Inc.

Optical Gaging
Products, Inc.
A QUALITY VISION INTERNATIONAL COMPANY

This document was produced by the Applications Engineering Group of Optical Gaging Products, Inc. (OGP)
850 Hudson Avenue, Rochester, New York 14621-4896 USA. Telephone: 585-544-0400. Fax: 585-544-8092.
Email: sales@ogpnet.com or service@ogpnet.com. Internet: http://www.ogpnet.com
Acknowledgements
Curriculum Developer and Writer: Nathaniel Rose
Content Input and Review:
Warranty
Optical Gaging Products, Inc. (OGP) warrants that the software will operate according to the specifications described in the
software reference manual and be free from known defects in materials or workmanship for a period of one year from the date
of shipment. During this warranty period, OGP will, at its option, repair, replace or provide a work-around solution to any
items that prove to be defective. In order to quality for such warranty service, a complete description of the problem, with
appropriate documentation (such as results, program listing, sample part and program) should be forwarded to OGP for our
inspection. Such items will be returned to the customer if requested.
OGP does not warrant that the operation of the software will be uninterrupted or error-free. The information in this manual is
subject to change without notice.
This warranty does not apply to defects resulting from customer supplied or configured computer equipment, operating systems
or software, unauthorized alteration or misuse, or operation outside the environmental specifications for the product.
THESE WARRANTIES AND OGPS LIABILITY HEREUNDER, ARE THE SOLE AND EXCLUSIVE
WARRANTIES AND ARE EXPRESSSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. IN NO EVENT SHALL OGP BE LAIBLE FOR ANY DIRECT, INDIRECT, SPECIAL,
CONSEQUENTIAL, INCIDENTAL, OR OTHER DAMAGES INCLUDING, AND NOT BY WAY OF LIMITATION,
LOSS OF PROFITS, AND WITHOUT REGARD TO THE FORM OF THE ACTION OR THE NATURE OF THE
CLAIM WHICH IS MADE.
Please Note
The information contained herein is based on the experience and knowledge relating to the subject matter gained by Optical
Gaging Products, Inc. prior to publication. No patent license is granted by this information.
Optical Gaging Products, Inc. reserves the right to change this information without notice and makes no warranty, express or
implied, with respect to this information. Optical Gaging Products shall not be liable for any loss or damage, including
consequential or special damages, resulting from the use of this information, even if loss or damage is caused by negligence or
other fault on the part of Optical Gaging Products, Inc.
Avant, Basic Bench, Cobra, Contour Projector, Flare, Flash, Focus, IQ 2000, Intelligent Qualifier 2000, MeasureFit,
MeasureMenu, MeasureMind, MeasureMind 3D MultiSensor, Q-Check, Q-SEE, Quest, SmartCheck, SmartReport,
SmartScope, Telestar, Vantage, and Top Bench are registered trademarks or trademarks of Optical Gaging Products, Inc.
Due to the nature of this material, a number of hardware and software products may be mentioned by name. In most, if not all,
cases these product names are claimed as trademarks by the companies that manufacture the products. It is not our intent to
claim these names or trademarks as our own.
2006 Optical Gaging Products, Inc. All rights reserved. Printed in U.S.A.
No part of this document may be reproduced or disclosed in any form or fro any purpose, other than personal use, without the
written permission of Optical Gaging Products, Inc.

About This Guide

Welcome to the SmartFit 3D training course!

Optical Gaging Products (OGP) has produced this Training Workbook as part
of its ongoing effort to provide users with useful, comprehensive
documentation.
We believe this manual will assist you in the use of the SmartFit 3D software.
If you should have any questions that are beyond the scope of this manual,
please do not hesitate to contact your authorized Sales Representative.

Organization
The SmartFit 3D Training Manual contains the following sections:
Section 1 Introduction
Section 2 Customizing SmartFit 3D
Section 3 User Interface
Section 4 Project Settings
Section 5 File Nomenclature
Section 6 Models
Section 7 Model Accuracy
Section 8 Measured Data
Section 9 Optimization Criteria
Section 10 SmartFit Environment
Section 11 Material Side Correction
Section 12 Advantages of Tolerance Envelope
Section 13 Release Function
Section 14 Prescribe Locators
Section 15 Weight
Section 16 SETS and Place Points / Geometries into a Set Command
Section 17 Coordinate System Overview
Section 18 Deviation Coloring
1

Documentation Conventions
To help you locate, interpret, enter, or select information easily, this manual
uses consistent visual clues and standard text formats. For example, capital
letters (or upper-case letters) are used to call attention to certain words and to
help eliminate ambiguity. These documentation conventions are explained in
the table below.
Type Style; Symbol

Used for

Example and
Explanations

Slash: /

Selections from a
main menu and
submenu(s)

Select File / New

Italic or Bold

Emphasized words

Commands to be
typed.
Keys to be pressed.
Buttons to be
pressed or clicked.
Menu items to be
selected.

bold

ALL CAPS

Initial Caps

Acronyms
File names
Path statements
Proper nouns
Product names
Sections; figures

Select the highest

magnification
Do not repeat this
step.
Type b:install; type
Exit.
Press the Enter key.
Click the Done
button or press the
Start / Stop button.
Select Contents
from the Help
menu.
ASCII; QVII
Edit INPUT.INI
View C:\W3_1
Navigation menu
SmartFit 3D
See Section 3

Training Manual Working Folder

Included with this manual is a CD that contains all the files needed to
complete this training manual. At certain points in the manual, you will be
asked to open a specific file from the working folder. You can place the
working folder anywhere on the local computer, but it is recommended for the
training that you place it on the Desktop.

Section 1
Introduction

What is SmartFit?
SmartFit is a stand-alone 2D/3D best-fitting and analysis software package. It
is an interactive software environment where the collected measured data is
analyzed, optimized, and compared to CAD and theoretical data giving the
quality control and manufacturing specialist unprecedented access to the
secrets of his process.
SmartFit compares measured data received from inspection systems (CMMs,
laser scanners, laser trackers, video systems), to the nominal representation of
the part (CAD model, drawings, nominal points), optimizing their position.
The different best-fitting mathematical methods provide fast, accurate and
reliable analysis, optimization and evaluation of conformance to form and
location for 2D/3D rigid bodies and assemblies.

Purposes and Goals

What problems does it solve?
What can I do with it?
SmartFit helps to:
Best-fit a part to its tolerance zones, avoiding the problems of the
commonly used least squares method not capable of finding the
optimum position of the part so that all measured points are put into their
respective tolerance zones.
Assess profile tolerances on complex surfaces by using:
w Tolerance Envelope or Tolerance Envelope Mini-Max methods.
Special methods for maximizing material for a machine.
Properly assess parts with non-fully constrained or difficult to handle
datums such as free form surfaces or compound datums.
Find the best coordinate system for a machine.
Determine the best tolerance achievable:
w Since all tolerances are correlated on a complex part, relaxing some
tolerance may bring expensive fixes into tolerance providing a
solution and savings to you.
Troubleshoot the manufacturing process. What if analysis.

w Finds set-up problems and recommend new, better datum targets

(locators).
w Allows treatment of patterns and sub-assemblies using the grouping
feature.
w Finds the outliers and excludes them from the optimization, thus
eliminating their bad influence on the rest of the features.
Analyze assemblies:
w Provides advice on corrections by simulation.
Influence the results interactively by changing the weight factors on
features or areas:
w Features on a part have different importance and so may cost less to
fix.

It produces more good parts, allowing you to save parts instead of

scrapping them.

How to Use the Software On-Line Help

You can access and view the Help topics by selecting Contents from the Help
menu.
The software displays the main Help viewer. It works much the same way as
the Internet Explorer browser.
The top pane displays the Help toolbar. It provides buttons for showing
and hiding the left-hand pane, printing topics, going back to previous
topics, and selecting other options.
The navigation pane on the left side displays tabs for the Contents, Index,
Search, and Favorites functions.
The topic pane on the right side displays topic content. If it does not fit
into one window, use the scroll bar on the right to view the rest of the text.
w You can jump to any topic that is shown in blue simply by clicking on
it. The color changes to indicate that the topic has already been
viewed.
w The selected book or page at the left is synchronized with the active
topic on the right.

Help Toolbar
The top pane of the Help viewer displays the Help toolbar. The buttons work
much the same way as the Internet Explorer browser.

Click the Hide button to hide the left-hand pane. If it is hidden, click on
this button to show the pane and tabs.
Click the Back button to go back to a previous topic.
Click the Options button to display a drop-down menu of options. For
example, you can select to print the topic.
Click the Whats new? Button to view the latest software enhancements.

