Introduction

1.1 Generation introduction

What exactly is a coordinate measuring machine ?

A coordinate measuring machine (CMM) is a device for measuring the physical geometrical
characteristics of an object. This machine may be manually controlled by an operator or it may
be computer controlled. Measurements are defined by a probe attached to the third moving axis
of this machine. Probes may be mechanical, optical, laser, or white light, among others.

Fig 1.1 Coordinate Measuring Machine

1.2 Description

The typical "bridge" CMM is composed of three axes, an X, Y and Z. These axes are orthogonal
to each other in a typical three dimensional coordinate system. Each axis has a scale system that
indicates the location of that axis. The machine will read the input from the touch probe, as
directed by the operator or programmer. The machine then uses the X,Y,Z coordinates of each of
these points to determine size and position. Typical precision of a coordinate measuring machine
is measured in Microns, or Micrometres, which is 1/1,000,000 of a metre.

A coordinate measuring machine (CMM) is also a device used in manufacturing and assembly
processes to test a part or assembly against the design intent. By precisely recording the X, Y,
and Z coordinates of the target, points are generated which can then be analyzed via regression

1
algorithms for the construction of features. These points are collected by using a probe that is
positioned manually by an operator or automatically via Direct Computer Control (DCC). DCC
CMMs can be programmed to repeatedly measure identical parts, thus a CMM is a specialized
form of industrial robot.

1.3 Specific parts

Machine body:

In modern machines, the gantry type superstructure has two legs and is often called a bridge.
This moves freely along the granite table with one leg (often referred to as the inside leg)
following a guide rail attached to one side of the granite table. The opposite leg (often outside
leg) simply rests on the granite table following the vertical surface contour. Air bearings are the
chosen method for ensuring friction free travel. In these, compressed air is forced through a
series of very small holes in a flat bearing surface to provide a smooth but controlled air cushion
on which the CMM can move in a frictionless manner. The movement of the bridge or gantry
along the granite table forms one axis of the XY plane. The bridge of the gantry contains a
carriage which traverses between the inside and outside legs and forms the other X or Y
horizontal axis. The third axis of movement (Z axis) is provided by the addition of a vertical quill
or spindle which moves up and down through the center of the carriage. The touch probe forms
the sensing device on the end of the quill. The movement of the X, Y and Z axes fully describes
the measuring envelope. Optional rotary tables can be used to enhance the approachability of the
measuring probe to complicated workpieces. The rotary table as a fourth drive axis does not
enhance the measuring dimensions, which remain 3D, but it does provide a degree of flexibility.
Some touch probes are themselves powered rotary devices with the probe tip able to swivel
vertically through 90 degrees and through a full 360 degree rotation.

1.4 New Probing Systems

There are newer models that have probes that drag along the surface of the part taking points at
specified intervals, known as scanning probes. This method of CMM inspection is often more
accurate than the conventional touch-probe method and most times faster as well.

The next generation of scanning, known as non-contact scanning includes high speed laser single
point triangulation, laser line scanning, and white light scanning, is advancing very quickly. This
method uses either laser beams or white light that are projected against the surface of the part.
Many thousands of points can then be taken and used to not only check size and position, but to
create a 3D image of the part as well. This "point-cloud data" can then be transferred to CAD
software to create a working 3D model of the part. These optical scanners often used on soft or
delicate parts or to facilitate reverse engineering

Micrometrology Probes:

Probing systems for microscale metrology applications are another emerging area . There are
several commercially available coordinate measuring machines (CMM) that have a microprobe
integrated into the system, several specialty systems at government laboratories, and any number

2
of university built metrology platforms for microscale metrology. Although these machines are
good and in many cases excellent metrology platforms with nanometric scales their primary
limitation is a reliable, robust, capable micro/nano probe. Challenges for microscale probing
technologies include the need for a high aspect ratio probe giving the ability to access deep,
narrow features with low contact forces so as to not damage the surface and high precision
(nanometer level). Additionally microscale probes are susceptible to environmental conditions
such as humidity and surface interactions such as stiction (caused by adhesion, meniscus, and/or
Van der Waals forces among others).

