1. Manuals
  2. Brands
  3. Lasertex Manuals
  4. Measuring Instruments
  5. HPI-3D
  6. User manual

Lasertex HPI-3D User Manual

Laser measurement system
Hide thumbs
Table of Contents

Advertisement

Quick Links

HPI-3D
Laser Measurement System
User
manual

Advertisement

Table of Contents
loading

Summary of Contents for Lasertex HPI-3D

  • Page 1 HPI-3D Laser Measurement System User manual...
  • Page 2 www.lasertex.eu...
  • Page 3 Research and Development Company Ltd. UL. RADZIONKOWSKA 17, 51-506 WROCLAW, POLAND Laser measurements systems. Tel/fax. 071-3466684 Measurement systems with data acquisition. email: lasertex@lasertex.com.pl Laser technique. Laser Measurement System HPI-3D User manual Rev. E10 Wroclaw 2017 www.lasertex.eu...

  • Page 4: Table Of Contents

    NTERFEROMETER SETUP FOR MEASUREMENT OWERING THE SYSTEM ON ................3-16 Starting hardware ................... 3-16 Starting software ..................... 3-16 ..........3-18 ETTING BASIC INFORMATION FROM THE SYSTEM ECORDING MODE ....................3-25 LAT MIRROR MEASUREMENTS OPTION ............3-25 BEAM ALIGNMENT ..................... 4-1 www.lasertex.eu...
  • Page 5 Display Panel ....................5-10 iii. Positioning Plot Panel ................. 5-11 iv. Positioning Measurement Values Panel ............5-12 Positioning Control Panel ................5-12 vi. Pull down menu - File ..................5-15 vii. CNC path generation .................. 5-15 viii. Compensation table preparation ..............5-17 www.lasertex.eu...
  • Page 6 Measurement Setup Preparations ..............6-6 OFTWARE DESCRIPTION ..................6-9 Introduction..................... 6-10 Display Panel ....................6-10 iii. Positioning Plot Panel ................. 6-11 iv. Positioning Control Panel ................6-12 Pull down menu - File ..................6-13 vi. CNC path generation ..................6-13 www.lasertex.eu...
  • Page 7 Measurement Setup Preparations ............... 7-12 – 3D EASUREMENT ETUP METHOD ..............7-15 Principles ......................7-15 Application Notes .................... 7-15 iii. Measurement Setup Preparations ............... 7-16 OFTWARE DESCRIPTION ..................7-18 Introduction..................... 7-19 Display Panel ....................7-20 iii. Straightness Plot Panel ................7-21 www.lasertex.eu...
  • Page 8 Optical path alignment of the axes: “2” and “4” ..........8-11 EASUREMENT PROCEDURE ................8-12 MEASUREMENTS – PITCH/YAW ..............9-1 ENERAL ESCRIPTION ..................9-1 EASUREMENT ETUP ..................9-1 OFTWARE DESCRIPTION ..................9-3 EASUREMENT PROCEDURE ................. 9-8 MEASUREMENTS - SQUARENESS ............10-1 ENERAL ESCRIPTION ..................10-1 www.lasertex.eu...
  • Page 9 EASUREMENT PROCEDURE ................13-12 MEASUREMENTS – ANGULAR POSITIONING ........14-1 ENERAL ESCRIPTION ..................14-1 EASUREMENT ETUP ..................14-1 Characteristics of Wally – Rotary Measurement System ....... 14-3 Theory of operation ..................14-6 Rotary measurements – hardware preparations ......... 14-7 iii. www.lasertex.eu...
  • Page 10 CONNECTING LASER HEAD TO MACHINE ........16-1 ENERAL ESCRIPTION ..................16-1 XTENSION ONNECTOR ..................16-2 Extension Connector pinout ................16-2 Extension Cable EX1 ..................16-3 iii. Encoder type outputs ................... 16-6 HPI-3D IN A MACHINE CONTROL LOOP ............16-10 CONFIGURATION ..................17-1 www.lasertex.eu...
  • Page 11 TYPE – 2 ............20-2 ASER EAD OUTPUTS DIGITAL TYPE – E ASER EAD OUTPUTS XTENSION CONNECTOR PINOUT ......20-3 YSTEM WORK CONDITIONS ................20-4 OWER UPPLY ....................20-4 INTERFACE ..................... 20-4 NVIRONMENT COMPENSATION ................. 20-4 INDEX ........................1 www.lasertex.eu...

  • Page 12: Introduction

    Safety considerations The Laser Interferometer HPI-3D is a Safety Class I product designed and tested in accordance with international safety standards. It is also a Class II Laser product conforming to international laser safety regulations. The instrument and the manual should be inspected and reviewed for safety markings and instructions before operation.

  • Page 13: Warnings

    NTRODUCTION b. Warnings Although the laser measurement system HPI-3D is design to be used in harsh environment, the following conditions must be met: The Laser Head must not be put near strong magnetic fields. The head should not be unscrewed from its base and if it is, it may not be put on a heat sink (e.g.
  • Page 14 Radzionkowska 17 51-506 Wrocław Poland Hereby certifies on its sole responsibility that the following product: Laser Measurement System HPI-3D which is explicitly referred to by this Declaration meet the following directives and standard(s): Directive 2006/95/EC Electrical Apparatus Low Voltage Directive...

  • Page 15: Quick Start

    The basic measurement unit is the wavelength of the laser, i.e. 632nm. The functionality of the instrument depends on the type of used optical components. The HPI-3D is can be used either as a stand alone device or with a PC computer and the dedicated HPI Software. b. How it works The HPI-3D measures shift of the moving element in relevance to the reference element as shown in the figure 2.1.

  • Page 16: Linear Optics

    To the linear optics belong Linear Interferometer IL1 and Linear Retroreflector RL1. The operation of the HPI-3D with the linear optics used is shown in the figure 2.1. The laser outputs the laser beam consisting of two polarizations: Horizontal (H) and Vertical (V).
  • Page 17 UICK TART The operation of the HPI-3D with the angular optics used is shown in the figure 2.2. The laser outputs the laser beam consisting of two polarizations: Horizontal (H) and Vertical (V). The IK1 splits the beam into two parts. Both beams are directed into the measurement path but are parallel shifted by 50.8 mm.

  • Page 18: Wollaston Optics

    To the angular optics belong Wollaston Prism WP2 and Wollaston Retroreflector WRP2. The operation of the HPI-3D with the Wollaston optics used is shown in the figure 2.3. The laser outputs the laser beam consisting of two polarizations: Horizontal (H) and Vertical (V). The WP2 splits the beam into two parts. Both beams are directed into the measurement path.

  • Page 19: How To Start

    BEAMS RETURING TO THE LASER ARE IN THE PLANE OF THE DRAWING. The Wollaston optics is mainly used for measurement of:  Straightness with Wollaston method  Axes squareness (with REW element)  Axes parallelism (with REW element) c. How to start www.lasertex.eu...
  • Page 20 UICK TART 1. Install HPI software from CD or from www.lasertex.eu LASER HEAD Bluetooth 3. Run HPI Software and connect PC with laser over USB or over Bluetooth interface www.lasertex.eu...
  • Page 21 UICK TART LASER HEAD 4. Align optical path 5. Start measurements www.lasertex.eu...

  • Page 22: Preparations

    USB memory. The installation process should start automatically. . 3.1. I CON OF THE SETUP APPLICATION Following components have to be installed for proper operation of HPI-3D system:  HPI Software application,  Directory of the languages Languages, ...
  • Page 23 During the installation process necessary parameters have to be set by the user. In the figure 3.2 there is shown a first windows that appears during installation. It allows choosing the installation language. .3.2. I NSTALLATION LANGUAGE SETUP WINDOW .3.3. W ELCOME WINDOW www.lasertex.eu...
  • Page 24 REPARATIONS .3.4. U NFORMATION WINDOW .3.5. P ROGRAM DESTINATION FOLDER WINDOW www.lasertex.eu...
  • Page 25 REPARATIONS .3.6. W INDOW APPEARING WHEN THE FOLDER NAME DOES NOT EXISTS IN THE CURRENT INSTALLATION PATH .3.7. M TART FOLDER SLECTION WINDOW www.lasertex.eu...
  • Page 26 REPARATIONS .3.8. D ESKTOP ICON SETUP WINDOW .3.9. W INDOW WITH INSTALLATION INFORMATION www.lasertex.eu...
  • Page 27 REPARATIONS .3.10. I NSTALLATION WINDOW DURING DATA COPY OPERATION .3.11. BDE (B ORLAND ATABASE NVIRONMENT DESTINATION FOLDER WINDOW www.lasertex.eu...
  • Page 28 REPARATIONS .3.12. FTDI DRIVER INSTALLATION .3.13. I NSTALLATION SUMMARY WINDOW www.lasertex.eu...
  • Page 29 .3.14. M ESSAGE APPEARING WHEN THE NEW DEVICE IS FOUND .3.15. M HPI-3D ESSAGE APPEARING WHEN THE DRIVER FOR DEVICE IS INSTALLED The HPI Software application can be launched from the HPI Software folder located in Programs tab in Windows Start Menu (assuming that the installation settings are not changed).

  • Page 30: Elements Of The Laser System

    Number of the system elements is configurable and its configuration is related to the required application. Following items are included in the standard set (for linear measurements): Laser head Power Supply Tripod stand Linear retro- reflector RL1 Linear interferometer IL1 www.lasertex.eu...
  • Page 31 REPARATIONS Base temperature sensor temperature sensor Wireless strobe Holding block HB1 Stainless rod Magnetic holder UM2 www.lasertex.eu 3-10...
  • Page 32 FIG.3.18. THE SUITCASE FOR TRANSPORT AND STORAGE OF THE INTERFEROMETER SYSTEM. Additional elements for angular measurements are: 1 x Angular Interferometer IK1, 1 x Angular Retro-reflector RK1, 2 x Beam directing mirror ZK1, 1 x Rotary table RE1. Additional elements for straightness measurements are: www.lasertex.eu 3-11...

  • Page 33: Interferometer Setup For Measurement

    1 x Right Angle Etalon for Wollaston measurements REW. c. Interferometer setup for measurement The Laser Interferometer HPI-3D is supplied from autonomous 24VDC/5A Power Supply. Communication with a PC computer is performed by USB or Bluetooth interface. The USB connection is faster thus it gives more possibilities in some measurements (i.e.
  • Page 34 Power Connector USB Connector Extension Connector FIG.3.19. CONNECTIONS OF THE HPI-3D. Through the Extension Connector it is possible to drive many peripherals directly from the laser head. This give huge possibilities of customization of the usage of the laser interferometer – e.g. in emulation of glass scales, driving stepping motors, dynamic measurements, etc.
  • Page 35 REPARATIONS The Power Button is used for switching the laser on or off and for signalization of the internal state of the laser. The meaning of the signaling of the Power Button is described in the table 3.1. www.lasertex.eu 3-14...
  • Page 36 Laser switched on; Stabilization phase 2 blinking fast Green - Laser switched on; Stabilization phase 3 blinking Orange Laser stabilizes. Beam path unaligned. Green Laser stabilizes. Beam path aligned. System ready for measurements! TAB.3.1. POWER BUTTON LED STATES www.lasertex.eu 3-15...

  • Page 37: Powering The System On

    When the software starts a splash screen appears (figure 3.21). Pressing F5 on the PC keyboard or the button marked Simulator causes the software to switch into simulation mode – connection to a HPI-3D device is emulated even if there is a real device connected to the computer! In the bottom part of the splash screen there are shown all HPI-3D devices currently connected to the PC either by Bluetooth or USB interface.
  • Page 38 3.22). After software installation, by default, the first trials are made over USB interface. When there is a successful connection made over other interfaces then the “successful” interface is taken as a first choice in next runs. www.lasertex.eu 3-17...

