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VSA Technical Manual

1. Bottom light source intensity 05 8 Elevation of the Z Trac assembly optional oO Quadrant lighting selection and intensity optional 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 O Left Q Right 15 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 General Programming for the VideoMic VSA in QC5000 QC5000 is an advanced software application featuring graphical user interfaces for simple point and click operation Programming the VideoMic VSA is based on the concept of programming for a specific part Each part contains both program steps and session settings Some steps are good practice to add to any program With the VideoMic VSA these steps take on more importance aiding in fluid measurement processing At the beginning of each program you should record the following program steps to ensure consistent results QC5000 must be in the Record Edit Program mode to accomplish some of the following steps Set point filtration on Goto Tools Options Point filtration Check Enable point filtration box Bring the transport to a place wh
2. 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 OOS SN 98 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 oO A DZ Lubricating the rail system The VideoMic VSA uses rails linear roller bearings and lead screws in the Z axis Proper and adequate 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 manufact
3. 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 General Care Through preventive maintenance the OPTEK 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 not take things apart Do not remove any covers or components from the system Leave all screws intact lf 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 metronics 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 69 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 e
4. Auto Focus This will activate the Auto Focus option v ed hoes Blu New VED Probe Crosshair The Crosshair places a crosshair on the left Light Control Crosshair monitor This is used for manual measurements SL ZETA New Tool This produces a Magic Wand on the left monitor Teach Ved Edge Simple With this you can create a Simple tool a Circle tool or a Buffer Probe Library 5 Buffer tool to a specific size and shape needed ZN S VED probe Tool types Magnifications mag_1 gt Nearest Simple this generates a Simple Tool on the left monitor Probe Path Data Farthest Buffer this generates a Buffer Tool on the left monitor E Average Nearest this generates a Nearest Buffer Tool on the left Circle monitor Width Farthest this generates a Farthest Buffer Tool on the left Height monitor Pattern Finder Average this generates an Average Buffer Tool on the left Giaa Dh ihe monitor Circle this generates a Circle Tool on the left monitor Height Enables the HEIGHT measurement function Distance Enables the DISTANCE measurement function Pattern Finder A pattern recognition utility used in association with Tools General Option probes Number of pattern tool search rings to set the parameters You must teach patterns and Search Ring Overlap in pixels Video Charts Opens a dialog to display a video chart Windows Menu DRO The DRO window displays the current position of the stage Part View The Part View conta
5. e If you make any changes here you must shut Position 15 down the QC5000 and restart a cancal Home Light Control Setup Cuy Cat CH2 CHS cHa CHS CHE CHT CHE e Lights setup is password accessible Mein Light Lent Y Chanel Type F nge e Call OPTEK for the password e QC5000 board has 8 channels of light control available Marie 1904 Lave 1000 Pytal Charme lt Sr wap ule 0 WOOODODRNOK Birma Flere Ww Disabil Ad Minera Tact Light Coal M Reverse Sticter Em Track Peaperee 48 CNC Setup This is password accessible call OPTEK for the password CNC Options Joystick setup This is the place to calibrate the joystick Atain Click on Teach and then follow the wizard instructions ARA There are individual controls for each axis Enable zR Confirm stage movement versus joystick throw Dead band 1 QC5000 CNC Options From the Tools pull down menu select CNC Options Separate pages for X Y and 2 During initial setup work with one axis at a time it will make your life much easier Jerk is a function to apply an S curve deceleration to CNC moves Check for motor output reversal on all three axes Do not change the settings unless directed by an OPTEK engineer Do not forget to enable all three axes CNC Options Digital Positioner A Digital Positioner is another name for a Trackball Check the enable boxes If you need to reverse a direction do it here
6. 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 34 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 lf 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 gt a uta Mes D 6 Fa to Auto Focus Wi Set the QC5000 to metric units Crosshair To perform a calibration the light levels New Tool 5 must be set correctly o lak 7 Position the slide under the 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 window First Edge Position the do
7. 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 materials 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
8. You MUST calibrate each magnification Notice the size of a pixel at each mag Sub pixel edge detection is utilized when measuring The edge detection is extremely sensitive in low light settings Pixel Calibration When you do a pixel calibration this dialog box will come up to prompt you to enter the size of the artifact you are using to calibrate with The size usually comes from the VED glass slide supplied with the system If you select continue the system will prompt you to measure the specified artifact If you say cancel it will return you to probe Library Probe Library VED Offset Tab e This Image shows the offset from magnification Med High to the master magnification High These offset are also known as Parcentricity and Parfocality e If you click on Teach the system will walk you through the calibration You should start this procedure at the highest magnification e Notice reference is not checked on lower magnifications Only the master probe HIGH in the group is checked e The same calibration needs to be done for each of the other magnifications except High which is the Master Probe in this group Camera Calibration 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 If your camera image is backwards or opposite you can change the Orientation here Remember to make this one of your first calibrations
9. 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 operator 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
10. Height probe will perform an auto focus and return a point with a critical Z value Construct a distance from a plane in the Z E Light to Dark use as VED Edge detection preference E Dark to Light use as VED Edge detection preference O Blob VED tool will return the center of a mass location of an irregularly shaped object The QC5000 Menus Each item found in the Main Menu Bar consists of a pull down menu items which correspond to many toolbar options The following information gives a brief explanation of the menus For more information please consult the QC5000User s Guide or use the on line help system QC5000 utilizes the concept of the part and run to ka 26 retrieve data saved in a measurement programming session This includes templates and databases in use along with the part program The File Menu New Part Run New Part allows the system to clear all data When chosen the system will revert to the Machine Zero and Machine Skew Also all data in the Feature List will be erased Open Closes the current part and opens a previously saved part file Save Saves the current data to an existing open part file Save As This saves the current data to a newly created part file Import This function is used to transfer DXF TAP or IGS files into the QC5000 software Export All highlighted data will be exported to a DXF file Print Preview This will show the
11. Sphere diameter to the correct size Touch Probe Calibration In Probe Library if Probes is the only option shows double click to expand it Go to the Probe Menu gt Probe Library gt Contact Probes gt Group_1 gt Tip_1 gt Size Ofs Tab gt Hit Teach Measure Four Points around the equator of the sphere and one on the top gt Hit OK Repeat steps 14 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 Probe Rack 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 Remove all Probe tips from the rack gt Manually load the tip for the desired Port Position the machine in front of the desired Port gt Hit Load 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 If the 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 Repeat for all remaining Probe tips Make a Backup qb2 file Help Backup Settings Various parameters can b
12. Stage used when programming offline Related Topics to tool firing Comment DDE Super Step User Message Delay Display Part View Map Start New Run Set Variable Soft Edge Teach Max Speed On Max Speed Off Refresh Part View Demo Stage Tool Configuration This allows you to configure how many points a tool Circle Buffer etc will acquire Light Control This opens a window that allows you to adjust the settings of all available lights on the system Focus This will execute an Auto Focus Command 32 Chapter 4 QC5000 Calibration Calibration of the VideoMic VSA in QC5000 Calibration Procedure Overview A Complete calibration consists of both optical calibrations and calibration of the movement system Optical Check parfocality 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 Adjustments to the Transport system Preparations Remove any tooling which might interfere including the HGP Grid Alignmen
13. The Probe Toolbar Click on view from the pull down menu or right mouse click over an existing toolbar Go to customize and remove the icons you don t need Leaving the icon for the Probe Library on the toolbar is helpful You can add other icons if you so choose Touch Probe Optional The touch probe option on the VideoMic comes in two different formats e Programmable automatic probe switching where the operator can program tool changes e Manual probe switching where the operator physically changes tools Calibration Procedure 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 Library on the left Double Click the Probes Group if no sub categories are shown Unload Probe Tips e Goto the Probe Menu gt Click Probe Library e Select Contact Probes gt Group_1 gt Tip_1 gt Unload Button above OK e Repeat step 2 for all remaining probes 92 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 Go to the Tools Menu gt Options gt Probes Tab gt Change