Technologies to achieve microscale probing include scaled down version of classical CMM
probes, optical probes, and a standing wave probe among others. However, current optical
technologies cannot be scaled small enough to measure deep, narrow feature, and optical
resolution is limited by the wavelength of light. X-ray imaging provides a picture of the feature
but no traceable metrology information.

Physical Principles:

Optical probes and/or laser probes can be used (if possible in combination), which change
CMMs to measuring microscopes or multi sensor measuring machines. Fringe projection
systems, theodolite triangulation systems or laser distant and triangulation systems are not called
measuring machines, but the measuring result is the same: a space point. Laser probes are used to
detect the distance between the surface and the reference point on the end of the kinematic chain
(i.e.: end of the Z-drive component). This can use an interferometrical, focus variation, a light
deflection or half beam shadowing principle

3
 Chapter2

Technical details

2.1 Parts:

Coordinate-measuring machines include three main components:

• The main structure which include three axes of motion

• Probing system
• Data collection and Reduction system - typically includes a machine controller, desktop
computer and application software

2.2 Features:

They are offered with features like:

• Crash protection
• Offline programming
• Reverse engineering
• Shop floor suitability
• SPC software and temperature compensation.
• CAD Model import capability
• Compliance with the DMIS standard
• I++ controller compatibility

The machines are available in a wide range of sizes and designs with a variety of different probe
technologies. They can be operated manually or automatically through Direct Computer Control
(DCC). They are offered in various configurations such as benchtop, free-standing, handheld and
portable

4
 Chapter 3

Discription

3.1 Specifying Coordinate Measuring Machine

The type, shape, size and dimensional tolerance of the part to be inspected determine the kind of
equipment to be considered. Flat parts (sheet metal stampings, plastic, rubber, etc.) can be
inspected faster with a video system. An optical comparator is likewise a 2-D device, best for
checking profiles or small flat parts by hand. They are not suited for production.

Height Gages, as the name implies, are good for checking heights on a surface plate. Inspecting a
hole pattern with this 1-D device by flipping the part, still practiced by some, is cumbersome,
time consuming and unreliable. In this day and age, when a small CMM does not cost more than
some height gages, this is a truly wasteful approach.

For 3-D measurements the CMM should be the equipment of choice. A motorized CMM with a
powerful computer and software does cost just a few thousand dollars more today than did a
manual CMM of the same size twenty five years ago. They were equipped with a digital readout
only. The variety and configuration of sensors available today give the user the possibility to
inspect just about any type of part, be it a complex aircraft valve body, a plastic or rubber part, a
glass lens or polished mold. Line lasers, capable of taking thousands of points per second can
digitize an odd shaped part in minutes.

In short, CMMs cover the whole gamut from simple to use manual units with a basic touch probe
and software to fully automatic machines in a production environment pre-programmed to
inspect the most sophisticated of parts to a fair accuracy. You can have anything in between.
Like the survival of the fittest, time has removed inferior designs from the market.

Of the many styles out there the traveling bridge, the gantry and the horizontal arm design are
most common with the traveling bridge being the most popular. Horizontal arm units, capable of
measuring large envelopes at acceptable accuracies are used mainly for large auto body parts,
large weldments, etc.

When selecting a CMM the following issues should be addressed first before looking at
accessories: a) size, b) manual or DCC (CNC), c) Inspection room or shop floor application.

(a) The size is obviously determined by your largest part.

5
Then again if this particular part shows up only 2 times a year, you should reconsider. The
smaller the unit the better. On the other hand you also have to look at the configuration of the
parts. If you have a part that is 12” wide, for instance, with 3” deep bores on either side that you
wish to access with an articulating head, you need an additional 5” of travel on each side. This
brings the total travel to 22” with no safety clearance added. Pre-qualifying these positions on the
reference sphere further adds to the necessary envelope.

