Inspection Plus software for Haas machining centres. Programming manual (H-2000-6222-0A-B)

E-2

Experience values Ee

The measured size can be adjusted by an amount stored in a spare tool offset.

Example

Measure a 40 mm diameter and update tool offset 20

G65P9814 D40. T20 E21

An experience value stored in tool offset 21 will

be applied to the measured size.

NOTE: The experience value is always added

to the measured size.

Also refer to Appendix F, “Additional spare tool

offsets”.

Reason for using this option

Component clamping forces in some applications can influence the measured size.

Therefore, an adjustment value to relate measurement to a traceable standard, such as a

co-ordinate measuring machine, is desirable. Thermal effects can also be compensated

by this means.

Publication No. H-2000-6222

F-2

Additional spare tool offsets

The range of tool offsets available is extended with the Type C tool offset installed on the

machine.

Each tool offset is actually four registers. These are tool length geometry and wear, plus

tool diameter / radius geometry and wear. There may be limitations on the maximum

values allowable in the wear offsets set by the OEM. In practice, it may only be possible to

use the geometry registers.

These can be addressed in the macro call line as follows:

Tool length geometry offsets

E1 to E100

Tool diameter / radius geometry offsets

E401 to E500

From the figures you can see that 400 can be added to the tool offset number to address

the additional range of registers.

These additional tool offset registers can safely be used for both 'Ee' experience values

and also with the SPC macro (O9835) 'Mm' input provided. The tool offset number is not

used as a normal tool offset location.

Publication No. H-2000-6222

G-2

Printing a macro output

Example of printing a macro output

---------------------------------------------------------------------

COMPONENT NO 31

FEATURE NO 1

---------------------------------------------------------------------

POSN R79.0569 ACTUAL 79.0012 TOL TP 0.2000 DEV -0.0557

POSN X-45.0000 ACTUAL -45.1525 TOL TP 0.2000 DEV -0.1525

POSN Y-65.0000 ACTUAL -64.8263 TOL TP 0.2000 DEV 0.1737

+++++OUT OF POS+++++ ERROR TP 0.1311 RADIAL

ANG -124.6952 ACTUAL -124.8578 DEV -0.1626

---------------------------------------------------------------------

COMPONENT NO 31

FEATURE NO 2

---------------------------------------------------------------------

SIZE D71.0000 ACTUAL 71.9072 TOL 0.1000 DEV 0.9072

+++++OUT OF TOL+++++ ERROR 0.8072

POSN X-135.0000 ACTUAL -135.3279 DEV -0.3279

POSN Y-65.0000 ACTUAL -63.8201 DEV 1.1799

Publication No. H-2000-6222

H-2

Output flow (bore/boss and web/pocket cycles)

Measure

N10

If error flag

#199 NEO

If U input

If #199

If E input

If size

NE 2

error

Probe fail

Size adjust

If pos

#3000

experience

error

N11

If H input

Flag #198=3

Output variables

#185 to #199

Probe

If size

If flag only

open

If W input

#3000

error

#170.4=1

Upper

Flag #198=1

tolerance

Print data to

RS232 port

exceeded

#3006

N10

If flag only

END

#170.4=1

If size

error

Out of

tolerance

#3006

#3000 alarms must reset machine

#3006 cycle start to continue

N13

Publication No. H-2000-6222

Output flow (bore/boss and web/pocket cycles)

H-3

N13

N15

N19

If M input

If T input

If S input

If pos

If V band

Work offset

error

exceeded

update

Flag #198=2

If F input

END

Set F=1

If flag only

#198=1

If pos

Update tool offset

error

error x F

Out of

If radius

position

too large

#3006

N15

Flag #198=5

If flag only

#170.4=1

Out of

tolerance

#3006

N19

Publication No. H-2000-6222

I-2

Use of macro variables

Local variables

#1 to #32

These are used within each macro as required for calculation etc.

Common variables

#161

Base number for calibration.

#166

Active tool length - calculated in macro O9723.

#167

Modal feedrate value is used in the protected positioning macro (O9810).

#168

Radius too large flag macro O9812, O9814, O9822, O9823 (also used for

temporary ATAN store in macro O9731).

#169

Fast feedrate value. This is set in macro O9724 at 5000 mm/min

(200 in/min) default value.