14. Toolbars sr us A a 23 The Probe Toolbar dE So ENS 23 The ENG TOolbare er ae ee re Ne 24 TheEVIEWTOOlBAr ren a Re 24 Special TOO Sar REN ea 25 The amp Dallm Toolbars re 25 VERTOOLBAP een ee ee soe 26 TR QESO0O Meurer tai 26 AA A ee bee 27 A A ATT 27 ME o UN ds ca 28 Wetea 2 E DORINT EEE ER RENTEN aE aT aE NEIL ETE GEE ed OE Ca CPOE TCT CER 28 DA O cheats de rear ern ee tines detepaectitee semessuce 28 PODE MENU ee ee esse rei een E deen E 29 WINdOWS MEM isasama ett ipod cial 29 Templates as VVINGOWS een are Ten 30 Probes VED Teacher nee Reese 30 VIEW MSN person ardor 30 The Tools Programming Meni crac riscos rd 30 E ING SIS an a cats taaOs 31 CNC Mode Steps Durno EQ asociacion italianas 31 PIOW COMO SIED Sensin lino illo 32 SOWA and Mens zen ee lee einlesen isses 32 Related TODICS TOTOO INN si Eee 32 Chapter 2 065000 Galibralion 2 see adesaneeadeeamersteaeees 33 Calibration of the VideoMic VSA in QC5000 uueessnnnssnnnnnesennnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnneennnen 34 Calibration Procedure Overview n eeneneueessnnnsssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnnnsnsnnnnnnnnnnnen 34 Adjustments to the Camera System uuuusssnsssnnnennnnnnnnnennnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnsnnennnnnnennnnnnnnnensnnnnnnnnn 34 Adjustments to the Transport system cccccccccssseeeeeeceeeeeeeeeceeeeeeeeseeeseceeesuease
15. and Z axis relative to the Datum Next to each axis is a button with the axis name on it Clicking on these buttons with your mouse or pressing the appropriate key on the keyboard zeros that axis at the present position A Zero point may also be entered through the Datum Zero menu or toolbar The Part View Window The Part View is the graphical representation of the part being measured A Loro Print To measure a zero point you may probe a point or construct a point from The Featu re List Wi ndow previously measured features When probing a point default probe l compensation will occur along the part mas which is closest to the The Feature List is where the measured created or constructed rection the probe was moving when the point was entered fand which is appropriate to the projection setting To construct azero select the features are p laced features to be used to construct the point and press OK The chango item in the edit mena should not be used to modity the result as this will have no aftect on the zero position The checkbowes In the Zero dialog The Resu lts Wi ndow mary he used to control whether each of the free axes are aflocted by j u i the zero function I Auto Zero is checked then the zero will be atfectedt The Results Windows displays all geometric information about according the projection of the point teature the current selected feature In addition to this information the Enter pt Cancel Results Win
16. arrow on the right side of the pane bars e This area can be made user settable Options VED Sets properties of the video window Some VED tool properties set here Scale Video to magnification Realign probes in High accuracy Mode Options Runs This limits the times a runs database can store data Options SLEC Not Used by OPTEK as NLEC is used Please see section on calibration Options Sounds e All QC5000 computers come with a built in sound card e Make sure enhanced sounds are checked e Click the checkbox for the sound you want to hear e You can test them by clicking the button next to the operation e This area may be made user settable 47 Options NLEC e Setup screen for NLEC Home Search Counts ano No Positions 5 e You must seta machine zero to use NLEC Max Valocity er 350 Position 1 e You must turn it on in Options General NLEC Maak EEN EGUNE E 270 Position 2 e Sc forget on AR nn Single Step Time a eaan is screen shou not be User Settable ee 5 e NLEC Must Be Calibrated SEE fe A QC5000 Zoom Setup Park Position a EELER imit 1 High e Zoom setup is password accessible Limit 2 High ar e Call OPTEK for the password ee ee Position 11 e These are the default settings eae Postion 12 e This area is not for user access See Position 13 e There is a potential for 10 Zoom Positions _Pasition 14
17. contents of the print buffer DDE Output Sends Data to an external application Exit To Windows This will close the QC5000 and exit to the Windows operating environment Edit Menu Cut Selected Features This function is used in programming and transferring information to other applications Copy Selected Features This function is also used in programming and transferring information to other applications Paste Paste Special This function will insert information from the clipboard to an application This is used in programming and transferring information to other applications Delete Selected Features All selected features in the Features list will be deleted Select All Features This will select all features found in the Features list Deselect All Select None Features This will deselect all features highlighted from the Features list Find Feature This will choose all the features that match the search criteria Change Feature Allows the user to change the selected Feature Name 27 Edit View Measure Datum Probe Save 5 Save s Import Export DUE uuu Page Setup Print Preview Print Exit 1 C QC50005C067194 5pa View Measure Di Cut Copy Paste Paste Special Delete Selection tt fe Cal Se m m Kr ect OA q Hina Features Change Feature Feature Properties Shows data for the selected feat
18. ii 57 Preventive Mainlenance a a de da ad a a el 58 Removal of the Hinged Glass Platen ii A A A A A A 58 LEDIONI UTNE FS place Men ernea ie 58 ED Protile Hgh Replacemen an 58 LED TOP LUON RepBlaccenienn ia AA AA AA AA EA A E m 59 LUNAS AIN IS FANS SN AA A AT A A AAA A ese aece eatc 59 Standard Steel Ral Si A era 59 Gabe oOrAr BEANS a ir A AA A A de eles 59 Gare Ol GCS WAV S it e ser os 60 Cleaning the Exterior Unas ida oil bos 60 cs ee ae NE NEE 60 UA ATI Senne ee ee a ee NE Eee ee a EL 60 EXI VIEWS nn ee ee ee es ee A ee a ne Er 60 OPER SERVER ee ee nee 67 Shaper T Waran ee ee ae ee en a a Cpe ae en ee eer ee ee a 68 OO 69 MAB EIT OF WARRANTS iio 69 SA amp General Oar Gacie ee a ee Een er 69 Mantencion saan 70 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 response 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 magnificatio
19. new magnification Disquality Selecting delete removes a magnification q Disqualify erases the data in the current calibration E int Warning do not select load unless the rack has been properly ox setup Properties Selecting OK exits Probe Library Omet Pesolan Aus Focus Meg E Seance Bone Camera impor lt Zoum Pasiben fi a Bet Cut ww 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 First Teach performs an edge teach Ceseni l l Wagawe u bae Min kam E baia ba Mee J 36 Probe Library Autofocus Tab This is where you teach the AUTOFOCUS range of each magnification 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 the 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 QC5000 s edge detection is far superior to the QC4000 The e
20. positioner is reversed Check Tools Options CNC Digital positioner 44 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 teach Joystick does not work Check the joystick calibration and connections 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 the wrong data Program created from DXF imported in wrong denomination DRO does not give correct data Possible scale errors Reader head loose or miss aligned DRO does not give any data Possible break in connections Available software setup options CNC Modifies the motion parameters of the transport acceleration deceleration integral factor DISPLAY DISPLAY RESOLUTION This must be set to match the scales that come with your machine This affects the pixel calibration thus the size of the features lt also affects the measurement capabilities SOFTWARE FENCES CORRECTIONS Sets software end stops for the transport travel range MACHINE ZERO Enables the setting of the Machine Zero AUTO MACHINE ZERO Enables the Automatic setting of the Machine Zero PARCENTRICITY Software correction for the center of the Field Of View FOV CAMERA CAL Software camera rotation correction VIDEO MONITOR SETTINGS and PIXEL CAL These are set a
21. 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 power supply switch turned on Back of Computer Is the line voltage correct 115 VSAC or 220 VAC Is the power cord plugged in Is the computer bios set up to turn on the computer after a power off condition 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 Has the joystick teach been performed in software The transport does not move in one or two directions Did the Homing sequence complete correctly Was the machine turned on with one or more axis activating a limit switch 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 homing sequence complete without errors Are the software fences user or machine setup correctly From the D
22. 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 Metronics QC5000 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 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 sen
23. 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 integral 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 QC5000 screen The features displayed are identified here and discussed in detail in Chapter 3 of this manual and the QC5000 User s Guide This display is typical and shows some software capabilities The display is easily altered and may vary depe