  • Page 39: Getting Basic Information From The System

    Other buttons open measurement screens. All options are described in details in following Chapters. Because of abundance of measurement types offered by the HPI-3D, some of the options are not visible and can be reached by using the buttons with arrows in the second row.
  • Page 40 Panel (figure 3.25) where are presented a digital result of the measurement and the signal level. There are also located buttons for changing the Units and a number of displayed Digits in the result. FIG.3.25. PANEL WITH MAIN DISPLAY www.lasertex.eu 3-19...
  • Page 41 Z). Adjustment and Laser head options are selected by the checkboxes located on the panel. However only one of them can be active, because they are mutually exclusive. Both options are very helpful in optical path alignment process (see chapter 4). www.lasertex.eu 3-20...
  • Page 42 Status Bar (figure 3.24) presents state of the Laser Head and state of the measurements. There are four fields: Connection, Laser, Signal and Velocity. In proper operation they should all be green. In table 3.2 there are shown the possible states of the fields. www.lasertex.eu 3-21...
  • Page 43 No measuring sensors At least 3 minutes after powering up detected the laser head: - Check if sensors are close enough to Sensors the laser head; - Check/replace sensors batteries; At least one sensor is No action necessary Sensors www.lasertex.eu 3-22...
  • Page 44 The measured machine is compensated to the temperature set in the Reference temperature edit box, located in the Configuration->Meteo panel (see figure 3.29). By default the reference temperature is set to 20 degrees C and should not be change unless necessary. www.lasertex.eu 3-23...
  • Page 45 REPARATIONS FIG. 3.29. CONFIGURATION WINDOW – METEO PANEL www.lasertex.eu 3-24...

  • Page 46: Recording Mode

    Flat mirror measurements - option The flat mirror measurements option enables to measure the displacement, velocity, positioning, and vibrations of a flat surface. The surface should have a mirror quality (surface flatness λ/8) and the reflection coefficient not less than 50%. www.lasertex.eu 3-25...
  • Page 47 In order to obtain correct result of measurements with double-pass flat mirror configuration, the option double-pass in the Configuration window should be chosen (fig. 3.33). Flat mirror FIG. 3.31. DOUBLE PASS FLAT MIRROR INTERFREOMETER Flat mirror Flat mirror FIG. 3.32. SINGLE PASS FLAT MIRROR INTERFREOMETER www.lasertex.eu 3-26...
  • Page 48 REPARATIONS FIG. 3.39. CONFIGURATION WINDOW – INTERFEROMETER TYPR CHOICE www.lasertex.eu 3-27...

  • Page 49: Beam Alignment

    FIG.4.1. ILLUSTRATION OF BEAM MISALIGNMENT The alignment of the optical set up should be conducted in the option Display. It can be done during Laser Head heating. Final check should be made when the system is ready to work. www.lasertex.eu...

  • Page 50: Electronic Alignment Tools

    Electronic alignment tools The beam path alignment process is usually time consuming so in order to simplify and speed it up the HPI-3D provides, together with standard mechanical elements like diaphragms, three unique electronic tools. The first is a function of electronic position of the laser head in space –...
  • Page 51 Beam Alignment tool – (diaphragms in „work” position) Control the strength of the returning beam either wirh Electronic Beam Indicator on the laser or with software beam indicator on the PC Correct position of the laser if necessary Stop FIG.4.2. BASIC BEAM ALIGNMENT RULES www.lasertex.eu...

  • Page 52: Preparations

    4.4) helps in the process of alignment. The diaphragm can be placed in two positions: " Alignment" – the laser beam goes out through opening in the diaphragm about 2 mm diameter, " Measurement" from the Laser Head goes out beam about 8 mm diameter, www.lasertex.eu...
  • Page 53 The Diaphragms are also used on most available optical components – see figure 4.5 – with the exception of Wollaston optics. FIG.4.5. DAPHRAGMS: ALIGNMENT POSITION (A) AND WORK POSITION (B) If it is required then the diaphragms can be taken off and put back later on. www.lasertex.eu...

  • Page 54: Laser Head Alignment Elements

    (figure 4.5c). Elements placed on the tripod are in general used for linear vertical and horizontal movement of the beam position, while the elements available on the laser head base are for angular vertical and horizontal movement of the beam. www.lasertex.eu...

  • Page 55: Electronic Beam Alignment Tool

    LIGNMENT iii. Electronic Beam Alignment tool One of the unique features of the HPI-3D laser is the Electronic Beam Alignment tool. This is a software tool displaying the position of the beams returning to the laser. The tool can be activated in the Display option by checking Adjustment check box in the Measurement panel –...

  • Page 56: Beam Alignment Process For Linear Optics

    2. Turn on the laser and align all elements along the measurement axis 3. Move the RL1 very close to IL1 (they can touch each other). Set their initial position so the beam returns back to the laser. LASER HEAD 4. Move the RL1 from the IL1 www.lasertex.eu...

  • Page 57: Beam Alignment Process For Angular Optics

    Be sure that during measurements in extreme nearest measuring position the retro- reflector does not touch the interferometer, because it can be a source of measuring errors. Beam alignment process for angular optics www.lasertex.eu...
  • Page 58 2. Turn on the laser and align all elements along the measurement axis 3. Move the RK1 very close to IK1 (they can touch each other). Set their initial position so the beam returns back to the laser. LASER HEAD 4. Move the RK1 from IK1. www.lasertex.eu 4-10...
  • Page 59 – it should be zero! LASER HEAD 6. Move the RK1 back to IK1 (the components must not touch!) and check the quality of the beam path alignment. Use available electronic tools – Beam Level Indicator and Electronic Beam Alignment Tool. www.lasertex.eu 4-11...

  • Page 60: Beam Alignment Process For Wollaston Optics

    WP2 LASER HEAD 3. Move the WP2 along the measurement axis. Aling the laser position so that the beam passes always through the middle of the WP2 diaphragms. www.lasertex.eu 4-12...
  • Page 61 Use available electronic tools – Beam Level Indicator and Electronic Beam Alignment Tool – the beams on the Alignment Tool have to overlap!. If they not over lap then rotate the WP2 so they are onto each other. www.lasertex.eu 4-13...

  • Page 62: Beam Alignment Of Linear Optics With Angle Etalon

    LIGNMENT h. Beam alignment of linear optics with angle etalon 1. Mount Laser Head, IL1, RL1 and RE3D on the measured machine 2. Turn on the laser and align all elements along the measurement axis www.lasertex.eu 4-14...
  • Page 63 LIGNMENT 3. Move the RL1 very close to IL1 (they can touch each other). Set their initial position so the beam returns back to the laser. 4. Move RL1 from IL1 www.lasertex.eu 4-15...
  • Page 64 IL1 component. 6. Move the RK1 back to IK1 (the components must not touch!) and check the quality of the beam path alignment. Use available electronic tools – Beam Level Indicator and Electronic Beam Alignment Tool. www.lasertex.eu 4-16...

  • Page 65: Beam Alignment Of Angular Optics With Beam Bender

    Beam alignment of angular optics with beam bender i. Laser Head initially not aligned 1. Mount Laser Head, IK1, RK1 and ZK1 on the measured machine 2. Turn on the laser and align all elements along the measurement axis www.lasertex.eu 4-17...
  • Page 66 LIGNMENT 3. Move the RK1 very close to IK1 (they can touch each other). Set their initial position and the position of ZK1 so the beam returns back to the laser. 4. Move the RK1 from IK1. www.lasertex.eu 4-18...
  • Page 67 RK1. Check the roll of laser head against IK1 and RK1 – it should be zero! 6. Move the RK1 back to IK1 (the components must not touch!) and check the quality of the beam path alignment. Use available electronic tools – Beam Level Indicator and Electronic Beam Alignment Tool. www.lasertex.eu 4-19...

  • Page 68: Laser Head Initially Aligned

    1. Align all elements (ZK1, IK1, RK1) along the new measurement axis. DO NOT TOUCH the laser head 2. Move the RK1 very close to IK1 (they can touch each other). Set their initial position and the position of ZK1 so the beam returns back to the laser. www.lasertex.eu 4-20...
  • Page 69 DO NOT TOUCH the laser head. REMARK: If the beams do not overlap then it means that the IK1 is rotated against RK1. Check the roll of laser head against IK1 and RK1 – it should be zero! www.lasertex.eu 4-21...
  • Page 70 LIGNMENT 5. Move the RK1 back to IK1 (the components must not touch!) and check the quality of the beam path alignment. Use available electronic tools – Beam Level Indicator and Electronic Beam Alignment Tool. www.lasertex.eu 4-22...

  • Page 71: Measurements - Positioning

    (i.e. the position displayed on the machine’s readout) with the true position measured by the interferometer. The HPI-3D device offers a unique feature of simultaneous measurement of positioning and estimation of straightness in horizontal and vertical planes. This 3D feature simplifies and significantly speeds up the process of machine geometry testing and improves measurement accuracy thanks to elimination of the cosine error.
  • Page 72 After uploading the file, the machine positioning should be measured again to obtain the end results. The end results can be stored or printed. All measurement steps are described in much greater detail inside the Chapter. www.lasertex.eu...
  • Page 73 Downloading corrections into machine machine (if necessary) (linear, incremental, Siemes, HP, Fanuc) Printing error report according to a chosen standard (NMTBA, ISO, VDI/DGQ, BSI, PN, JIS) FIG.5.1 LINEAR POSITION ERROR CORRECTION PROCEDURE www.lasertex.eu...

  • Page 74: Measurement Setup

    T, P and H in usual conditions (T=293K, P=1000hPa, H=50%):                       www.lasertex.eu...

  • Page 75: Principles - Base Temperature Compensation

    EASUREMENTS OSITIONING The changes of the wavelength are compensated automatically by the HPI-3D laser head only if the TH sensor is used properly, i.e. placed near the laser beam path. The air pressure is measured inside the laser head. ii. Principles – base temperature compensation One of the important factors limiting the precision of every machine is the temperature.

  • Page 76: Measurement Setup Preparations

    – the length of the non-used scale part or the distance between the beginning of the scale and the Zero mark. The HPI-3D is capable of automatic compensation of the thermal expandability of the Scale. The user has only to properly use Base Temperature sensors (i.e.
  • Page 77 – see the Chapter 17) have to be taken into consideration. The usage of the air temperature sensor and at least one base temperature sensor (T1 or T2 or T3) is absolutely necessary! More than one base temperature sensor should be used on long measurement axes, especially where a temperature gradient is possible. www.lasertex.eu...
  • Page 78 5.2 and 5.3) but also in directions perpendicular to the laser beam. These configurations are shown in figures 5.4 and 5.5. In those two configurations the laser beam has to enter the IL1 from the bottom of the element. Only the retro- reflector RL1 can be moved. www.lasertex.eu...
  • Page 79 EASUREMENTS OSITIONING FIG.5.4. OPTICAL PATH SET UP FOR POSITIONING MEASUREMENTS IN Y AXIS FIG.5.5. OPTICAL PATH SET UP FOR POSITIONING MEASUREMENTS IN Z AXIS www.lasertex.eu...

  • Page 80: Software Description

    FIG.5.6 MAIN MENU ii. Display Panel The top part of the Display Panel (block 1 of figure 5.7) is used for basic control of the laser operation. Through this panel it is possible to monitor the quality of the www.lasertex.eu 5-10...

  • Page 81: Iii. Positioning Plot Panel

    On the plot the points are placed in two colors: the deviations measured during forward movement of the machine is shown with blue circles while the deviations measured during reverse movement are shown with red triangles. The www.lasertex.eu 5-11...

