This PDF contains the detail description of CARL-ZEISS O-INSPECT 543 Operation Instruction & Guidance

1. INDUSTRIAL TRAINING REPORT
ON
CARL ZEISS
CMM
O-INSPECT 543
SUBMITTED BY:
MITESH JARIWALA

2. CONTENT
 Basics of CMM
 How do coordinate measuring machines work?
 How to Turn On Machine
 Calibration
 Alignment of Axis Directions
 Modes of operation in CMM
 How to define clearance plane
 Steps to start optical measurement
 Method for executing measurement using optics
 How to execute program in CMM
 Execution of program stepwise with example

3. Coordinate Measuring Machine
Definition:
A coordinate measuring machine is 3D device for measuring the
physical geometrical characterises of an object.
Description:
The typical CMM is composed of three axes an X, Y, and Z.
These axes are orthogonal to each other in a typical three dimension
coordinate system.
Each axis has a scale system that indicates the location of that axis.
The machine will read input from the touch probe as directed by
operator or programmer.
The machine then uses X, Y, Z coordinate for each of these points to
determine size and position with micrometre precision typically.

4. Parts:
Coordinate measuring machine include three main components:
1. The main structure which includes three axis of motion
2. Probing system
3. Data collection and reduction system – typically includes machine
controllers, desktop computer and application software.
Definition of probe:
It is the sensory part of CMM responsible for sensing different
parameters required for measurement.
Fig1. Shows sensory part called tactile or probe for sensing different parameters

5. How do coordinate measuring machines work?
After placing a work-piece on the machine table, a probe is used to
measure different points on it by mapping the X, Y, Z coordinates.
The probe operates either manually via an operator or automatically
via a control system.
These points then uploaded to computer interface where they can be
analysed using modelling software (e.g. CALYPSO)
Fig2. Shows Carl Zeiss CMM O-inspect 543

6. HOW TO TURN ON MACHINE
Starting procedure
1. Turn ON Raw Power (UPS ON)
2. Turn ON CPU
3. Turn ON Controller
4. Open Calypso Software
Closing procedure
1. Close Calypso Software
2. Turn OFF Controller
3. Turn OFF CPU
4. Turn OFF Raw Power (UPS OFF)
Fig Shows Zeiss Joystick with ON/OFF Push Button Switch
Zeiss Controller
SWITCH

7. Calibration
What is calibration?
It is the process of verifying and adjusting the accuracy of monitoring
equipment and machine by comparing them with standards of known
accuracy.
The adjustment of instruments is performed by compensating the error
into the instruments
It is performed in regular intervals so as to ensure that instrument is
reliable.
Steps to perform calibration for (O-INSPECT543)
1. Click on CMM
Fig3. Shows windows for calibration methods

8. 2. Now click on Stylus system, after clicking on stylus system,
following window will appear & click on manual stylus system
change
Fig4. Defines Hand symbol for manual stylus system change

9. 3. By clicking on manual stylus system change, it will show window
as seen below
Fig5. Shows window for selecting Master Probe for calibration
4. From sensor types select XXT & from styli system select master
probe
5. Now click on Ref. sphere position
Fig6. Shows ref. sphere for Tilt & Rotation Angle of sphere

10. 6. After selecting Ref. sphere following window will appear
Fig7. Shows window in which tilt and rotation should adjust according to
sphere position
[Note: Depending on sphere angle, tilt angle & rotation should be
entered else accident can occur while calibration]
7. After clicking ok, place probe in the direction of stylus shaft,
window is shown below
Fig8. Shows window to touch probe on sphere, to start calibration

11. 8. After the competition of calibration, again from window select
qualify stylus and calibration will start again.
Fig9. Shows window to change probe after the calibration of Master Probe

12. Alignment of Axis Directions
What is alignment?
Before starting any measurement on work-piece we have to define axis
directions such as X, Y, Z. After proper alignment, all the direction of
axis will be display in calypso CAD window.
Steps to perform Alignment process
1. Place the work-piece properly on surface table where
measurement is to be done.
2. Using probe define plane in all directions according to axis (X, Y, Z)
3. Click on Measurement, then start alignment, in that enter the
entire plane respectively in Spatial & Planar Rotation.
4. After that also define X, Y, Z origin respectively and finally after
alignment CAD window will open represent axis of the direction.

13. Step 1
Fig10. Shows to start alignment process
Step 2
Fig11. Shows base alignment settings

14. Step 3
Fig12.shows to define plane in spatial & planar rotation
Step 4
Fig13. Shows window to define plane in x, y, z origin

15. Modes of operations in CMM
There are various mode of operation in CMM, depend upon operator
requirements.
Some of them are as shown below.
1. Roundness
2. Roundness angle
3. Waviness
4. Flatness
5. Flatness ref
6. Straightness
7. Cylindricity
8. Profile
9. Line profile
10. Form
11. Curve form
12. True position
13. Concentricity
14. Coaxiality
15. Perpendicularity

16. 16. Parallelism
17. Angularity
18. Distance
19. Angle between features
20. Runout
After selecting specific operations on a work-piece, at the end we
can run program in which we have to specify clearance data and
everything needed.
Define Roundness
Roundness is the measure of how closely the shape of an object
approaches that of a circle. Roundness is dominated by the
shape's gross features rather than the definition of its edges and
corners, or the surface roughness of a manufactured object. A
smooth ellipse can have low roundness, if its eccentricity is large.
Define Waviness
Waviness is the measurement of the more widely spaced
component of surface texture. It is a broader view of roughness
because it is more strictly defined as "the irregularities whose
spacing is greater than the roughness sampling length".