24. 5000 Customize Meinl ernennen 50 GUStOMIZO TODD AS veis cuand pieles 50 GUSIOMZE ENORM rien 50 Sia o ec 50 C5000 Core ales een letter 50 BaCk Your SYSTE erras seele ddtasdaateatsoneddesyseaseencoeaadenscaseasdere RE 50 PROBELIBRAR Y u a ee e a a E E 50 Probe LID IV oranes aona A a a a e RE 50 QC5000 Calibration Procedure Probe Library cccccccccccnnnnnoconononononononnnnnocononnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 51 Probe Library VED EVED PrODES nee einen inseriert 51 QC5000 VED Edge Terna 51 Probe Library VED Mag Tab ccccccccecccceeceeeeeeeeecaeeeeeeeeseeeseeeeeeaeseeeeeeseeeeeeeesseeeeeeeesseaaeeeeesaeaeecesesseaeeeeessaegeeeeeeeas 51 Probe Library VED Autofocus Tab occooonnccncccccocccnncononnnonononnnncnnnnonnnncnnnnonnnnrnnnnnnnnnnnnnnnnnnrrnnnnnnnnnnnnrnnnnnrnnnrnnnanennnos 51 Probe Library VED Resolution Tab ooocccncccccccccnccononnnonnconnnncnnnnnnnnncnnnnonnnnnnnnnonnnnnnnnnnnnnrrnnnnnnnnrnnnnnnnnnrnnnrnnnanennnos 52 A be nE a eE E a aa aaa R 52 Probe Library VED Offset Tab oooccccccconnccnccccoocconccononnconnnonnnncnnnnononncnnnnnnnnnnnnnnnrnnnrnnnnnnnnrnnnrnrnnnnnnnnnnnnnrnnnnnnnancnnnns 52 Camera Gel 0 2 1110 g ee ee ee 52 The rrobe Toda saca 52 TOUCH Probe OPINA Aes mater 52 LASER OPIO Me aida 54 Ghapier o Maitena as 56 Maintenance dt a A A a AA a sh 57 General Tar A e ee 57 Maintenance cn tds 57 Cleaning Exterior SUNMICE S trance a A eu Ran
25. Calibration Camera Skew Parcentricity Calibration Cross Calibration Go back and check all the calibrations by measuring the appropriate artifacts Probe Library VED 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 QC5000 VED Edge Teach Edge type indicates dark to light light to dark or first edge Edge Algorithm describes which edge type will be used Auto Strongest or First Teach performs an edge teach Select the edge algorithm edge type and then click on teach The system then selects the appropriate edge strength Notice the edge strength graph when selecting the Advanced button When exiting this dialog box make sure to say OK and not cancel Probe Library VED Mag Tab Selecting New creates a new magnification Selecting Delete removes a magnification Disqualify erases the data in the current calibration Selecting OK exits Probe Library Probe Library VED Autofocus Tab This is where you teach the AUTOFOCUS 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 the up direction Make sure your Z is counting positive in the up direction 91 Probe Library VED Resolution Tab Select Teach to do your Video Pixel Calibration
26. 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 57 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 lower 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
27. If you change a setting hit the Apply button There are individual controls for normal and fine speeds When you move the trackball current values should change as well if not the signal is absent from trackball CNC Options Software Fence If you plan to use the software fence you MUST have a repeatable machine zero enabled Remember to check the Enable boxes If you select Teach a Software Fence Wizard will walk you through setting up the fence In this section you can set up a software fence to prevent the stage from crashing into the limits You can also set up a user fence to prevent moves outside a certain area 49 QC5000 Customize Menu This area is used to change the appearance and option available on the Toolbars Status bar and operational Error assistance messages This is password accessible call OPTEK for the password Customize Toolbars Select Tools Customize Toolbars Select the Toolbar to change the buttons shown within it Copy and or Remove icons to make the change Hit Apply to see your changes before exiting OK to make this user settable From the pull down menu select View Toolbars or right mouse click over an existing toolbar Highlight the toolbar name and then click show or hide You can have up to four custom toolbars Remember to say OK not Cancel when exiting Customize Errors This is the place where you can turn of error messa
28. OPERATIONS TECHNOLOGY INC VideoMic VSA Technical Manual QC5000 VIDEO MEASUREMENT AND INSPECTION WORKSTATION For S N Model 713VSA Version G January 2008 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 ooccccooccccncncconnnnnonccnnnccnnnnnnancnnnonnnnnnnnnnccnnncnnnnnnnancnnos 1 AAA neben 5 A A I ai 6 System Descrip Mic EEE 6 Camera Head ASSIM EIER A 7 KY OPIA Trans POr alocada cds 7 Table Assembly IET ica 7 BIECHONICS Ale Aids 7 CONTA DA ee lee 7 COMO A er ea es ee A unse 7 O ae A E E E A NT 8 OMI A A MEN ee ee nes A A IE 8 Documentation torihe OP TER Vido MI ee ar aa 8 The Eonkol Banel ne ee A Nase ea ae ee 9 Power CUIO Switch LOCA MON Suri een 10 Oe Fat PINGS Sen es ee ne O dead 11 Chapter GellNg otare scusi e o O ee ee 12 OPTEK VideoMic VSA Power On Procedure ti eier 13 OMI Sequence OC 5000 iiaiaia odias ci 13 Operational CHECK OUT asa olle een 13 Ghecksystem satelv and INlEaNly acentos tl 13 RAIN Ne PAKS ee ee ee e ee reihe 13 MACAEL Diesen pe ee TREIBER Tees 14 Brit PP III nr 14 Tooling Fixtures or Hinged Glass Platen ccccccccccccssssececcceeeeceecceeeeeceeeseeaseeeeesaeaeeeeesseaaeeeeesaeageceesssaageeesensagseeees 14 Ss o o A 14 The Computer DIS ee eine Eea EONA EAE 14 Screen Window and Video WINKOW ccccssssececccseesececcceeeecececseueeceeesseaeeceesesaa
29. a clean thermally stable vibration free environment If possible always ensure the very best situation for your inspection and measurement machines System Description The OPTEK system allows movement in six directions Left and right are referred to as the X Axis Front to back be 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 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 securing 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 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 bu
30. atum 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 Did the Zoom homing sequence complete without errors after the axis homing sequence 17 Measuring a part General considerations prior to measuring Decide on the orientation of the part and choose a Zero point Consider your part drawings if available Secure the item to be measured on the stage Use a tooling fixture a hinged glass platen or tape Learn the toolbox options Set it up to provide the tools you will need for the features to be measured or constructed Please see next chapter Customize your toolbars Find an appropriate magnification Multiple magnifications and associated calibrations are options on the VideoMic VSA Experiment with lighting Choose a lighting situation and adjust to give a good firing edge detection Use the VED Teach capabilities Choose a measuring tool such as circle buffer or simple etc Select what kind of feature you are measuring Line Angle Circle etc Fire the tool and view the points obtained to accept or reject the data Set the Tool configuration for the number of points needed to give a good measurement Probe Probe Library choose a tool Set max scans for your configuration Make any constructions needed for future measurements Customize a report format for data output Preparation for Recording a Pa
31. d There are several forms of button pressing Clicking Press the LEFT to select or RIGHT mouse button once to access optional features Clicking the middle scroll button fires a selected tool Double Clicking Press the LEFT mouse button twice quickly Dragging Hold down the LEFT mouse button over a file name while moving the Mouse Dropping releasing the button in a Drag mode The mouse is also used on the video area in conjunction with the VED tools This controls the orientation and position of the tools Using the Keyboard Commands executed by the mouse may also be executed using various keystrokes Pressing the ALT key and the underlined letter of a menu activates menu commands Once inside a menu repeat the process or use the up down arrow keys and press enter once the proper item is selected QC5000 Basics The following section will introduce the parts and features of the QC5000 screen For further information on this or any other part of QC5000 please refer to the QC5000 User s Manual 4 b Varz2 05 Comesian MM L DMS NLECOn Narregam EEE The QC5000 Screen 1 20 The QC5000 Screen The QC5000 screen is made from several individual windows These are the DRO Feature List Results Part View and Program View The Toolbars may be viewed as individual windows or docked to the windows they are typically used with In addition to these windows a Menu bar a Status Bar and a Title Bar can be
32. dge 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 camera_1 162 375400 Administra Delete VedProbes Six 375400 Administra ComtaciProbes 54 5800 Administra Sel Current ETA 375 00 Administra Disquadity HI Properties Praperties NATI E PA EEE TA Offset Orientation General Offset Resolution Auto Fores Mag Tech Orientation Camera Skew x 10 001820003829 Optical Axis J 02856000 Teach Y 1 001 44575581 Heverse Hoz T Yer Teach 3 Probe Library Offset Tab This frame shows the offset from magnification Med High 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 Med High Notice reference is not checked Only the master probe in the group is checked The same calibration needs to be done for each of the Prpertes magnifications except High which is the Master Probe in Oluet Revelation AuteFoces Weg group Transpor
33. dow contains two menus Tolerancing and Change Pa A REN TE 21 The Program View Window The Program View Window displays the steps within a recorded program The Unit of measure and Coordinates are toggles Each time these commands are selected they will toggle between Inch and Millimeter or Cartesian and Polar Customization QC5000 allows the user to move windows to fit the need of the customer When arranging windows keep toolbars docked to or near the windows they are used with This is one possible arrangement of the windows in a single monitor e DEDO Past Ma Circie 3 created 1 0940 0 1675 Tame 11 57 PM 2 4000 Y 1 4000 Z 0 0000 0 0000 runout 0 0000 PP xY 11157 PM Dato 173071 TAX boki r e e i PS e e e r er f e r er E q e r A Cortosien MM alo dto Temp OMS SLECMLEC Of MS Camera 1 Psim E n hut ia dl ES a Conese as 0m caT PETT Wia a Typical QC5000 Screen Display Remember you can customize any and all toolbars to save monitor real estate If a tool is never used remove it from the toolbar 22 QC5000 Tables Toolbars in QC5000 The Measure Toolbar x Ir ODER Point Enables the Point measurement function Returns a coordinate for any probe used Works well with any probe understanding what information will be returned center of mass average etc Line Enables the Line measurement function A Line will appear on the Part Vi