(b) Manual or DCC.

Financial issues aside, this is largely a function of part quantity or a combination of quantity and
complexity. A prototype shop should have a manual unit and a production environment requires
a DCC unit. Aside from the fact that CNC units have dramatically come down in price, medium
part quantities e.g. 10-30 can be efficiently checked manually with a pre-written program. An
unskilled operator then simply touches the points on the part as commanded by the screen. The
in and out of tolerance condition may be printed out.

A ROI calculations sheet is available for cross-over quantities making a decision as to manual or
DCC easy.

If a part is complex and small, with fine features, a DCC unit is recommended even for small
quantities. It is hard to negotiate a .5mm stylus into a 1.5mm hole without breaking it.

(c) Shop floor or inspection room application.

Since an inspection room has to cover all eventualities it should be equipped with a fair size unit,
the top of the line software offered by the OEM, an indexable probe head (manual or motorized)
and a good selection of styli and extensions. This requires a well trained and/or experienced
operator. Any new operator should be well trained by the OEM.

When selecting a shop floor CMM robustness of the equipment has to be considered. Mechanical
bearing units are inherently more reliable, since they do not require a constant supply of dry and
clean air which can create a maintenance headache. Air bearing CMMs are a poor choice for
applications in a dirty environment, requiring an expensive enclosure that a mechanical bearing
unit with covers and bellows can do without. The potential user should educate himself on this
issue.

Production CMMs are usually dedicated to one or just a few specific parts. Parts should be
fixtured. Fixtures can be supplied by the user or the OEM. The same goes for the part programs.
Probing systems should be as simple as possible. Motorized probe heads should be avoided in
high production situations if the part is not too complex. Probes with detachable stylus modules
and a stylus rack may accomplish the same task at half the price if no more than 6-8 orientations
are required. Angled styli orientations can be created with stylus knuckles.

6
Fast start menus make the operation and program selection easy for shop floor personnel.

If the temperature in the shop varies substantially from 68°F (20°C), the standard OEM
calibration temperature, you may want to look at a temperature compensation package or
purchase a unit with metal scales on metal structures if you inspect metal parts. It is always a
good practice to let the part “soak” to reach the same temperature as the CMM.

3.2 Sensors:

The electronic touch trigger probe, the scanning probe, the single point laser, the line laser and
the video camera are the sensors offered on CMMs today.

Touch Trigger Probes, being the least expensive yet capable of measuring just about everything
on a machined part, are used in the majority of applications. They usually consist of a probe
head, fixed or indexable, the touch probe itself and the styli. DCC machines may be outfitted
with a motorized indexable head (7 ½°), but add substantially to the overall cost. For a few
thousand dollars more you can purchase a small DCC CMM.

Probes with detachable stylus modules are a good investment, especially for DCC units. They
allow the use of a stylus rack (6 stalls) akin to a tool changer on a machining center. Modules are
held in place magnetically and detach in the event of a collision without damaging the probe
itself. A multitude of styli (measuring tips) are available from several sources that cover just
about any measuring task, from a .3mm ball tip to a 1” diameter disc to a cylinder for thin sheet
metal.

Mechanical Scanning Probes are used to gather a high number of points in bores and surfaces
of prismatic parts and for digitizing non-linear unknown surfaces. Higher density points give you
a more accurate picture of the feature as required by ANSI 14.5 e.g. roundness, cylindricity and
flatness. These probes are obviously more expensive than trigger probes and require a high end
controller.

The Single Point Laser is also used for digitizing. It is an excellent tool to check the profile of
delicate surfaces e.g. coated optics and soft parts since it does not physically touch the part.

The Line Laser is the fastest way to digitize or inspect non-linear surfaces and contours like cell
phone housings or car body parts. The lines are up to 2” wide taking 4000 or more points per
second. The accuracies range from + .001” to + .00025”. It is a powerful tool in conjunction with
CAD software having a 3-D best fit option. The line laser is popular for reverse engineering.