Navigation Pane
The Help navigation pane displays tabs for the Contents, Index, Search, and
Favorites functions.
Click the
tab to view the list of main Help topics, represented by
icons of closed books. Double-click on the desired topic to open the
book and view a list of subtopics. Then double-click on the desired topic
to view it in the topic pane.
Click the
tab to view the list of all the index keyword entries. You
can use the scroll bar to search for the desired topic or type the word you
are looking for in the field at the top. Then double-click on the desired
topic to view it in the topic pane.
Click the
click the

tab and type the word that you are looking for. Then
button to display the topics that contain the word. To

view a specific topic, click on the title and then click the
button.

Click the
button to display the topics added to the Favorites list.
To add the displayed topic to this list, place the cursor in the topics list,
click the right mouse button, and select Add from the pop-up menu.

Hardware Key
SmartFit 3D will only run if its hardware key (or dongle) is plugged into
any available USB port on the computer the software is installed on. The
software can be installed on more than one computer at a time, but will only
run on the one that has the key attached to it.
The key that OGP uses right now is the Sentinel SuperPro from Rainbow
Technologies. You should not remove the key while running SmartFit 3D.
You can get more information and updated drivers for all operating systems
from the Rainbow web site. Look for driver downloads on their Support page.

Section 2
Customizing SmartFit 3D

Profiles
A profile is a file that stores the way you have customized SmartFit 3D from
session to session. The files (with an .sfprof extension) reside in the SmartFit
3D home directory.
After any customization of SmartFit 3D using Customize, remember to save
changes to the current profile.
To Load a profile:
On the Tools menu, click Load profile.
To save a profile:
On the Tools menu, click Save current profile.

Adding a Shortcut Key

You can customize shortcut keys in SmartFit 3D by assigning shortcut keys to
commands that do not already have them or by removing shortcut keys you
dont want. If you dont like the changes you make, you can return to the
default shortcut key settings at any time.
To turn shortcut keys on:
1. On the Tools menu, click Customize (or right-click the menu bar and
select Customize).
2. Click the Options tab.
3. Click Show ScreenTips on toolbar.
4. Click Show shortcut keys in ScreenTips.
To change or add a shortcut key:
5. On the Tools menu, click Customize (or right-click the menu bar and
select Customize).
6. Click the Keyboard tab.
7. Select the category of command.
8. Select the command name from the list. Currently assigned shortcuts
are displayed on the right.
9. To remove a command, click it and then click Remove.

10. To add a command, click in the Press New Shortcut Key box and type
the key combination you want for the command.
11. Click Assign to set the new shortcut.
Remember to save the new item in your profile. On the Tools menu, click
Save current profile and either make it the default or give it a personal name.

Configuring SmartFit 3D
The following options can be set in the smartfit.ini file, which is read when
SmartFit 3D loads. It controls how the work session will be configured.
Users have the opportunity to set a variety of functions in a number of
categories. The following are examples.
CalcAtOpenPntNumLimit

If you have a very large number of

measured points (e.g. more than 10000)
you can enable a point filter that will speed
up the motion of the CAD model while you
pan or rotate it.
In this example, the number of points will
be reduced to 5000 during the move.

DragAndDropFileOpen

Controls drag-and-drop file-loading.

=1, enabled
=0, disabled

AutoHideSlideSteps

Change the default value of 5 to a smaller

number to speed up the sliding of windows
when they are docked.

Create a New Menu

To create a new menu:
1. On the Tools menu, select Customize (or right-click the menu bar and
select Customize.)
2. The Commands tab should be open.
3. Click New Menu in the Categories list.
4. Click the New Menu command in the right pane and drag the pointer
to the menu bar at the top of the screen.
5. Drop it where you want the menu to appear. You can nest the menu
below an existing menu: for instance, you can add a submenu to the
existing View menu.
8

6. Right-click the new menu.

7. Select Button Appearance.
8. Type a name for the new button in the Button text box.
9. Press ENTER or click OK.

To add commands to a menu:

1. On the Tools menu, select Customize (or right-click the menu bar and
select Customize.)
2. Click the Commands tab.
3. Click category.
4. Click a command and drag it to a toolbar.
5. When you are finished adding commands, click Close.
Remember to save the new item in your profile. On the Tools menu, click
Save current profile and either make it the default or give it a personal name.

Toolbars
To reset a toolbar or the menu bar:
1. On the Tools menu, select Customize (or right-click the menu bar and
select Customize.)
2. Click the Toolbars tab.
3. Click the toolbar you want to reset. If you want to reset the menus,
click Menu bar.
4. Click Reset.
5. To reset all toolbars including the menus, click Reset All.
To create a custom toolbar:
1. On the Tools menu, select Customize (or right-click the menu bar and
select Customize.)
2. Click the Toolbars tab.
3. Click New.
4. Name the new toolbar.
5. Click OK.
6. Drag the new toolbar away from the Customize dialog.
7. Add a command to the toolbar. (Refer to previous section).
Dock the new toolbar to a position on screen by dragging its handle or title
bar, or let it float.
9

Remember to save the new item in your profile. On the Tools menu, click
Save current profile and either make it the default or give it a personal name.

Create a Tool or Command

You can create a tool to open many different types of files residing on your
computer.
To create a tool:
1. On the Tools menu, click Customize (or right-click the menu bar and
select Customize).
2. Click the Tools tab.
3. Click the New button.
4. Type a name into the box that appears.
5. Click the search button to the right of the Command box.
6. Select the type of file to search for by clicking in the Files of type box.
7. Find your file and double-click it.
8. Click Close to save the new command.
New tools are automatically added to the Tools menu. However, you can
move them to any menu.
To add a tool to a menu or toolbar:
1. On the Tools menu, click Customize (or right-click the menu bar and
select Customize).
2. Click All Commands and scroll to the very bottom of the list. The
new command should be there.
3. Click the command and drag it to a menu or toolbar.
4. Click Close.
Remember to save the new item in your profile. On the Tools menu, click
Save current profile and either make it the default or give it a personal name.

Edit a Toolbar, Menu or Shortcut Menu

To change the commands on a toolbar or regular menu:
1. On the Tools menu, click Customize (or right-click the menu bar and
select Customize).
2. Click the Commands tab if it is not displayed.
3. If you are editing a menu, open the menu you want to edit.

10

4. Drag commands back and forth between the toolbar or menu and the
Commands list.
5. Click Close when you are finished.

To change the commands on a shortcut menu:

1. On the Tools menu, click Customize (or right-click the menu bar and
select Customize).
2. Click the Menu tab.
3. Select the menu to edit in the Select context menu box. The menu
appears.
4. Click the Commands tab (still in the Customize dialog).
5. Drag commands back and forth between the menu and the Commands
list.
6. Click Close when you are finished.
Remember to save the new item in your profile. On the Tools menu, click
Save current profile and either make it the default or give it a personal name.

11

This page was left blank intentionally.

12

Section 3
User Interface

MODEL
WINDOW

WINDOW
INFORMATION

WINDOWS

Toolbars
To move the toolbars other than where they default to, left click and hold
where there is not a button and drag to a new location.
All available toolbars can be accessed through either View / Toolbars or
right-click on any active toolbar. Hovering the pointer above any tool icon
will display a screen tip.
Main:
Click & Action:
Modified Selected:
13

Select:
Appearance:
Whiskers:
Material Side:
Labels:
Navigation:
Zoom:
Scenes:
Tools:
ManualFit:
Create:
Construct from Selected:

Windows

Available commands common to some or all of the windows:

Select all points.
Selects all points and features.
Unselect all points.
Deselects all points and features.
Add label.
Add / edit label for a point or feature.
14

Delete selected features.

Will delete anything you have selected, including locators. Be
careful: you cannot undo this unless you close the file without
saving changes and reload the file. If you delete a point, all
remaining numbers will be renumbered.
Construct group from selected points.
A group is a set of points that may belong to different features and
shapes. Groups are useful when you want to apply tolerances,
weights, etc. to or to see statistics for a particular set of points.
Remove weight.
Removes weight from selection.
Remove tolerance.
Removes tolerance from selection.
Note: Icons associated with each type of point and surface in the list vary. As well, some points
comments are displayed differently.

Weighted points are bolded (unless their weight is 1).

Hidden points are italicized.

Excluded points are dimmed.

Points with tolerances are green and have a different icon.

Out of tolerance points are red.

15

Data Summary

This display will give you a quick idea of how well

SmartFit has been able to optimize the file with the
current criteria.
The top pane shows a variety of statistics about
your file.
The bottom pane shows the results of the most
recent optimization run of your data.

