p5 p7

08/05/02 Length.doc

In-process Application

LENGTH

P5 OPERATOR GUIDE

P7 OPERATOR GUIDE

SYSTEM SOFTWARE VERSION:P5 Software Version: from V3.1 to V3.5

P7 Software Version: from V1.0 to V1.4

Data reported in this booklet are to be referred to standard system software releases indicated in thispage.

In case of application with different software release the relevant manual can be requested to thenearest Marposs Distributor Office making reference to software code “CMxxxxxxxx” printed on thelabel in the electrinic gauge back.

mai change the features and data reported in this booklet in any moment andwithout notice, in order to inprove the product.

Print performed from: www.marposs.com

© Copyright 2002

P5 / P7 – Operator Guide 3

TABLE OF CONTENTS

1. LENGTH APPLICATION .........................................................................................51.1. Menu Maps...................................................................................................................5

1.1.1. Automatic Mode - Length Menu Map ...............................................................6

1.1.2. Manual Mode - Length Menu Map ...................................................................7

1.2. Viewing the Length Programming .......................................................................81.2.1. Control points..................................................................................................................121.2.2. Measurement Elaboration for Interrupted Surfaces .........................................................131.2.3. TIR (Total Indicator Reading) (Option) ............................................................................151.2.4. Stock Removal (Option) ..................................................................................................16

1.3. Viewing Length Measurement ...........................................................................171.3.1. Viewing the Measurement in Manual Mode.....................................................................171.3.2. Viewing the Measurement in Automatic mode.................................................................18

1.4. Viewing the Length Zeroing values .....................................................................191.4.1. Viewing the Zeroing values in Manual mode ...................................................................191.4.2. Viewing the Zeroing values in Automatic mode ...............................................................19

1.5. Zeroing length.............................................................................................................201.5.1. Introduction .....................................................................................................................201.5.2. Mechanical Zeroing of Length ..............................................................................211.5.3. Electrical Zeroing of Length ..................................................................................231.5.4. Zero Adjustments for Length ...........................................................................................25

1.5.4.1. Zero Adjustment in Manual mode .............................................................................................251.5.4.2. Zero Adjustments in automatic mode........................................................................................26

1.5.5. Zero Reset for Length ..........................................................................................30

1.6. Control Points for Length ...................................................................................311.6.1. Viewing Control Points ....................................................................................................311.6.2. Changing Control Points value ........................................................................................32

4 P5 / P7 – Operator Guide

P5 / P7 – Operator Guide 1. Length Application 5

1. LENGTH APPLICATION

This section covers the measurement application of LENGTH and its configuredoptions.For this section of the guide, the length has been programmed as Part Type 1, Cycle2 and Head 1. This gauging cycle can be defined with different Part Types and Cyclenumbers as long as they match the machine’s logic programming.

1.1. Menu Maps

Operator tasks are performed in both Automatic and Manual modes. Only the menumap folders with operator functions -Viewing, General Adjustments and Utilities -are shown on the following pages.

6 1. Length Application P5 / P7 – Operator Guide

1.1.1. Automatic Mode - Length Menu Map

FOLD

ERS

Viewings General adjustment

SUB

-FO

LDER

S

View measure View zeroings View programming Zero adjustment Modify controls

PAG

ES

View measureSection 1.3.2

Zero valuesSection 1.4

ProgrammedvaluesSection 1.2

Zero adjustmentSection 1.5.4.2

Modify controlsSection 1.6.2

If any of these options is notinstalled, then the page and thecorresponding icon are not seen.

* If the measurement applicationhas this option installed, see theappropriate paragraph in Section1.2..

F2 – Interrupted surfaces *

F3 – TIR *

F1 – Control points (Section 1.2.1)

F4 – Stock Removal *


1.1.2. Manual Mode - Length Menu Map FO

LDER

S

Utilities

SUB

-FO

LDER

S Measure zeroings Measure Setup View sub-folder

PAG

ES

MechanicalzeroingSec. 1.5.2

ElectricalzeroingSec. 1.5.3

ZeroadjustmentsSec. 1.5.4.1

ViewmeasureSec. 1.3.1

Surface typesetup(1)

ViewzeroingsSec. 1.4

ViewprogrammingSec. 1.2

Getting around the program

Enter

moves down to the next level

moves up one level.

moves between folders, sub-folders or pages on the same level.

If any of these options is not installed, thenthe icon and the corresponding page are notseen.

* If the measurement application has thisoption installed, see the appropriateparagraph in Section 1.2.