7
Video attachments for CMMs require additional software and back-lighting and are therefore not
widely used.

3.3 Software:

Measuring software is the most important part of a CMM next to the physical structure. It may
be your main purchasing criteria. Most OEM’s have their own brand, some do not. You should
inquire as to how long the software has been on the market. It is very hard to evaluate CMM
software in just a couple of hours unless you are an experienced CMM operator. The big names
in the industry do not necessarily have the easiest to use systems, which is what the buyer should
be looking for. Whichever software takes the least number of keystrokes or mouse clicks to
measure a feature or a complete part is the better one. Fancy graphics and many windows do not
measure a part. If time permits take a somewhat complex part to the vendors and compare
inspection and DCC programming time as well as the ease to do so.

Beyond user friendliness you may need other features like real time SPC, export to CAD or a 4th
axis.

You should be cautious with the much talked about CMM program writing from CAD. It’s O.K.
for simple parts, but a DCC motion program with a motorized head and widely varying styli is
fraught with pitfalls. If and when it has progressed to a point where it’s close to being seamless,
it would require quite a knowledgeable operator. Most people do not recognize the fact that a
CMM is not a simple single point system like a machine tool with only one fixed and defined
coordinate system where the part to be machined is always aligned to the axis travels. Therefore
a CMM programmer, not necessarily the operator has to have a good grasp of 3-D points in
space and coordinate system transformations. Good and thorough training of the programmer is
imperative. Once a program is written a lesser trained person may push the buttons. There is
many a CMM that sits in a corner because nobody knows how to use it.

When evaluating software you also may inquire about the platform (Windows and C++) and
whether there are service contracts with future upgrades available. Proper support is important.

3.4 Accuracy:

The potential user should understand the difference between resolution, repeatability, and
accuracy. In brief; resolution is the least count of the measuring system. Repeatability is how
well the CMM repeats a given dimension or feature; this is always some multiple of the
resolution and includes the non-repeatability of the probe, which in some instances exceeds that
of the CMM itself. Linear accuracy, taken along each axis travel, is how much any linear
dimension deviates from the absolute NIST standard. The volumetric accuracy is usually

8
determined with a ball bar according to B89.4.1a or another artifact and includes the non-
linearity of the ways, out of sureness condition, length variation of all axes to one another as well
as the non-repeatability of the probe. Consequently this number is substantially higher than the
linear accuracy. If you have a collision, lose the compensation table or upgrade to a better
software system down the line, re-mapping the CMM will be expensive. CMMs with intrinsic
accuracy have the lowest maintenance cost over their life span.

Chapter 4

9
 CMM PRODUCTS

4.1 Check master:

Fig4.1 Checkmaster Benchtop CMMs

Checkmaster Reliability:

The compact Checkmaster is a bench top CMM ideal for lab or production floor. Hardened
stainless steel ways and steel scales on steel structures offer uniform linear expansion
minimizing thermal errors. The low cost means you can put competent inspection capability in
multiple locations throughout your plant.

Intrinsic Accuracy Manual CMM:

We test every CMM before it leaves the factory for repeatability and accuracy, that meets or
exceeds the industry standards as defined in ANSI B89.4.1a-1998. Our testing includes a
repeatability test that exceed a minimum of 150 cycles, often recording a total range of 2.0 µm
(0.00008") or better! These stringent targets are maintained without the need for expensive
software compensation maps. Our goal is to build the CMM mechanically correct that will
deliver the results you expect, year-after-year.

10
Every Checkmaster is designed and packaged for fast and secure installation by the customer.
All key components are protected during shipping by specially designed brackets, that when
removed, ensures the CMM is ready for your first inspection.

4.2 Phoenix:

Fig4.2 Phoenix

The Phoenix line of CMMs offers two popular sizes to fit your quality inspection needs.

