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LASER
CHECK
® ® ® ®
Surface Roughness
Measurement Gages
5872C Manual Version 5_4
1 3 7 E a s t A l t o n , S u i t e B
S a n t a A n a , C A 9 2 7 0 7
P H O N E : 7 1 4 - 6 6 8 - 9 1 1 5
F A X : 7 1 4 - 6 6 8 - 9 1 1 9
i n f o @ o p t i c a l d i m e n s i o n s . c o m
w w w . o p t i c a l d i m e n s i o n s . c o m
®
O P T I C A L
D I M E N S I O N S
®
LLC
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Table of Contents
Related Manuals for Optical dimensions LASER 5872C
Summary of Contents for Optical dimensions LASER 5872C
- Page 1 LASER CHECK ® ® ® ® Surface Roughness Measurement Gages 5872C Manual Version 5_4 1 3 7 E a s t A l t o n , S u i t e B S a n t a A n a , C A 9 2 7 0 7 P H O N E : 7 1 4 - 6 6 8 - 9 1 1 5 F A X : 7 1 4 - 6 6 8 - 9 1 1 9 i n f o @ o p t i c a l d i m e n s i o n s .
- Page 2 Assembly, Diagnostics, and Operation of the Lasercheck Gage, Components, and Accessories and is not to be used otherwise or reproduced without written consent of Optical Dimensions, LLC. The Lasercheck gage is patented technology protected under US Patent Number 5,608,527.
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Page 3: Table Of Contents
TABLE OF CONTENTS PERFORMANCE SPECIFICATIONS ...................... 1 ......................1 TORAGE OMPUTER EQUIREMENTS ............................1 THER EATURES SAFETY ................................ 2 ..............................2 LECTRICAL ................................. 2 ASER WARRANTY ..............................3 LIMITATION OF WARRANTY ....................... 3 ....3 USTOMS TATEMENT FOR ETURNING ASERCHECK QUIPMENT TO PTICAL IMENSIONS... - Page 4 Export ............................15 .......................... 16 UTOMATED PERATION Numerous Continuous Measurements / Roll Grinding................. 16 Setting up Windows Software for External Inputs................16 Automatic Parameters for Automatic Start, Stop and Save Options..........16 Individual Parts / Parts Inspection....................... 18 Setting up Windows Software for External Inputs................18 Automatic Parameters for Automatic Start, Stop and Save Options..........
- Page 5 Step 2 Mid Range ......................... 34 Adjust Max “X Value” / Adjust Min “X Value” ..............34 Adjust Slope ..........................35 Raise / Lower Curve ......................... 35 Step 3 High Range ........................35 Adjust Intercept ........................35 Adjust Exponential ........................35 Step 4 Low Range.........................
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Page 6: Performance Specifications
Performance Specifications Measurement / Detection Method Angle resolved laser scattering Measurement speed Single measurement in < 0.5 seconds Measurement range 1.00 µinch to 80 µinch / 0.012 µm to 2.0 µm Repeatability 3.0% of measured value Spot size (area-measured) 5 mm X 1 mm Environmental considerations (temperature / humidity): Operating -10º... -
Page 7: Safety
SAFETY Electrical Lasercheck has been designed as a sealed and enclosed system. Voltages to operate the measurement head are low (0 to +5 Volts) to minimize shock hazard. A power supply in the control unit converts 110/220 Volt AC from a wall receptacle to low regulated DC voltages that power the system. High voltages are present and they are dangerous. -
Page 8: Warranty
No other warranty, whether expressed or implied, will be valid. For warranty service or repair, the Lasercheck system must be returned to Optical Dimensions, Santa Ana, CA after prior authorization has been obtained from Optical Dimensions. Buyer shall prepay shipping charges to Optical Dimensions. -
Page 9: Maintenance
Lasercheck housing and electronics are well grounded. The head is sealed at all seams and holes to protect components from external contaminants. The user should not open the measurement head. If opened without prior authorization by Optical Dimensions, the warranty provided by Optical Dimensions will be void. Cleaning the Window The internal optics and electronics are cleaned during assembly and kept within the sealed head. -
Page 10: Introduction To Lasercheck
INTRODUCTION TO LASERCHECK Overview Lasercheck is designed to perform high speed, accurate, non-contact measurements of surface roughness. A built in visible laser diode emits a laser beam from the bottom of the gage illuminating the surface beneath it. After striking the surface, the laser light is reflected and scattered back into the Lasercheck detection system. -
Page 11: Setting Up The Instrument
6) CD or 3.5 inch floppy disk with Lasercheck Calibration & Setup Files, Plus Manual Measurement Head Control Unit CHECK LASER ® ® ® ® ® ® ® ® ® OPTICAL DIMENSIONS Basic Connections Control Box Rear Panel of Box Front Panel of Box OPTICAL DIMENSIONS Input Output Sensor Printer Status ®... -
Page 12: Physical Mounting