Features

This display shows you all the pertinent information

relative to any feature currently active in the
SmartFit model window.

geometries from the nominal CAD file

measured points

locate points.

All changes must be applied using the Apply

Changes button.

16

Groups

A simple listing of general statistics about all or

some of the points (only in groups) in the current
data file.
You can display information for all groups or from
a specific group using the selection box at the top of
the window.
Remove Selected Groups / Group Items.
Removes entire groups from the analysis or
just individual items from the group.

GoTo Group Statistics

Switches to the Statistics window relative to
only the Grouped features.

Statistics
Statistical results for the current fit.
Make Excel Report (F10)
Select the statistics you want include in the
spreadsheet in the resulting dialog. When you click
OK, Excel will open and the report will appear in it.
NOTE: Microsoft Excel must be loaded on your
computer for this command to work.
Histogram
Shows the actual numbers in the categories SmartFit
calculates for the data values.
Distribution
Shows the results as percentages.
Original
data or Current
data refers
to the display of statistics from either before
(original) or after (current) an optimization has been
run.
Static and Dynamic Scale
Refers to the deviation ranges shown on the
horizontal axis in the window. Static can be useful if
you want to compare distributions / histograms for
different groups. The deviation ranges are the same
for each group. In dynamic mode, the deviation
ranges change from group to group depending on the
deviation span for each group.
Make Chart Screen Shot
17

Coordinate Systems

From this window you can see what your existing

coordinate systems are, create new ones or modify
or delete existing ones.
Create / Modify Coordinate Systems.
This command opens the dialog to create a new
coordinate system.

Delete Unreferenced Coordinate System.

Deviation

Shows any point that has deviations, either before

or after optimization. The offending coordinates are
in red in the display.
Show Out-of-Tolerance Points.
Include Excluded Points.
Enable Custom Filter.
Filter points according to criteria to be set in a
subsequent input window.

Selected Items Properties.

18

Results

This window shows statistics for your data and

allows you to filter out points you may not want in
the results list.
Measured.
Deviation.
Toleranced.
Weight.

Locators

A list of the locators (fixture points) and their

statistics. Only the statistics for the significant
coordinates are shown.
Grid Switch.
Color Switch.
Create a Locator.

19

Deviation Coloring

If the following are true:

Tolerances have been set on some nominal

points.

Show nominal points is turned on.

Either a calculation or optimization has been

performed.

Some points are out of tolerance.

You can now set the colors of the deviation points

to your liking.

Window Navigation
Most of the windows in SmartFit are dockable. Meaning that they are able to
be positioned anywhere on the main desktop. This section will help to explain
the different window options and where they can be placed.
The windows that we just discussed are considered informational, and most
often are found to be tabbed either on the bottom of the screen or up the right
side of the screen.

To Rearrange the Order of the Tabs Along the Bottom of the Window
Drag a tab to another position along the tab bar.

To Float a Docked Window

1. Click and drag the windows tab. The window-placement icons appear.

20

2. Drag your pointer to any place on-screen except over one of the
window-placement icons.
3. Let go of the mouse button.
4. Resize the window by clicking and dragging its borders. Tabs can be
dragged outside the SmartFit application window if it has been
reduced in size.
5. To float all the tabs, double-click in any tabs title bar when it is in its
normal docked location. Double-click there again to return them to
their docked position.

To Dock a Window Somewhere Else

1. Click and drag the windows tab. The window-placement icons
appear.
2. Drag the mouse pointer over any of the icons. A shadow appears
showing where the window will be docked if you let go of the mouse.
3. Select a placement and let go of the mouse.

To Dock a Floating Window

1. Double-click the windows title bar. It will return to its last docked
location, OR
2. Right-click the windows title bar and select Docked from the menu,
OR
3. Click and drag its title bar to the information panes tab bar.

To Auto Hide the Windows

1. Click the pushpin icon
at the top right corner of any window to
turn AutoHide on. Windows will slide to one side of the application
window. They reappear when you place the mouse pointer over at tab.
2. Click the pushpin again to have the windows always visible (normal
mode).

To Close a Window
Select the close icon in the windows title bar.

21

New Graphics Window

Select Windows / New Windows / Graphics or press F12.
The new window becomes the active graphics window.
The new window shows the same initial view as the original graphics
window, but you can change almost everything in it independently from the
other window.
Graphics windows can be dragged outside the SmartFit application window (if
it is reduced in size) or to a second monitor (if available). They can also be
added to the information tab bar (with the Features, Data Summary, Results,
etc. tabs) by dragging the graphic windows title bar to the information tab
bar.
NOTE: ManualFit changes will affect all graphics window displays.

22

Section 4
Project Settings

General Settings

Problem dimension: Allows you to change the dimension of measured points. If you
switch from Spatial (3-D) to Flat (2-D), the Z coordinates of all measured points will be
assigned a value of zero after you press Calculate in the Best Fit dialog.
Linear dimensions: Select the unit name from the list and the number of significant
digits for numbers. SmartFit 3D can change an imported files unit type, or leave it
along.
Angular dimensions: Select the unit name from the list and the number of significant
digits for numbers. SmartFit 3D can change an imported files unit type, or leave it alone.

23

Cover Sheet

Important information relative to the current active project. This information will also be used
when a report is generated.

Model Meshing Quality

To make a quick adjustment, simply use the slider. Click Apply to immediately see the change
in the models appearance.

24

Data Import Defaults

These settings will apply to ALL points being imported.

Coordinate system Select the coordinate system for the imported data.
Tip radius Enter the tip radius of the measuring ball.
Distance tolerance Select maximum and minimum values for all points in the data set.
To set tolerances on a subset of points, either edit the data file before importing it, or
change the values after importing the file using Features or Groups.
Distance weight Select a weight value for all points in the data set. If you do not do
this a value of 1 will be given to all imported data, which is the default value. To change
this later (so you can vary the imported points weight in best fit), see Applying weight.

25

This page was left blank intentionally.

26

Section 5
File Nomenclature

The new DAT file format (v2.0) is now the standard file format for SmartFit.
Current versions of SmartFit cannot save in the old format. SmartFit will load
old DAT files, but will save them only in the new format (you will be warned
before you replace an old format DAT file). Saving in the new format will not
change the files name. To do that, use Save As instead and it will be saved
with an SFD extension.
SFD and DAT file extensions in SmartFit 3D are considered project files. A
file is considered a project when measured data, nominal data, or both have
been imported into SmartFit and then saved. This naturally creates confusion
with users of OGP software because a DAT file represents measured data.
Any newer projects that are saved in the latest releases of SmartFit are
considered an SFD file. In the older versions of SmartFit, a project file had
the DAT extension. Therefore, some project files used for training purposes
may have the DAT file extension.

CAD Files

Project Files

Measured
Data Files

SFM ( SmartFit Model) : SmartFit 3D Project File.

IGES (Initial Graphics Exchange Specification)
VDAFS ( Verband der Automobilindustrie )
STEP ( Standard for the Exchange of Product Data )
STL ( Stereo Lithography )
DXF ( Drawing Interchange Format )
SFD (New format)
DAT (Old format)

SFD (New format)

DAT (Old format)
TXT
ASC
XYZ
STL

File / Open: When an SFD / DAT project file is opened using this function, all features
(nominal & measured data) are imported.
File / Import / CAD File

27

File / Import / Measured Data File: When an SFD / DAT project file is opened using
this function, the measured data points are the only features that are imported.

28

Section 6
Models

CAD File Types (Models)

SFM ( SmartFit Model) : SmartFit 3D Project File.

IGES (Initial Graphics Exchange Specification) : Neutral data format describes product design
and manufacturing information created and stored in CAD/CAM systems. U.S. national
standard to aid in the exchange of geometry, annotation, and structure information between
dissimilar CAD systems.
VDAFS ( Verband der Automobilindustrie ): German neutral file format for the exchange of
surface geometry that was developed to exchange free form surfaces. VDAFS supports
elementary curve and surface geometry entities and some topology to define more complex
models. VDAFS is used by the German automotive industry to define surface models such as
car bodies.
STEP ( Standard for the Exchange of Product Data ): Its goal is to interrelate all geometric and
nongeometric data in a useful and meaningful way so that the complete description of a product
can be shared between CAD systems. STEP is made up of a group of APs (application
protocols), which are collections of working documents that address different disciplines.
STL ( Stereo Lithography ): Is an ASCII or binary file used in manufacturing. It is a list of the
triangular surfaces (facets) that describe a computer generated solid model. This is the standard
input for most rapid prototyping machines.
DXF ( Drawing Interchange Format ): A two-dimensional (2D) graphics file format supported
by virtually all PC based CAD products. It was created by AutoDesk for the AutoCAD
system.