  • Page 82: Positioning Measurement Values Panel

    There are two possibilities: true value of the distance or point number. v. Positioning Control Panel Positioning Control Panel is comprised of three main parts (Figure 5.11):  Line with control buttons  Line with measurement status information  Line with laser status information. www.lasertex.eu 5-12...
  • Page 83 Pressing “Repeat” button also starts new measurement but the results would supersede the results of the last measurement series. By pressing “New” button all registered results are cleared and a new measurement is started. www.lasertex.eu 5-13...
  • Page 84 Configuration. The bottom line shows information common to all options of the HPI Software, i.e. the state of Connection, Laser, Signal, Sensors and Rotary encoder. The functionality of the line is described in another Chapter. www.lasertex.eu 5-14...

  • Page 85: Pull Down Menu - File

    CNC path and preparing compensation table. vii. CNC path generation CNC path generation options allows automatic preparation, by the HPI-3D software, the G-code program compatible with most CNC control systems. The options of the path generation are set in the separate window as shown in the figure 5.13.
  • Page 86 (7 m/s = 420000 mm/min).  Stop Time – the time the machine stops at every measurement point. This time is necessary for the HPI Software to capture measurement point. The proper value of this parameter depends on the tested www.lasertex.eu 5-16...

  • Page 87: Compensation Table Preparation

    Should not be used for normal measurements.  g code/Heidenhain – it is possible either to generate the standard G- code program or a version compatible with Heidenhain machine controls. viii. Compensation table preparation www.lasertex.eu 5-17...

  • Page 88: Pull Down Menu - Edit

    In the pull-down menu option Edit (fig. 5.15) there are options for setting measured machine data (Fig 5.16), defining machine error limits (fig. 5.17), previewing obtained positioning results, editing positioning points (when option Target Points from List from menu Measurement is active) and changing overall positioning configuration. www.lasertex.eu 5-18...

  • Page 89: Machine Error Limits

    FIG.5.15. POSITIONING PULL-DOWN MENU EDIT FIG.5.16 MACHINE DATAWINDOW x. Machine error limits In the Edit option the user can setup allowable error limits of the machine for different norms (option Machine error limits - Fig. 5.17). The results of the whole www.lasertex.eu 5-19...
  • Page 90 (see Fig. 5.18). This option is especially useful when there are checked many machines of the same type and the same requirements on their accuracy are expected. FIG.5.17. MACHINE ERROR LIMITS WINDOW www.lasertex.eu 5-20...

  • Page 91: Positioning Points Generation

    EASUREMENTS OSITIONING FIG.5.18. MACHINE ERROR LIMITS COMPARATION PANEL xi. Positioning points generation www.lasertex.eu 5-21...

  • Page 92: Configuration Of Positioning Measurement

    (can be negative), distance (must be positive) and interval (must be positive) or number of points. The points are calculated when Calculate button is pressed. Obtained points can be saved to a file. xii. Configuration of Positioning measurement www.lasertex.eu 5-22...
  • Page 93 5.21, 5.22, 5.23 and 5.24. Usually the Linear method is used. In the Cycles in series field the number of complete measurements cycles is set. The greater number of cycles is used the better result is achieved. At least three cycles are recommended for proper calculation of statistics. www.lasertex.eu 5-23...
  • Page 94 EASUREMENTS OSITIONING FIG.5.21. MACHINE MOVEMENT IN THE LINEAR MODE (S – STARTING POINT) FIG.5.22. MACHINE MOVEMENT IN THE PENDULUM MODE (S – STARTING POINT) www.lasertex.eu 5-24...
  • Page 95 Measurement points can be either captured manually (with keyboard space or Strobe button) or captured automatically by the software. For automatic capture parameters set in the Point detection tab are used. For numerically controlled machines the Automatic point capture and Automatic point generation should be chosen. www.lasertex.eu 5-25...
  • Page 96 3D straightness measurements are performed. Longer machine stop time in measurement points is required.  Unidirectional measurements – if checked then the measurement is finished when machine return movement is detected and not when the machine returns back to zero. www.lasertex.eu 5-26...
  • Page 97 50.11mm, then a desired measurement point of 50.20 mm is taken with machine error of -0.09 mm. In the case when laser measures 60.61mm the measurement point of 60.60 mm is taken with machine error of 0.01 mm. www.lasertex.eu 5-27...

  • Page 98: Pull Down Menu - Measurement

    Points calculation is performed in first measuring cycle. Option exclusive with “Points from list”. Points from list – when this option is selected on the screen appears a window for positioning points edition. This window enables to write or calculate distance www.lasertex.eu 5-28...

  • Page 99: Preparations For Measurement

    All cycles (active cycle is drawn using solid line but remaining cycles are illustrated using only points). Show pictogram command is used to present a schematic diagram of selected measurement method. d. Preparations for measurement i. Measurement window FIG.5.28 CHOICE BETWEEN 1D AND 3D POSITIONING www.lasertex.eu 5-29...

  • Page 100: And 3D Measurements

    (figure 5.29). The data from actual measurement series are shown in the table and on the chart connected with lines. Points from previous obtained series are visible on the chart as blue circles or red triangles. iii. Measurements in machine coordinate system www.lasertex.eu 5-30...

  • Page 101: Setting Measurement Points

    Capture option as described earlier in this chapter. In the automatic mode the system itself recognizes the moment of stop, the value of target point, the direction of movement and the series number. e. Rules of automatic positioning measurement www.lasertex.eu 5-31...

  • Page 102: Remarks On Measurements And On Data Analysis

    3 seconds. The measured distance by the laser system is saved in the table of results. After one cycle, if Stop after each cycle is set or after the whole measurement process the window with results appears (figure 5.32). www.lasertex.eu 5-32...
  • Page 103 Buttons Remove and Add can be used to remove or add the measurement cycle. It is possible to change the measuring cycle in which accidental error is suspected. Button Browse opens data browsing window (figure 5.33) where each data cycle can be viewed and analyzed. www.lasertex.eu 5-33...
  • Page 104 In order to get the final report the Report button has to be pressed. The screen of the computer after pressing the button Report is presented on fig. 5.34. www.lasertex.eu 5-34...
  • Page 105 Under the graph there are: buttons used for report Preview, Print the report, change of the graph Parameters, and return to the previous window. The axis scale can be changed using Axis Scale (automatic scaling or assignment, minimum and maximum values) option available by right mouse click on the graph. www.lasertex.eu 5-35...
  • Page 106 Preview or Print buttons are pressed. The simplified version consists of three pages: the title page, the results page and the chart page – see also figure 5.35. The logo on the title page can be changed in the Configuration- www.lasertex.eu 5-36...

  • Page 107: Machine Error Compensation

    Depending on the chosen output data format different set of parameters appears in the Error Compensation window (figures 5.37-5.39). Below there are described most commonly used data formats. www.lasertex.eu 5-37...

  • Page 108: Absolute And Incremental Data Formats

    In the case of the absolute format the values of errors are absolute, non-relative. In the case of the incremental format the errors in the certain point are calculated relative to the errors in the previous point, taking error in the first measurement point as zero. www.lasertex.eu 5-38...

  • Page 109: Siemens Data Format

    As shown in the figure 5.38 the format of the Siemens file differs greatly from the absolute/incremental format. The Siemens type file can be stored to a file and uploaded directly to the corrected machine (with 828 or 840 drives). www.lasertex.eu 5-39...

  • Page 110: Fanuc Data Format

    It is possible to set proper Data offset (should be in 0-1023 range), change the machine Base point (not necessary when the machine coordinate system is used) and change the compensated Axis name. www.lasertex.eu 5-40...
  • Page 111 EASUREMENTS OSITIONING www.lasertex.eu 5-41...

  • Page 113: Measurements - Dynamic Positioning

    Next in the software there should be generated the program for machine movement (G Codes). The generated program drives the machine in compliance with the ISO230-2 standard according to the path shown in the Figure 6.1. www.lasertex.eu...
  • Page 114 After uploading the file, the machine positioning should be measured again to obtain the final results. The final results can be stored or printed. All measurement steps are described in much greater detail inside the Chapter. www.lasertex.eu...
  • Page 115 – D EASUREMENTS YNAMIC OSITIONING FIG.6.2 LINEAR POSITION ERROR CORRECTION PROCEDURE www.lasertex.eu...

  • Page 116: Measurement Setup

    T, P and H in usual conditions (T=293K, P=1000hPa, H=50%):                       www.lasertex.eu...

  • Page 117: Principles - Base Temperature Compensation

    EASUREMENTS YNAMIC OSITIONING The changes of the wavelength are compensated automatically by the HPI-3D laser head only if the TH sensor is used properly, i.e. placed near the laser beam path. The air pressure is measured inside the laser head.

  • Page 118: Measurement Setup Preparations

    – the length of the non-used scale part or the distance between the beginning of the scale and the Zero mark. The HPI-3D is capable of automatic compensation of the thermal expandability of the Scale. The user has only to properly use Base Temperature sensors (i.e.
  • Page 119 – see the Chapter 18) have to be taken into consideration. The usage of the air temperature sensor and at least one base temperature sensor (T1 or T2 or T3) is absolutely necessary! More than one base temperature sensor should be used on long measurement axes, especially where a temperature gradient is possible. www.lasertex.eu...
  • Page 120 6.3 and 6.4) but also in directions perpendicular to the laser beam. These configurations are shown in figures 6.5 and 6.6. In those two configurations the laser beam has to enter the IL1 from the bottom of the element. Only the retro- reflector RL1 can be moved. www.lasertex.eu...

  • Page 121: Software Description

    – D EASUREMENTS YNAMIC OSITIONING FIG.6.5. OPTICAL PATH SET UP FOR POSITIONING MEASUREMENTS IN Y AXIS FIG.6.6. OPTICAL PATH SET UP FOR POSITIONING MEASUREMENTS IN Z AXIS c. Software description www.lasertex.eu...

  • Page 122: Introduction

    Through this panel it is possible to monitor the quality of the input signal, i.e. the beam strength, the current value measured by the laser and machine feed rate. Number of displayed digits can also be modified. www.lasertex.eu 6-10...

  • Page 123: Iii. Positioning Plot Panel

    On the plot the points are placed in two colors: the deviations measured during forward movement of the machine is shown with blue color while the deviations measured during the reverse movement with red. (see Figure 6.9). www.lasertex.eu 6-11...

  • Page 124: Positioning Control Panel

    Case B is visible during analyses of the obtained results. By pressing “New” button all registered results are cleared and a new measurement is started. Pressing “Report” opens Dynamic Positioning Report Window as shown later in the Chapter. FIG.6.11. STATUS BARS IN POSITIONING WINDOW www.lasertex.eu 6-12...

  • Page 125: Pull Down Menu - File

    Other important commands available in the File menu are options for generating CNC path and preparing compensation table. vi. CNC path generation CNC path generation options allows automatic preparation, by the HPI-3D software, the G-code program compatible with most CNC control systems. The www.lasertex.eu...
  • Page 126 Axis – the measured machine movement axis should be chosen (X, Y, Z, U, V, W, A, B, C).  Feed Rate – the maximum machine feed rate in the chosen axis during measurements can be modified. The chosen value cannot be greater www.lasertex.eu 6-14...

  • Page 127: Compensation Table Preparation

    Suitable format of the compensation table for machine control system has to be selected from Data format drop-down list. Together with the data format additional parameters can be configured. www.lasertex.eu 6-15...

  • Page 128: Pull Down Menu - Edit

    The option is described in more detail in the end of the Chapter. FIG.6.14. COMPENSATION TABLE PREPARATION WINDOW viii. Pull down menu - Edit In the pull-down menu option Edit there are options for setting measured machine data (Fig 6.15) and for changing overall positioning configuration. www.lasertex.eu 6-16...

  • Page 129: Configuration Of Positioning Measurement

    In the Dynamic positioning tab in the Configuration window the options of the linear positioning measurements (Fig. 6.16) can be set, i.e. the path to the folder for storing measurement data. On the configuration tab there is also shown the scheme of the machine movement required for proper measurements. www.lasertex.eu 6-17...