#170

Setting variable used in macro O9724.

#171

Print, component number (6-digit) increment by 1, with each heading

program #171 = 0 to reset.

#172

Feature number (4-digit) increment by 1, with each print macro call

program #172 = 0 to reset.

#173

Start and end of block position zone normal setting 0.05 mm (0.002 in). If

the skip position is within this zone, the cycle aborts, with a Probe Open

or Probe Fail alarm.

#174

Stored X skip position at the end of the basic move macro O9726

#175

Stored Y skip position at the end of the basic move macro O9726.

#176

Stored Z skip position at the end of the basic move macro O9726.

#177

X average skip position at the end of the X diameter move macro O9721.

#178

Y average skip position at the end of the Y diameter move macro O9722.

#179

Inch/metric multiplier (0.04/1.0)

#180 to #184

Output data #180 to #184 is stored when the feature-to-feature macro

O9834 is used.

#185 to #199

See Chapter 4, “Variable outputs” for an output reference chart.

Publication No. H-2000-6222

Use of macro variables

I-3

Common retained variables

The actual variables available are the limiting factor and depend on the base number used

for adjusting the range of #500 variables used for data storage.

The variable allocation described below assumes that the default base number of 556 (set

in macro O9724) is being used.

#556 (556 + 0)

(XRAD) X calibration radius

#557 (556 + 1)

(YRAD) Y calibration radius

#558 (556 + 2)

(XOFF) X axis stylus offset

#559 (556 + 3)

(YOFF) Y axis stylus offset

#560 (556 + 4)

(Reserved for other software packages)

#561 (556 + 5)

(Reserved for other software packages)

#562 (556 + 6)

Basic move control factor. This is used to control the back-off distance in

the basic move before the final gauge move. It should be fine tuned on

installation to suit the machine. Refer to Figure I.1 for a diagrammatic

representation.

A default value of 0.2 is installed by the software. The actual factor

should normally be between 0 and 1.0. Reduce the value to reduce the

back-off distance.

NOTE: This value can be found by using the optimisation macro O9836.

The value must be set in the Settings macro O9724.

(a)

(c)

(b)

#562 (556 + 6)

(BMCF)

Move 1 fast feed to find the surface

a = Fast feed

Move 2 recover off the surface

b = Gauge feed (100 mm/min)

Move 3 gauge feed 100 mm/min (3.94 in/min)

c = Return

Figure I.1 Basic move control factor

Publication No. H-2000-6222

I-4

Use of macro variables

#563 (556 +7)

(Reserved for other software packages)

#564 (556 +8)

(Reserved for other software packages)

#565 (556 +9)

Active vector radius used in macros O9821, O9822, O9823

#566 to #597

These are reserved for vector calibration data and multi-

stylus storage as described below:

#566 (30 degree)

#567 (60 degree)

#568 (120 degree)

#569 (150 degree)

Vector calibration data

#570 (210 degree)

#571 (240 degree)

#572 (300 degree)

#573 (330 degree)

#574 to #577

Multi-stylus data K1

#578 to #581

Multi-stylus data K2

#582 to # 589

Vector multi-stylus data K11

#590 to #597

Vector multi-stylus data K12

Publication No. H-2000-6222

J-2

General probing applications

Example 1 - Part identification

If a group of components can be identified by a single feature, a probe can be used to

inspect that feature and decide which component is present. This is done by using data

from the output chart following a measuring program.

Each part surface is known to be within ±0.5

Figure J.1 Part Identification

G65 P9810Z84.F3000

Protected move to start position

G65P9811Z70.

Single surface measure (target C surface)

IF[#187GT73.]GOTO100

If error greater than 73.0 go to N100

IF[#187GT71.]GOTO200

If error greater than 71.0 go to N200

IF[#187GT69.]GOTO300

If error greater than 69.0 go to N300

GOTO400

N100(PROGRAM TO MACHINE A)

continue 'A’ component

GOTO400

N200(PROGRAM TO MACHINE B)

continue 'B' component

GOTO400

N300(PROGRAM TO MACHINE C)

continue 'C' component

Publication No. H-2000-6222

General probing applications

J-3

N400

M30

Example 2 - Probe measure every nth component

Often it is a requirement to probe every Nth component in the interests of reducing overall

cycle time.

