap screws Remove the back o
31. rom oil contamination NOTE OPTICS CLEANING IS NOT REQUIRED AS A PART OF A PREVENTIVE MAINTENANCE SCHEDULE OPTICS SHOULD ONLY BE CLEANED WHEN NECESSARY Lenses should be cleaned utilizing a lens cleaning kit including Lint free wipes air in a can and streak free cleaning solutions Wiping or rubbing lenses may damage them by scratching the surface or removal of optical coatings Lubricants Operations Technology recommends the following lubricants 1 Leadscrews Dow Corning Lubricant 33 Extreme Low Temp Bearing Grease Medium Consistency or equivalent 2 Linear Bearings and Rails Dupont Krytox or equivalent 3 Granite Polish TCS Granite Surface Plate cleaner or equivalent ALL MAINTENANCE IS TO BE PERFORMED BY A QUALIFIED SERVICE PERSON OR FACTORY REPRESENTATIVE Caution A factory representative or qualified service technician must perform all maintenance DANGER Ensure All Power To The System Is Off And The Power Cord Is Disconnected From The Electrical Outlet To Avoid Any Injuries OPTEK SERVICE Operations Technology Inc Telephone 908 362 6200 Fax 908 362 5966 Website www optek net E Mail service optek net 30 Chapter 7 Warranty Warranty ITEMS COVERED BY THIS WARRANTY Standard Equipment This is defined as all equipment which is outlined and defined on the Operations Technology Incorporated product lists Special Equipment This is defined as all options and equipment designed an
32. s to Operations Technology Incorporated via approved routing charges prepaid Upon determination of liability Operations Technology Incorporated will either submit a quotation for repairs or rectify the defect at no charge to the user This warranty cannot be countermanded by the purchaser and is the only warranty relative to this transaction No other warranty expressed implied or statutory shall apply ALL MAINTENANCE IS TO BE PERFORMED BY A QUALIFIED SERVICE PERSON OR FACTORY REPRESENTATIVE Turn off the power prior to working on the unit Service amp General Care Through preventive maintenance the OP TEK system will prove a benefit to your company The components used in the OPTEK Video Series will provide years of service with little maintenance if the following guidelines are followed Keep the system clean The working environment should be as clean dry and dust free as possible Do nottake things apart Do not remove any covers or components from the system Leave all screws intact If repair is needed contact your OPTEK representative e Call for help e Call OPTEK at 908 362 6200 or contact your local representative if there are any questions or problems e Keep the system up to date To check for the latest version of software check the Internet at www Heidenhain com For the latest hardware updates check the Internet at www OPTEK net If you do not have access to the Internet fax 908 362 5966 requ
33. tegral to the computer They are of the automatic type and may or may not be on at that time The Computer Display Screen Window and Video Window The main display for all functions is the IK5000 screen The features displayed are identified here and discussed in detail in Chapter 3 of this manual and the IK5000 User s Guide This display is typical and shows some software capabilities The display is easily altered and may vary depending on options and how previous operators have chosen to present information The Main Menu Bar A horizontal area at the top left of the screen with many drop down menu choices within it Status Bar Found across the bottom of the screen Used to display information of the current settings and toggle between settings The DRO Digital Read Out shows the transport X and Y position relative to the reference frame Datum Part View Window displays graphical information of a part and its features E JEenturms gt Program Ress report zeipese ea Video A window that displays the camera VED tool image Where measurements are taken from Results Window Found at the top right this has numerical measurement information about an individual highlighted feature 4 222s Canesten MM Ll DMS NLECOn TNaF sgam EEE 13 Feature Stamp A separate pane opened from a box in the upper left of the Results Window It contains graphical information about the select