  • Page 130: Preparations For Measurement

    On the bottom display the value of the current machine feed rate is presented. Fields of Start position and End position should be used in order to tie the machine coordinate system with the machine coordinate system. www.lasertex.eu 6-18...

  • Page 131: Measurements In Machine Coordinate System

    2) The time of machine stand still duration in the positioning point must be no less than 1 second 3) Backlash compensation move of the machine should exceed 1.0 mm. www.lasertex.eu 6-19...

  • Page 132: Remarks On Measurements And On Data Analysis

    Machine pull-down list. If the error value exceeds limits for the machine, this error is displayed in red. Under the graph there are: buttons used for report Preview, Print the report, change of the graph Parameters, and return to the previous window. www.lasertex.eu 6-20...

  • Page 133: Machine Error Compensation

    Error Compensation window (figures 6.21-6.23). Below there are described most commonly used data formats. Before the points are generated the user has to choose the Step between compensation points or the Point count. Only then pressing the Update button will generate the compensation file. www.lasertex.eu 6-21...

  • Page 134: Absolute And Incremental Data Formats

     error in reverse direction  mean error In the case of the absolute format the values of errors are absolute, non-relative. In the case of the incremental format the errors in the certain point are calculated www.lasertex.eu 6-22...

  • Page 135: Siemens Data Format

    Siemens data format The Siemens data format file is usable in most commonly used machine control units produced by Siemens. The choice is between types 828 and 840. For older control units the incremental data format should be used. www.lasertex.eu 6-23...

  • Page 136: Fanuc Data Format

    (with 828 or 840 drives). It is possible to set proper Measurement system, change the machine Base point (not necessary when the machine coordinate system is used) and change the compensated Axis name. iii. Fanuc data format www.lasertex.eu 6-24...
  • Page 137 It is possible to set proper Data offset (should be in 0-1023 range), change the machine Base point (not necessary when the machine coordinate system is used) and change the compensated Axis name. www.lasertex.eu 6-25...
  • Page 138 – D EASUREMENTS YNAMIC OSITIONING www.lasertex.eu 6-26...

  • Page 139: Measurements - Straightness

    Measurement Setup – Angular optics i. Principles The operation of the HPI-3D with the angular optics used is shown in the Figure 7.1. The laser outputs the laser beam consisting of two polarizations: Horizontal (H) and Vertical (V). The IK1 splits the beam into two parts. Both beams are directed into the measurement path but are parallel shifted by 1’’...
  • Page 140 The measured distance can then be used to obtain either the The laser head with angular optics is insensitive to linear movements. rotation angle (pitch or yaw of the machine) or the vertical movement of the optical component (IK1 or RK1). www.lasertex.eu...
  • Page 141 The Laser Head measures the parameter x while the distance between beams s and the base length L must be set in the parameters of the HPI Software. Then the rotation angle  and the movement in the vertical direction h can be calculated from: www.lasertex.eu...

  • Page 142: Application Notes

    (for straightness measurements). It is worth to notice that such straightness measurement method requires proper choice of measurement points. Choosing points denser than the carriage size results in excessive values of the straightness errors (the shape of the error is proper). www.lasertex.eu...

  • Page 143: Measurement Setup Preparations

    RK1 and the laser head does not change more than a few centimeters. The second limitation comes from the heterodyne effect present in the HPI-3D laser. This effect influences the angle according to (l is the change of distance between the laser and RK1 during measurements) : (7.2)
  • Page 144 7.6. Each of the elements can be moved. During Angular straightness measurements the usage of the air temperature sensor is recommended. Base temperature sensors do not have to be used. LASER HEAD FIG.7.6 OPTICAL PATH SET UP FOR ANGULAR STRAIGHTNESS MEASUREMENTS- SCHEMATIC. www.lasertex.eu...
  • Page 145 Angular straightness measurements can be performed not only along the laser beam (as shown in figures 7.7 and 7.8) but also in directions perpendicular to the laser beam. Such configuration is shown in figure 7.9. In this configuration only the retro-reflector RK1 can be moved. www.lasertex.eu...

  • Page 146: Measurement Setup - Wollaston Optics

    In order to keep the highest precision of the measurement the position of both beams on the alignment tools should stay within 200m window for the whole linear movement range. c. Measurement Setup – Wollaston optics i. Principles www.lasertex.eu...
  • Page 147 In the Figure 7.11 there is shown the explanation of the operation of the WP2 element. This prism is constructed of two birefringent triangle prisms cemented together. Both prisms are built from the same material but their ordinary and extraordinary axes are perpendicular to each other, i.e. refraction coefficient of the www.lasertex.eu...
  • Page 148 180-angle. The prisms used in the WRP2 in y axis reflect the beam with ½’’ translation (like the retroreflector RL1). In the x axis the beam is reflected with no translation (like in a mirror). www.lasertex.eu 7-10...

  • Page 149: Application Notes

    There are no such problems when the WP2 is moved instead. The only disadvantage is the smaller measurement range. WP2 can be moved ±2mm while maximal measurement range of the WRP2 is ±30mm (but only when the distance between WP2and WRP2 is 4.5 m). www.lasertex.eu 7-11...

  • Page 150: Measurement Setup Preparations

    During measurement the WRP2 element should be stationery, i.e. its distance from the laser head should not change. During Wollaston straightness measurements the usage of the air temperature sensor is recommended. Base temperature sensors do not have to be used. WRP2 LASER HEAD www.lasertex.eu 7-12...
  • Page 151 X only the straightness of path in X axis is measured. The same situation is with Z setup. In both configurations the measurements should be performed with the moving of WP2 element. FIG.7.15 OPTICAL PATH SET UP FOR WOLLASTON STRAIGHTNESS MEASUREMENTS IN X AXIS. www.lasertex.eu 7-13...
  • Page 152 – S EASUREMENTS TRAIGHTNESS FIG.7.16 OPTICAL PATH SET UP FOR WOLLASTON STRAIGHTNESS MEASUREMENTS IN Z AXIS. www.lasertex.eu 7-14...

  • Page 153: Measurement Setup - 3D Method

    Measurement Setup – 3D method i. Principles The HPI-3D laser head is capable of detecting the position of the returning beam. The position of the returning beam changes with the movement of the retroreflector RL1 perpendicular to the laser beam axis. This phenomena for one axis is shown in the Figure 7.17.

  • Page 154: Measurement Setup Preparations

    Tripod stand (not recommended)  Air temperature sensor  Base temperature sensor 3D straightness measurements require optical elements IL1 and RL1 to be aligned along laser beam as shown in the figure 7.18. Only the retro-reflector RL1 should be moved. www.lasertex.eu 7-16...
  • Page 155 (as shown in figures 7.18 and 7.19) but also in directions perpendicular to the laser beam. These configurations are shown in figures 7.20 and 7.21. Also in those two configurations only the retro-reflector RL1 can be moved. FIG.7.19 OPTICAL PATH SET UP FOR 3D STRAIGHTNESS MEASUREMENTS IN X AXIS. www.lasertex.eu 7-17...

  • Page 156: Software Description

    – S EASUREMENTS TRAIGHTNESS FIG.7.20. OPTICAL PATH SET UP FOR 3D STRAIGHTNESS MEASUREMENTS IN Y AXIS. FIG.7.21. OPTICAL PATH SET UP FOR 3D STRAIGHTNESS MEASUREMENTS IN Z AXIS. e. Software description www.lasertex.eu 7-18...

  • Page 157: Introduction

    3) Panel for changing the operation mode;  4) Straightness value table – a table containing consecutively numbered samples and measured straightness value (or two values in 3D mode);  5) Panel with control buttons and status information. www.lasertex.eu 7-19...

  • Page 158: Display Panel

    Wollaston it is micrometers and for 3D it is millimeters. For the 3D option the value displayed on the panel is only an auxiliary one – the straightness readouts are shown on the Straightness Plot panel described below. www.lasertex.eu 7-20...

  • Page 159: Straightness Plot Panel

    This is shown in the Figure 7.25. Pressing this button makes possible retaking any measurement point. The remeasurement procedure is described further in the Chapter. iii. Straightness Plot Panel FIG.7.26 STRAIGHTNESS PLOT PANEL IN THE ANGULAR AND WOLLASTON OPTIONS www.lasertex.eu 7-21...
  • Page 160 In the bottom right corner of the panel there are displayed the edge values of the straightness, i.e minimal value Min, maximal value Max, amplitude of the straightness Ds=Max-Min. In the case of 3D measurements those values are shown for each axis. www.lasertex.eu 7-22...
  • Page 161 Figure 7.28 will appear. The options in this menu are used for modification of displaying of horizontal and vertical axes of the chart. The chart can also be copied to clipboard (“Copy to clipboard” option) for further pasting into a document editing software (like Microsoft Word or OpenOffice Write). www.lasertex.eu 7-23...

  • Page 162: Operation Mode Panel

    Zoomed chart view can be shifted by pressing the right mouse button on the chart (and not on the axes as the pop-up menu would appear!) and moving the mouse pointer in the desired direction. iv. Operation Mode Panel www.lasertex.eu 7-24...

  • Page 163: Straightness Measurement Values Panel

    The last mode is described in another Chapter of this document. v. Straightness Measurement Values Panel In the Values Panel there are displayed numerical values of the straightness measurements (Figure 7.31). These are the same values that are shown on the chart(s). www.lasertex.eu 7-25...
  • Page 164 There are three possibilities (see Figure 7.32): rounded values of the distance (A), true value of the distance (B) and number of points (C). FIG.7.32 VALUES PANEL – DIFFERENT MODES. CLARIFICATIONS IN TEXT www.lasertex.eu 7-26...

  • Page 165: Straightness Control Panel

    Automatic Point Capture mode, while the latter during the Manual Point Capture mode. The measurement can be stopped directly (“Stop”) or indirectly (“Menu”). After pressing the “Menu” button the software always asks if the measurement is to be stopped first. www.lasertex.eu 7-27...

  • Page 166: Straightness Pull-Down Menus

    Before saving the file the program asks about changing machine data (option available from pull-down menu Edit->Machine data), like machine type, machine serial number, measured axis or machine operator. Those values allow describing performed measurement for later analysis and they are also present on the printed report. www.lasertex.eu 7-28...
  • Page 167 Base length – angular retro-reflector RK1 base length can be set (default is 100mm); the option available also in Configuration->Parameters; Configuration – opens Configuration window as shown in the figure 7.36. FIG. 7.36. STREIGHTNESS CONFIGURATION OPTIONS. In the Configuration it is possible to set: www.lasertex.eu 7-29...
  • Page 168 In the Measurement pull-down menu it is possible to change the method of capturing measurement points. Either a manual method (PC keyboard or the manual Strobe can be used) or a semi-automatic (time) one can be used. FIG.7.38. STRAIGHTNESS PULL-DOWN MENU VIEW. www.lasertex.eu 7-30...

  • Page 169: Reports

    Print or Preview on the measurement analysis window (fig. 7.39). The report can be generated in the basic form where only the plot of the measured values is shown (fig. 7.40) or in the extended version, which contains tables with measured data. FIG.7.39. STREIGHTNESS MEASURED DATA ANALYSIS WINDOW. www.lasertex.eu 7-31...

  • Page 170: Straightness Measurements Procedure

    Measurement procedure – Angular optics - preparations The Straightness measurement in Angular mode is based on moving angular Retro-reflector RK1 by an interval set in the Base Length parameter (usually 100 mm) and measuring the angular deviation of the RK1. www.lasertex.eu 7-32...
  • Page 171 The time interval should be tailored to the experience of the user. It is suggested to set the time to 10 s and to decrease it if needed. The time interval is increased and decreased by pressing ,  keys on the computer screen. www.lasertex.eu 7-33...