29

Importing CAD File

1. Select File / Import / CAD File or single click the Import CAD icon
from the Main toolbar.
2. Locate a CAD file from the working folder on the computer and either
double click the file in the dialog or single click the file and select the
Open button. (See below)

3. Select the appropriate units from the dialog box.

CAD file with detected Units.

4. Select OK.

30

CAD file with no detected units.

Displaying Models

Displaying Cross-Sectional View of Your Model

SmartFit 3D has four ways of seeing inside or through a filled surface.
To make it transparent:
1. Click on the surface you want to see through with Select geometry
. To select multiple surfaces, hold CTRL down as you click on
them.
2. Click the Features window (or select it from the list on the Windows
menu).
3. Adjust the Opacity slider by clicking along the slider (try the middle of
the slider first).
4. Click Apply changes.
5. Turn Transparency mode

on.

To hide it:
1. Click on the surface you want to hide (it will not be deleted) with
Select geometry

2. Click on Hide selected

3. To see the surface again, click Show selected

To cut or fly through it:

1. Click Isometric view

2. Click Zoom extents

3. Click Fly

(camera distance).

4. Click Perspective view

5. Left-click and drag upwards in the active graphics window a couple of

times until a change in the image occurs. Usually the image gets
lighter because you are now on the inside of the part.
6. Right-click to use Aim (camera direction) to help navigate your way
through the model.
7. Click Perspective view
31

8. To view the invisible cutting plane, left-click for camera direction

(aim)

and right-click for camera distance (fly)

Other Model Views

Rotate: Rotates image around the current pivot point. This command allows you
to view the model from very precise directions and is probably the most useful tool in
SmartFit for viewing models.
Tip: Mouse commands that work while Rotate mode is active:
Pan: click and drag the right button.
Real time zoom: click and drag the middle button.
Pan: Moves the view in the active graphics window.
Tip: Mouse commands that work while Pan mode is active:
Real time zoom: click and drag the right button.
Zoom: scroll wheel.
Rotate: click and dray the middle button.
Autospin: Turns on automatic spinning of the model. Click and drag.
Zoom window: Zooms in to a rectangle you draw on-screen.
Zoom Center Window: Zooms into a dynamic window.
Zoom to fit: Fits image into active window.
Zoom realtime: Zooms dynamically as you move the mouse.
Tip: Drag diagonally across the active graphics pane from bottom left to top right
for best results.
Zoom In: Zooms into the on-screen image. Often this command can be invoked
with the scroll wheel on the mouse.
Zoom Out: Zooms away the on-screen image. Often this command can be
invoked with the scroll wheel on the mouse.
Top View: View the top of your model.
32

Bottom View: Views the rear of your model.

Left View: View the model from the negative x side (right side).
Right View: Views the model from the positive x side (left side).
Front View: Views the front of the model.
Rear View: Views the rear of the model.
Isometric View: Views the model in isometric.
Undo View: Returns to the previous viewpoint. You can go back 25 views.
Redo View: Returns to formally undone viewpoint.

Appearances

Show Curves: Controls the display of curves on the model.

Show Filled Surfaces: Controls the display of filled (solid) surfaces on the
model.
Show Wireframe: Controls the display of surface wireframes.
Show Silhouette: Controls the display of wireframe silhouettes. The surfaces
are filled with lines. Compare the wireframe icon with the silhouette icon.
Show Triangle Mesh: Controls the display of the triangle meshes of a surface.
Show Hidden Lines: Displays model with hidden lines removed from view.
Surface colors are also removed but surface edges are still displayed. Wireframe
and triangle mesh lines are removed.

33

Update Pivot Command (Navigation / Update Pivot)

Updates the pivot

(rotation center) coordinates according to the current pivot mode.

The pivot mode can be Origin, Normal, or Screen Center: (Navigation / Pivot Mode)
Normal
pivot mode recalculates the center of mass of the currently
visible objects.
Screen Center

pivot mode moves the pivot to the screen center.

Pivot at Origin
mode function is disabled because the pivot is fixed at
the models origin (0,0,0).

The tools described above for displaying models is only a partial list. Most of what was
displayed is the primary tools active in the default toolbars. The setup of your toolbars is
an individual preference. View / Toolbars / Customize will give you access to the
following dialog box that can be used to drag and drop new icons for specific tools. Drag
them out of the dialog to add, drag them in to the dialog to remove.

34

Section 7
Model Accuracy

One misconception that is apparent in industry is that CAD files are perfect.
In other words, IGES files being imported into SmartFit must always be
considered nominal in nature. That assumption is incorrect in some cases.
The issue lies in how the CAD file is created. Direct translators do exist, but
this method requires many different types of translators that each CAD
package must support. See figure 7.1 below. To standardize the industry,
neutral file formats were developed to alleviate these issues. See figure 7.2.

CAD A
CAD A

CAD E

CAD B

CAD E

NEUTRAL
FILE

CAD D
CAD D

CAD B

CAD C

CAD C

Figure 7.1: Situation with direct data transfer

Figure 7.2: Situation using neutral file.

Most of the CAD file formats that SmartFit 3D can import are considered to
be neutral files in a neutral file format. Neutral files and neutral file interfaces
are needed in order to exchange product data between CAD systems.
These neutral file formats, such as IGES and STEP, can be very complex in
nature due to the fact that they need to support many different disciplines.
SmartFit 3D is only one of many. The 3D model file is translated from one
native CAD format (sending system) to an IGES or STEP file. This file is
then translated into another native CAD format (receiving system). In this
process, the many entities that are present in the file get mapped. Therefore,
the sending system takes native entities and translates them into a supported
neutral entity. If an entity is not supported in a neutral file, it is usually
ignored. Not only do we have a loss of data, but this same concept could also
affect the accuracy of the file. This loss of information has become acceptable
in industry, so be aware.
So what can we do about this? The 3D Core that SmartFit 3D is based upon
allows us the ability to construct 3D entities within the software to verify if
the neutral file is valid or not.

35

The following steps will demonstrate how to verify the validity of a CAD file.
1. Using the method just explained in Section 6, import CIRCULAR PART
BAD FORM.IGS from the working folder on the computer. When
prompted, choose Inches as the units.
2. Select File / Project Settings or press the F5 key on the keyboard to
access the project settings.
3. Select the number of digits to be six (6). If the units were millimeters,
three (3) or four (4) significant digits would be sufficient.
4. Switch to an isometric view by selecting the
icon from the scenes
toolbar or going to Navigation / Special Views / SE Isometric.
5. Select the immediate select / deselect icon
from the select toolbar
or go to Edit / Modified Pointed / Select Deselect Move Label.
6. While holding the Ctrl key down, select the two surfaces at the end of
the part (labeled 1 & 2 in the figure below).
1

7. Select the Construct Cylinder icon

from the Construct from
Selected toolbar or go to Tools / Construct from Selected / Surfaces /
Cylinder.
8. In the window that opens, select the Calculate button.
9. Note the specs of the currently constructed cylinder. See below.

36

The big thing to note here is the Deviation range that is shown in the red box.
This value is the form error for the constructed cylinder. The form error
of the nominal features is a very important parameter, which in itself shows
the quality of the CAD file. A good model would have a deviation range
equal to or less than:
0.01 micrometers = 0.00001 mm = 0.000004 inches
The error of this CAD file for the specific feature selected is 0.00067 inches.
This would be considered a bad model. There is more than 0.0006 of error
associated with this file even before measured data has been fit to it.
Now check the features shown labeled in the figure below.
1

1. Cone (Error 0.000000)

2. Cyl

(Error 0.001220)

3. Cyl

(Error 0.000089)

4. Cyl

(Error 0.000560)

5. Cyl

(Error 0.000561)

5
4

One final point to make is in regards to reverse engineering. Within the OGP
MeasureMind 3D MultiSensor software, there is the ability to export the
model window (CAD representation) to and IGES file. When the model
window is currently displaying actual data, the IGES in turn is exported and
created from actual data. In this case, if there is a form error on a cylinder that
was measured using the OGP machine, that same error should appear in the
IGES upon creation. Therefore, these files should be used as working files to
determine roughly what the actual size of the part is.

37

This page was left blank intentionally.

38

Section 8
Measured Data

What is measured data?

Measured data can typically be found in an ASCII text file, which contains an
X, Y, and Z value for each data point that was measured on the part. The
method of measurement is completely independent of SmartFit.

