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FH HANNOVER
LFM
Coordinate Measuring
Qua 10/2011
Coordinate Measuring
Page 1
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
1 Introduction
Compared to conventional workpiece measuring, computer-aided coordinate measuring machines (CMM) help to save much time and provide more details regarding a workpiece's dimensional, shape and position error. In the laboratory, CMM model MicroVal 343 will be presented and used to explore the efficiency, specifics and limits of coordinate measuring.
2 Basics
2.1 Coordinate measuring, principle of measurement
Conventional workpiece tests use special test equipment or gauges to possibly directly measure dimensional, shape and position errors or to verify tolerance compliance. Physical samples of different geometry therefore require different special test instruments and frequently ancillary equipment plus a lot of time for preparing the test array. The term coordinate measuring machine (CMM) covers every type of instrument that uses optical or tactile means to scan points on a workpiece surface, references them to a technically determined coordinate axis system, and feeds the data to a computer for further processing. More often than not, CMMs are of the Cartesian rectangular type (Figure 1).
Qua 10/2011
Coordinate Measuring
Page 2
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Computer-aided coordinate measuring starts with mechanically contacting or optically focussing on the parts of the contour relevant to the measuring task (geometrical elements such as points, lines or circles) to measure critical points within the machine's coordinate axis system. Analytical geometry or regression analysis are then applied to these points to compute the parameters of every geometrical element required to represent the complete shape of the sample. Depending on the feature under inspection, the parameters characterising a geometrical element (e.g. the centre point coordinates and the diameter of a circle) are taken to determine the geometric variables and compare them to the setpoints and tolerances.
Fig. 2: Conventional CMM designs The moving parts are held by bearings which guide them along axes of the machine. Ideally, the guides are orthogonally arranged because they establish the directions of the machine's coordinate system.
Qua 10/2011
Coordinate Measuring
Page 3
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Where guides are not perfectly perpendicular, orthogonality will not be perfect either. Guides not being accurately orthogonal, linear and level will substantially affect CMM precision.
Qua 10/2011
Coordinate Measuring
Page 4
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Fig. 4: Classification of CMM contact probes Qua 10/2011 Coordinate Measuring Page 5
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Most contact probes are mechanical and fall into the two categories of measuring and switching contact probes (Figure 5). Points on the object are measured by making the probe which may be spherical, discoidal, cylindrical etc. contact the object. When a switching contact probe attains a defined contact state or a defined probe deflection, it will generate a switch signal (e.g. by interrupting an electric circuit) such that the position readings provided by the linear measuring systems on the measuring axes can be taken. Manually operated CMMs normally feature a simple and sturdy switching contact probe. Measuring contact probes pick up the deflection of the contact pin spring-mounted inside the probe head, using small distance measuring systems in the three directions of CMM axes. There are two alternative methods of taking the readings: First, the drives in the coordinate axes are actuated until the contact pin has zero deflection, then the position readings of the distance signalling systems in the measuring axes are taken. The amount of contact pin deflection is added to the current values of the linear measuring systems in the CMM axes, the result being the coordinate values of the measured contact element position.
Qua 10/2011
Coordinate Measuring
Page 6
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Nobody will expect the workpiece to be aligned with the CMM's axes since this would take much too much effort. A more feasible approach is to perform a coordinate transformation to adapt the workpiece's to the CMM's coordinate system and vice versa. Thus, elements determining the workpiece's coordinate system (workpiece position) are contacted prior to starting the measurement. A 3D coordinate transformation will later convert the points measured in the CMM's coordinate system into points of the workpiece's coordinate system. Care should be taken to make the workpiece's coordinate system match that of the drawing as best as possible. Normally, specific alignment programs will determine the position and rotation of the workpiece's coordinate system in relation to the CMM's coordinate system. The resulting angles and shifts along the X-, Y- and Z-axes are taken to convert the CMM's axes into real-life workpiece coordinates. In the easiest case, after probing a workpiece, the transformation angles of 6 points as well as the relative positions of the CMM's and the workpiece's coordinate systems can be computed. Other geometrical elements such as cylinders, cones, centres of circles, intersections or points of symmetry can be used to determine a workpiece's coordinate system.
Qua 10/2011
Labor Fertigungsmesstechnik
FH HANNOVER
LFM
Determine the workpiece position (establish the workpiece's coordinate system) Perform the measurements
Take the design drawing and the measuring task as reference for analysing the elements under test. The feature to be tested may be derived from one or several geometrical elements. Thus, the diameter of a hole is determined by a surface element, for example. It is equivalent to the diameter of the probed cylinder surface. Once measured, elements can be repeatedly used for other analyses.
3 References
Dutschke, W.: Pfeifer, T.: Weckmann, A.: Fertigungsmetechnik. Stuttgart: B. G. Teubner 1990 Fertigungsmetechnik R. Oldenbourg Verlag 1998 Koordinatenmetechnik Carl Hanser Verlag 1999
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Coordinate Measuring
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