  • Page 172: Measurement Procedure - Angular Optics

    Move the IK1 or the RK1 by the distance set in the Edit->Base length option (default 100mm) and wait on the next point capture. Continue the measurement until the last point is reached. 10. Stop the measurement. iii. Measurement procedure – Wollaston optics – preparations www.lasertex.eu 7-34...

  • Page 173: Measurement Procedure - Wollaston Optics

    Set up the laser on the measured machine and align the optical path. Start the HPI Software and select Straightness option. Choose the measurement method: 3D. Choose whether the points are to be captured manually or automatically Press Start button www.lasertex.eu 7-35...
  • Page 174 Move the IL1 or the RL1 by the distance set in the Edit->Base length option (default 100mm) and wait on the next point capture. Continue the measurement until the last point is reached. Stop the measurement. www.lasertex.eu 7-36...

  • Page 175: Measurements - Flatness

    Measurement Setup For flatness measurements the angular optics plus additional mirrors should be used. Necessary components are:  Laser Head  Power Supply  Angular Interferometer IK1  Angular Retro-reflector RK1  Two Beam Benders ZK1 (see figure 8.2) www.lasertex.eu...
  • Page 176 1 000 [mm] 1 100 1 200 1 300 1 400 1 500 1 600 FIG.8.1. FLATNESS MAP OF AN EXEMPLE SURFACE. Optional elements are:  USB cable  Manual Strobe  Magnetic holder UM2  Tripod stand  Air temperature sensor  Base temperature sensor www.lasertex.eu...
  • Page 177 LASER HEAD FIG.8.3 OPTICAL PATH SET UP FOR FLATNESS MEASUREMENTS – SCHEMATIC. During flatness measurements the usage of the air temperature sensor is recommended. Base temperature sensors do not have to be used. www.lasertex.eu...

  • Page 178: Software Description

    HPI Software program window looks like it is shown in the Fig. 8.5. The Flatness Measurement Summary window consists of three main parts:  Display – presents flatness of the surface calculated according to straightness measurements for axes;  Schematic chart – allows to select axis;  Panel with buttons. www.lasertex.eu...
  • Page 179 8.6 appears. In this window it is also possible to change the measured axis and analyze the straightness results of each individual axis. The axis can be selected by clicking the proper axis on the axes chart or by choosing it from the No. axis pull down list. www.lasertex.eu...
  • Page 180 FIG.8.7. FLATNESS PULL-DOWN MENU FILE. Before saving the file the program asks about changing machine data (option available from pull-down menu Edit->Machine data), like machine type, machine serial number, measured axis or machine operator (see figure 8.8). Those values allow www.lasertex.eu...
  • Page 181 The flatness option can be configured in the Flatness tab (Fig. 8.9.) located in the Configuration window accessible from the Main Menu or from pull down menu Edit->Configuration. www.lasertex.eu...

  • Page 182: Alignment Of Optics For The Flatness Measurements

    8 axes. The axis can be selected by clicking the proper axis on the axes chart or by choosing it from the list (Fig. 8.10.). There are also shown: directions of measurements in the axes and margins that must be kept during measurements. www.lasertex.eu...

  • Page 183: Optical Path Alignment Of The Axis "1

    ZK1 is used. The way of using it is shown in the Figure 8.11. The alignment procedure is the same as described in Chapter 4 for angular optics with an additional beam directing element (ZK1) in the path. www.lasertex.eu...

  • Page 184: Optical Path Alignment Of The Axes: "5" And "7

    ZK1 are used. The way of using them is shown on Figure 8.12. The alignment procedure is the same as described in Chapter 4 for angular optics with an additional beam directing element (ZK1) in the path. www.lasertex.eu 8-10...

  • Page 185: Optical Path Alignment Of The Axes: "2" And "4

    ZK1 is used, but alignment procedure is quite similar to the axis “4”. The alignment procedure is the same as described in Chapter 4 for angular optics with an additional beam directing element (ZK1) in the path. www.lasertex.eu 8-11...

  • Page 186: Measurement Procedure

    Move the RK1 by the distance set in the Edit->Base length option (default 100mm) and wait on the next point capture (or capture it manually). Continue measurements until all points on the path are measured. Stop the measurement. If not all axes are measured then repeat points 4-7. www.lasertex.eu 8-12...
  • Page 187 Print or Preview on the measurement analysis window. The report can be generated in the basic form where only the plot of the measured values is shown or in the extended version, which contains tables with measured data. www.lasertex.eu 8-13...

  • Page 189: Measurements - Pitch/Yaw

    For Pitch/Yaw measurements the angular optics should be used. Necessary components are:  Laser Head  Power Supply  Angular Interferometer IK1  Angular Retro-reflector RK1 Optional elements are:  USB cable  Manual Strobe  Magnetic holder UM2  Tripod stand  Air temperature sensor www.lasertex.eu...
  • Page 190 Pitch/Yaw measurements can be performed not only along the laser beam (as shown in figures 9.1 and 9.2) but also in directions perpendicular to the laser beam. These configurations are shown in figures 9.3 and 9.4. In those two configurations only the retro-reflector RK1 can be moved. www.lasertex.eu...

  • Page 191: Software Description

    Software description Pitch and Yaw errors can be measured in the Pitch/Yaw option, chosen from the Main Menu. The HPI-3D program window looks like it is shown in the Fig. 9.5. The window consists of four main parts: www.lasertex.eu...
  • Page 192 Time interval is configured on the panel with  and  buttons. Manual point capture – points are captured when the Point capture button on the panel, Space key on the keyboard or Manual Strobe button is pressed. FIG.9.6. PITCH/YAW PULL-DOWN MENU MEASUREMENT. www.lasertex.eu...
  • Page 193 (option available from pull- down menu Edit->Machine data), like machine type, machine serial number, measured axis or machine operator (see figure 9.8). Those values allow describing performed measurement for later analysis and they are also present on the printed report. www.lasertex.eu...
  • Page 194 Print or Preview on the measurement analysis window (fig. 9.9). The report can be generated in the basic form where only the plot of the measured values is shown or in the extended version, which contains tables with measured data. www.lasertex.eu...
  • Page 195 Configuration->Straightness window. There is performed a configuration of statistic calculation method (fig. 9.10) which is used for measurement data processing. End point fit or Least squareness fit can be chosen to use statistical methods. The None option enables to perform an analysis of raw results. www.lasertex.eu...

  • Page 196: Measurement Procedure

    FIG. 9.10. PITCH/YAW CONFIGURATION OPTIONS. d. Measurement procedure Set up the laser on the measured machine and align optical path. Start the HPI-3D software and select Pitch/Yaw option. Choose the desired point capture method. Press Start button and run the machine.

  • Page 197: Measurements - Squareness

    In this case the necessary components are:  Laser Head  Power Supply  Linear Interferometer IL1  Linear Retro-reflector RL1  Right angle etalon RE3D or REW www.lasertex.eu 10-1...
  • Page 198 Squareness measurements based on the 3D method require optical elements IL1 and RL1 to be first aligned along the laser beam as shown in the figure 10.2A. The element RL1 should be moved. Obtained results of the axis straightness should be saved for further processing. www.lasertex.eu 10-2...
  • Page 199 The measurements consist of two parts. In the first part the WP2 is moved between the laser head and the REW prism (Fig. 10.3A). During the second part the WP2 should be placed between REW and WRP2 (Fig. 10.3B). www.lasertex.eu 10-3...
  • Page 200 – S EASUREMENTS QUARENESS WRP2 FIG.10.3A. OPTICAL PATH SET UP FOR WOLLASTONE SQUARENESS MEASUREMENTS - SCHEMATIC FOR FIRST AXIS. RETURN BEAMS NOT DRAWN FOR FIGURE CLARITY www.lasertex.eu 10-4...

  • Page 201: Software Description

    Software description Squareness is measured in the Squareness option, chosen from the Main Menu. The HPI Software program window looks like it is shown in the Fig. 10.4. The Squareness Measurement Summary window consists of three main parts: www.lasertex.eu 10-5...
  • Page 202 10.5 appears. In this window it is possible to change the measured axis and analyze the straightness results of each individual axis. The axis can be changed by clicking the proper axis on the axes chart or by choosing it from the No. axis pull down list. www.lasertex.eu 10-6...
  • Page 203 FIG.10.6. SQUARENESS PULL-DOWN MENU FILE Before saving the file the program asks about changing machine data (option available from pull-down menu Edit->Machine data), like machine type, machine serial number, measured axis or machine operator (see figure 10.7). Those values www.lasertex.eu 10-7...
  • Page 204 FIG.10.7. MACHINE DATA WINDOW The squareness option can be configured in the Configuration window accessible both from the Main Menu or from pull down menu Edit->Configuration in the Straightness tab (figure 10.8). www.lasertex.eu 10-8...

  • Page 205: Alignment Of Optics For The Squareness Measurements

    The squareness measurement consists of the straightness measurements for two axes. The measurement axis is selected on the measured surface as shown in the figure 10.9. In this figure there are also shown: directions of measurements and margins that have to be kept during measurements. www.lasertex.eu 10-9...
  • Page 206 In both cases the measurements have to be performed in the directions pointed by arrows on the schematic graph on the main screen of squareness measurement (fig. 10.9). FIG.10.10 OPTICAL PATH SET UP FOR 3D STRAIGHTNESS MEASUREMENTS IN X AXIS www.lasertex.eu 10-10...

  • Page 207: Measurement Procedure

    Set up the laser on the measured machine and align the first optical path. Start the HPI Software and select Squareness option. Press Measurement button on the Squareness summary screen. Choose the proper axis on the axis choice chart and press Start, New or Repeat button. www.lasertex.eu 10-11...
  • Page 208 Print or Preview on the measurement analysis window. The report can be generated in the basic form where only the plot of the measured values is shown or in the extended version, which contains tables with measured data. www.lasertex.eu 10-12...

  • Page 209: Measurements - Parallelism

    In this case the necessary components are:  Laser Head  Power Supply  Linear Interferometer IL1  Linear Retro-reflector RL1  Right angle etalon RE3D www.lasertex.eu 11-1...
  • Page 210  Wollaston retro-reflector WRP2  Right angle etalon REW For both methods the optional elements are similar:  USB cable  Manual Strobe  Magnetic holder UM2  Tripod stand  Air temperature sensor  Base temperature sensor www.lasertex.eu 11-2...
  • Page 211 IL1 and RL1 to be aligned along laser beam as shown in the figures 11.2A and 11.2B. The element RL1 should be moved. The beam should be directed to the perpendicular axis with the use of the right angle etalon RE3D. www.lasertex.eu 11-3...
  • Page 212 Wollaston parallelism measurements require optical elements WP2 and WRP2 to be aligned along laser beam as shown in the figure 11.3. The element WP2 should be moved first along Axis 1 and then along Axis 2. No right angle prism is necessary for this measurement. www.lasertex.eu 11-4...

  • Page 213: Software Description

    Menu. The HPI Software program window looks like it is shown in the Fig. 11.4. The Parallelism Measurement Summary window consists of three main parts:  Display – presents measured straightness of axes and calculated parallelism;  Schematic chart – allows changing the currently edited axis;  Panel with buttons www.lasertex.eu 11-5...
  • Page 214 11.5 appears. In this window it is possible to change the measured axis and analyze the straightness results of each individual axis. The axis can be changed by clicking the proper axis on the axes chart or by choosing it from the No. axis pull down list. www.lasertex.eu 11-6...
  • Page 215 FIG.11.6. PARALLELISM PULL-DOWN MENU FILE Before saving the file the program asks about changing machine data (option available from pull-down menu Edit->Machine data), like machine type, machine serial number, measured axis or machine operator (see figure 11.7). Those values www.lasertex.eu 11-7...
  • Page 216 FIG.11.7. MACHINE DATA WINDOW The parallelism option can be configured in the Configuration window accessible both from the Main Menu or from pull down menu Edit->Configuration in the Straightness tab (figure 11.8). www.lasertex.eu 11-8...