Import Measured Data

1. Select the icon
from the main toolbar or access from the file
menu. File / Import / Measured Data File.
2. Select the file from the import dialog. See below.

Location of File

OK
Name of File

39

3. If you want to place the measured data into a specific set, choose it
from the list. Otherwise, select New (empty) Set.

Choose to allow SmartFit to automatically place

datapoints into groups.

Choose to allow the comma to be a separator. In

some countries, the comma replaces the period.
For example 5.24 is written 5,24 in Germany.

1
2

Choose an option for what is to be done with the

measured data to be input. If an option is not
currently available due to current conditions, it
will be grayed out.

4. Choose the data import defaults that would apply to the fit.
1

1
2

2
3

4
4

Choose which coordinate system to import the

data into.
If the data coming from the measuring device is
uncorrected, choose this option and fill in the tip
radius.
Enter maximum and minimum values for ALL
points in the data set. To set tolerances on a
subset of points; change the values after
importing the file using the Features or Groups
windows.
Enter a weight value for ALL points in the data
set. If you do not do this, the default value of 1
will be given to all imported data.

At this point, both the nominal geometries and measured data are present in
the SmartFit model window and ready for fitting. Before we actually perform
the fit, the next section will discuss the different fitting routines that are
available in the software.

40

Section 9
Optimization Criteria

The SmartFit best-fitting optimization routines are the core of its

programming and make it the powerful software it is.
SmartFits goals are to try to reposition a part so that all its points are within
tolerance, and at the same time to minimize any deviation from the nominal
position of those points.
The heuristic for optimization:
1. Castings usually have to be machined.
2. A part is held in a fixture with locators.
3. The fixture is aligned to the CNC machine.
4. The CAD model is immobilized on the fixtures locators.
5. Castings are always slightly larger than the final part.
What SmartFit tries to answer is:
Can this casting be manufactured into the final part?
It does this by optimizing the position of the locators of the object in its jig.
New locator positions are output, which allow you to easily compensate your
machining jig or die to finish or produce the part with the least work.

Criterion
Least Squares:

Minimizes the sum of squares of deviations (or distances)

subject to the applied optimizing conditions (tolerances and
weights).

(W x )
n

Root Mean Squares (RMS):

2
n

Minimizes the square root of the sum of squares of

deviations (or distances) subject to the applied optimizing
conditions (tolerances and weights).

(W x )
n

nDev

41

2
n

Minimum Sum of Deviations:

Minimizes the sum of the absolute values of deviations (or

distances) subject to the applied optimizing conditions
(tolerances and weights).

(W x | |)
n

Minimum-Maximum:

Minimizes the maximum deviation (or distance) subject to

the applied optimizing conditions (tolerances and weights).

Max (Wn x |n|)

Uniform Deviations:

Tries to make the absolute values of deviations (or

distances) equal to each other, subject to the applied
optimizing conditions (tolerances and weights).

(W x || | - A|)
n

where A

Minimum Standard Deviation:

| |
n

(significant coordinates OR distances)

Minimizes the standard deviation, subject to the applied

optimizing conditions (tolerances and weights).

(W x ( - A) x ( - A))
n

Tolerance Envelope:

Minimizes the sum of squared violations of the tolerances,

applied to coordinates (or distances) subject to the applied
optimizing conditions, i.e. it tries to keep the points within
or to move them into a tolerance envelope.
It follows from the definition of this method that the
minimum value that can be reached for the optimization
criterion is equal to 0, which will mean that all applied
tolerances are satisfied. Consequently, a positive value will
signify that there are unsatisfied tolerances.
The following points apply to the criterion discussed in this
section as well as to Tolerance Envelope Mini Max.

42

1. This Envelope criteria only processes points to which tolerances are

applied. Thus, it may happen that the deviations to the rest of the
points will have unacceptable values after optimization.
2. The object of optimization to a point is set automatically to coordinate
if a coordinate tolerance is applied, or to distance if a distance
tolerance is used.

(W x )
n

2
n

where n2 is: lotoln - n if n < lotoln

or:

n - uptoln if n > uptoln

or: 0 if n within range of [lotoln, uptoln]

Tolerance Envelope Mini-Max:

Minimizes the maximum violation of the tolerances,

applied to coordinates (or distances) subject to the applied
optimizing conditions, i.e. it tries to keep the points within
or to move them into a tolerance envelope.
The main difference between this criterion and the previous
one is that while Envelop squares stops the optimizing
procedure when tolerances are satisfied Envelope
minimax tries to find the most internal position within
the tolerance limits applied.
For example, let us assume 0.3 +0.3 tolerance limits are
applied but 0.25 +0.25 can also be achieved. In that case
the Envelope squares will stop immediately after 0.3
+0.3 tolerance limits are satisfied. On the contrary, the
Envelope minimax will continue searching and will
find the position at which 0.25 +0.25 tolerance limits are
satisfied. In that case the criterion value obtained after
optimization will be equal to 0.05.
In general:
Optimization criterion value

Meaning

Negative

Better than specified

tolerancing conditions exist.

Zero

Tolerancing conditions
exactly satisfied.

Positive

Unsatisfied tolerancing
conditions exist.

43

Max (Wn x 1n, Wn x 2n)

where

1n = lotoln - n
2n = n - uptoln

44

Section 10
SmartFit Environment

One of the key aspects of SmartFit is in its ability to be a very interactive

software package. We commonly refer to it as a What-If tool. SmartFit can
have many different answers, referring to the results shown at the bottom of
the diagram below.

Group
Tolerance

Calculation

Math

Nominal/CAD

Filter

Measured
Weights/Exclud
Release
Statistic

Result 1

Result 2

Result N

Each result would be considered a recipe. A recipe is usually made up of a

series of main components. In our case, there are two, nominal CAD data and
measured data (center circle above). But what happens if we start to change
the characteristics (topic arrows pointing to the center circle) of each
component. Then we have a slightly different recipe. This can go on to the
nth degree.
In the following sections, we are going to discuss the many tools available to
you that can be used in generating different recipes.

45

This page was left blank intentionally.

46

Section 11
Material Side Correction

The material side tools control how the sides of surfaces are displayed and
which direction the material surfaces normal vector points.

Match Material Sides

Immediate Material Side Flip
Flip Material Side of Selected
Toggle Two-Sided Curves

The commands are only available if you have imported a file containing a
surface.
A surfaces material side is the side that faces into the material. The material
is under the surface since surfaces represent real machined parts.
A surfaces normal vector points out of the material.
Surfaces are automatically assigned different colors by SmartFit: the surface is
any color (front) other than dark brown when its normal vector points toward
you, and dark brown (back) when it points away.
A three-dimensional models surfaces must all be oriented with their material
sides toward the interior of the model to produce a valid optimization.
The original state of surfaces (immediately after loading) is they have
different colors, which means that surface normal vectors point to different
directions. This is the case with many models; the surface directions are
simply not well defined.
With Match Material Sides, SmartFit tries to make the model uniformly
colored. Note that for some sophisticated parts it may not be fully successful,
but still it provides tremendous help to the user compared to doing it
manually.
When the Bestfit or Optimize button is pressed, you are asked if the models
sides are correct. If you are not sure, click No and the Material Side
Correction Wizard will take you through the process.

47

Knowing which is the front and back of a surface can be important to

understand the graphic image and signs of deviations since material side
influences optimization.

48

Section 12
Advantages of Tolerance Envelope

1. Select File / New to clear out anything that may be active.

2. Select File / Import / CAD File or single click the Import CAD
icon from the Main toolbar.
3. Select PROP.IGS from the working folder on the computer. When
prompted, choose Millimeters as the units.

4. Using what was discussed in Section 11, ensure that the material
conditions of the part are correct. You will also be notified when you
perform the Best-Fit on whether the material conditions are correct. If
you are not sure, the wizard will walk you through on how to fix that.
5. Select File / Import / Measured Data File or single click the Import
Measured Data

icon from the Main toolbar.

6. Select PROP1.DAT from the working folder on the computer.

7. Select Set1 as the target for the measured data and select Next.

49

8. Select Finish in the data import defaults window.

NOTE: These settings, if

used, would apply to ALL
points being imported.

9. In the case where the measured points are not orientated to the nominal
geometry, the Manual Fit functions need to be used prior to any
optimizations.
ManualFit is the process of moving a set of measured points with your
mouse to the approximate position of the data files nominal points.
This process is most often used when fitting IGES models, which can
be scanned at very different orientations than the nominal model.