17. Define Flatness
Flatness is a form control. The flatness control (c) defines how
much a surface on a real part may vary from the ideal flat plane.
Tolerance Zone: The flatness tolerance zone is the volume
between two parallel planes. The distance between the parallel
planes is the stated flatness control tolerance value.
Define Straightness
Straightness is the shortest distance between two points. When
using a compass or a laser one thinks of straightness as 180
degree line. When talking TGP a straight bar can be defined as
one without a bend or curve.
Define Concentricity
Concentricity is a complex tolerance used to establish a tolerance
zone for the median points of a cylindrical or spherical part
feature.
Define Perpendicularity
In elementary geometry, the property of being perpendicular
(perpendicularity) is the relationship between two lines which
meet at a right angle (90 degrees). A line is said to be

18. perpendicular to another line if the two lines intersect at a right
angle.
Define Angularity
Angularity is the symbol that describes the specific orientation of
one feature to another at a referenced angle. It can reference a
2D line referenced to another 2D element, but more commonly it
relates the orientation of one surface plane relative to another
datum plane in a 3-Dimensional tolerance zone.
Define True position
True position is the deviation from the theoretical location of the
hole or feature as shown on the drawing. A True Position of 0.000
would mean the hole is exactly where it is supposed to be. A True
Position of 0.010 means the hole is 0.010 off from where it is
supposed to be.

19. How to Define Clearance Plane
What is clearance plane?
We can define CP as a zone in which CMM move its axis to take
measurement. We have to define plane in every direction i.e. is
–X, +X, -Y, +Y, -Z, +Z. After defining CP, CAD model is as shown in
figure.
Fig14. Shows clearance plane
Steps to define clearance plane
1. Click on clearance plane from the window
2. Now from clearance window define axis in all direction i.e. –X,
+X, -Y, +Y, -Z, +Z

20. 3. Before assigning CP, check all the parameters of measurement
plan editor in which clearance & retract should be checked else
collision of probe can occur.
4. Without assigning CP, CMM program would not run, so it is
necessary to give proper CP.
Step 1
Fig15. Shows clearance plane icon

21. Step 2
Fig16. Shows window to enter values in CP
Step 3
Fig17. Shows icon for measurement plan editor
Step 4
Fig18. Shows window to edit clearance and retract distance

22. Steps to start optical measurement
What is optical measurement in CMM?
Optical measurement is a measurement technique that relies on
the use of optical sensor to collect measurement. The advantage
of optical measurement is that it is non-invasive. No contact is
required, beyond contact with the stage of an optical measuring
device. Probes do not touch the object being measured and the
device does not rely on destructive measurement techniques and
most important point is that it can measure the work-piece where
probe cannot measure.
Steps to perform optical measurement completely in detail
1. Again drag your cursor towards CMM and click on it.
2. Click on stylus system icon where you will get manual stylus
system change.
3. From manual stylus system change, probe & camera can be
selected.
4. After selecting camera, go to illumination settings where you
adjust light settings according to clear visibility of work-piece.

23. 5. With the help of z-axis Joy-stick, clear the visibility of an object
to maximum possibility then using Auto-focus, image will be
perfectly clear to start measurements.
Step 1
Fig20. Shows window to open stylus system
Step 2
Fig21.shows icon to select camera for measurement

24. Step 3
Fig22. Shows manual stylus system change
Step 4
Fig23. Shows window to select camera for optical measurement

25. Step 5
Fig24. Show illumination settings to change light settings
Step 6
Fig25. Shows window to adjust lights for better visibility

26. Method for executing measurement using optics
1.Place the work-piece properly w.r.t camera and start laser pointer
to determine the vision of camera.
2.After the proper adjustment of vision stop laser pointer and click
on illumination settings for light focus settings.
3.Try to focus on work-piece with the help of joy-stick after that
focus with the help of Auto-focus from the menu to get perfectly
clear image for measurement.
4.Start measurement for anything like circle, square, line or any
complex that can’t be measure with the help of tactile.
5.For circle select 3 points on the circle then 1 point inside the circle
to determine circle exactly.
6.After all the measurement, it can be switched to CADVIEW then
create 3D line for planer rotation used in alignment
7.Go to alignment in planner select 3D line, in Y select “Circle”, in X
origin select “Circle” and in Z define point defined on work-piece.
8.Define clearance plane from CAD model, set all values and set to
Auto-light to run program.

27. How to execute Program in CMM
1. Place the work-piece on CMM for measurement, then using
tactile take axis in every direction i.e. is for X, Y, Z.
2. From window click on base alignment and in that specify axis for
spatial and planner rotation also define X, Y, Z origin.
3. After proper alignment, the direction of axis should be noticed in
CAD window.
4. If the direction of axis is proper take all the necessary
measurement from diagram and define tolerance & everything.
5. Go to measurement editor plan and check for clearance and
retract distance, edit it according to requirement.
6. Define clearance plane for work-piece that is already explained
earlier how to define CP and check for all characteristics, Clear
Existing Results and speed in mm/s.
7. After completing all the things, program can be executed.

28. Execution of program stepwise with example
Before starting measurement it is necessary to calibrate with
sphere for better accuracy. Calibration is also necessary with the
changing of probe.
Step 1
Fig26. Shows loading of work-piece on CMM

29. Step 2
Fig27. Shows CAD view after alignment
Step 3
Fig28. Shows measurement taken from Drawing

30. Step 4
Fig29. Shows measurements taken from Drawing
Step 5
Fig30. Shows icon for measurement plan editor

31. Step 6
Fig31. Shows window to edit clearance and retract distance
Step 7
Fig32. Shows clearance plane to define axis

32. Step 8
Fig33. Shows window to define clearance in every directions
Step 9
Fig34. Shows clearance of a work-piece for measurement

33. Step 10
Fig35. Shows window for setting selection, Results, CMM
Step 11
Fig36. Shows icon to start the program
THE END