  • Page 217: Alignment Of Optics For The Parallelism Measurements

    The parallelism measurement consists of the straightness measurements for two axes. The measurement axis is selected on the measured surface as shown in the figure 10.9. In this figure there are also shown: directions of measurements and margins that have to be kept during measurements. www.lasertex.eu 11-9...
  • Page 218 In both cases the measurements have to be performed in the directions pointed by arrows on the schematic graph on the main screen of parallelism measurement (fig. 11.9). Configuration of optical components for 3D and Wollaston methods are shown in the figures 11.10 and 11.11. www.lasertex.eu 11-10...
  • Page 219 If both axes are measured, Back button should be pressed. Obtained parallelism measurements summary (fig. 10.1) can be saved, printed or exported to a text file (File->Save, File->Print or File->Export). www.lasertex.eu 11-11...

  • Page 220: Measurement Procedure

    When straightness of all axes is measured then the Back button should be pressed. The software returns to the Parallelism Summary screen – see figure 11.1 10. For 3D measurement type the correct axes (Vertical or Horizontal) should be chosen for comparison. www.lasertex.eu 11-12...
  • Page 221 Print or Preview on the measurement analysis window. The report can be generated in the basic form where only the plot of the measured values is shown or in the extended version, which contains tables with measured data. www.lasertex.eu 11-13...

  • Page 223: Measurements - Vibration

    The laser measurement system HPI-3D is capable of detecting machine vibrations in the frequency range from 0 to 500 Hz in Bluetooth mode and 0 to 50 kHz in USB mode.
  • Page 224 Vibration measurements can be performed not only along the laser beam (as shown in the figures 12.1 and 12.2) but also in directions perpendicular to the laser beam. These configurations are shown in the figures 12.3 and 12.4. In those two configurations only the retro-reflector RL1 can be moved. www.lasertex.eu 12-2...
  • Page 225 – V EASUREMENTS IBRATION FIG.12.2 OPTICAL PATH SET UP FOR VIBRATION MEASUREMENTS IN X AXIS FIG.12.3. OPTICAL PATH SET UP FOR VIBRATION MEASUREMENTS IN Y AXIS FIG.12.4. OPTICAL PATH SET UP FOR VIBRATION MEASUREMENTS IN Z AXIS www.lasertex.eu 12-3...

  • Page 226: Software Description

    IBRATION c. Software description Vibrations are measured in the Vibration option, chosen from the Main Menu. The HPI-3D program window looks like it is shown in the Fig. 12.5. The window consists of four main parts:  Display – presents measurement signal level and percent of gathered samples;...
  • Page 227 Edit->Machine data), like machine type, machine serial number, measured axis or machine operator (see figure 12.7). Those values allow describing performed measurement for later analysis and they are also present on the printed report. www.lasertex.eu 12-5...
  • Page 228 Print or Preview on the measurement analysis window (fig. 12.8). The report can be generated in the basic form where only the plots of the measured values and calculated frequency transformation are shown (fig. 12.9) or in the extended version, which contains also tables with measured data. www.lasertex.eu 12-6...
  • Page 229 It is also possible to copy the straightness graph to the clipboard and then paste it for example to a Word editor document. Copy to clipboard command is available from popup menu that appears after right-click on the area of the graph. www.lasertex.eu 12-7...

  • Page 230: Measurement Procedure

    IBRATION d. Measurement procedure Set up the laser on the measured machine and align optical path. Start the HPI-3D software and select Vibration option. Configure Vibration measurement. Press Start button and run the machine. In the continuous mode press Stop button; in the single-shot mode wait for the end of measurements Save the results and/or print the measurement report.
  • Page 231 – V EASUREMENTS IBRATION Interferometer Retroreflector Laser Interferometer Laser Vibrations Vibrations not important important Retroreflector FIG.12.11. VIBRATION MEASUREMENT IN DIFFERENT AXES www.lasertex.eu 12-9...

  • Page 233: Measurements - Dynamic

    General Description Dynamic measurements are usually used for characterization of subtle machine movement. The laser measurement system HPI-3D is capable of characterizing the tested machine with up to 1000 samples per second in the Bluetooth mode and up to 100000 samples per second in the USB mode. In both modes the measurement resolution is 100pm.
  • Page 234 FIG.13.2 OPTICAL PATH SET UP FOR LINEAR DYNAMIC MEASUREMENTS IN X AXIS Dynamic measurements can be performed not only along the laser beam (as shown in the figures 13.1 and 13.2) but also in directions perpendicular to the laser www.lasertex.eu 13-2...
  • Page 235 These configurations are shown in the figures 13.3 and 13.4. In those two configurations only the retro-reflector RL1 can be moved. FIG.13.3. OPTICAL PATH SET UP FOR LINEAR DYNAMIC MEASUREMENTS IN Y AXIS FIG.13.4. OPTICAL PATH SET UP FOR LINEAR DYNAMIC MEASUREMENTS IN Z AXIS www.lasertex.eu 13-3...

  • Page 236: Dynamic Measurements Of Angle

    LASER HEAD FIG.13.5 OPTICAL PATH SET UP FOR ANGULAR DYNAMIC MEASUREMENTS - SCHEMATIC Angular straightness measurements can be performed not only along the laser beam (as shown in the figures 13.5 and 13.6) but also in directions perpendicular to www.lasertex.eu 13-4...
  • Page 237 These configurations are shown in the figures 13.7 and 13.8. In those two configurations only the retro-reflector RK1 can be moved. FIG.13.6. OPTICAL PATH SET UP FOR ANGULAR DYNAMIC MEASUREMENTS IN X AXIS FIG.13.7. OPTICAL PATH SET UP FOR ANGULAR DYNAMIC MEASUREMENTS IN Y AXIS www.lasertex.eu 13-5...

  • Page 238: Dynamic Measurements Of Straightness (Wollaston)

    Tripod stand  Air temperature sensor  Base temperature sensor Dynamic straightness measurements require optical elements WP2 and WRP2 to be aligned along laser beam as shown in the figure 13.9. Each of the elements can be moved. www.lasertex.eu 13-6...
  • Page 239 Dynamic straightness measurements can be performed in two configurations – horizontal X (figure 13.10) or vertical Z (figure 13.11). In the configuration X only the straightness of path in the X axis is measured. The same situation is with the Z setup. www.lasertex.eu 13-7...

  • Page 240: Software Description

    Software description All types of dynamic measurements are performed in the Dynamic option, chosen from the Main Menu. The HPI-3D program window looks like it is shown in the Fig. 13.12. The window consists of four main parts: ...
  • Page 241 0. Only when the counter finishes decrementing, the acquisition is started. Choosing the DC Block option causes switching on the high pass digital filter in the path. This option can be used for example to eliminate thermal expansion effects from the measurement. www.lasertex.eu 13-9...
  • Page 242 Print or Preview on the measurement analysis window (fig. 13.15). The report can be generated in the basic form where only the plot of the measured values is shown or in the extended version, which contains tables with measured data. www.lasertex.eu 13-10...
  • Page 243 It is also possible to copy the straightness graph to the clipboard and then paste it for example to a Word editor document. Copy to clipboard command is available from popup menu that appears after right-click on the area of the graph. www.lasertex.eu 13-11...

  • Page 244: Measurement Procedure

    FIG.13.15. DYNAMIC DATA ANALYSIS WINDOW d. Measurement procedure Set up the laser on the measured machine and align optical path. Start the HPI-3D software and select Dynamic option. Configure Dynamic measurement. Press Start button and run the machine. Wait for the end of the measurements or press Stop button.

  • Page 245: Measurements - Angular Positioning

    (i.e. the position displayed on the machine’s readout) with the true position measured by the laser interferometer. The laser measurement system HPI-3D together with the rotary encoder is capable of measuring any rotation angle with precision down to 1 arcsec. The System allows measuring angle in different units.
  • Page 246 – A EASUREMENTS NGULAR OSITIONING  USB cable  Manual Strobe  Magnetic holder UM2  Tripod stand  Base temperature sensor LASER HEAD FIG.14.1. OPTICAL PATH SET UP FOR ROTARY MEASUREMENTS IN-AXIS - SCHEMATIC www.lasertex.eu 14-2...

  • Page 247: Characteristics Of Wally - Rotary Measurement System

    The power supply of the Wally is identical and exchangeable with the power supply of the HPI-3D laser head. Although it is possible to use the Wally in a standalone configuration, it is recommended to operate it together with the HPI-3D. The main advantages of the combined laser/encoder operation are: ...
  • Page 248 Before measurements it is necessary to mount the whole kit depending on the mechanical configuration. In the figures 14.3 and 14.4 there are shown necessary elements for milling machines (turning tables) and for turning machines. Assembled rings do not have to be disassembled if not necessary. www.lasertex.eu 14-4...
  • Page 249 UNIT, 2 – MOUNTING RING, 3 – RING FOR TURNING TABLES, 4 – SCREWS M4X8, 5 – TEMPORARY TOOL FOR FINDING TABLE CENTER FIG.14.4. CONFIGURATION OF WALLY FOR TURNING MACHINES MEASUREMENTS. 1 – CENTRAL UNIT, 2 – MOUNTING RING, 3 – RING FOR TURNING MACHINES, 4 – SCREWS M4X12. www.lasertex.eu 14-5...

  • Page 250: Theory Of Operation

    Bluetooth interface. The laser can be also connected over USB port. The presence of the powered on the encoder is detected after connection and signalized by the yellow color on the Rotary link field in the Status bar. www.lasertex.eu 14-6...

  • Page 251: Iii. Rotary Measurements – Hardware Preparations

    First the assembled ring has to be installed in the center of the rotation of the machine’s measured axis. For this purpose special tool can be used – see element 5 in the figure 14.3. Then the central unit has to be placed inside the ring, rotated clockwise and fastened with both wings. www.lasertex.eu 14-7...
  • Page 252 – see figure 14.7. For measurements off the rotation axis there is necessary precision right angle set (delivered separately). The elements of the off-axis setup are shown in the Figure 14.5 and the assembled system in the Figure 14.8. www.lasertex.eu 14-8...
  • Page 253 – A EASUREMENTS NGULAR OSITIONING FIG.14.7. ROTARY SYSTEM ASSEMBLED FOR TURING MACHINES MEASUREMENTS FIG.14.8. ROTARY SYSTEM ASSEMBLED FOR OFF-AXIS MEASUREMENTS www.lasertex.eu 14-9...

  • Page 254: Rotary Measurements - Battery Charging

    HPI-3D laser head. The charging process takes around two hours to complete, yet 20 minutes charge is usually enough for 8 hours of measurements.

  • Page 255: Software Description

    Laser head position should be changed only in horizontal or vertical plane (no angular adjustments). c. Software description The described device option can be used either for measurement of any rotation angle or for angular positioning measurement. i. Connecting with Wally www.lasertex.eu 14-11...

  • Page 256: Measurements Of The Rotation Angle

    On the screen there should appear a window Display as shown in the fig. 14.11. The functionality of the window is very similar to the one described in the chapter 3 with the difference that options necessary for rotary measurements are www.lasertex.eu 14-12...
  • Page 257 IK1 and RK1 first. Only when the elements are aligned the Wally link segment should be double clicked. The procedure of setting the link, as described in Theory of operation section, should be started. When the procedure is finished successfully the Wally link segment turns green and the measurements are possible. www.lasertex.eu 14-13...
  • Page 258 RK1 element by rotating the element and monitoring input beam strength. - after pressing the button the curent position of Wally is remebered. The, after for example machine movement, the position can be retained by pressing the button www.lasertex.eu 14-14...