Activate / Deactivate the ManualFit

Pan the Measured Points
Rotate the Measured Points
Plane Rotate the Measured Points

a. Click on any one of the ManualFit Rotate, Plane rotate, or Pan

commands and then click and drag on your points to bring them
roughly to the correct orientation.
b. Click one of the Special views and then click anywhere in the
graphic pane and drag the points near your object.
c. Repeat steps 1 and 2 using different Special views and both the
Move and Rotate ManualFit tools until the points are nearly
aligned to the object.

50

d. If you click Activate / Deactivate the ManualFit transformations,

the points will return to their starting positions.
e. To exit the ManualFit mode, click on one of the navigation
commands (rotate, fly, etc.)
10. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.
11. Choose Yes from the material sides warning message. If you are still
unsure from step 9 above, choose No and walk through the wizard step
by step.
12. Select Optimize, and then Close.

The least squares criterion is being used as a general fit routine. We are
only concerned right now about getting the measured data as close to the
nominal geometry as possible.
In the SmartFit model, the pink points are considered actual points, while
the white points are projections of actual points onto the nominal surface.
See below.

51

13. Switch over to the Features window. If the window is not present,
choose from the Windows pull down menu or press Ctrl + 1.
14. Within the Features window, select the Select all Listed Measured
Points icon
Features tab.

or press Ctrl + M. A point data tab will appear in the

15. Select the Tolerance active check box.

16. Fill in 0.000 for Tolerance min. and 100.000 for Tolerance max. This
may seem like a large tolerance, but you have to realize it is a ship
propeller that is approximately 2500 millimeters long.
17. Select the Apply Changes button in the point data tab.
18. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.
19. Select Optimize.
NOTE: There should be three (3) tolerance-violating points. This
means that the least squares best-fit criterion minimized the sum of the
squares to the best of its ability but was still not able to force all of the
measured points within the tolerance envelope.
20. Select the Apply Tolerances check box at the bottom of the parameters
window. The criterion pull down menu will default to Tolerance
Envelope.
NOTE: The Tolerance Envelope criterion ONLY considers points
with associated tolerances. Points without associated tolerances are
excluded from the optimization. If your fit contains both points with
and without associated tolerances, you are better off using Least
Squares and the Apply Tolerances checkbox. That way, the points that
do have a tolerance associated with them will be optimized into their
respective tolerance bandwidth while the points that do not have
associated tolerances will optimize under the standard Least Squares
best-fit criterion.
21. Select Optimize, and then Close.

52

22. Use the available tools in the Whiskers toolbar to exaggerate the
whiskers for easier viewing.

Toggle Nominal Original Whiskers

Toggle Nominal Current Whiskers
Zoom Whiskers
Toggle Whisker Arrows
Show Tolerance Violating Part of Whisker Only

23. Review the results in the Data Summary window. Windows / Data
Summary or Ctrl + 0.
24. Review the Deviations window. Windows / Deviations or Ctrl + 5.
NOTES:
-

Sorting capability exists in this window by selecting the columnheading label.

Labels can be applied to any amount of measured points by first

selecting the point(s) and then selecting the Add Label icon

Custom filters can be applied to the deviations window by

selecting the appropriate icon

within the window.

Note the other tools available while in this window.

25. In the Deviations window, select the Curr.Dist.Dev. column header to

sort the deviations in ascending order.
NOTES:
-

All points are in tolerance, so a deviation of 0.2211mm indicates

that the smallest amount of material will be that value from the
given tolerance zone.

The part will clean up, but with VERY LITTLE material in that
area.

This can be quite disconcerting when the tolerance of the part is

100mm.

53

The question is whether we can minimize the maximum error in an

effort to increase that value while still keeping all points within
tolerance.

The answer is the Tolerance Envelope Mini-Max criterion.

26. Select Tools / BestFit or single-click the BestFit (Optimize) icon

from the Tools toolbar.
27. Select the Tolerance Envelope Mini-Max criterion from the drop down
list.
28. Select Optimize.
29. NOTE: The current criterion value is now approximately 3.5mm.
This is the scenario we were looking for. All points are still in
tolerance and the maximum error has been minimized to a point where
safe clean up is possible.
30. Select Close.
31. Review the Data Summary window for the new results.

54

Section 13
Release Function

1. Select File / New to clear out anything that may be active.

2. Select File / Import / CAD File or single click the Import CAD
icon from the Main toolbar.
3. Select HINGE1.IGS from the working folder on the computer. When
prompted, choose Millimeters as the units.
4. Select the Select Geometry icon

5. Left click, hold, and drag a box around the joining pin and also the half
hinge with only one joining cylinder. See below.

6. Select the Features window.

7. Expand the IGES folder out so that all the surfaces can be seen. The
selected surfaces should be highlighted showing they have been
selected.
or right-click anywhere
8. Select the Delete Selected Item(s) icon
within the Features window and select Delete Selected Items.
9. Select the Isometric icon, then the Zoom Extents icon.

55

10. Following the guidelines stated for material sides, the dark brown
sides must be switched to coincide with the other sides (green). This
can be done by using the available icons in the ManualFit toolbar. See
below.

11. Import the measured data file RELEASEHOLES.DAT from the

working folder into Set1 without any defaults. Notice that the
lightning bolt is flashing indicating that SmartFit has all it needs to
perform a bestfit.
12. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.
13. Select Optimize, and then Close.
14. Using the icons available in the Appearance toolbar, hide the filled
surfaces and ensure the wireframe is shown. This should give you a
very good visual of the current fit. See below.

NOTE: The error whiskers indicate a misalignment of the holes to the

body. This misalignment must be determined so that the operator can
adjust the fixture setup to coincide with the translation and rotation of
these holes relative to the body.
15. Select the Features window if not already there.
16. Using the Shift key, select the first 1196 points.
17. Select the Construct Group icon

56

from the Features window.

18. State a comment of Release Holes in the dialog and press OK. See
below.

19. SmartFit should automatically switch over to the Groups tab. If it

doesnt, select it.
20. Select the GROUP1 label within the Groups window. A Group
Release tab should appear towards the bottom of the window.
21. From the Release mode pull down box, choose Trans. In XY plane &
rot. Around Z-Axis.
22. Select the Apply Changes button.
23. Choose the Toggle Vector icon
from the Appearances toolbar. A
large double-ended arrow appears in the active graphics screen
showing the plane and vector of the release. The released group
(highlighted yellow) will move along this vector. The animation will
continue even if you rotate the image. It is only descriptive and does
not reflect actual distances. The next time you run a calculation or
optimization on your data, the data will reflect changes brought about
by releasing the group.
24. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.
25. Select the Apply Release checkbox that appears at the bottom of the
active window.

57

26. Select Optimize, and then Close. See below.

27. Within the Group Release tab of the Groups window, you will now
notice that there are non-zero values for the degrees of freedom
associated with the specific vector that was chosen. See below.

NOTE: The operator now knows that the fixture setup he is using needs to
be translated 1.914 mm in X, 1.098 mm in Y, and rotate the entire setup
by 4.54 degrees.
28. To view an Excel report of the fit, select File / Export / Excel Report,
choose the Excel Report icon

, or press F10.

29. Choose what options you want and then select Create Report.

58

Section 14
Prescribe Locators

What is a locator?
It is a location established to immobilize a part in a fixture. A machining jig
consists of locators that a CNC program is referenced to. Therefore, if the
locators are off position, that error could be transferred to the actual part being
machined.
Locator points are an integral part of SmartFit. In a lot of cases, support
points (datum points, locators) are used to create the coordinate system of the
measurement. If the part is inspected relative to those locators and found to
have areas that do not have enough material for a machining operation, you
then have a part that needs to be scrapped.
Not so fast!
If the relation to the actual geometry is not optimal, they can be modified. In
other words, if a part is out-of-tolerance based on the datums points, it does
NOT necessarily mean that it is a bad part.
Could we move the locator points to a position that would result in a safe
machining operation?
The best fit that occurs within SmartFit will try to force all the data points to
fit within a tolerance bandwidth. Upon completion of the fit, you will have
new locator point positions that would need to be changed on the machinery
to ensure a safe machining operation on the part.
1. Select File / New to clear out anything that may be active.
2. Select File / Import / CAD File or single click the Import CAD
icon from the Main toolbar.
3. Select LOCATORS.IGS from the working folder on the computer.
When prompted, choose Inches as the units.
4. Update the material sides using the ManualFit tools.
5. Import the measured data file PRESCRIBELOCATOR.DAT from the
working folder into Set1 with a distance tolerance of -0.0000 inch
(Min) and +0.0250 inch (Max).
6. In the Features window, select points 331 through 456. This should
highlight all the points on the outer sides of the part.
7. In the Point Data tab, update the maximum tolerance to 0.035 inches.
59

8. Select Apply Changes.

9. Access the Locators tab.
10. Select the Create a Locator icon.
11. In the Create / Modify Locator dialog, fill in the X, Y, Z value and
select the Y values as the significant coordinate. See below.