F2 – Interrupted surfaces *

F3 – TIR *

F1 – Controls point(sec. 1.2.1)

F4 – Stock Removal *

(1) This page is not seen if the surfaceis smooth.


1.2. Viewing the Length Programming

All the programmed values can beviewed in either Automatic or Manualmode on the ”View Programming” page.Additional pages can be viewed by usingthe F1-F6 function keys or highlighting

an option and pressing Enter

.

Automatic mode Manual mode

The data viewed concern the selected Part/Cycle.

Note: In Manual mode, select Part/Cycle.In Automatic mode the Part/Cycle selection is made by the machine’slogic.

Measuring Head data

Head : number of measuring head (1, 2 or 3) combined with the part/cycle selected.

Nominal value: nominal value of measurement (only with measuring heads enabledfor “zero shift”).

To reach this page:

- Select Manual or Automaticmode.

- Refer to the Menu maps onpages 6 and 7.

Measuringhead data

Measurementtype (integral)data

Options

Zero shift data (onlywith measuring headsenabled for “zeroshift”).

Value of Feedback pulse(option)

Measurement type


Master deviation: the difference between the nominal value of master and thegauged measurement of the workpiece used as such.

Delay: time passing between the “start cycle” signal supplied by the logic system andthe internal enabling to gauge for starting the measuring cycle.

Highlight the box before the head number with , and press Enter

to view thefollowing sub-page:

Viewing resolutionresolution value for the current set (1.0 µm or 0.1 µm for metric system;0.00001” or 0.000001” for imperial system - inches).

Viewing Zero ShiftOnly with measuring heads enabled for “zero shift”.

Use to highlight the box beside the “Nominal value” data, then press Enter

toreach a sub-page showing the current zero shift values.

or

The Check Box status defines the type of zero shift to be used in the cycle:the programmed zero shift is used

the internal (calculated) zero shift is used

Viewingresolution

Zero shift calculated based onthe length nominal value.

Programmed zero shift (independent ofthe length nominal value).


Integral Measurement

Type – type of integral measurement. The following options represented by icons areavailable:

Real time value

Maximum value elaboration

Minimum value elaboration

Mean value elaboration

Mobile Mean elaboration

Meas. RPM – number of workpiece revolutions/minute (present only for Maximum,Minimum, Mean Value and Mobile Mean elaborations).

Rev.Fraction – Fraction of workpiece revolution on which the measurementelaboration is based (present only for Maximum, Minimum, Mean Value andMobile Mean elaborations).

Measuremet Type

T1 ➜transducer 1 ; T2 ➜ transducer 2.This determines how the length is calculated (T1+T2, T1-T2, -T1-T2 or T2-T1)


Measurement Parameters

Controls. The number of control points is set at the configurationlevel.Surface Elaboration. Icon present only if the measurementfunction for interrupted surfaces has been enabled.

Options

The options are enabled during the application configuration stage. If any of theseicons are missing, then the corresponding option is not available.These options can be enabled or disabled upon programming; the options are activewhen the box to the left of the icon is filled in.

TIR Stock removal


1.2.1. Control points

The gauge is configured with a fixed number of control points, including a zero point.To change the value or remove a control point see section 1.6.2 "Changing ControlPoints value" on page 32.

To view the programmed control points, press F1 or highlight and

press Enter

.

Viewing Control Points in Manual mode

Viewing Control Points in Automatic mode

Note: In Manual mode, select Part/Cycle.In Automatic mode the Part/Cycle selection is made by the machine’slogic.


1.2.2. Measurement Elaboration for Interrupted Surfaces

The interrupted surfaces measurement is electrically damped based on both part typeand on rotation speed. Interrupted surfaces need to be damped to keep themeasurement values stable.The characteristics of interrupted surfaces elaboration are defined uponprogramming.

To view the data relevant to Interrupted surfaces measurement press F2 or

highlight and press Enter

.

Viewing data for Interrupted Surfaces in Manual mode

Viewing data for Interrupted Surfaces in Automatic mode

Note: In Manual mode, select Part/Cycle.In Automatic mode, the Part/Cycle selection is made by the machine’slogic.

Surface Elaboration Type – indication of part type used as a reference for themeasurement elaboration.

Smooth part

Slotted part (even number of interruptions)

Slotted part (odd number of interruptions)

Measurementelaboration type Index

MaximumSettling Time

Measurementacquisition time


Part with key way

Maximum Settling Time – (only available for interrupted surfaces) time passingbetween the start cycle and the moment in which the software starts elaboratingthe damped measurement.