  • Page 259: Measurements Of Angular Positioning

    The menu bar of this window contains following options: File, Edit, Measurement, View, and Help. In the File option (figure 14.14) there can be found commands for reading measured data from a file, saving the data to a file, printing measurements results or exporting them to a file. www.lasertex.eu 14-15...

  • Page 260: Cnc Path Generation For In-Axis Measurements

    CNC path and preparing compensation table. v. CNC path generation for in-axis measurements CNC path generation options allows automatic preparation, by the HPI-3D software, the G-code program compatible with most CNC control systems. The options of the path generation are set in the separate window as shown in the Figure 14.15 for in-axis measurement and in the Figure 14.16 for off-axis measurements.
  • Page 261 The chosen value cannot be greater than machine limitations (see manual of the tested machine).  Stop Time – the time the machine stops at every measurement point. This time is necessary for the HPI Software to capture measurement www.lasertex.eu 14-17...
  • Page 262 Off axis measurement – opens elements used for machine path generation for off-axis measurements – see Figure 14.16. Option is active only after software unlocking – please contact local distributor for more details. Path generation for off-axis measurement is described in more details in the next chapter. www.lasertex.eu 14-18...

  • Page 263: Cnc Path Generation For Off-Axis Measurements

    Manual generation of such a path is very difficult thus in the HPI Software there is included step-by-step tutorial, explained below. 0) Phase 0 – Wally and laser are to be mounted on the machine as described in previous paragraphs. www.lasertex.eu 14-19...
  • Page 264 X, Aux is axis Y. The values from the machine absolute coordinate system are the written in the software as well in the P0 fields. 2) Phase 2 - machine is to be rotated in the measured axis by +45 degrees (figure 14.18) www.lasertex.eu 14-20...
  • Page 265 3) Phase 3 – Wally is to be rotated in the same direction like the machine. As shown in the figure 14.19, in the Phase 3 there available two buttons with arrows. Pressing the buttons rotates Wally by predefined +45 or -45 degrees. www.lasertex.eu 14-21...
  • Page 266 OSITIONING FIG.14.19. PHASE 3 OF THE OFF-AXIS PATH GENERATION 4) Phase 4 – Machine is to be moved in the linear Main axis until the crosses return to the position they were during Phase 1 (see Figure 14.20). www.lasertex.eu 14-22...
  • Page 267 <10 cm. The absolute positions of the machine in the Main and Aux axes are to be written into the P0+45 fields in the software – see figure 14.21. 6) Phase 6 - machine is to be rotated in the measured axis by -90 degrees (figure 14.22) www.lasertex.eu 14-23...
  • Page 268 – A EASUREMENTS NGULAR OSITIONING FIG.14.21. PHASE 5 OF THE OFF-AXIS PATH GENERATION FIG.14.22. PHASE 6 OF THE OFF-AXIS PATH GENERATION www.lasertex.eu 14-24...
  • Page 269 IK1 and RK1 becomes similar to the value during Phase 1. The required accuracy is <10 cm. The absolute positions of the machine in the Main and Aux axes are to be written into the P0-45 fields in the software – see figure 14.24. www.lasertex.eu 14-25...
  • Page 270 14) Summary – after the movement phases the machine and the Wally should be in the start position and the software should show the summary screen as presented in the Figure 14.25 with collected data. From the generated data the CNC path is generated. www.lasertex.eu 14-26...

  • Page 271: Pull Down Menu - Edit

    (Fig 14.27), defining machine error limits (fig. 14.28), previewing obtained positioning results, editing positioning points (when option Target Points from List from menu Measurement is active) and changing overall positioning configuration. FIG.14.26. POSITIONING PULL-DOWN MENU EDIT www.lasertex.eu 14-27...
  • Page 272 – A EASUREMENTS NGULAR OSITIONING FIG.14.27. MACHINE DATAWINDOW www.lasertex.eu 14-28...

  • Page 273: Machine Error Limits

    (option Machine error limits - Fig. 14.28) are configured. The results of the angular positioning measurements are compared with these limits (see Fig. 14.29). This option is especially useful when there are checked many machines of the same type and the same requirements on their accuracy are expected. www.lasertex.eu 14-29...

  • Page 274: Positioning Points Generation

    14.30. Points can be entered manually or can be generated from the input parameters: start position, distance and interval or number of points. The points are calculated when Calculate button is pressed. Obtained points can be saved to a file. www.lasertex.eu 14-30...

  • Page 275: Configuration Of Positioning Measurement

    In the Rotary encoder tab in the Configuration window the important parameters of the angular positioning measurements can be set (Fig. 14.31). There are four available methods for checking machine’s positioning: Linear, Pendulum, Pilgrim standard and Pilgrim effective (buttons in Measurement method panel). www.lasertex.eu 14-31...
  • Page 276 These options are used to configure a time delay required by the machine to settle the position successfully and the acceptable level of vibration (level of vibration depends mainly on the measured machine). Min Points Interval configures minimal distance between positioning points. www.lasertex.eu 14-32...

  • Page 277: Pull Down Menu - Measurement

    Points from list – when this option is selected on the screen appears a window for positioning points edition. This window enables to write or calculate distance values for positioning points which are compared to measured points during positioning measurement. Option exclusive with “Automatic points generate”. www.lasertex.eu 14-33...

  • Page 278: Measurement Procedure

    (Target Points From List). Points are detected with 1 degree tolerance in automatic mode. In case of manual mode accuracy is also defined. During the measurement points can be captured automatically or manually as described earlier in this chapter. i. Rules of automatic positioning measurement www.lasertex.eu 14-34...

  • Page 279: Remarks On Measurements And Data Analysis

    In every cycle the measured machine rotates the retro-reflector for programmed distance clockwise and counterclockwise. After each rotation the machine should stop for a short time (at least one second). The measured angle by the laser system is saved in the table of results. www.lasertex.eu 14-35...
  • Page 280 In order to get the final report the Report button has to be pressed. The screen of the computer after pressing the Report button is presented in fig. 14.35. www.lasertex.eu 14-36...
  • Page 281 The logo on the title page can be changed in the Configuration. In the Extended Report additional pages with measurement results are added. The number of additional pages depends on the number of measurement points. www.lasertex.eu 14-37...
  • Page 283 – A EASUREMENTS NGULAR OSITIONING www.lasertex.eu...

  • Page 285: Measurements - Velocity

     Laser Head  Power Supply  Linear interferometer IL1  Linear retro-reflector RL1 Optional elements are:  USB cable  Manual Strobe  Magnetic holder UM2  Tripod stand  Base temperature sensor  Air temperature sensor www.lasertex.eu 15-1...
  • Page 286 Velocity measurements can be performed not only along the laser beam (as shown in the figures 15.1 and 15.2) but also in directions perpendicular to the laser beam. These configurations are shown in the figures 15.3 and 15.4. In those two configurations only the retro-reflector RL1 can be moved. www.lasertex.eu 15-2...

  • Page 287: Software Description

    EASUREMENTS ELOCITY FIG.15.3. OPTICAL PATH SET UP FOR VELOCITY MEASUREMENTS IN Y AXIS. FIG.15.4. OPTICAL PATH SET UP FOR VELOCITY MEASUREMENTS IN Z AXIS. c. Software description www.lasertex.eu 15-3...
  • Page 288 By clicking on a part of the graph and moving the mouse rightwards the graph can be zoomed. By clicking on a part of the graph and moving mouse leftwards the zoom is cancelled. The graph can be printed or saved to www.lasertex.eu 15-4...
  • Page 289 Before saving the file the program asks about machine data (option available from pull-down menu Edit->Machine data), like machine type, machine serial number, measured axis or machine operator (see figure 15.7). Those values allow describing performed measurement for later analysis and they are also present on the printed report. www.lasertex.eu 15-5...
  • Page 290 Print or Preview in the measurement analysis window (fig. 15.8). The report can be generated in the basic form where only the plot of the measured values is shown (fig. 15.9) or in the extended version, which contains tables with measured data. www.lasertex.eu 15-6...
  • Page 291 It is also possible to copy the velocity graph to the clipboard and then paste it for example to a Word editor document. Copy to clipboard command is available from popup menu that appears after right-click on the area of the graph. www.lasertex.eu 15-7...

  • Page 292: Measurement Procedure

    FIG.15.10. VELOCITY CONFIGURATION OPTIONS. d. Measurement procedure Set up the laser on the measured machine and align optical path. Start the HPI-3D software and select Velocity option. Choose desired Velocity unit in the Configuration window (optional). Press Start button and run the machine.

  • Page 293: Connecting Laser Head To Machine

    ACHINE a. General Description The main functionality of the HPI-3D are measurements of machine geometry with the use of a PC computer connected over BT or USB interface. The functionality can be significantly enhanced by the Extension Connector available at back of the laser as shown in the figure 16.1.

  • Page 294: Extension Connector

    Power Button Power Connector USB Connector Extension Connector FIG.16.1. CONNECTIONS OF THE HPI-3D. b. Extension Connector i. Extension Connector pinout The Extension Connector available at the back of the laser head is a miniature Hirose Connector LX40-20P CL No. CL245-0017-0. The pinout of this connector is shown in the table 16.1.

  • Page 295: Extension Connector Pinout

    Encoder type Digital Output pins – functionality partially configurable through HPI Software; Used for digital output of A-Quad-B or Shift/Sign output;  Encoder type Analog Output pins – analog output in SinA/CosB format (see later in this Chapter). ii. Extension Cable EX1 www.lasertex.eu 16-3...

  • Page 296: Extension Cable Ex1

    Extension Connector while on the other end there is a standard female three-row DSUB15 connector. The signals available on the DSUB connector are described and can be configured in the HPI Software in Configuration- >Extension Connector panel. www.lasertex.eu 16-4...
  • Page 297 Negative output of Differential A signal pair (Digital AquadB Output)  Negative output Differential Module signal pair (Shift/Sign Output) Digital Output  Positive output of Differential B signal pair (Digital AquadB Output)  Positive output of Differential Sign signal pair (Shift/Sign Output) www.lasertex.eu 16-5...

  • Page 298: Encoder Type Outputs

    Extension Cable. iii. Encoder type outputs On the output of the HPI-3D there are available two types of encoder outputs: digital (A-Quad-B format, TTL) and analog (SinA/cosB format, 1Vpp). Both types are available at the same time on the Extension Connector and the EX1 cable – see figure 16.4.
  • Page 299 ONNECTING ASER EAD TO ACHINE LASER HEAD FIG. 16.4. ENCODER SIGNAL GENERATION The output signals are in real time compensated versus environmental parameters change. The process is shown schematically in the figure 16.5. www.lasertex.eu 16-7...
  • Page 300 The coprocessor is responsible for adding corrections to the original optical signal and for generating the output signal in a desired standard. The standard of the output encoder type signals can be changed by the user in Configuration->Extension Connector- www.lasertex.eu 16-8 >Output Standard box.
  • Page 301 SinA +/- 1V CosB Resolution FIG. 16.7. OUTPUT SIGNAL – SINA/COSB FORMAT The analog sinA/cosB signal consists of two analog signals sinA and cosB shifted in phase by +90° or -90° depending on the direction of movement (figure www.lasertex.eu 16-9...

  • Page 302: Hpi-3D In A Machine Control Loop

    24 MHz. Because of the encoder type signals available at the Extension Connector it is possible to use the HPI-3D in a machine control loop. The laser configured with the linear optics can be used as a very high-precision position encoder.
  • Page 303 Pin 7 /Aout Pin 8 Bout Pin 9 /Bout Pin 10 FIG. 16.9. CONNECTING LASER HEAD TO A MACHINE Method of connection depends on the type of inputs of the machine as it is shown in the figure 16.9. www.lasertex.eu 16-11...