There should be capability for vertical adjustment of the Lasercheck relative to the surface once installed for fine alignment purposes plus horizontal or rotational adjustment. The optional X-Y-Z head mount from Optical Dimensions provides the required adjustment flexibility. -
Page 13: Software Setup
from the outside. This form of seal will be “breakable” or removable should you wish to later remove this mounting and use the Lasercheck in a different process. An understanding of alignment principals of Lasercheck is required for development of fixturing. Please read the section “LASERCHECK ALIGNMENT PRINCIPALS AND PRECEDURES”... -
Page 14: Basic Operation Using Control Box Pushbuttons
Basic Operation Using Control Box Pushbuttons Once the cables are attached and measurement head is mounted and aligned, you are ready to perform a measurement. Lasercheck is run from the control unit keypad and LCD screen or optionally the Windows software on the host computer. -
Page 15: Highlighting
Highlighting The “^”, “>”, and “Select” buttons on the front panel of the Lasercheck are used to highlight and select desired options. Pushing the “ ” push button on the front panel switches which main menu is ACTIVE and highlighted in CAPITAL letters. Options in that highlighted menu can be scrolled through are with a “>” on the LCD screen. -
Page 16: Performing Measurements
Performing Measurements Once the measurement head is mounted and aligned, the cables attached, and the software is installed in the host computer you are ready to perform a measurement. Lasercheck is set up and run from the Windows software on the host computer. Detailed instructions on specific setups and operations can be found in the software users manual. -
Page 17: Entering The Setup Module
Entering the Setup Module From the main window of the Lasercheck software select the “Setup” push-button. This invokes the “Password Entry” dialog box. Enter the password “4956”, and click OK. Setup for Lab System Under the Setup menu, select “Setup” and “Automation Type”. Select Lab System so that the software can be used to control the measurement process. -
Page 18: Manual Operation
the “Units” drop down box to select roughness displayed in Microns, Microinches, Nanometers, or Angstroms of roughness . Other display options are described in the software manual. Select “OK”. Now save the modified setup file by clicking “Save Setup” and renaming it to “filename.stp”. Manual Operation Perform Measurements Module From the main window of the Lasercheck software select the “Perform Measurements”... -
Page 19: Return
Return Selecting “Return” from the Run Menu at any time closes the current graph and returns you to the “Measure Menu”. Start Selecting “Start” from the Run Menu starts the Lasercheck and the graph begins displaying roughness information. A graph of roughness vs. reading number will begin appearing in real time on the screen. In addition, statistics of all measurements will be displayed digitally in real time at the top left and right corners of the graph, and the current measurement in the top center of the graph. -
Page 20: Export
After saving the measurement, you will be returned to the data graph screen and the new filename you have created will be present in the upper right corner of the graph. Export Export can be used to export a text format file of the data named “Lasrdata.txt” to the active directory on your computer. -
Page 21: Automated Operation
Automated Operation The Lasercheck can be used with external inputs to start and stop the measurements in an automated installation. The inputs on the back of the Lasercheck control box are read by the Lasercheck Windows software, so the Lasercheck must be connected to a host computer for this option to work. The windows software is designed to work with external inputs in two modes for automated applications. - Page 22 Lasercheck Head Air Knife “Start and Large Continuous Surface “Stop” Prox Sensors “Start and “Stop” Prox Sensors Lasercheck Head Mounted over Large Surface for Continuous Automated Inspection There are drilled and tapped holes on the Lasercheck sensor head that can be used for mounting and installing the Lasercheck in a continuous automated inspection application.
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Page 23: Individual Parts / Parts Inspection
Individual Parts / Parts Inspection Setting up Windows Software for External Inputs Under the Setup menu, select “Setup” and “Automation Type”. Select “Parts Inspection” so that the software can be used to perform automated measurements on individual parts. Automatic Parameters for Automatic Start, Stop and Save Options Under the Setup Module, select Open, and open the setup file named “automatic.stp”... - Page 24 Lasercheck Head Air Knife Parts Parts Parts Conveyor “Start and “Stop” Prox Sensors Lasercheck Head Mounted on Conveyor for Automated Inspection There are ten drilled and tapped holes on the Lasercheck sensor head that can be used for mounting and installing the Lasercheck in an automated inspection application.
