ZEISS Master GearOperating manual

Industrial Metrology

2

Content

1 Artefact ZEISS Master Gear 3

1.1 Description of the artefact 3

1.2 Scope of delivery / bill of materials 3

2 System requirements 3

3 Preparations 3

3.1 Installation of the date on the hard drive 3

3.2 Storage location of measurement plans and custom printouts 3

3.2.1 CALYPSO 3

3.2.2 GEAR PRO 3

4 Construction of the stylus system 4

5 Mounting the artefact 4

5.1 Selection of the fixture 4

5.2 Anchor of the artefact 4

6 Proceeding in CALYPSO 5

6.1 Measurement without Rotary Table 5

6.2 Measurement with Rotary Table 7

7 Proceeding in GEAR PRO 8

7.1 Automatical measurement out of CALYPSO 8

7.2 From CALYPSO seperated measurement out of GEAR PRO 8

3

1.1 Description of the artefact

1.2 Scope of delivery / bill of materials

The following artefact is a high-precision Master Gear

manufactured by Frenco. This Master Gear is delivered

with DAkkS / DKD – Calibration according to DIN EN

ISO/IEC 17025 : 2005.

Characteristics:

• Module: 2,5

• Number of teeth: 30

• Pressure angle: 20°

• Helix angle: 0°

• 1 x artefact: • ZEISS Master Gear (Module: 2.5; Number of teeth: 30)

• 1 x Flash Drive: • Operating Manual (OM_Frenco_Master Gear)

• Certificate + Measurement conditions

• Pictures (Fixture, Alignment, Stylus system)

• Data of the stylus system (PCF-File; SSC-File)

• Measurement plans (Calypso, GearPro)

• Examples of custom printouts (Calypso, GearPro)

• With Rotary Table (RT)

• Without Rotary Table (RT)

1 Artefact ZEISS Master Gear

CMM-Type: ZEISS CMM of type “DuraMax RT“

Controller: Micro computer control

Data system: Computer with operating system Windows XP (at least SP 2)

or Windows 7 (32bit or 64bit) and ZEISS measuring software “CALYPSO”

and „GEAR PRO - involute“

Software: CALYPSO ≥ Rev. 5.4.12

GEAR PRO ≥ Rev. 4.0.0.0

2 System requirements

3.1 Installation of the data on the hard driveCopy the whole directory on the Flash Drive to an optional location on the Hard Drive.

From Flash Drive: Drive:\Zeiss_Master_Gear_m2.5_z30

To hard drive: Optional location

3.2 Storage location of measurement plans and custom printoutsBy default the measurement plans and custom printouts will be saved on specified pathes. These pathes

are defined from the Carl Zeiss IMT GmbH but at all times they could be changed by the user himself. The default pathes are:

3.2.1 CALYPSOExemplary for CALYPSO-version 5.4:

Drive:\Program Files (x86)\Zeiss\CALYPSO 5.4\home\om\workarea\inspections\...

3.2.2 GEAR PROExemplary for GEAR PRO-version 4.0:

Drive:\Program Files (x86)\Zeiss\GearNT\GearCat\...

3 Preparations

4

POS Name Qty Ordernumber DK L ML DS DG Weight

1 Stylus 1 626113-0151-040 1,5 40 31 1 5 1,6

A VAST XXT TL3 18p 1 620161-9017-000 143

B XXT TL3 stylusplate 1 620161-8075-000 4,6

4 Construction of the stylus system

Fixture on the Rotary Table

Due to the bore hole the Master Gear could fixed on the Rotary

Table by the chuck which is included in the scope of delivery of

the DuraMax RT.

Here you are able to use alternative clamping systems like a

three jaw chuck.

Alignment of the gear on the chuck

ATTENTION: The teeth marked with number 1 has to be aligned

in positive X-direction.

5 Mounting the artefact

5.1 Selection of the fixture

5.2 Anchor of the artefact

5

Start CALYPSO

Open the measurement plan “ZEISS_Master_Gear_m2.5_z30”:

When the measurement plan is opened for the first time, the following message is displayed:

Acknowledge the message with “Open plan as it is” and “OK”.

Step 1:

Step 2:

6 Proceeding in CALYPSO

6.1 Measurement without Rotary Table

Qualify the master stylus using the reference sphere

The workpiece temperature sensors (if available) must be attached

to the reference sphere or its vicinity beforehand.

When using the RSH-compact reference sphere holder (see picture

on the right side) the reference sphere is screwed vertically into the

holder (tilt angle: 180°, rotation angle: 0°).

Step 3:

Qualify the stylus system

Open the stylus system management (shown below) and import the PCF-File.

“ZEISS_Master_Gear_m2.5_z30.pcf”

After importing the PCF-File, the stylus could be qualified with the Button “

CNC probing system qualification“.

Step 4:

6

Definition of the manual alignmentStep 5:

Important features to define the manual alignment:

The screen display guides the user through manual alignment.

Features of the manual alignment

1Probing the outside circle (Circle_Outside_Ø66) with minimum 4 points.

2Probing the upper plane (Plane_Top) with minimum 4 points.

3Probing one point (Z_NP_Teeth_Top) on the top of one teeth.

1

2

3

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WarningStep 6:

Retract the stylus and click “OK”. Thereafter, the CMM directly enters CNC mode.

6.2 Measurement with Rotary Table

Open measurement plan “ZEISS_Master_Gear_m2.5_z30_RT”

Before starting the measurement the Rotary Table has to be turned to home position.

Below step 3 to step 6 of the measurement without Rotary Table could be repeated.

Step 1:

Step 2:

Step 3:

This could be realized with activating the button „RT home position“ in the Rotary Table menu one time.

There by the Rotary Table will turn to home position before starting the run.

8

7 Proceeding in GEAR PRO

7.1 Automatical measurement out of CALYPSO

7.2 From CALYPSO seperated measurement out of GEAR PRO

With a connection to a characteristic element in CALYPSO

in the measurement plan there will automaticly opened the

GEAR PRO Software and the GEAR PRO measurement plan

will be started. Consequently by starting the CNC-run in

CALYPSO the GEAR PRO Software needn´t to be opened.

If the base alignment already is qualified manually or in the way of CNC-run, GEAR PRO can be opened manually. Thereupon

the GEAR PRO measurement plan can be startet seperately from the CALYPSO measurement plan.

By starting the GEAR PRO measurement plan the GEAR PRO user interface will be opened. Thereby an inspection status

window will be represented. This window shows the progress of the measurement.

Start GEAR PRO manually with the Gear-Button in the tool bar of CALYPSOStep 1:

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On the sreen appears a window which you have to confirm to start the measurement. In this window there

could be executed some changes at the CNC-run of the GEAR PRO measurement plan.

The user interface with the view of the CAD-model will be displayed on the screen.

Open measurement plan “ZEISS_Master_Gear_m2.5_z30_RT.gear”

Start the measurement in GEAR PRO with the Start-button

Step 2:

Step 3:

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Carl Zeiss3D Automation GmbH73431 Aalen / Germany

Phone:Fax: E-mail: Internet:

Carl ZeissIndustrielle Messtechnik GmbH 73446 Oberkochen / Germany

Phone:Fax: E-mail: Internet:

+49 73 61 6336 0+49 73 61 6336 29orders@3d-net.dewww.probes.zeiss.com

+49 73 64 20 6336+49 73 64 20 3870imt@zeiss.dewww.zeiss.de/imt