34. e set to modify and optimize the performance of the machine These are not available to the operator Trained personnel should only access these parameters To access these parameters contact your OPTEK factory representative to obtain the access codes for modifying these programs 53 Laser Optional The Optimet Laser has three modes of operation Point Line and Patch for each available lens The lenses on the Optimet Laser system must be changed manually to change the lens just unscrew it from the base of the laser In order to set the current lens for the Optimet laser select the Probe menu gt Probe Library gt Optimet gt Select the Installed Lens gt Hit Set Current Once the correct lens is selected changing between VED or Laser measurement is as easy as selecting the appropriate tool Laser Calibration amp Operation The following procedure will require a Certified Ring Gauge OPTEK initially calibrates all Laser systems with a 12 7mm Ring Gauge If the gauge is 12 7mm skip the next section and proceed to the Calibration Ring Gauge Size Go to the Tools Menu gt Optimet settings gt In Size in MM of our laser calibration artifact gt Change to the Radius of the new Ring Gauge Optimet Laser Calibration Ensure the VED Simple Probe is selected before continuing e Goto the Probe Menu gt Probe Library gt Optimet e Select the lens to be taught gt Hit Teach a Point Line and Patch are all taught at once
35. ed for each axis and Stepper is selected e Click on APPLY SETTINGS and then you should have motion control with the joystick Close the Joystick Setup window ys aa ay ESOO Encoder Setup Board Versi Code Yersion DSP 1 03 Custom Encoder Setup Aas Dicky Type Wave umn SSCS toes Aue Scale Type intep Display Type Mods C Cunen Beidenhain C xl Tweed Joystick Setup C Yar Wae a er CzAs C TIL we C Qis C Pseudo Sinusoidal x10 Courier Limi Swich Setup Calibrate Cancel Encoder Setup Running Encoder Setup Run the Encoder Setup program encsetrn exe Encsetrn exe is new in version 2 1patch5 Encsetrn exe automatically determines the type of board you have First setup the joystick to run in Encoder Setup by going into Joystick Setup Select Axis X Y or Z Select Scale Type TIY Select Interpolation Use 5X Select Display Type Use Wave first then after Cal check Phase Click on Calibrate and follow the prompts For 2um resolution select 10X Click OK to close the encoder setup Remove the encoder icon from the desktop Setting up in Encoder Setup QC5000 Factory Options e Viewing editing factory options e To enable certain Options you will need to obtain a key code Call OPTEK e Do not click options whose function is not clear to you clicking on something not installed can cause a
36. edium Consistency or equivalent 2 Linear Bearings and Rails DuPont Krytox or equivalent 3 Granite Polish TCS Granite Surface Plate cleaner or equivalent Exploded Views Electronics Panel 60 61 62 X axis and Lead Screw 63 X axis Y axis Transport 65 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 6 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 and 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
37. eeeesaeaeeeeesaaeseeeessaaeeeeessaaseceeessaneeeees 34 Calibration Procedure ccccccssseeccccceeeeeceeecaeuseceecsaeeeeeeessaeeceeessaaseceeseseaeceessseaseeeeesseaseeeessaaaeeeessseaaeeeeessaaaeeeesssaagss 34 Adjusting the Camera Squareness uuuusssnnensnnnennnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnernennnsnnennnnnnnnnernnnnnnnnnn 34 Camera Rotation Correction ccccccccsssssseecceeeeceeeeeeececeeeeeeeeeseceeeeeeeaeeaeeeceeeeesseaeaseeceeeesssaeaeseeeeeeeessaaaaeeeeeeeessaaagsses 34 A ee ee 35 QC5000 Calibration procedure for the Probe Library ccccccccccccccccncnccnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnonononnnnnnnnnnnonineness 36 PODE RIDIA Mag Tabs ee aa 36 Probe l ibrary VED Probe S 2 022 2 ha ac a che aie epee ince a e a a a A 36 Probe Bibra AUlOlOCUS La rears ee bat cas ee a 37 Probe Library Resolution Tabea weten a akan Oats cued ae 37 Camera Calibration Camera SKEW sci nn A en 37 Probe Library Offset Tab ea aa Mic Aa teen 38 Transport Movement Callibration ccccccsssscccccceesseeeccceaeeeceeccseseeceeeseaaeceessaeaseeeeeseeueceeesseaaeeeeesaaageceesssaseeeesnsagseeess 38 065009 Grid Gallbration Procedure cada ds 38 OVERVIEW ds dd da esse a Madi ial is 38 veny ine E al nn ne 38 OPTEK Ultra Precisi n Gra Method scsi eect A A SR EL 39 The NEEC Controlan a E ec del A O ee eases A ee es 39 Ment OPTIONS A ee ee eee 39 NES Background MOnato re A lA AAA AA At A 40 Non Linear E
38. ence Frame Your reference frame is temporary until you save it If you need to use several reference frames on a single part you will want to save reference frames 25 VED TOOL BAR Tools are sometimes called Probes 1 New Tool This creates a custom tool to the situation Crosshair The Crosshair probe is the only probe that does not perform edge detection This probe is used to stake a point and send the X Y coordinates to the QC5000 Simple A Simple probe is used to find a single edge point Buffer The Buffer probe is the only probe that will return multiple points to the QC5000 You can select between 1 and 100 points on the Buffer probe E E Width The Width probe will scan the edge of two lines and return one point on each edge use this with the distance command Nearest The Nearest probe is a block probe used to find the nearest X Y coordinates from the direction of the arrow a Farthest The Farthest probe is a block probe used to find the farthest X Y coordinates from the direction of the arrow sa Average The Average probe is a block probe used to find the average X Y coordinates of all points detected on a poorly defined or rough edge Ed Circle The Circle probe is used to find the diameter and center X Y coordinates of a circle Uses LMC MMC and with the least squares best fit algorithm SM Heig ht The
39. ere the work may be easily and safely loaded Seta GO TO LINEAR position for loading a work piece Tools Go to Position Set initial lighting levels including which light sources are utilized and at what intensity to most clearly distinguish the desired feature Light settings are saved within program steps Add a user message Tools Programming Special Steps User Message Using a prompt with tips on sample positioning sample numbering setting checks or other instructions are helpful Set tooling if available on your system Employ the user message again here Teach VED This records the chosen edge type and edge strength setting If a program will measure a variety of features that require different Teach and Picture settings record additional steps to change those settings anywhere in the program as needed 1 Program all measurement steps Go to the unload position Go to Tools CNC mode Go to Linearto set the unload position near the center of X travel 1 less than maximum Y travel This position would also be used for loading the subsequent sample Do all constructions and reporting Select features File Export This generates and outputs a report while unloading the part and loading the next Restart the sequence 16 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
40. ew as a solid line Requires a minimum of two points or tool firings Works well with the buffer probe AIC Enables the Arc measurement function Requires a minimum of three points or tool firings Works well with the circle probe Arcs less than 45 degrees are considered unreliable and will return a warning Circle Enables the Circle measurement function Requires a minimum of three points or tool firings It will appear on the Part View as a complete circle based on the video information within the probe boundaries Works best with the circle probe Slot Enables the user to define a slot with the minimum of five points Define the width with a minimum 3 points and the length with two The default slot is round ended with parallel sides tangential to the ends Works well with the simple probe Distance Enables the Distance Measurement function Distance will appear on the Part View as a Phantom line with an arrow showing the direction of measurement Distances may be taken from points or perpendiculars to lines Angle Enables the Angle measurement function An Angle measurement generates the following four features on the part view and in the feature list the angle the vertex point and the two lines that were measured to generate the angle The Probe Toolbar Probe Library access the features of the probe library Tools Probes and Magnifications 23 The CNC Toolbar Axis Lock prevents both axis from operating at the same
41. facturer normally supplies calibration data for a grid as a report The data must be put into a format that the NLEC Manager can understand After this file is created it is saved as a file with an extension of ACF Import the file into MS Excel MS Excel helps here as columns must be deleted Save as a text file Using a text editor create a file in the format Gray shown below and save the file with the extension ACF soo En EOS AAA AA A e E C Uca O A T a oo ETT TOO E CA oa 299908 Rowincrement ontheaid O go 760 025 299800 Second row third point 60 3o either X or Y Once ACF file is generated save for the grid calibration process When finished a message appears informing you the operation has been completed 42 Note A TAB character separates the left and right columns The skew axis is not used at this time and can be Chapter 5 Troubleshooting Symptoms and possible causes Before making any changes use the restore method inside QC5000 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 Restoring Your System to a Previous S