Index – measurement damping filter for interrupted surfaces: 1 (minimum), 2 or 3(maximum).

Measure Time: time required for measurement acquisition (data enabled only if “Part with keyway” has been selected at the “Measurement elaboration type” item).


1.2.3. TIR (Total Indicator Reading) (Option)

It allows to determine the workpiece eccentricity to the rotation axis by using just acontact (T1).The TIR option can be enabled or disabled upon Programming. The option is enabledwhen the small box to the left of the icon is filled in.

To view the TIR measurement data press F3 or highlight and pressEnter

.

Viewing TIR measurement data in Manual mode

Viewing TIR measurement data in Automatic mode

Note: In manual mode, select Part/Cycle.In Automatic mode, the Part/Cycle selection is made by the machine’slogic.

TIR control – value beyond which the T.I.R. measurement must be considered out oftolerance.

TIR RPM – rotation speed of the workpiece during T.I.R. check.TIR delay – time delay before taking the T.I.R. measurement.


1.2.4. Stock Removal (Option)

It allows to carry out machining cycles in which a predetermined quantity of stock isremoved instead of reaching the zero value.The Stock Removal can be enabled or disabled upon Programming. The option isenabled when the small box to the left of the icon is filled in.

To view the Stock Removal data, press F4 or highlight and pressEnter

.

Viewing data for Stock Removal in Manual mode

Viewing data for Stock Removal in Automatic mode

Note: In Manual mode, select Part/Cycle.In Automatic mode, the Part/Cycle selection is made by the machine’slogic.

Stock Removal Amount amount of stock to be removed.


1.3. Viewing Length Measurement

The View Measure Bargraph page iswhere the size of the workpiece can bemonitored during the grinding cycle inboth Manual and Automatic modes.

Typically, the View Measure Bargraphpage is defined as the Home page(default screen).

1.3.1. Viewing the Measurement inManual Mode

Select the corresponding Part/Cycle.

Note: Electrical zero from this page, by means of the Zeroing button , ispossible only after a mechanical zeroing has been performed.

To reach this page:

Select Automatic or Manualmode then choose one:

Press .

Press then . Refer to Menu maps on pages 6

and 7.

Selected Part/Cycle

Retraction status

Numerical andgraphicalrepresentation ofmeasuring head

Bargraph ofmeasurement

Numerical value ofmeasurement

Electrical Zeroingbutton


1.3.2. Viewing the Measurement in Automatic mode

Note: In Automatic mode the Part/Cycle selection is made by the machine’s logic.

When TIR, Ovality, Remspeed, etc. options are installed, this tab has an additionalicon.

Icon indicating additional pages.

Press or to reach the other pages.

TIR

Bargraph of measurementNumerical value ofmeasurementControl point status:

under limit over limit

Numerical and graphicrepresentation of currentmeasuring head

Current Part/Cycle

Bargraph of measurement

Numerical value ofmeasurement

Control points (the squaresfill in as the controls arereached)


1.4. Viewing the Length Zeroing values

The Zero Summary page containsinformation about the various zeroingfunctions of the gauge system and canbe viewed in either Manual or Automaticmode.

Viewing Zeroing values in Manual and Automatic Modes

Zeroing Value – sum of the accumulated zeroing values from electrically zeroing thegauge system.

Master Deviation – a programmed value for the difference the reference master isfrom the target size of the workpiece.

Zero Adjust – the accumulated zero adjustments entered upon the workpiecemachining.

Measure Feedback – measurement value coming from outside following a post-process measurement. If this option is not available, then this line is missing.

1.4.1. Viewing the Zeroing values in Manual mode

Select the Part/Cycle.

1.4.2. Viewing the Zeroing values in Automatic mode

Note: In Automatic mode, the Part/Cycle selection is made by the machine’slogic.

To reach this page: Select Manual or Automatic

mode then choose one:

Press then . Refer to Menu maps on pages 6

and 7.


1.5. Zeroing length

1.5.1. Introduction

Zeroing is the process of setting up and adjusting the gauge and a measuring head toa master workpiece to assure that post-process inspection of the workpiece yields thedesired final dimensions.Types of Zeroing:

Mechanical Zeroing – physically adjusts the fingers/contacts so that they are withinthe foreseen measurement range.

Electrical Zeroing – adjustment operation to be performed periodically to obtain themaximum accuracy and reliability of measurements on the workpiece.

Zero Adjustments – Corrections made when after a post-process inspection of theworkpieces small differences in size are found.