  • Page 305: Configuration

    In order to do this the user should choose the right communication interface (USB, Bluetooth or Simulator) and press Reconnect. After a while an appropriate message will be displayed (with communication success or failure). www.lasertex.eu 17-1...
  • Page 306 FIG. 17.1. CONFIGURATION WINDOW – INTERFACE PANEL Panel WiMeteo The options available in the WiMeteo panel (fig. 17.2) are used to control the operation of the wireless module. It is responsible for communication with environmental sensors and rotary encoder. www.lasertex.eu 17-2...
  • Page 307 Address field, the sensor number should be chosen and then the Register button should be pressed. Sensor number 0 is TH sensor, while sensors numbered 1-3 are respectively sensors T1-T3. www.lasertex.eu 17-3...
  • Page 308 Right angle prism Error is the parameter of the Right Angle Etalon REW element. The coefficient is delivered with every REW element. This field is password protected to avoid inadvertent modification of the parameter. The password is: “54321”. www.lasertex.eu 17-4...
  • Page 309 Its path is set in the Logo path field. The file should have bmp file format. Parameters: Base length, Wollaston Coefficient and Right angle prism Error should be set to proper values after EVERY installation of the HPI Software on the new computer or in the new folder. Panel General www.lasertex.eu 17-5...
  • Page 310 (so called double pass) interferometer is used in the optical path. In all other cases, i.e. for all other types of optical components the single-pass option has to be selected. Improper choice of the Interferometer type option results in large measurement error! www.lasertex.eu 17-6...
  • Page 311 Automatic measurements of selected parameters can be switched on or off in the Measurement parameters box. It is also possible to change the Reference temperature which is the temperature the measured machine is corrected to. Usually 20.00°C is set. Panel Extension Connector www.lasertex.eu 17-7...
  • Page 312 On the left side of the panel there is visible the schematic drawing of the connector with the description of the functionality of the pins. The functionality can be modified with the list buttons in the right part of the panel. Each modification has to be approved by pressing Set button. www.lasertex.eu 17-8...
  • Page 313 The data visible in the Statistics panel (fig. 17.7) are for information only. Laser work time shows how long the laser tube was switched on during its lifetime. After 20000 hours the laser should be shipped to factory for testing and calibration unless recommended calibration times are used. www.lasertex.eu 17-9...
  • Page 314 FIG. 17.7. CONFIGURATION WINDOW – STATISTICS PANEL Panel Firmware update The HPI-3D device is fully software defined, which means that the digital processing of the signals is a very important part of the device. All internal digital modules are available through the USB interface and their firmware can be easily modified in the Firmware update panel.
  • Page 315 Wait for the device to be programmed – up to 10 minutes Other panels Other panels available in the Configuration are described in the respective chapters:  panel Positioning in Chapter 5;  panel Velocity in Chapter 6;  panel Straightness in Chapter 7; www.lasertex.eu 17-11...
  • Page 316 ONFIGURATION  panel Flatness in Chapter 8;  panel Vibrations in Chapter 12;  panel Rotary Encoder in Chapter 14. www.lasertex.eu 17-12...

  • Page 317: Principles Of Operation

    The detector counts the frequency difference between reflected beams - f (see fig. 18.1). The measured value of the displacement is calculated according to Where: N – number of pulses, l - light wavelength. www.lasertex.eu 18-1...

  • Page 318: The Construction Of Real Interferometers

    The frequency of the beam in the measurement arm changes with the movement of the moving reflector. The polarization of the reflected beams is changed to circular with the use of a l/4 waveplate. After 0° and www.lasertex.eu 18-2...
  • Page 319 A l/4 waveplate changes circular polarization to linear. The main difference between two described methods is that in the heterodyne one the beam frequency in reference arm differs from the beam frequency in the measuring www.lasertex.eu 18-3...
  • Page 320  f Polarizers - frequency resulting from the Doppler effect  f vertical polarization Photodetectors horizontal polarization Reference path Counter Counter Measurement path Substractor FIG.18.3. THE BLOCK DIAGRAM OF AN INTERFEROMETER, WORKING ACCORDING TO THE HETERODYNE METHOD www.lasertex.eu 18-4...

  • Page 321: The Influence Of The Outside Conditions On The Measurement Accuracy

        057627 From the above equations one may obtain the refraction coefficient dependences on T, P and H in usual conditions (T=293K, P=1000hPa, H=50%):            www.lasertex.eu 18-5...

  • Page 322: The Accuracy Of Laser Interferometers

    A dead path error is an error associated with the change in environmental parameters during a measurement. This error occurs when some part of the light path (a dead path) is not included in the temperature (both air and base), pressure and humidity compensation. www.lasertex.eu 18-6...

  • Page 323: Cosine Error

    Laser head The correct deployment of the optical components for reducing a dead path error head, because it is than very difficult to reduce a dead path. FIG.18.4. AN ILLUSTRATION OF A DEAD PATH ERROR iii. Cosine error www.lasertex.eu 18-7...

  • Page 324: Abbe Error

    Laser beam Reflectors  Machine's movement axis FIG.18.5. THE BEAM UNALIGNMENT AS A CAUSE OF A COSINE ERROR The only method of eliminating the cosine error is a proper laser beam alignment done before a measurement. iv. Abbe error www.lasertex.eu 18-8...

  • Page 325: Laser Stability Error

    (where a refraction coefficient is constant) and when a low stability laser is used (e.g. a semiconductor laser). The stability of usually used in laser measurement systems, HeNe gas lasers is 0.02 ppm, so the stability error may be neglected. vi. Other errors www.lasertex.eu 18-9...

  • Page 326: A Summary Of Laser Measurement System Errors

    18.7 and 18.8. Different scales of the charts should be taken into account. FIG.18.7. A CALCULATION OF ERRORS FOR A LASER MEASUREMENT SYSTEM WITHOUT Laser Environment Cosine Dead path Electronics Unlinearities Thermal drift Positioning error [um/m] THE COMPENSATION OF THE ENVIRONMENT www.lasertex.eu 18-10...
  • Page 327 RINCIPLES OF OPERATION Laser Environment Cosine Dead path Electronics Unlinearities Thermal drift 0,05 0,15 0,25 Positioning error [um/m] FIG.18.8. A CALCULATION OF ERRORS FOR A LASER MEASUREMENT SYSTEM WITH THE COMPENSATION OF THE ENVIRONMENT www.lasertex.eu 18-11...

  • Page 329: Troubleshooting

    ROUBLESHOOTING General Description The troubleshooting of the possible problems with the HPI-3D is shown in this chapter on the basis of block diagrams. In each diagram the first block on the top names the problem that is dealt by the diagram.
  • Page 330 Software Software Power off laser head Restart HPI Restart HPI Software and Software and choose the right choose the right Wait 10 second device number device number Power on laser head Restart HPI Software FIG.19.1. CONNECTION FAILED CHART www.lasertex.eu 19-2...
  • Page 331 Restart HPI Software Power on laser head Restart HPI Software FIG.19.2. CONNECTION BROKEN CHART Problems with connection with wireless sensors The diagram charts for solving problems with connection with one or more sensors are shown in the figure 19.3. www.lasertex.eu 19-3...
  • Page 332 Press WiMeteo Reconnect button Restart HPI Software Wait 4 minutes FIG.19.3. SENSOR(S) CONNECTION PROBLEM CHART Problems with linear measurements The diagram charts for solving problems with measurements and laser stabilization are presented in the figures 19.4 and 19.5. www.lasertex.eu 19-4...
  • Page 333 Restart HPI Software Does the laser Switch the laser Wait until laser measure? stabilises Close HPI Software Power off laser head Wait 10 second Power on laser head Start HPI Software FIG.19.4. NOT MEASURING LASER PROBLEM CHART www.lasertex.eu 19-5...
  • Page 334 Power off laser head Realign the optical path so Wait 10 second that no reflection returns back to the laser Plug in USB cable (if applicable) Power on laser head Restart HPI Software FIG.19.5. NOT STABILISING LASER PROBLEM CHART www.lasertex.eu 19-6...

  • Page 335: Technical Data

    Squareness  720   0,2 % Rotary measurements 0,04 arcsec L = axis length in meters b. Laser head Laser type HeNe laser with frequency stabilization Heating time Approx. 5 min 632,990566 nm Wavelength (vacuum) 632,992031 nm www.lasertex.eu 20-1...

  • Page 336: Laser Head Outputs - Analog

    Laser Head outputs – digital, type 2 Signal type Shift / Sign Voltage level 5 V differential CMOS Signal resolution User defined: from 0.1nm/pulse to 5um/pulse in 0.1nm/pulse step Pulse width 5 ns Maximal signal frequency 100 MHz www.lasertex.eu 20-2...

  • Page 337: Extension Connector Pinout

    Positive output of Differential Module signal pair (Shift/Sign Output) 5V Supply Analog Output Negative output of Differential Cosine signal pair (Sine/Cosine Output) Analog Output Negative output of Differential Sine signal pair (Sine/Cosine Output) Analog Output Positive output of Differential Cosine signal pair (Sine/Cosine www.lasertex.eu 20-3...

  • Page 338: System Work Conditions

    Bluetooth 2.0 + EDR Connection Point-to-Point (pico net) Frequency 2.400 to 2.4835 GHz Tx Power Max 18 dBm (Class 1) Rx Sensitivity -86 dBm typical Coverage Up to 25m Environment compensation Wavelength compensation Manual Environments parameters entered from keyboard www.lasertex.eu 20-4...
  • Page 339 With the use of 1 to 3 wireless temperature sensors . Temperature sensor Pt-1000 Time constant 10 s Net weight 150 g Our products are subject to continuous further development and improvement. Subject to technical changes without prior notice. www.lasertex.eu 20-5...

  • Page 341: Index

    7-25, 8-5, 9-5, 10-7, 11-5, 12-5, 13-11, 15-5 battery, 3-15, 3-22 Distance, 12-6, 13-13, 20-1, 20-2 Beam alignment, 4-1 Dynamic measurements, 13-1 Beam Benders, 8-2 Bluetooth connection, 3-14 , 3-7, 3-22, 20-6 NVIRONMENT Error Table, 5-37, 14-42 Excel, 3-23 www.lasertex.eu...
  • Page 342 Pilgrim Effective, 5-29 Linear positioning, 5-11, 6-12 Pilgrim Standard, 5-29 Linear retro-reflector, 3-10, 5-7, 6-8, 12-2, 13- Pitch, 7-32, 7-45, 7-46, 7-47, 8-14, 9-1, 9-2, 9-3, 2, 15-2 9-4, 9-5, 9-6, 9-7, 9-9, 9-10, 10-14, 11-13 Logo path, 17-6 www.lasertex.eu...
  • Page 343 2, 11-2, 13-5, 13-6, 14-4 troubleshooting, 3-20, 19-1 RL1, 3-10, 3-21, 3-26, 4-10, 5-7, 5-8, 5-10, 6-8, 6-9, 6-11, 12-2, 12-3, 13-2, 13-4, 15-2, 15-3 rotary encoder, 3-26, 14-1, 14-2, 14-4, 14-9, Uninstall, 3-9 14-18, 14-19, 17-3 USB, 3-8 www.lasertex.eu...
  • Page 344 Yaw, 7-32, 7-45, 7-46, 7-47, 8-14, 9-1, 9-2, 9-3, Velocity plot, 15-5 9-4, 9-5, 9-6, 9-7, 9-9, 9-10, 10-14, 11-13 Velocity value table, 15-5 Vibration measurements, 12-1, 12-2, 12-3, 13- 2, 13-3 ZK1, 3-13, 8-11, 8-12, 8-13 Vibrations, 5-41, 12-5, 14-39, 14-44 www.lasertex.eu...

Table of Contents