42. found on the screen top or bottom The position of a window may be changed by clicking the title bar and dragging it to a desired location Window sizes may be changed by moving the cursor over the edges of the pane clicking and dragging the edge when a double pointed arrow appears Two considerations for window size and placement are the ease of use and effective use of available screen space customized for the user Your screen may differ from the examples seen in this manual The following section will introduce the parts and features of the windows The Title Ba UK HUND Partaintitied lelxi The Title Bar is always located on the top of a window You will find the name of the software and the part file that is currently running The Menu Bar The Menu Bar lists all available menus Because QC5000 is capable of having several options the Menu Bar will display only the options available according to the systems options File Edit View Measure Datum Probe Tools Windows Help The Status Bar The Status Bar usually contains the time date unit of measure and coordinate system When visible it will appear at the bottom of the screen and is used to toggle between settings Items may be added or removed from the status bar through Tools Customize Status bar 62104 Cartesian MM mag_1 Auto Temp DMS Ho Program h 43 374 11 391 The DRO window Digital Read Out The DRO window Shows the current tool position in the X Y
43. ges It is OK to turn off user messages if you need to once operators have become proficient in the QC5000 use You can turn tool tips on and off here This area is best not set to user settable Customize Status Bar Turn items on the status bar on and off here QC5000 Core Files e There are 6 Core Files in the QC5000 Untitled 5US Supervis 5SY Datamaps 5MP Encoder 5ES Settings OEM NLEC txt e Always make back ups Click on Help then Backup Settings The generated file includes the data from all core files in one file a ee Back up Your System GOTO Help Backup Settings Once named the file will be saved into the QC5000 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 PROBE LIBRARY Probe Library e This is an extremely important part of the QC5000 and is password accessible call OPTEK for the password e This is the place to set up your Camera Magnifications Probe Rack and do all your calibrations e Probe Library works similar to Windows Explorer Click something on the left it opens up and expands to the right e f you turn on Auto Finish it will make calibrating easier 50 Remember anything you want to calibrate must be on the right side QC5000 Calibration Procedure Probe Library Setup your Magnifications Assign Zoom Positions Teach Autofocus and Video Edge Detection Pixel
44. ing a value or formula If Goto Conditional to go to a label Else a Label to direct the flow to a new sub step Goto Label A redirect from a sub step Label used to create a sub step or routine Offset Positions Allows you to manually enter a coordinate that will offset the current coordinate Save Offset Positions Saves the Offset position Restore Offset positions Restores saved Offsets Software and Menus Programming Special Steps Comment Use to document the program It will not execute in a program DDE This applies a DDE Link while executing a QC5000 program Delay Command This will pause a program for a specified number of seconds Super Step encloses all selected steps in one major unit User Message This will insert a message specified by the programmer during program execution Requires a manual OK to continue Display Part View A toggle for the part view Run Part This will execute a new QC5000 program while and exit the current program in the QC5000 Start New Run Starts a run Set Variable Used to enter operator input into the program Soft edge teach used to find edges in difficult situations used a completely different algorithm than conventional edge teach Max Speed On Screens will not update in this mode to save CPU cycles Max Speed Off Screens will update in this mode and will not save CPU cycles Refresh part view Use this when updating has been turned off Demo
45. ins a graphical representation of items measured Feature List The Feature List is a display of all measured items Results Window The Results Window displays all geometric information about a particular item Live Video This window shows the Image from the Video Capture Card Always keep the video image on the right monitor on dual monitor systems Excess CPU usage will result if it is on a conventional monitor Help Program View This allows the operator to view and edit steps within a program Y DR v Part View v Results v Live Video New Template Open Template Save Templates Save Template As v Runs v Features Program Jim Report Time v Lomers 29 Templates as Windows All templates are opened and saved from here It is recommended that the user save templates with a unique name This ensures the original templates remain unchanged The new template name will show at the bottom of the menu list Runs opens the runs database window template Features opens the features window template Program opens the program listing window template Reports opens the reports window template Time opens the runs database Time window template Corners opens the runs database Corners window template Jim opens the runs database JIM window template Probes VED Teach Turn soft edge off in Programming special steps to view this histogram and dialog Teach The Teach Tool is used t
46. n 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 intuitive 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
47. nding 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 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 b F2122J05 Canesten MM 11 M3 NLECOn Ne Pregram 14 Feature Stamp A separate pane opened from a box in the upper left of the Results Window It contains graphical information about the selected 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 o
48. ntenance 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 Do not take things apart e 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 metronics 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 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 Clean exterior surfaces of equipment As needed based on the operating environment Clean and lubricate the rail systems Every month Lubricate the ball screws
49. nter of the glass platen 10 Conduct a test of the Operator s controls joystick trackball interlocks etc 1 Ensure the X and Y axis are positioned in the center of travel 2 Ensure the Emergency Stop button is in the up position Press the Power On button 3 If necessary turn on the monitor Use the individual power button for this 4 Ifthe PC is not on turn on the PC and follow the on screen instructions 5 Ensure the HGP is lowered and no objects are in the light interrupt path q 6 Ensure all Control Panel LED s are off Fine position amp Z axis toggle Das 7 8 9 Caution Note The transport cannot move with the HGP open Be certain the HGP is closed while setting Machine Zero Homing Sequence QC5000 Once QC5000 is started a window will appear asking if you would like to begin the automatic homing sequence 53 Do you want 10 begin the automatic homing sequence if Yes make sure that the Motors are tumed on Select Yes and observe the dialog boxes 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
50. nu To import a file proceed to step 3 To create a new data file proceed to step 4 Select File Import to import an artifact data file ACF and produce an output file that represents the points that will actually be measured for calibration Use the graphic tools within this window to rotate flip and or select a subset of grid points as needed The Orient menu allows you to rotate and or flip the grid data to line it up with the way the artifact will be placed on the measuring stage You can drag a selection rectangle around a group of grid points to de activate all of the points outside the selection rectangle Use the Edit dialog to enter the grid header information When complete select File Save to save the grid data in QC5000 v2 format You will need to repeat this process only if a different calibration artifact is used if the same calibration artifact is used in a different orientation or a different subset of grid points is measured Otherwise the resulting calibration data file can be used repeatedly for several calibrations Use File Open when you want to use the same artifact file again Please see the end of this section to create this file if not present in you calibration directory or the OPTEK directory To create a grid data file from scratch select File New Fill in the fields in the dialog box It is important to correctly enter the grid type grid units grid dimensions and grid element spacing This information is used to genera
51. o teach edge characterization Either edge type dark or light Light to Dark This tool will force the current probe to seek edges going from a Light area to a Dark area It will only seek edges in the same direction that the arrow of the probe is pointing Dark to Light This tool will force the current probe to seek edges going from a Dark area to a Light area It will only seek edges in the same direction that the arrow of the probe is pointing First Edge This tool will scan in the direction of the probe arrow seeking the first edge it encounters Strongest This tool will scan in the direction of the probe arrow seeking the strongest edge it encounters Auto Automatically picks an edge Soft Edge Teach Sets the edge found as a percentage across total transition under the probe View Menu Measure Datum Probe Toc l Zoom All Zoom In This incrementally makes the features in the Part View larger om Window Zoom Out This incrementally makes the features in the Part View smaller RD Zoom to Selected Features This zooms in on the features selected in the Zoom Special E Feature List Dar Preset View Selects from CAD style views for 3D systems Show Reference Frame Indicator A Toggle Preset View Record Zoom This command is for the Programming Mode The present Set Viewpoint Zoom will be recorded as a step in the program for a visual aid to the es erom Probe el adi View Rotator Show Position Indica