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Page 25: Start" And "Stop" Sensor Wiring Inputs
“Start” and “Stop” Sensor Wiring Inputs External inputs to trigger the starting and stopping of measurements can be push buttons, proximity sensors, or any type of input that momentarily closes contacts. For individual parts in Parts Inspection mode use input 1 for start and input 2 for stop. For a continuous surface in Roll Grinding mode use input 3 for start and input 2 for end/save. -
Page 26: Lasercheck Alignment Principles And Procedures
Lasercheck Alignment Principles and Procedures This section contains information on principals and procedures to install and align Lasercheck heads. The keys to getting accurate and repeatable data are controlling alignment and cleaning the surface. How Does Lasercheck Work? The visible (650-nm.) laser illuminates the surface with a shallow incident angle to measure surface roughness features. -
Page 27: Alignment
Alignment Vertical The shallow incident angle allows Lasercheck to measure similar roughness features to a stylus gage. It also creates sensitivity to vertical misalignment. The specular laser beam must fall on one of the first 3 to 9 detectors in the 35-element photodiode array; the next 26 (closest to the incoming laser beam) are used to calculate surface roughness. -
Page 28: Horizontal
Horizontal The Lasercheck is also sensitive to horizontal misalignment on curved surfaces. When you look under the Lasercheck from the “laser” end of the head, you will be able to see where the light is reflected after hitting the surface. If it is correctly aligned, you will see the reflected and scattered light bouncing back into the center of the detector window. -
Page 29: Measure/Headtest Dialog Box
Measure/Headtest Dialog Box Measure/Headtest Screen A and B are printed out from our Measure/Headtest selection in our windows software. In this screen, you will see Lasercheck values displayed beside numbers 1 to 37. Numbers 1 to 35 are voltage readings from the 35 array detectors. Also displayed is a sum of voltages from all detectors and a “relative”... -
Page 30: Measure/Headtest Screen B
Measure/Headtest Screen B Measure/Headtest Screen B is a display from a rougher surface, Ra of about 30 microinches. Because the surface is relatively rough, the specular beam is now lost as it bounces off the surface into Lasercheck. There is no obvious large voltage anywhere in the array. The standoff reading indication is no longer reliable. -
Page 31: Measure/Align Dialog Box
Measure/Align Dialog Box Figure 9 Figure 9 shows the Measure/Align screen from the Lasercheck Windows software. Measure/Align provides the same information as Measure/Headtest but in a different format and display. The relative indication of the Lasercheck standoff height from the surface as indicated in the Measure/Headtest screen is indicated in the top portion of the dialog box. -
Page 32: Verifying Alignment Procedures
You should also note that the maximum reading observed on SUM will typically be lower on rough or non- metallic surfaces than on smooth and metallic surfaces because less light is reflected and scattered into our detectors on rough or non-metallic surfaces. Verifying Alignment Procedures Set Head Close Correct Position Horizontal and vertical alignment should be close before performing any alignment with Measure/Headtest... -
Page 33: Air Knife/Squeegee Accessories
Air Knife/Squeegee Accessories Optical Dimensions has designed an Air Knife and Squeegee accessory for cleaning surfaces that are subjected to coolants, lubricants, etc. in the process. For accurate measurements, Lasercheck requires a clean surface. The Air Knife and Squeegee designs have been tested to determine they adequately clean surfaces in the process to allow accurate Lasercheck measurements. - Page 34 The above figure shows a view of Lasercheck illustrating air knife positioning for surfaces approaching Lasercheck from the end of the box (maximum 1/8” away). Proximity sensors are also in the view. The proximity sensors alert the electronics to perform measurements whenever a part is in position.
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Page 35: Appendix - Setup Files
Appendix - Setup Files Setup file format FILENAME= Grind START_INPUT= MEAS RA_UNITS= MICROINCHES RA_THRESHOLD= 12.00 CAL1= -11.90 14.81 0.00 0.46 CAL2= 0.00 3.90 2.50 4.70 CAL3= 1.10 -6.44 26.80 CAL4= CAL5= FILENAME This is the prefix of the filename to which the data is saved. The prefix must be five characters that are used to create an incremental data file;... -
Page 36: Appendix - Calibration Procedures
Appendix - Calibration Procedures Instructions for using the Setup File and Calibration Template.xls Calibration of the Lasercheck gage involves testing known surfaces with the Lasercheck and developing a correlation between the Lasercheck readings and the actual Ra roughness values on several surfaces with different roughness values. -
Page 37: Statistics And Accuracy
Statistics and Accuracy It is important to remember that more calibration measurements provide better statistics and better calibration, especially if a wide range of roughness is used in the calibration. It is also important to remember that stylus gages measurements often lack repeatability depending on surface uniformity, the environment the measurement is taken in, condition of the instrument and condition of the actual stylus tip. -