NOTE: Significant coordinates are the coordinate or coordinates

that SmartFit will use to optimize your data. For some points it is
only relevant if the point is moved in one direction when
optimized, so only that direction is significant. The other
coordinates are vital to place the point in space, but not relevant to
optimization. If the point is defined in a polar or spherical
coordinate system, all three (or both in 2D cases) coordinates must
be significant because the calculations inside SmartFit work in
Cartesian coordinate system, so the coordinates will be converted
to it and their meaning will change.
12. Create five (5) more locators using the values indicated in the table
below. The highlighted dimension for each locator is the significant
coordinate.

60

13. Select Tools / BestFit or single-click the BestFit (Optimize) icon

from the Tools toolbar.
14. Select Optimize. Note that there are 58 out-of-tolerance points after
the optimization is complete.
15. Select the Apply Tolerances checkbox.
16. Select Optimize. Note that all points are now in tolerance.
17. Select Close.
18. In the Locators window, note the current coordinates relative to the
original coordinates. See below.

NOTE: Because locator points are part of the optimization, they

also move along with the data points. This enables the operator to
move the fixture locations to allow for a better machining
operation. However, moving these locators takes time and costs
money. The reason for this exercise is to constrain the locator
from moving during the optimization to determine whether all
points can still be in tolerance.
19. In looking through all six (6) locators, note the small deviation
between the original and current coordinates for locator # 4.
20. In the Locators window, double-click on LOC4.
21. Within the Edit Parameters window, select the constrain checkbox and
ensure the Prescribed value is identical to the Original coordinates.
22. Select the Modify button, and then Close.
23. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.

61

24. Select Optimize. Note that all points are still in-tolerance.
25. Select Close.
26. To view an Excel report of the fit, select File / Export / Excel Report,
choose the Excel Report icon

, or press F10.

27. Choose what options you want and then select Create Report.

62

Section 15
Weight

Weight is the amount of importance you give a point or points in optimization.

For example, if you want to obtain smaller deviation for a certain point, give it
a higher weight than other points. SmartFit will then take this into account
when calculating a best fit. If a point has a weight of 0, it will not be taken
into account during optimization, thus not affecting the process.
Distance weight equal to one (1) means that during the optimization such
points will be taken into account once, as opposed to, for example a distance
weight equal to two (2) where they will be taken into account twice. A value
equal to one is the default.
1. Select File / New to clear out anything that may be active.
2. Select File / Import / CAD File or single click the Import CAD
icon from the Main toolbar.
3. Select Part_Fl.IGS from the working folder on the computer. When
prompted, choose Millimeters as the units.
4. Update the material sides using the ManualFit tools.
5. Import the measured data file WEIGHTCHOICE.DAT from the
working folder into Set1 without any defaults.
6. Create a group called Body containing MeasP0001 through
MeasP0390.
7. Create a second group called Rosette containing MeasP0391 through
MeasP1590.
NOTE: In viewing the front view of the graphics window, it becomes
obvious that the data points on the rosette cannot be rotated correctly
without affecting the data points on the body. The goal is to determine
whether there is a form error present or if it could possibly be a
misalignment of the two features. See below.

63

8. Select Tools / BestFit or single-click the BestFit (Optimize) icon

from the Tools toolbar.
9. Select Optimize, and then Close.
10. Exaggerate the error whiskers. See below.

NOTE: It should become obvious that the data points cannot be fit
together properly due to the misalignment of the two parts. If you
rotate the rosette so that it is aligned, the body becomes even more
misaligned. The same goes for aligning the body.
11. Within the Groups window, select GROUP1 (Body).
12. In the Point Data tab at the bottom of the window, change the weight
to a value of zero (0).
13. Select Apply Changes.
14. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.
15. Select Optimize, and then Close. See below.

NOTE: Since the body was given a weight of zero (0), the fit only
looked at the data points relative to the rosette.
16. Within in the Groups window, select GROUP1 (Body).
64

17. Set the weight in the Point Data tab back to one (1).
18. Select Apply Changes.
19. Within the Groups window, select GROUP2 (Rosette)
20. In the Point Data tab, change the weight to a value of zero (0).
21. Select Apply Changes.
22. Select Tools / BestFit or single-click the BestFit (Optimize) icon
from the Tools toolbar.
23. Select Optimize, and then Close. See below.

NOTE: Since the points on the rosette were given a weight of zero
(0), now the points relative to the body are aligned. Given that the
previous fit showed a Ry transformation vector of 3.3degrees and this
fit is showing an Ry value of 3.7 degrees, it can be fair to say that this
misalignment is equal to 7 degrees.

65

This page was left blank intentionally.

66

Section 16
SETS and Place points / geometries into a Set Command

What is a Set in SmartFit?

The elements SmartFit works with (like B-splines or mesh surfaces, curves,
constructed or created geometric elements, measured points, locators, etc.) are
all called features.
All existing features (if any) can be seen in their graphical representation, in
the Main graphics window and any of the new graphics windows, when the
All Features graphical tab is clicked.
These features can also be found in a special Features window (one of the
basic working windows), with their names (or numbers for the points) and
all their information. Our purpose in this section is to clarify the structure of
the features and the features tree, which can be examined from the Features
window.
The features (except locators) are organized as part of different sets. In other
words, the sets and locators are the main items in the features tree (see
structure example below).

Sets have consecutive, incrementing numbers following the order of their

creation. Set is a complex term that includes Geometries and / or measured
points. A sets structure and contents are shown upon clicking the expand box
in front of it.
67

The example tree from the previous screen shot is shown below.

Geometry is a new common name in SmartFit for surfaces, curves, and other
elements, but not measured points.
Set1 contains measured points and geometry elements (surfaces) under the
.IGS file name they belong to.
If a Set contains measured points only, its Geometries list will be empty. See
Set2.
Set3 contains a constructed plane element.
Set4 contains created elements.

When and how can a new set be created?

SmartFit enables you to create a new set in the following cases:
1. At the end of the Create or Construct commands. (Choose destination
dialog)
2. When SmartFit finalizes the Import CAD file command. (Choose
destination dialog)
3. After selecting the measured data file during Import Measured data file
command. (Import measured data wizard)

68

4. At the end of a Place points / geometries into a set command.

NOTE: If there is no existing set, SmartFit will automatically create Set1
immediately after completing any of the Create commands or the Import CAD
file command.
When a new set is created, the next consecutive number from the features list
is assigned to it and it appears immediately in the Features window. At the
same time, on the bottom line of the graphics window, a new tab appears with
a relevant name Set2 for instance.
To see the set contents in the graphics window, click the desired tab from the
bar.

What does Place points / geometries into a set do?

1. Explicitly associates some measured points with one or more specific
geometric features, the commands main purpose. This guarantees that
the same points will always be associated with the feature during
optimization.
2. Place points or geometries belonging to one ore more sets into another
existing set, just like moving the elements between sets.
3. Place any point or geometry element into a new set for task-specific
evaluations.

Case # 1 Associate a Measured Point to a Surface

A measured point is associated with a surface or curve element when its
relevant nominal point lies on that element. The nominal points (coordinates)
are represented by the projection points (coordinates). In other words, a
measured point is associated with a geometric element if the point is currently
projected onto it.
Selected points (in yellow), as originally belonging to Set1, have been
associated with the wrong surface. See below.

69

There are two reasons for this:

1. The points and the entire model are in a common set Set1, which is
the only existing one at the moment.
2. SmartFit has determined that the wrong surface is the nearest one to
the points and calculated the current distance between the points and
the model.
The solution is to separate the desired points and geometries into a different
set. When SmartFit does that, some other surface will be the nearest to the
points.
1. Select File / New.
2. Select File / Open or single click the File Open icon

3. Select Associate_Ex1.sfd from the working folder.

4. Select the measured points that are currently associated with the
bottom surface of the model. (7 points)
HINT: Use the Ctrl key. Also, it may be easier to pick the points with
a wireframe model. Just make sure you switch back to a solid model,
as you will need to pick the associated surface.
5. While still holding the Ctrl key down, select the desired surface to
associate the points to.
6. Release the Ctrl key.
7. Select Edit / Modify Selected / Place Points Geometries into Set
from the Modify Selected toolbar.

or choose the icon

8. The Change place dialog appears. From the enumerated set list, select
New (empty) set. Otherwise, you will not be able to modify the
association, which is the whole point of the exercise.
NOTE: Leave the Keep selected geometries together with their
points checkbox checked, which it is by default. You do not want to
change the association for the other points (not selected points, but
points that are currently associated with the selected surface).
9. Create two new graphical windows so that you can see the All
Features tab in the main window, along with Set1 and Set2 in the other
windows.
10. Now all optimizations will run with the points being associated with
the correct surface.