52. 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 After the appropriate information has been placed in the Standard Size Continue Lancel possible VED Pixel Size window Click OK to exit the Edit Calibration window 35 QC5000 Calibration procedure for the Probe Library y This operation is for factory representatives who are installing ve Fer ee rre Duu new QC5000 operating system computers to existing machines Contacirrobes fise ae Set Current 1 Setup your Magnifications ge Dial 2 Assign Zoom Positions 3 Teach Autofocus and Video Edge Detection jie 4 Pixel Calibration Unload 5 Camera Skew ox 6 Parcentricity Calibration 7 Go back and check all the calibrations by measuring the peenes Resctetion Anto Feces Mog appropriate artifacts RER This is an extremely important part of the QC5000 x j 001820009823 This is the place to set up your Camera Magnifications VED ad o casi tools and do all your calibrations Probe Library works a lot like Windows NT explorer Click something on the left it opens up and expanas to the right If you turn on Auto Finish it will make calibrating easier Remember anything you want to calibrate must be on the right side Probes Vad camera_ x Admeiste itp Probe Library Mag Tab ss S 77x 3 5 00 Adra cta Selecting new creates a
53. program can be used to measure the calibration grid Recommended 2 Create a part program from the import of a DXF file which represents the ACF data Turn NLEC off Go to program properties and uncheck use machine zero Record a skew and zero Import the DXF Choose record Select the imported features from the features list Choose tools programming auto program from features In the program window group edit the measurement steps for scan direction edge transition and tolerance Place a toggle breakpoint after the skew and zero steps and save the program Follow the directions as given in the overview at the beginning of this section The NLEC Controller Menu Options File New Create a new grid data file from scratch File Open Open an existing grid data file QC5000 v2 format File Import Import an artifact file ACF QC4000 File gt format Orient gt File Edit Edit the existing grid header information Whisker gt File Export Export the error information to a calibration file QC4000 format AA File Save Save existing grid data along with its calibration information QC5000 v2 format Orient Rotate Plus Rotate the grid data 90 degrees counter clockwise Orient Rotate Minus Rotate the grid data 90 degrees clockwise Orient Flip Horizontal Flip the grid data about the horizontal axis top to bottom Orient Flip Vertical Flip the grid data about the vertical axis left to right Whisker xxx Select the er
54. re the calibration grid Run a part program that establishes skew and zero and measures each of the grid elements Then select Calibrate Import to process the data from the feature list Select File Export nlec txt to create an NLEC correction file When calibration is complete you can also select File Save to save a complete calibration report including nominal measured and deviation data This file should be given a different name than the grid data file saved in step 3 or 4 40 CALIBRATION FILE Background This file is maintained for each calibration artifact position on a given machine It contains the nominal actual and deviation information for a set of points in an error grid Before calibration the measured data is equal to the nominal data and the deviation is zero After calibration the measurement results and deviation are recorded This file is not used by the NLEC routines to correct raw machine coordinates The data must be exported to a QC4000 format NLEC correction file nlec txt Sample contents of this file follow Calibration File ID Art1_Full_90 Deg Calibration File Version 1 0 Machine Type OPTEK 1273V Machine Serial Number OTI 012345 Machine Calibration Date 07 September 1999 Artifact File Path C QC5000 calib A96352 art Artifact Serial Number 96352 Measurement Units mm Artifact Grid Type Circle Artifact Zero Column x Artifact Zero Row y Artifact Skew Pnt 1 Col x Artifact Skew Pnt 1 Row y Artifact Ske
55. rement 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 QC5000 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 OPTEK VideoMic workstation 11 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 Move the transport by hand in all directions lt should move freely Start QC5000 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 ce
56. ror whisker magnification or turn it off Perform a datum skew measuring two grid features along an edge Calibrate Start Start the grid calibration process For best results the features should be as far apart as possible Calibrate Restart Re start the calibration process from the beginning Calibrate Cancel Terminate the calibration process without saving the data Calibrate Import Import the calibration data from the features already in the feature list NLEC Background Information Non Linear Error Correction User Interface Design in QC5000 The objective of this design is to provide a service technician with the ability to create and update the NLEC tables within the QC 5000v2 It does this by providing a simple interface to assist in the manipulation of artifact and calibration data Using this interface calibration proceeds as follows 1 Start the QC5000 software and ensure that the machine zero is set correctly Select the menu item Tools Options The Supervisor tab will display Enter the password check the box to keep privileges then select the General Options tab Select the NLEC tab Press the Calibrate button The NLEC Controller Window will open Close the Options dialog to proceed with using the NLEC controller window There are two ways to generate nominal grid data You can import an artifact data file or create a new data set from scratch Use a right button click on the grid background to open the NLEC me
57. rror Correction User Interface Design in QC5000 cocccconcccnncncnoccnnncnononcnonononanrnnnonnnancnnncnnnanrnnnnonanncnnnns 40 Entering the Grid Data by ACF Artifact Coordinate File oooocccncccconncnncnccnnccnnonononcnnnononancnnnnnnnancnnnonnnanennnnos 42 Chapter o HroublesnoOIN diari o a poa ibas 43 Symptoms a a possible CAUSES aeaa iii bd 44 Restoring Your System to a Previous State imc u et es N i 44 SYIMPIOMS se ee iia ne 44 Avallable sortware SselUB 6PlOnse re o e o 45 SO Ware Facloly Setlist a ee et ee ee ee eh 45 OE 5000 Setup Proce Ue nee ee rsee 45 EFICOGEL SOLL game mete So et a ee a a See a ee ee a ee ae 46 OG 5000 Factory OBlIOns reiasa e 46 Display Properties WIMAOWS AP ee ile 46 Seting UD MS BSC S asa cia 47 Options ENCOder S TaD a ad 47 Options General TaD eea a eisen 47 Opos DISRIAY zen ee en a a enter 47 6 To gf BUNONS anren o a a meee ere ere eee 47 Options WED rss tate se te er ee oe eee ct ce ee ee 47 Option RUNAS di te ee a ee ee eee 47 Options SLEC Not Used by OPTEK as NLEC is used Please see section on calibration ccccnccc 47 Options Sound S estaca di Ar da 47 OPHONS NEEC Sii iii 48 OES00D ZOOM Scsi tal 48 Mole o A A 48 O I E EEN EEEE AAA EA EEE TAE E E EE 49 NG Optlons J OVSUCK Sel rrii cial ica ciis 49 OE 5000 A linrelenenreietee l nge 49 ENE Opti ns Digital POSIIONEON essen eu 49 ANO lc o A baveanensetaewne teueed nants 49 16
58. rt Program When preparing to write a program a ten step process must be completed to allow you to run this program later This process is as follows Start a new part Go to File New part Start the Record mode Measure two features These may be two tooling holes in the longest axis of the board or board edges in the X and Y axis Skew on either the two tooling holes or the longest axis of the board edges measured Zero on either the lower left circle or the intersection of the two edges of the board Measure all of the features required to construct the relationships Construct points angles distances and heights Move the stage to a loading position Report the data to a file Stop the Record mode Save the program will get a 5pa part program suffix 18 Chapter 3 QC5000 Software This chapter will help you operate the basics of the software Windows and QC5000 Welcome to one of the most powerful metrology packages available on the market today QC5000 is a Windows based software package incorporating pull down menus data linking and on line help Getting around in Windows Since the software is Windows based the mouse and keyboard can be used to select and manipulate items Using the Mouse The mouse is a tool used for pointing to parts of the screen Moving the mouse moves the mouse arrow on the screen Once the arrow is on something you wish to manipulate a button must be depresse
59. runaway condition a system crash or other unpredictable errors Display Properties Windows XP e To adjust the display resolution in the QC5000 you must use the Windows Display Properties in the Control Panel e Set the screen resolution for 1280 X 1024 pixels e Make sure the Color Palette is set to True Color 32 bit If not your video will not work properly e Setthe refresh frequency to 75 Hz 46 Setting up the Basics e Select tools options from menu bar and enter the Supervisor password Call OPTEK for the password Options Encoders Tab e Select Limit Switches as Reference Marks e Check each axis to see if it needs to be reversed e Setthe resolution to the value that matches the value of the machine Example Enter 0005 mm if the resolution of the machine is 5um Options General Tab e f you want to save your user settings click save now e Make sure to click on Reference Marks e Don t want to change your datum when you skew uncheck the box e Want Datum Magic to start on a probe hit check the box Options Display e Use this tab to setup the Display Resolution of the DRO e You can also lock the QC5000 window positions from the Locks tab Options Buttons e This is the section of general options where you assign functions to the joystick buttons control panel buttons and the footswitch if present e Potential assignments are shown if you click the drop