Building on decades of experience with shop floor Coordinate Measuring Machines, Helmel now
offers the Phoenix... a heavy-duty, DCC version of its popular Checkmaster benchtop manual
CMMs. The Phoenix is made for harsh environments, with well-placed covers that prevent
temperature shock. Its steel measuring scales on metal structures assure uniform expansion.

The Phoenix CMM incorporates all the time-proven features of its "big brother", the Microstar:
hardened precision-ground ways, dual beam bridge with reliable V-and-Flat bearing arrangement
and intrinsic accuracy. The latter is very important to reliably retain accuracy over time and
reduce calibration cost. The Phoenix comes equipped with a full granite base and ergonomic
stand.

The motorized system is outfitted with the powerful PMAC controller, the latest computer
system and our proprietary GEOMET software, the best CMM package on the market.

11
4.3 Microstar:

Fig4.3 Microstar “L” Bridge

Microstar "L" Bridge Type CMMs Series

The "L" Series is Helmel's product line designed for your larger applications.

Large capacity range-of-moving bridge type CMMs built on a massive granite base including a
raised granite beam for the Y axis guideway. This design improves the bridge geometry,
providing dimensional and thermal stability, while positioning the Y axis drive closer to the
center of moving mass Dual beam steel bridge structure. Designed for stiffness, low mass and
balance for swift, accurate movements. Suited for lab or plant floor use.

Non-contact optical steel encoder scales, mounted on steel members assure uniform thermal
behavior. Solid design emphasizes powerful bearing ratios in its use of hardened and ground
ways and precision pre-loaded, mechanical linear bearings, insuring dynamic accuracy. Straight
and square construction guarantees intrinsic mechanical accuracy without relying on volumetric
error correcting software tricks so you save money on every calibration .

CNC MICROSTAR "L" SERIES CMMs feature a state-of-the-art layout with joysticks, motion
controller, PC and the GEOMET Measuring System for Windows. Helmel features the ultimate

12
drive system: brushless non-contact linear motors consisting of a coil between parallel rows of
magnets running the full length of travel. There are no other moving parts. Conventional drives
must convert rotary motion to linear motion, inducing torque into the machine structure while
requiring gear reduction and friction. Our linear motors eliminate the heat, vibration, wear,
backlash and cogging of rotary motor systems. Even better, when the motors are off, you are free
to use your MICROSTAR for manual measurement.

We use the American made PMAC programmable multi-axis motion controller from Delta Tau ,
considered to be the most powerful on the market. The open architecture allows it to be easily
upgraded in the field as motion features are enhanced.

Our joystick control is enclosed in a durable die-cast aluminum housing with all needed function
keys so you won't have to go to the PC every time you want to perform an operation at the
machine during the self-teach programming cycle.

4.4Axium:

Fig4.4 High Precision - 4-Axis Shaft Measuring Machine.

Automatic Shaft Analysis

in the Factory Environment:

The Helmel Axium Shaft Measuring Machine has been developed to provide precise, automatic
dimensional measurement of cylindrical and shaft-like or manufactured parts. The Axium is well
suited to crankshaft inspections. The SMM is hardened for use in production and on the factory
floor, and requires minimal training for non-metrology employees.

Designed as a 4-Axis System:

13
Although the Axium has been designed as a 4-axis measuring system, it can be configured as a
3-axis system to fit your manufacturing needs. The Geomet metrology software is designed for
measurement, verification and GD&T applications. The Geomet software is resides on a
powerful Windows based system which contains the motion controller with proprietary motion
control software.

The Helmel Axium shaft measuring machine presents a horizontal format, with a major
cylindrical axis oriented left to right, duplicating the way most shafts are manufactured and
ground. Parts are typically staged between centers, or on solid or rotating Vees. The system
employs the Renishaw Touch Trigger or scanning probes for part sensing and can incorporate an
automatic stylus changing system for totally automatic operation.

14
 Chapter 5

CMM Probe System

Electronic Touch Trigger Probes are without any question used in the majority of the measuring
tasks. Touching the part physically assures reliable and repeatable measurements.