The following programming method can be employed -

O5000(PART PROGRAM)

#120=0

Reset counter

#121=5

Count limit

(START OF MACHINING)

conventional part programming

N32

(START OF PROBE ROUTINES)

IF[#120LT#121]GOTO33

If counter less than 5 jump to N33

T01M06 (PART INSPECTION) Select inspection probe

probing routines

#120=0

Reset counter to zero

N33

(CONTINUE MACHINING OR END)

#120=#120+1

Increment counter

rest of machining program

M99P1

Return to N1

M30

Publication No. H-2000-6222

One-touch measuring

K-1

Appendix K

One-touch measuring

Contained in this appendix

Introduction

K-2

Why use a one-touch probe cycle?

K-2

Machine distortion

K-2

Comparing cycle times

K-2

Installing the one-touch cycles

K-3

Macro edits

K-3

Measuring the feedrate

K-3

Stand-off and overtravel distance

K-3

System operation

K-4

Using standard skip

K-4

Additional variables used

K-4

Approach feedrates

K-4

Back-off distance #562 (556 + 6)

K-5

False trigger loop

K-5

Acceleration and deceleration allowance

K-5

Q input

K-6

Measuring move detail

K-6

One-touch measuring move logic

K-7

Publication No. H-2000-6222

K-2

One-touch measuring

Introduction

The Inspection Plus software package provides an optional one-touch measuring

capability to supplement the standard two-touch cycles. The one-touch cycles are

intended for use on machines with a fast probe trigger detection ability so that high

measuring feedrates can be used.

Why use a one-touch probe cycle?

A one-touch cycle offers the benefit of reduced cycle times and fewer probe triggers per

cycle. It can be used when the nominal surface position is known to within a small window

of uncertainty.

Machine distortion

The machine is under stress during acceleration and deceleration and therefore the

recorded trigger values may have errors depending on machine tool condition.

Comparing cycle times

A program was prepared to perform five surface measurements as follows:

Start 50 mm above the ring gauge

Measure a 50 mm bore at 5 mm deep (four cardinal points)

Retract to 5 mm above, move over and make a Z measure on top of the ring gauge

Retract to 50 mm and return to the centre

Table K.1 shows cycle time comparisons only. Check for suitable measuring feed rates on

your machine.

Table K.1 Cycle time comparison

Time in

seconds @

500 mm/min

120 mm/min

60 mm/min

30 mm/min

Two-touch cycle

27.6

One-touch cycle

0.5

18.0

18.5

20.0

22.4

Stand-off

1.0

18.2

19.8

22.2

27.2

distance

2.0

18.7

22.4

27.4

37.1

3.0

19.1

24.4

32.2

47.0

Publication No. H-2000-6222

One-touch measuring

K-3

Installing the one-touch cycles

NOTE: The new one-touch basic move macro O9726 is only compatible with the

software supplied with this package. Previous versions are not compatible.

Before installing the one-touch cycles, the standard two-touch cycles must already have

been installed.

The one-touch cycles file (401200885) contains a new one-touch macro O9726. This

should be loaded once the existing two-touch macro O9726 has been deleted from

memory.

Macro edits

Macro O9726, shown below, may be edited for measuring feed rate and stand-

off/overtravel distance values:

:9726(REN BASIC MEASURE -1T)

#9=500*#179(EDIT MEAS FEED)

* Feed - edit 500 value

#28=#9/1000(EDIT ZONE)

accel / deceleration zone

#31=0

IF[#17NE#0]GOTO2

#17=3*#179(EDIT)

* stand off - edit 3 value

NOTE: * denotes this value must be in millimetres

Measuring the feedrate

The default value is 500 mm/min (20 in/min). This may be changed by editing the macro;

for example, if the servo delays are included in the results.

Stand-off and overtravel distance

The default value is 3 mm (0.12 in) in the X, Y and Z axes. Edit the macro to set a new

default or, alternatively, use the ‘Q’ input to override the default value (see page K-6).

Publication No. H-2000-6222

K-4

One-touch measuring

System operation

Refer to the chapters of this manual for a full description of the cycles and their use.

Using standard skip

Based on a typical 4 millisecond scan time of the PLC, the standard two-touch method

uses a feedrate of 30 mm/min (1.18 in/min). This gives a measuring uncertainty of

0.002 mm (0.0001 in).