60. s runs the program from the first grid measurement step Most tolerances will show up as failed RED and should be ignored at this point When the program is finished running In the NLEC controller window right click in gray area Then click on File Save give it a sensible name NLEC Reference and save it in CA QC5000 as date of cal txt This save is just for a calibration record In the NLEC controller window right click in gray area again Then click on File export and accept the default name and location for the export This exports all of the adjusted NLEC grid data from the controller to a text file that will be read by the QC5000 Turn on the NLEC Click on Tools Options NLEC and put a check mark in the box Enable Shut down QC5000 and restart Verify the Calibration Choose the calibration program File Open calibration check 5pa Add Fields to the features template Check the calibration note the x difference from nominal and y difference from nominal fields to the feature window Measure the grid with the same program as in calibration with no changes in edge teach or lighting The tolerances should now be green with NLEC enabled Export the data Save as CAL Data and date of calibration csv file Recalibrate if necessary 38 OPTEK Ultra Precision Grid Method Use if an Ultra Precision Grid and calibration ACF AND DXF data files are available 1 Optionally a part
61. s the programming session Editing Steps gt Pause Program Execution During This command stops or Pauses a CNC Made Steps gt program execution allowing the operator to EDIT program steps or enter a Zn messages To continue program execution choose Run program at selected step gt from the PROGRAM menu Special Steps gt Editing Steps Programming Wizards gt Single Step allows the user to step though steps Remember measurement steps have sub steps these must also be single stepped though v Record Edit Mode Toggle Break point to set a predetermined stop in a program View Only Mode Edit selected steps Enters edit mode and aids in group edits Set Current step 5 ula iG IET CNC Mode Steps During amp Editing Set Manual Mode This allows the operator to manual enter points at position Editing Steps i Set Power Assist Mode Allows the operator to drive to position and enter CNC Made Steps E features Set Full CNC Mode All control and motion is by the computer Focus Lock On No programs will run Special Steps Focus Lock Off Allows the operator to run the currently loaded program Set output line Some units are equipped to control external equipment Programming Wizards gt Set Manual Mode Set Power Assist Made Set Full CNC Mode Focus Lock On Focus Lock Off Set Output Line 31 Flow Control Steps Loop Create a repeating grid or array of features If then A conditional Statement check
62. seeeessseaseeeeseuaaeeeeessuaaeeeeesseageeeesssaaess 14 A a ONA 15 Quadrant Hond aa ai des 15 PGA ang Otura lo coi arsesre 16 General Programming for the VideoMic VSA in QC5000 cooooccnncccccncccnncccnoccnonononancnnnonnnnennnnonnnncnnnnonnnnrnnnnonnnnrnnnnonnns 16 Startup Troubleshooting CheckliSt oooccccccoconccnnccononccnncononncnnnconnoncnnnnnnnnncnnnnnnnnnrnnnnnnnnnrnnnnnnnnnrnnnnnnnnnrnnrnnnnnnrinennnnns 17 Problems and possible CAUSES cccccccseeeeceeeceeeeeeeeecaeeeeeeeseeeseeeeeseeseeeeeeseeeeceeesaeeeeeeeesseaeeceeesseaeeeeesseeeeeessaegeeeeeeeas 17 MICAS UGING a Dalla e nee 18 General Considerations prior tO measuring ccccccsseeecceccseeeceeesaeueeceeeeseeseeeeesueaseeeeeseeaseeeeesueaseeeessseaseeeeeseaeeeeeesagess 18 Preparation for Recording a Part Program ccccccsssececsseeeeeceeeeeecseeeeeeneeeeeseeueeessaeeesseeeeeeseeeessaeeeesseaeesesaeeeeesaaes 18 Chapter 3 QC5000 Software uuesssssssnnnnessnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnnnnnnnnnnnnnnnnsnsnnnnnnnnsnnnsnnnnnnnnnnnnenn 19 Windows MIOS o eee 20 GELANG aro 8 ated aha WII WS a a 20 USME e Sr eee eR ee eee cn ee 20 QGB000 BASICS ur A O eh et ec ee 20 A atl ieee Cease as eee N Saucer 21 Theile Batir e os an a do let ts a do es E 21 Ihe Menl DA do e e id de 21 The Status Batan li A lea 21 The DRO window Digital Read QU e id tales 21 CUSOMIZ AMAN o ante e e a de ad es 22 100lbars in IESO ed da 23 The Measure
63. so it makes no difference which is selected e Using the Simple Probe measure eight points around the Ring Gauge gt Hit OK e Follow the Onscreen Instructions a Focus the Laser on a flat surface on top of the Ring Gauge b Move the laser to the center of the ring gauge gt Hit Enter Pt e Repeat steps 2 through 4 For any additional lenses The Optimet Laser Offset is now taught and will have to be verified Laser Verification To ensure maximum accuracy the Z Axis value may need to be adjusted slightly e Select the Simple Probe gt Measure eight points around the Ring Gauge to form a circle gt Zero the X Y amp Z of that circle e Select the Optimet Point Probe gt Focus the laser on the top of the Ring Gauge gt Move the laser to the center of the Gauge gt Hit the Check button e Measure a single point on the top of the Ring Gauge a This point will be Used to check the Z Axis height Check the offset between VED and Laser If the X or Y Axis measurement from step 7 are off repeat steps 2 through 4 to correct the Z Axis continue below e Goto the Probe Menu gt Probe Library gt Select Optimet gt Select the current lens 54 e The Point Line and Patch tools will need to be corrected individually gt Add the Inverse of the difference between VED and Laser to the Z Axis offset of each laser tool e Recheck gt Repeat steps 6 through 8 until satisfactory results are achieved 55 Chapter 6 Maintenance Mai
64. 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 from 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 M
65. t Mechanical adjustment Grid Measurement Determines the errors and applies software compensation by NLEC calibration Implementation of NLEC Calibration Software compensation for errors Verification The calibration check program Software verification of the compensation by NLEC 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 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 Probe1 Probe library Select VED
66. t Movement Calibration om QC5000 Grid Calibration Procedure to the HIGH other this het Teach ls TIE aima OVERVIEW 1 m 1 Lp 16 17 Start QC5000 Ensure that all other optical and mechanical adjustments and calibrations have been done first Turn off the NLEC Click on Tools Options Nlec and uncheck the Nlec Enabled check box Open the calibration program This should be in C Optek Calibration Calibration 5pa Place toggle breakpoint after skew and zero steps Right click on the first grid measurement step Click on Editing steps Toggle break point Open NLEC controller Click on Tools Options NLEC Click Calibrate Right click in the background between grid stations For certified grids only Click on File Import and browse to the ACF file that matches the Grid s n For other grid masters click on File New and enter all relevant information Verify columns rows correct for grid stations to be used Right click in the background between grid stations Click on Calibrate Start Run the program Click on the New Run button The machine will measure the skew and zero points and then stop at the break point that was set in step 4 Inthe NLEC controller window right click on the lower left grid station and then left click on Zero This tells the NLEC controller where the zero and skew line exist Click on the button Run from current step thi
67. t as close as possible to the center of the Video monitor er Go to Probe Probe library Click the magnification of interest and choose the Taal Config Resolution tab Adae Cice Select Teach to edit the calibration je h Cenal Enter the size of the calibration dot The actual size of the dot is found on the back of the Focus 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 z you to enter the size of the artifact you are using to calibrate with The Yed Artifact Size x New Calibration Edit Calibration t Default Calibration size usually comes from the VED glass slide supplied with the system If you select continue the system will prompt you to measure the specified Artifact Size TT 000 artifact lf you say cancel it will return you to the Probe Library window a area select the circle tool twice This will center the tool in the Video window Using the digital positioner track ball Move the transport system until the dot is as close to the center of the circle tool as 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
68. t the factory Any change to the video image size shape or position will affect the calibration and thus require a new pixel calibration Software Factory Setup Certain parameters are set at the factory in both supervisors set up and the QC5000 files This section introduces the settings for the OPTEK systems Perform all necessary backups before making and changes The OPTEK System comes from the factory with up to five programs which have been configured specifically to your machine If these files must be re installed you will find them in the maintenance directory of the QC5000 software or on the disks which ship separately but with the machine QC5000 needs this data to correctly operate the OPTEK system QC5000 Setup Procedure Run the Encoder program Check the Display Properties Set the Options Set up Encoder Resolution 45 General Options Setup CNC Options Setup Light Setup Zoom Setup Machine Zero Setup Customize your the QC5000 m Encoder Encoder Setup e Make sure the QC5000 is not open e Double Click on the Encoder Icon e Running this program created the file called Encoder 5ES Set OPTEK encoders to TTL Joystick Setup Click on the Joystick setup button Use this setup screen to allow the motors to work in open loop for scale calibration e Click on CAL CENTER move the joystick to all extremes then click APPLY CAL e Check to make sure Normal Speed is set to 50mm sec enabled is check
69. t worldwide 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 Power Cutoff Switch Locations Machine Cover Cooling Fan 100psi air input Input power 115VAC or 220VAC Leveling foot Circuit breaker and Lockout switch 10 Operating Principles The use of the VideoMic depends on five main 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 measu