Renishaw, as the main supplier, has a great variety of Heads and Probes available. We have
standardized on a particular selection that has been proven popular and relatively complete.
Programmable motorized probe heads for automatic indexing are offered for DCC machines.

We have put together an Probe System Summary Page for your review. This
information illustrates the main components of your system and highlights certain
applications.

5. 1 Probe System Configuration Summary:

This page is designed to provide an overview of a complete probe system. Additional information
can be obtained from the product links below, and in the left menu.

The mechanical part of the probing system is available in four different arrangements to suit
particular applications, CMM sizes and budgets. The styli or measuring tips are common to all
systems.

Two Piece System:

15
The 5-way mechanical switching probe is built into the probe
head. The compact design extends the Z-capacity of the CMM.
Probe extensions, such as the M8 - PEL family can not be used.
Standard extensions between the probe head and styli can be
used. The lower cost makes it attractive for small machines or
for simple parts on larger machines.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

TP-ES, TP1S/TP1SM

Three Piece System - M8 Thread Mount:

The separate touch probe screws into the probe head via a M8
thread. This style allows the use of M8 - 13mm diameter probe
extensions (PEL family) between the probe and the head to reach
into deep parts, see example below. Touch probes can be
exchanged if damaged or worn.

The M8 thread mount is compatible with the standard TP2 and

TP6 touch probes.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH1, PH5, PH6, MP100 PH1(1), MH8 PH10T

Note 1 - PH1 provides non-repeatable indexing.

Three Piece System - TP20, Integral Kinematic Mount:

16
 The separate touch module attaches to the probe head via the
integral kinematic stylus mount. The use of this style allows
changing of the stylus module, either manually or in
conjunction with a stylus change rack, without the need to re-
qualify.

This style allows the use of extended length modules to reach

into deep parts, see example at right. Stylus modules mount to
the probe head using a magnetic mount and can break away
from the probe head which provides extended crash protect.
The modules can be exchanged if damaged or worn.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

MH20(1), MH20i RTP20(2)

Note 1 - MH20 provides non-repeatable indexing.

Note 2 - The RTP20 is powered by the motors on the CMM.

Four Piece System-M8 Thread Mount,Stylus Change Module:

The touch probe is a two piece design with a detachable stylus

module. Facilitates the use of several pre-qualified styli.
Modules can be changed manually or automatically using an
optional stylus module change rack with DCC machines.
Applies to TP-20 and TP-200 touch probes.

This style allows the use of M8 - 13mm diameter probe

extensions (PEL family) between the probe and the head to
reach into deep parts.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH1, PH6, MP100 PH1(1), MH8 PH10T

Note 1 - PH1 provides non-repeatable indexing.

17
 SP25 Compact Scanning Probe System:

The SP25 scanning system is attached to the probe head through

the use of an autojoint. Supports both scanning and touch-trigger
operations through the use of the TP20 stylus modules.

The scanning system can utilize a variety of SM25 modules to

extend the reach between 20 mm (0.78 in) to 400 mm (15.75 in).
The probe system can be mounted on the PH10M/MQ motorized
probe head. For a complete description of the SP25 probe system,
click here.

Requires the use of the Renishaw UCC scanning controller.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH6M PH10M

5.2 CMM Probe Heads :

Your probe system starts with the Probe Head. The selection of the probe head will determine the
touch probe type, extension capabilities, articulation and even scanning.

TP-ES:

18
CMM Style: Manual and DCC

Two piece system, one body mounted in a fixed vertical axis.

Most economical touch probe. Includes the Standard Probe Kit
listed here, plus a M3/M2 adapter.

TP1S/TP1SM:

CMM Style: Manual and DCC

Two piece system, one body mounted in a fixed vertical axis. The
TPs/TPSM is a 1 inch diameter, shank mounted probe that is
ideally suited for manual CMM operations due to its robust design
and extended over travel range. It has an M3 stylus mount that
carries a wide range of styli.