Generally, the two-touch method is well suited to this situation because the back-off

distance can be optimised to provide a short measuring move; for example, less than

0.5 mm (0.020 in). If the one-touch cycles are chosen, the stand-off distance should be

kept small and higher feedrates used if accuracy of measuring is not critical.

NOTE: Measuring uncertainty is related to the feedrate.

Table K.2 Example using the 4 millisecond scan time allowance

Feedrate

Measuring uncertainty

30 mm/min

0.002 mm

60 mm/min

0.004 mm

120 mm/min

0.008 mm

500 mm/min

0.033 mm

Additional variables used

The following additional variables are used by this software:

#174

This is used to store the X axis measured skip position. The value is set in

macro O9726.

#175

This is used to store the Y axis measured skip position. The value is set in

macro O9726.

#176

This is used to store the Z axis measured skip position. The value is set in

macro O9726.

Approach feedrates

The feedrate for the approach to the stand-off position in macro O9726 is set at

3000 mm/min (120 in/min) in the X, Y and Z axes.

Publication No. H-2000-6222

One-touch measuring

K-5

Back-off distance #562 (556 + 6)

This variable is not used in the one-touch cycles.

False trigger loop

At the end of the measuring move a false trigger test is made to see if the probe is

triggered against a surface. If the probe has reseated, the measuring move continues.

Four attempts are made before a “Probe open” alarm occurs.

Acceleration and deceleration allowance

To avoid the possibility of capturing bad data (see Machine distortion on page K-2), the

one-touch basic move sets a checking zone dimension at the start and end of the

measuring move. If the data captured is within these zones, a “Probe open” or “Probe fail”

alarm is generated.

The zone dimension is related to the feedrate and is currently set as follows:

Zone dimension = measuring feedrate / 1000

(i.e. zone factor = 1000)

NOTE: See Macro edits on page K-3 for details of setting the measuring feedrate.

Table K.3 Example of zone allowance using default zone factor 1000

Feedrate

Acceleration and deceleration allowance

30 mm/min

0.03 mm

60 mm/min

0.06 mm

120 mm/min

0.12 mm

500 mm/min

0.50 mm

NOTE: The allowable measuring range is the Q stand-off distance + twice this zone

value.

These values will be suitable in most cases, but optimisation or adjustment may be

required on some machines. A test program can be prepared to test the measuring

accuracy as follows:

Set the measuring feed rate in macro O9726.

Set a large Q value (for example, 3 mm (0.12 in) or greater).

Publication No. H-2000-6222

K-6

One-touch measuring

Prepare a test program to measure a surface.

Measure the surface, ensuring the trigger is in the constant velocity zone (i.e. middle

of measuring move) and record the first measured value.

Make a small STEP adjustment to the programmed surface position (for example,

0.5 mm) and repeat the test, recording the total STEP dimension and the measured

value.

Repeat step 5, making several STEP changes (in the same direction). You will see

when the measured result deviates from the first recorded value. This is the point

where measurement becomes affected by acceleration/deceleration.

Calculate the acceleration/deceleration value:

A = absolute (‘Q’ value - total STEP value)

Calculate the zone factor (see the descriptions above):

Zone factor = measuring feed rate / A

Q input

q = Overtravel and stand-off position

The programming input and format is the same whether using one or two-touch cycles.

The exception is that the Q input, which with two-touch cycles controls the overtravel

distance, also controls the stand-off position for the one-touch cycles (see also

Acceleration and deceleration allowance on page K-5).

NOTE: The Q value represents the allowable measuring range. The actual overtravel and

stand-off distance is automatically increased by the acceleration and deceleration

distance (see Acceleration and deceleration allowance on page K-5).

Measuring move detail

One-touch

Stand-off position

Stand-off and overtravel positions

Figure K.1 Measuring move detail

Publication No. H-2000-6222

One-touch measuring

K-7

One-touch measuring move logic

Start

IF probe

fail

short move

IF probe

open

Move to

stand-off

False

position

trigger

move

check

Measure

move

IF false

trigger

loop > 4

Store position

Return to start

IF false

trigger

END

Alarms

Publication No. H-2000-6222

Inspection Plus software for Haas machining centres. Programming manual (H-2000-6222-0A-B) - page 6