70. tate With the Supervisor s password entered GO TO Help Restore Settings Select the time or file you want to revert to and then click on the OK button You will be prompted that the QC5000 settings have been saved restored and the software will shut down Restart the software and perform the homing sequence Symptoms Noise In Transport Drive systems Determine what axis the noise is coming from and where Humming Air bearing out of adjustment or linear motor Tuning issue Scraping Air bearing out of adjustment dirty surface plate or debris stuck under the transport Grinding Mechanical part loose worn or misaligned Movement problem Stage moves are unusual Clean the surface plate Stage moves on its own Calibrate Joystick Stage vibrates or hums Clean and adjust the air bearings Stage does not move at all Blown fuse Homing sequence error software fences machine or user not set correctly or amplifier error One or more axis activating a limit switch during the power on and start up sequence SET Home or Reset Auto Zero datum set machine zero Stage movement is confined to a certain region SET Home or Reset Auto Zero datum set machine zero Stage moves in one direction only One or more axis activated a limit switch during the power on and start up sequence Move all axis off of limit switches restart machine and complete the homing sequence Controls do not operate as expected Digital
71. te a nominal grid and it will control the calibration process The other information is used for traceability Select OK to generate a nominal grid You can then use right button selection over a grid element to view the grid data The grid point edit dialog can also be use to adjust the grid nominal data if calibration information is available for the grid When editing is complete select File Save to save the grid data in QC5000 v2 format Select Calibrate Start to start a calibration process A series of instructions will then be displayed to lead you through the calibration process Grid features must be circles for a Circle grid type and points created as line intersections for a Cross grid type Measure two of the active grid features along one edge to establish skew Measure the single point in the most lower left active grid point corner to establish zero Next measure each one of the grid points Each measurement will be indicated in the artifact display so that you can keep track of progress When the measurements are completed select File Export to create an NLEC correction file This file must be named NLEC TXT in order to make it the active calibration file The right button Whiskers menu can be used to control the display of short lines that represent the difference between the measured and grid data This can be turned on after grid measurement is complete or before measurements are made Optionally a part program can be used to measu
72. time for testing and navigation purposes View 949449 Toolbar Zoom Out This will incrementally zoom out reduce all features within the part view Zoom In This will incrementally zoom in enlarge all features within the part view Zoom to Selected Features This is used to make Selected features appear larger The features must be selected on the feature list or from the part view 24 Special l p These tool are usually found on the customized toolbars Tools Continuous Fire allows the user to instantly see teach changes The Datum Toolbar Datum Magic can be used to simplify the process of establishing a reference frame Select Datum Magic by selecting Datum from the main menu and then selecting Datum Magic from the datum drop down menu or you can select Datum Magic by clicking on the Datum Magic icon located on the datum toolbar ZerO allows the operator to set a new Datum Point Zero Coordinate System Secondary Line Skew Skewing electronically aligns a part to indicate the rotation of the part s axes relative to the measuring machine s axes Primary Plane For complete instructions on probing a plane look under planes in the Features chapter of this manual Remember a plane requires at least three points spread out across the parts surface Additionally you can construct a plane from previously measured features e g a midplane may be constructed from two previously probed planes etc Save Refer
73. tor This will turn the position indicator on or off in the Part View Show Position Indicator Layer Control This will redraw all the features in the Part View for 3D aho elemice Poe caos systems only Toolbars Access the available toolbars on each system includes custom toolbars Units switch from inches to millimeters and back Layer Control The Tools Programming Menu Pr The PROGRAM menu is unlike the other menus in that different menu Lume VG selections will appear as the operator enters different modes of programming The following lists all program menus and the mode the operator must be in for the selection to appear The mode will appear in brackets and will indicate if the selection will appear Prior to recording a program During a programming session After programming or while Editing a program 30 Record Edit Prior This initiates the programming sequence Set current Step Sets the highlighted step to current New entries are places after this position v Record Edit Mode Auto Program from Features This is an Advanced User command It allows View Only Mode the advanced operator to automatically create a program from the features in the Set Current Step feature list that have been measured or Imported and edited Please refer to the programming section in the QC5000 manual for more information Auto oaan Pause Recording During This command conclude
74. ttons Computer e Network Card e Frame Grabber Board e xX Y and Z Axis board with onboard light I O and programmable zoom controller Part Locations X axis and camera head assembly Monitor Optional _ Hinged Glass 7 Platen HGP BE ni taiii ndar Keyboard amp Mouse E Control panel Y axis transport assembly Height adjustment Granite table Computer system Electronics bay Software The VideoMic utilizes Microsoft s Windows operating system and Metronics QC5000 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 QC5000 this book The Metronics QC5000 User s Guide describes the software features available to users programmers and maintenance professionals QC5000 Software on line help and dialogue boxes This information becomes available in QC5000 when you expand a dialogue box resizing it with the mouse OPTEK and Metronics Power Point presentations See your OPTEK representative Windows on line help Accessed through the Windows Graphical User Interface GUI The OPTEK VSA QC5000 Operation Manual binder includes schematics optional utilities and advanced hardware and software maintenance procedures Note If the equipment is used in a manner not
75. ure Measure Magic F2 View Men lt un Point F3 Zoom All EA Zoom Window Line F4 Zoom Special Are F5 Pan Circle FG Reset View Set Viewpoint Slot Fe View From Probe Blob F8 View Rotator l Show Position Indicator Distance F9 Show reference Frame Indicator Angle F11 Layer Control AAA A ne Plane Ctrl F3 Cylinder Ctrl F4 Measure Menu Sphere CuleFS Point Cone Ctrl F6 Enables the POINT measurement function as Line Magnetic Plane Ctrl F Enables the LINE measurement function _____ gt zuQ lt aR Enables the CIRCLE measurement function Arc Enables the ARC measurement function Angle Enables the ANGLE measurement function Datum Menu Set Machine Zero This will set the machine zero point The Machine Zero point is located at the Probe Tools Windows extreme left and front of the transport stage The machine moves the stage to the Datum Magic rear and right of the X Y stage travel To position the zero point under the lens In gt S addition the Z axis is moved to the lowest position Primary Non feat gt Zero Secondary Non feat This allows you to set a part zero point Fu Non feat Skew IRA This allows you to electronically align Skew on a feature Projection Auto gt Level Magnetic Pl Off gt This levels the part enabling accurate height measurements for 3 Axis systems EN ISE otate ne Temp 28 Probe Menu E Tools Windows Help
76. urer 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 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 OPTEK 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 Particle size in microns Pressure Dew point F including vapor ppm Vol at 100 psig mg cubic meter A 94 0 8 o CA A TA 500428 E 15 AICA 0 1 1 0 5 0 15 6 Te 51500 Note OPTEK Recommends air quality of Class 3 or better 99 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
77. ut 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 QC5000 User s Manual or later in this manual There is an excellent interactive online manual for QC5000 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 QC5000 is running 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
78. w Pnt 2 Col x Artifact Skew Pnt 2 Row y Number of Columns nx 3 QA Number of Rows ny 5 First Active Column x0 1 First Active Row y0 2 Last Active Column x1 3 Last Active Row y1 5 Column Spacing dx 25 4000 Row Spacing dy 25 4000 Artifact Element Size 0 0500 NLEC Zero X machine 19 8765 NLEC Zero Y machine 43 2109 Artifact Skew Angle 0 0765 User Note This artifact must be cleaned before use Column Row Artifact X Artifact Y Measured X Measured Y Error X Error Y 1 1 0 0000 0 0000 0 0000 0 0000 0 0000 0 0000 1 2 0 0000 25 4000 0 0000 25 4000 0 0000 0 0000 1 3 0 0000 50 8000 0 0000 50 8000 0 0000 0 0000 1 4 0 0000 76 2000 0 0000 76 2000 0 0000 0 0000 1 5 0 0000 101 6000 0 0000 101 6000 0 0000 0 0000 2 1 25 4000 0 0000 25 4000 0 0000 0 0000 0 0000 2 2 25 4000 25 4000 25 4000 25 4000 0 0000 0 0000 2 3 25 4000 50 8000 25 4000 50 8000 0 0000 0 0000 2 4 25 4000 76 2000 25 4000 76 2000 0 0000 0 0000 2 5 25 4000 101 6000 25 4000 101 6000 0 0000 0 0000 3 1 50 8000 0 0000 50 8000 0 0000 0 0000 0 0000 3 2 50 8000 25 4000 50 8000 25 4000 0 0000 0 0000 3 3 50 8000 50 8000 50 8000 50 8000 0 0000 0 0000 3 4 50 8000 76 2000 50 8000 76 2000 0 0000 0 0000 3 5 50 8000 101 6000 50 8000 101 6000 0 0000 0 0000 Row and column are the artifact grid point numbers Columns are tab delimited so that the data can be easily read into Excel 41 Entering the Grid Data by ACF Artifact Coordinate File The grid manu
79. xterior 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 4 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 70
80. 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 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 13 Machine Zero Machine zero is critical as it is the reference for the calibration system The QC5000 will go through a homing process immediately on startup see Homing Sequence or using the mouse choose

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