PH6:

CMM Style: Manual and DCC

The compact vertical and fixed head accepts all M8 mounting

probes (TP2, TP6, TP20, TP200). Economical approach if
indexing is not required. Recommended for production
applications in conjunction with the stylus rack with up to 6 stylus
configurations.

Compatible with the MCR20 and SCR200 stylus change racks.

PH6M:

19
CMM Style: Manual and DCC

The PH6M is a fixed head with an autojoint connection that is

compatible with multiwired probes SP25M, SP600M and TP7M.
TP20 touch probes can be used with the use of the PAA1 adapter.

PH1:

CMM Style: Manual and DCC

A manual probe head that offers non-repeatable, articulation in

the A and B axes. The A axis swivels 0° to 115° with a cap head
lock screw. The B axis rotates 360° in 15° spring tensioned
indexable increments. Offers limited over travel for crash
protections. Accepts all M8 mounted touch probes (TP2, TP6,
TP20, TP200).

PH5:

20
CMM Style: Manual and DCC

A manual probe head that offers support for up to 5 M8 style

probes heads. Accepts all M8 mounted touch probes (TP2, TP6,
TP20, TP200).

CMM Style: Manual and DCC

Manually indexable probe head with 720° repeatable positions

eliminating the need to re-qualify. Provides indexing 360° in the
horizontal plane and 105° of elevation in 7,5° steps. Accepts all
Autojoint mounted touch probes (TP7M, TP6A) or M8 style
touch probes when using the PAA1 adapter (TP2, TP6, TP20,
TP200).

MH8:

CMM Style: Manual and DCC

Manually indexable probe head with repeatable positioning

eliminating the need to re-qualify. Provides indexing 360° in the
horizontal plane and 90° of elevation in 15° steps. Accepts all M8
mounted touch probes (TP2, TP6, TP20, TP200).

Compatible with the MCR20 and SCR200 stylus change racks.

MH20i:

21
CMM Style: Manual and DCC

Manually indexable probe head with a built in TP20 probe and

kinematic mount for TP20 modules. The exchangeable modules
allow the use of multiple styli configurations eliminating the need
for re-qualifications. Provides indexing 360° in the horizontal
plane and 90° of elevation in 15° steps.

Note: The MH20i is not compatible with the MCR20 module

change rack.

RTP20:

CMM Style: DCC

A low cost / low profile solution to index the probe head

automatically. This compact probe head is designed for use on
DCC style CMMs only. Indexes in the A and B direction in 15°
increments utilizing the powered axes of the CMM to articulate
and lock the probe head. Based on the MH20i probe head and
compatible with the TP20 touch probe.

Compatible with the MCR20 stylus change rack.

PH10:

22
CMM Style: DCC

The new PH10T motorized probe head allows complete, rapid,

and repeatable inspection of most complex components with
minimum human intervention. Full orientation of your TP2, TP6,
TP20 or TP200 probe between any of 720 positions, under
manual or program control, turns your 3 axis CMM into a 5 axis
machine. Index steps are 7,5°.

Compatible with the MCR20 and SCR200 stylus change racks.

PH10M:

CMM Style: DCC

The PH10M probe head is designed with the Autojoint to

accommodate longer extensions (300 mm) as well as the heavier
scanning probes, SP25M, SP600M and TP7M. The autojoint is
compatible with the ACR1, probe and extension change system.

With the use of the PAA1, standard M8 mounting touch probes

can be used (TP2, TP6, TP20, TP200). When using the PAA1
adapter, the system is compatible with the MCR20 and SCR200
stylus change racks.

MP100:

23
 CMM Style: Manual

The MP100 MultiProbe is designed to extend your manual

CMM capabilities by including a video, non-contact probe
system to compliment your existing touch probe capabilities.

The MultiProbe includes a high-resolution color CCD camera

with a video crosshair generator and LED ring illumination. The
unti incorporates a M8

5.3 CMM Touch Trigger Probes:

A key member of your probe system selection is the touch trigger probe. The touch trigger probe
provides the connection between your probe head and the stylus and contains the necessary trigger
capability to record a data point, or scan data when in contact with the artifact.