Zero Resets – removes the offsets generated by the system during the last electricalzeroing.

Zeroing Conditions

Static – The master workpiece is NOT rotating.Dynamic – The master workpiece is rotating and wet by the coolant.

When to zero the gauge system?

TYPE OF ZEROING CONDITIONS

Mechanical Zeroingfollowed byElectrical Zeroing

At initial setup

Electrical Zeroing

At grinder start upAt the beginning of each work shiftAfter changing Part Type

Zero Adjust When the workpiece size changes

Zero Resetfollowed byMechanical Zeroing &Electrical Zeroing

When the zeroing range of the measuringhead has been exceeded.After replacement of any measuring headcomponent (head, contacts, fingers, etc.)After any mechanical changes are made to thegauge system.


1.5.2. Mechanical Zeroing of Length

Mechanical zeroing MUST be done to a master workpiece: At initial set up of the gauge system. If the allowed zero adjustment range has been exceeded. After any mechanical or electrical changes to the gauge system (fingers, contacts,

...).Mechanical zeroing must be performed only in Manual mode and statically.

Note: Each measuring head that has been defined MUST be MechanicallyZeroed.

Mechanical Zeroing of a measuring head:

1. Gauge in Manual Mode.2. Select the Part/Cycle relevant to the head to be zeroed.3. Eliminate any zeroing offsets:

- press then ;

- press F5 or highlight the Zero Reset button and press Enter

.

- a question box appears asking to Reset: press to highlight “Yes” and

press Enter

.

4. Press then to highlight the Mechanical Zeroing page icon.

5. Place the master workpiece into the machine.6. Adjust the finger/contact assemblies of the measuring head so they can be

inserted into gauging position safely.

Zero Reset

Numerical and graphicview of measurementvalue of the firsttransducer -T1

Numerical and graphicview of measurementvalue of the secondtransducer -T2


The adjustment mode of the finger/contact assemblies depends on theadjustment method used (with adjustable guides or with contacts).

7. Bring the measuring head to gauging position.8. Adjust the finger/contact assembly (T1) making the contact touch the master

until the measurement value on the upper digital display of the MechanicalZeroing page is next to zero (± 10 µ).

9. Adjust the finger/contact assembly (T2) making the contact touch the masteruntil the measurement value on the upper digital display of the MechanicalZeroing page is next to zero (± 10 µ).

This completes the mechanical setup of the measuring head; now perform an ElectricZeroing (see section 1.5.3 on page 23).

Measurement valuenext to zero.

Measurement valuenext to zero

Cable

Measuringhead support

Finger/contact assembly – T1

Contacts DO NOT touch master

Finger/contact assembly – T2

Measuring head

Measuring head


1.5.3. Electrical Zeroing of Length

Electrical Zeroing MUST be done: In manual mode on a master workpiece. Dynamically, i.e. with the master workpiece rotating and wet by coolant. Regularly, usually at the beginning of each work shift and/or when the grinding

wheel is switched on.

Note: Each measuring head that has been defined MUST be electrically zeroedfor each work cycle in which it is used.

Electrical Zeroing Procedure:

1. Gauge in manual mode.2. Select Part/Cycle.

3. Press then . The Zeroing button is highlighted.

4. Position the master workpiece in machine (master workpiece rotating and wet bycoolant).

5. Bring the head to gauging position.

6. Press F4 or Enter

.7. A question box appears for zeroing confirmation.

8. Press to highlight “Yes” and press Enter

.Electrical zeroing is completed.

If no error messages are displayed the electric zero-setting procedure has beencorrectly performed.

Electric zeroingbutton


The Gauge can be switched to Automatic operating mode.

Note: Electric zero-setting with integral measurement.Once completed the electric zero-setting procedure the measurement isstill displayed (graphic and numerical display) dynamically (viewing of themeasurement variation during the part rotation).


1.5.4. Zero Adjustments for Length

Zero adjustments are made when a post-process inspection of the workpieceshows an incorrect size.

Example:The workpiece is undersize: enter a zero adjustment with the same value but withopposite sign.

APPLICATION PART TOO SMALL PART TOO BIGOUTSIDE measure Add SubtractINSIDE measure Subtract Add

This can be done in either Manual or Automatic mode.

1.5.4.1. Zero Adjustment in Manual mode

Select Part/Cycle and press Enter

.

Note: Zero adjustments in manual mode affect the next cycle.