Page 38: Stylus And Lasercheck Ra Values
1. Export measurement files containing Lasercheck calibration measurement values from the Lasercheck controller. Then "Left-Click" on the Push-Button below labeled "Insert Lasercheck Values" to import the values into this spreadsheet program. Select the appropriate directory and file containing the data when prompted. -
Page 39: Filename
Filename = Manually enter a filename here. This will be carried through the spreadsheet and used in naming the setup file when transferred into the controller. Try to use a name that is descriptive of either the process or the job and parts that it is to be used on. -
Page 40: Adjust Slope
this may include some or all of the values. Try to find the linear data set than isolate those values with these scroll buttons. Adjust Slope Use the Coarse and Fine scroll buttons to match the slope of the linear green curve and the associated data points. -
Page 41: Adjust Exponential
INSTRUCTIONS FOR THIS PAGE Lasercheck Calibration Curve 12.0 y = -0.50 x^2 + 5.90 x + 0.00 1. Use the Adjust Exponential y = 0.00 x^2 + 4.80 x + 0.60 controls to best fit the red curve to the smooth range of data points. -
Page 42: Step 6 Export Setup File
INSTRUCTIONS FOR THIS PAGE Lasercheck Calibration Curve 160.0 y = -0.50 x^2 + 5.90 x + 0.00 1. Review the overall calibration curve y = 0.00 x^2 + 4.80 x + 0.60 fits for all roughness regions. If any part 140.0 y = 1.20 x^2 + -7.44 x + 31.81 of the calibration does not visually... -
Page 43: Export "File Transfer" Or "Manual Input" Setup File
Export “File Transfer” or “Manual Input” Setup File Pushing either of these buttons will create a setup file with a default name of “std.set” or “manual.set”. When this is done, you should rename this file to a descriptive name for the finishing process or job it is to be sued on and later loaded onto the controller. -
Page 44: Threshold
Threshold Threshold indicates the Ra value at which the calibration software switches from providing values using “smooth” mode Ra calculation algorithms to providing values using “rough” mode Ra calculation algorithms. RA_UNITS RA_UNITS indicates the units of roughness that will be displayed on the controller. -
Page 45: Appendix - Input And Output Pinouts
Appendix - Input and Output Pinouts Input: 9-Pin Female D-sub Connector Internal Opto relay: Pin 1, 6, 2 = Opto relay 1, 2, 3 Optically Isolated. Must be connected to power (can use control box voltage – Pin 9). Pulls low to activate. Voltage Range: 3VDC to 50VDC, ideal 5VDC Max Ratings: 60 mA Internal part: QT Optoelectronics MCT9001... -
Page 46: Typical Wiring Example
Typical Wiring Example: 1) Using Unpowered Switches for inputs: a) Connect Power for Opto relays using Control Box Voltage (Pin 9) Opto Supply 1 (Pin 1) Opto Supply 2 (Pin 6) Opto Supply 3 (Pin 2) +Voltage (Pin 9) b) Connect Switches between Ground (Pin 7) and Input Pin Input 1 (Pin 3) Input 2 (Pin 8) Input 3 (pin 4) -
Page 47: Output: 9-Pin Female D-Sub Connector
Output: 9-Pin Female D-sub Connector Failed part output. Closes when measurement is out of software specified range. SPDT Relay, Resistive load Max: 200mA Max Ratings: 30VDC @ 1A, 125VAC @ 0.1A Internal parts: Omron G6E, connected internally with 28AWG ribbon cable Signal Analog_Out + (0-10V / 4-20mA) Not Used... - Page 48 Pin 1 9 to 24 Volt EXTERNAL Power Source 4 milliamp @ LOW_ANALOG 20 milliamp @ HIGH_ANALOG Pin 6 NOTE: 9 to 24 Volt power must be connected in series with Current Monitor (Must be External power source):...
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Page 49: Appendix - File Management
Appendix - File Management File System Window • From the Control Box Main Window, push the switch (^) push button to highlight the word SYSTEM. • Scroll to the word “files” with the scroll (>) push button • Push the Select push button. The following screen will be displayed: Manage files: FILES: >Send The file management options available by scrolling are:... -
Page 50: Receive Command
PC display while files being transferred to PC from Control Box Receive Command This selection transfers setup files from a PC via the serial null modem cable. The Lasercheck installation software creates a file named sendset.bat on the C:\Program Files\Lasercheck\Control Box directory. Copy any setup files that you wish to transfer to that same directory. -
Page 51: Reset Command
Reset Command This selection should only be used if the user experiences difficulties with files and software in the controller. Scroll to FILES: >Delete on the control box with the scroll (>) push button and push the Select push button. The LCD displays the following screen. Reset to factory files? >y/N... -
Page 52: Appendix - Upgrading Controller Software
Appendix - Upgrading Controller Software Prepare Controller • Attach a serial null modem cable from the RS232 port on the back of the Lasercheck control to a serial (com) port on the back of your computer. (NOTE: Some newer computers, especially notebooks, only have USB ports;... -
Page 53: Finish
When the headvc.exe file has been transferred, the control box will return to the File System Window and the DOS window on the PC will indicate that the file(s) have been successfully transferred. Finish • Exit the DOS program. • Power Cycle the control box (turn the main power on and off again).