34. the Datum Menu choose Set Machine Zero Follow the on screen prompts Cannot see an Image Are the lights adjusted properly Do you have an object in the field of view Other Symptoms and possible causes Before making any changes use the restore method inside IK5000 In truth all problems can be reduced to two types Software problems and hardware problems Try to determine if the hardware or the software is then cause of your symptoms and narrow it down from there Hardware problems are either breakage or alignment problems Software problems can be thought of as corrupt or missing files Software can be corrupted by electrical interference spikes bad shutdowns or operator error 23 Restoring Your System to a Previous State With the Supervisor s password entered GO TO revert to Symptoms Noise In Transport Drive systems Is it in the X or Y system only Humming Scraping Grinding Movement problem Stage moves are unusual Stage moves on its own Stage vibrates or hums Stage does not move at all Stage movement in confined to a certain region Stage moves on one direction only Controls do not operate as expected Digital positioner is reversed Check Tools Options CNC Digital positioner Joystick causes a move in the wrong direction Check Software supervisors set up for joystick or Files preferences in the CNC Menu Set the deadband etc Joystick does not work Check calibration and conne
35. tive Measurement programs are created quickly by either recording measurements made on a sample part or by importing CAD computer aided design data and selecting the features to be checked User customized reporting of tolerance compared data and pass fail information can be linked locally or via network to SPC Statistical Process Control software spreadsheets databases or simply printed The OPTEK measurement systems work best in a clean thermally stable vibration free environment If possible always ensure the very best situation for your inspection and measurement machines The OPTEK VideoMic VSA System Description The OPTEK system allows movement in six directions Left and right is referred to as the X Axis Back and forth is referred to as the Y Axis Up and Down is referred to as the Z Axis Measurements can be made in all three axes The unit must be positioned so the rear of the machine is accessible in order to operate the Main Disconnect if needed The unit must be plugged into an outlet with a protective grounding terminal Caution A Qualified Service Technician must perform any required maintenance 5 Parts Description Camera Head Assembly e Z Axis Camera transport e Programmable Zoom Lens e Light Sources Top light ring for surface features On Axis illumination for indented features Optional Z Trac lighting for difficult situations X Y Split Axis Transport e Hinged Glass Platen used for s
36. utofoc s Tab C 20 Probe Library Resolution Tab 2 R u u ap ankaka pasa EERE OEA RRES AAKA sn en terne ethernet nnns rennen rennen nns 20 Camera Calibration Camera SKEW I ener en nnne nns tnr interi en rr sans sn trrs etre sein nn sens enne 20 Probe Library zOffseti Ez oL 21 Ghapter 5 Troubleshooting sied icut riam A eo Fa Re ee n Pe TR Rd are E Rn ER Sega a 22 Startup Troubleshooting Checklist enne n n snnt en nente sinn nsn sassa 23 Problems and possible Causes z 4444004snnnannnennnnnnnnnnnnnnnnnnnnnnnnnnnannnennnnnnnennnnnnennnnnnnnnnnnnnnnnnnnnn ns KOENEN PUETE n KIRG RARA 23 Other Symptoms and possible causes U esent en tetris inns enters enne sassa 23 Restoring Your System to a Previous State L nn rana names 24 Symptoms es ose odds ec cac eel cA LL ALS GL edle i 24 LS un n E EE C TET 24 Back Up YOURS SM nsn D rA ULL A AC SEULS nce oue ee 25 Ghapter 6 Maintenance am nu LI tL UELLE ELS 26 Maintenance ms SEHEN Lil ccn eru t kun edet teres 27 General Gargse es Li I Ei DEUDA UP ke En Vers ee ma ee 27 Maintenance Schedule ua sm aus mu in DE rA ULL NC SCALE mince cue eA A ETE 27 Gleaming Exterlor SUtfaees s et eet cune lenibus niei eb uS 27 Preventive Maintenance ce RR IRR D ee dica t be e baee re edes 28 Removal of the Hinged Glass Plate Missieri aaa ea eaaa adia
37. vity of this machine is the same as many others cleanliness If a simple preventative maintenance schedule is followed the machine will run effectively However if the system is not cleaned and lubricated binding and eventual accuracy loss may result Clean exterior surfaces of equipment As needed based on the operating environment Clean and lubricate the rail systems Every month Lubricate the ball screws Every six months Clean Pneumatic Filters amp Separators Every month Clean the lens system Prior to calibration or when required Cleaning Exterior Surfaces Clean the painted surfaces of the equipment with a damp cloth Use an all purpose cleaning solution If necessary a protective wax may be used on the painted surfaces The granite should be cleaned with Granite Surface Plate Cleaner Z 212 or a compatible cleaner This can be ordered from The Calibration Solution 9865 N Alpine Road Machesney Park IL 61115 Phone 815 877 0880 FAX 815 877 2062 www thecalibrationsolution com 27 Preventive Maintenance Operations Technology recommends the following lubricants 1 Lead screws Dow Corning Lubricant 33 Extreme Low Temp Bearing Grease Medium Consistency or equivalent 2 Granite Polish TCS Granite Surface Plate Cleaner Z 212 or equivalent Recommended preventive maintenance can be preformed every 1 6 months depending on the environment 1 Check the air filter regulators on the pneumatics panel located in the lowe
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