Changing Zero Adjustment value

1. Press to highlight the field

To reach this page: Select Manual or Automatic

mode then choose one:

Press then . Refer to the Menu maps on

pages 6 and 7.

Part drawing

Bargraph of Σ value

Sum of zeroadjustments (Σ)

Value of zero adjustmentvalue entered

Bargraph and numericaldisplay of measurement value

Zero Adjustment Reset key


2. Press or to increase or decrease the value.

3. Press Enter

.4. The value is algebraically added to the bargraph shown both at the top of the

page and in numerical form beside the “Σ” symbol (summation of zeroadjustments).

Resetting Zero Adjustments

1. Press F5 or highlight and press Enter

. A “Reset?” question box willappear.


. The zero adjustments are reset.

1.5.4.2. Zero Adjustments in automatic mode

Note: Zero adjustments in automatic mode are made while grinding and affectthe current cycle.

Zero adjustment for the current Set (part/cycle)

Zeroadjustments reset

Part drawing

Bargraph of Σ value

Sum of zero adjustments(Σ)

Zero adjustmentvalue entered

Bargraph and numericaldisplay of measurementvalue


Changing the zero adjustment value

1. Press to reach the page



4. Press . The value is algebraically added to the bargraph shown both at thetop of the page and in numerical form beside the “Σ” symbol (summation of zeroadjustments for the cycle).

Zero adjustment with Set (Part/Cycle) selection

The zero adjustments entered for the selected Part concern all the cycles using thesame head and belong to the same part. The common correction value is subtractedin the same way following an electric zero-setting.

Selecting the Set (Part/Cycle)

1. Holding down press to highlight the Part/Cycle selection box below.

Part drawing

Bargraph of Σ value for theselected cycle

Sum of zero adjustments(Σ) for the selected cycle

Zero adjustment valueentered for the selected cycle Number of selected Part

Zero adjustment value enteredfor the selected Part

Sum of zero adjustments(Σ) for the selected Part


2. Press or to view the selected Part/Cycle, otherwise press or

to change the Cycle number and or to change the Partnumber.

3. Press to confirm the Part/Cycle selection made. The programautomatically exits the selection box and returns to the page.

Changing the zero adjustment value for the cycle




4. Press . The value is algebraically added to the bargraph shown both at thetop of the page and in numerical form beside the “Σ” symbol (summation of zeroadjustments for the cycle).

5. Press .

Changing the zero adjustment value for the part



Cycle NumberPart Number

Current Part Type



4. Press . The value is algebraically added to the bargraph shown both at thetop of the page and in numerical form beside the “Σ” symbol (summation of zeroadjustments for the part).

5. Press .


1.5.5. Zero Reset for Length

This function removes all offsetsgenerated by the system during the lastelectrical zeroing (the transducers value isshown).

It can be selected only in manual mode: After mechanical changes to the

gauge system. When the maximum Zero Adjustment

value available has been reached.Electric Zeroing Reset Procedure:

1. Select Part/Cycle.

2. Press F5 or highlight and press Enter

. A “Reset?” question box will appear.


.

4. Press and to highlight the Mechanical Zeroing page icon.

The gauge system MUST NOW be Mechanically then Electrically Zeroed (see page20).

To reach this page: Select Manual mode, then

choose one:

Press then . Refer to the Menu map on page

7.

Reset button

MechanicalZeroing page


1.6. Control Points for Length

Thresholds, programmed based on stock size, at which the feeding rate will change.1.6.1. Viewing Control Points

The programmed control points value can be viewed in either Automatic or Manualmode.

Control points in Manualmode

Control points in Automatic mode

Note: In manual mode, select Part/CycleIn automatic mode, the Part/Cycle selection is made by the machine’slogic.

To reach this page:

- Select Manual or Automaticmode.

- Refer to the Menu maps onpages 6 and 7.


1.6.2. Changing Control Points value

During the grinding process, it may be necessary to modify the control points value toreach the optimum cycle.

Note: In Automatic mode, the Part/Cycle selection is made by the machine’slogic.

Note: Changes made to the Control Points affect the current cycle.

1. Press to highlight the control point to be changed and press Enter

.

2. Press to highlight the digit that needs changing.

3. Press or to increase or decrease the digit.

4. If more than one digit needs changing, press to highlight the next digit,

then press or to increase or decrease the digit.

5. Press Enter

,

6. Press to highlight “Apply to measure” and press Enter

.

The control point value has been changed.

*************************** End of Document ***************************

To reach this page:

- Select Automatic mode

Press then .

Control pointto be changed

Apply to measurebutton

p5 p7

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