70

11. Rerun this exercise, but uncheck the box mentioned in step 8 above to
view what happens. All the points that were not selected should
associate with the nearest surface assuming the picked surface was not
there.

Case # 2 Moving Elements Between Existing Sets

This case leaves off from step 11 from case # 1.
1. Select all the measured points on the second row up from the bottom
surface.
2. Using the Place Selected Points / Geometries into a Set command,
place the points into Set2. SmartFit immediately moves the points and
associates them automatically with the nearest surface from the
destination set.
3. Select the final row of points and place them also into Set2.

Case # 3 Moving Points or Geometries into a New Set

This case leaves off from Case # 2.
1. In the Groups window, select GROUP1. All points on the inside
cylinder should highlight yellow.
2. Place the points into a new set, Set3.
NOTE: In this case, there is no geometry element in Set3. The points
cannot be associated. Their Nominal and Current coordinates are
coincident, deviations are zero and no whiskers can be seen. The most
important thing to note is that these points will not take part in the
optimization and will not influence the result.
RULE: Concerning Set Structure SmartFit simultaneously optimizes
the measured points of the sets only against the model placed in the
same set.

To demonstrate the advantages provided by the new data structure based on

sets, we will create an element and send it to Set3. The example shows how
the points can be optimized against different models for the purpose of
making analyses for other reasons. The models can be imported from outside,
or can be constructed or created internally to SmartFit.

71

3. Select Tools / Create / Surface / Cylinder or select the Create a

Cylinder icon

found in the Create toolbar.

4. Update the appropriate values in the Geometry data tab. See below.

5. Select the Modify button.

6. Select the OK button.
7. Place into Set3.
8. Perform a Bestfit. After the optimization, the points will be associated
with the cylinder that was just created. If, after that, the same points
are placed back into Set1, they will once again be associated with the
original model cylinder surface.

72

Section 17
Coordinate System Overview

Your original CAD file and its related measured points are all in one or more
of the coordinate systems SmartFit 3D uses.
Sometimes more than one coordinate system is used in a single file. For
example, a single part of a multi-part die could be measured with respect to a
coordinate system specific to it.
Coordinate systems are all defined in relation to the global coordinate system.
You can define coordinate systems in your data file or to create them from
within SmartFit 3D. These coordinate systems (if any) will be auxiliary ones.

The Global Coordinate System

This is the basic coordinate system for SmartFit 3D. It is always present and
cannot be removed.
It is:
An arbitrary Cartesian coordinate system.
The basis for the large coordinate system icon displayed in the SmartFit
3D graphics window.
The basis for the resulting transformation vector.
The basis for the ManualFit transformation.

Cartesian Coordinate System

The Cartesian coordinate system is used to uniquely determine each point in
the plane through two numbers, usually called the x-coordinate and the ycoordinate of the point. To define the coordinates, two perpendicular directed
lines (the x-axis or abscissa and the y-axis or ordinate), are specified, as well
as the unit length.
This type of coordinate system can be used in 3D space by added a Z
component. It provides the three physical dimensions height, width, and
length. The coordinates are in the form (x, y, z).

73

Polar Coordinate System

A polar (cylindrical) coordinate system is a coordinate system that essentially
extends the two dimensional polar coordinate system by adding a third
coordinate measuring the height of a point above the plane. This is similar to
the way in which the Cartesian coordinate system is extended into three
dimensions. The third coordinate is usually denoted h, making the three
cylindrical coordinates (r, , h).
The Position of each point is determined with its polar (cylindrical)
coordinates;
Polar Radius (r) the distance from the origin and the projection of the
point on the polar plane
Polar Angle () relative to the reference axis
Height (h) a positive or negative value relative to the origin along the
axis.

Spherical Coordinate System

The spherical coordinate system is a coordinate system for representing
geometric figures in three dimensions using three coordinates, (, , ),
where:
represents the radial distance of a point from a fixed origin
represents the zenith angle from the positive z-axis
represents the azimuth angle from the positive x-axis.
The three coordinates are defined as:
0 is the distance from the origin to a given point P.
0 180 is the angle between the positive Z-axis and the line formed
between the origin and P.
0 360 is the angle between the positive X-axis and the line from the
origin to the P projected onto the XY plane.

74

Conversions from Cartesian

Cylindrical:
X = r cos
Y = r sin
Z=h

Spherical:
X = sin cos
Y = sin sin
Z = cos
Creating Coordinate Systems
1. Make sure that you have a project file open.
2. Choose Tool / Create / Coordinate System from the pull down
menu or choose the Create Coordinate System icon
Coordinate Systems window. See below.

in the

3. Specify the Type of the coordinate system to be create Cartesian,

Polar, or Spherical.
4. Determine the Step, where the specified transformations
(Translation and Rotation) will be executed. Step #1 is selected as
default.
75

5. Click Add new step if you need more then one step.
6. Edit the Translation and Rotation values to be executed at the
selected Step.
NOTE: Steps and transformations belonging to them are executed
in the order they are listed.
7. Use Remove selected step, Up, or Down to adjust the desired
order for the steps, if needed.
8. Click Store as a new coordinate system. The created coordinate
system will be displayed by its resulting transformations, where the
transformations from all the steps are summarized.

76

Section 18
Deviation Coloring

Deviation coloring is a method for visualization of distance deviations by

colors, specified in the deviation coloring scale.
Display / Deviation Coloring

NOTE: The deviation coloring is available on in Point-to-Surface mode.

Deviation Coloring Modes

There are three deviation coloring modes available in SmartFit 3D:
1. Colored Points
In this mode, the Nominal points are represented like square dots,
colored according to the current distance deviation values at these
points and their correspondence against the deviation coloring
scale.
2. Spots
In this mode, the Nominal points are represented like spots over
the surfaces. The spots are colored according to the current
distance deviation values at the respective nominal points and their
correspondence against the deviation coloring scale.
NOTE: A slider allows for the adjustment in size of the colored points or
spots.
3. Color Map
With this method the nominal points keep their normal color
(white), which do not have to be displayed as a preference. Here,
all surfaces are colored according to the deviations of the points
currently associated with these surfaces, producing a smooth and
clear image.
NOTE: A slider allows for the adjustment in resolution of the map.

Deviation Coloring Scale

The deviation coloring scale specifies the correspondence between the current
distance deviations of the points and the colors they are represented, in any of
the deviation coloring modes.
77

There are two general cases:

Absolute:
This mode is always available. It considers the current deviations as they
are. The deviations are spread in the scale with respect to parameters like:
- Color Scale Top / Bottom
- Green Range Top / Bottom
- Absolute Coloring Recommendation Properties
NOTE: Use the Recommend button to the get the proposed scale limit
values by SmartFit, in accordance with the current Absolute Coloring
Recommendation Properties parameters.
Tolerance Relative
This mode is available when tolerances have been applied to points.
The Color Scale Top / Bottom parameters are fixed to 100% of the
tolerance zone.
Each measured point is analyzed individually, with respect to its own
tolerance zone (if more than one tolerance zone is present).
The Green Range Top / Bottom only can vary, specifying the critical
sectors in the tolerance zones ( 75% by default).
The Number of Segments parameter is fixed to 3.
The Number of Digits parameter is fixed to 1, due to the representation in
percentage of limits values.
NOTE: Points that are not toleranced (if any) will not take part in this
mode.

Deviation Coloring Window

Available commands:
Toggle Deviation Color Scale
Toggles On / Off deviation coloring scale, when any of the deviation coloring
modes are already selected.
Deviation Coloring by Colored Points
Deviation Coloring by Spots
78

Deviation Coloring by Color Map

Go To Statistics
Absolute Coloring Recommendation Properties
Scale Symmetry Center
The symmetry center can be equal to:
-- Zero: The scale limits parameters (Color scale top
/ bottom) become symmetrical getting the highest
absolute deviation as reference.
-- Average Deviation
Green Range Size
The sizes of the two green fields can be established using:
-- Standard Deviation
-- Scale Steps Should be Equal: As part of the other
fields, when all of them are equal.

79