Some touch trigger probe models provide stylus separation extending the range of functionality for
your CMM.

TP2 Touch Probe:

This is the traditional slimline switching probe for most

applications. The small diameter, 13mm or 0.51", allows
access into restricted areas. Its adjustable stylus force
enables the probe to support a wide range of styli and
extensions. Can be attached to the ends of the same
diameter extension bars (PEL family) for longer reach.
For manual or DCC applications.

Available in the 6-way configuration for minus-Z

measurements.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH1, PH5, PH6, MP100 PH1, MH8 PH10T

24
TP6 Touch Probe:

A larger, more robust probe than the TP2. The body diameter is
25mm or 0.98". Recommended for shop and production
applications. The extended stylus force range of 10g-30g allows
the use of longer styli without the problem of false triggers.

The TP6A model connects directly to the

Autojoint mounting on compatible probe heads.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH1, PH5, PH6 PH1, MH8 PH10T

TP20 Modular Probe System:

Mounting M8

Mounting Magnetic, Indexed

Stylus Mounting M2

±0.35 µm (±0.000014") to
Repeatability
±0.65 µm (±0.000026")

±0.6 µm (0.000023") to
Lobe Variation
±2.0 µm (0.000079")

Trigger Force XY: 0.06 N to 0.10 N

The TP20 is basically a two-piece TP2. The switching mechanism is in the module,
which attaches magnetically to the probe body via a repeatable kinematic mount. Since
the modules are less expensive than a TP2, multiple stylus configurations for repetitive
parts become less costly. Add to this the MCR20 Stylus Rack and you approach the
versatility of a costly motorized probe head. The detachable module also prevents costly
damage in the event of a collision.

Available in the 6-way configuration for minus-Z measurements.

*NOTE: The RTP20 utilizes the motorized axes of the CMM for articulation.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

25
 PH1, PH5, PH6, MP100 PH1, MH8 PH10T, RTP20*

TP20 Stylus Modules:

CMM Style: Manual and DCC

The MCR20 system has 5 standard length modules, plus two

extended length modules to fit your inspection needs.

These modules also mount directly to the MH20 and MH20i

indexing probe head without the use of the TP20 touch probe
body.

Body
Force Trigger Max Stylus Len.
Length

LF Low 0.06 N 13 mm 10 mm

SF Standard 0.08 N 13 mm 10 mm

MF Medium 0.10 N 13 mm 25 mm

EF Extended 0.10 M 13 mm 50 mm

6W 6-way 0.14 N 24 mm 10 mm

EM1 Standard 0.08 N 88 mm 10 mm

EM2 Standard 0.08 N 113 mm 10 mm

TP200 Modular Probe System:

Probe Body

Mounting M8

26
 Probe Interface - PI200

The TP-200 is a highly sensitive and accurate probe based on micro strain gauge
technology. It favors a detachable module like the TP20; the outside appearance is quite
similar. The body diameter again is 13mm (.51"). Triggering takes place in the probe
body, the modules are therefore less expensive. The lobing error, associated with the
other mechanical probes is absent. It is, therefore, recommended for accurate roundness
measurements in bearing bores and the like. To achieve the higher accuracy it is
imperative that the qualification speed and the speed while taking points are the same and
constant. Consequently this Probe should NOT be used on manual CMMs.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH1, PH5, PH6 PH1, MH8 PH10T

SCR200 Stylus Modules:

27
CMM Style: DCC

The SCR200 system has 3 stylus modules to fit your inspection

needs. The EO module is designed to provide extended Z-Axis
over travel of 12.5 mm to higher speed applications where the
CMM may require extended over-shoot distances.

Body
Force Trigger Max Stylus Len.
Length

20 mm
LF Low 0.06 N 13 mm
50 mm (1)

50 mm
SF Standard 0.08 N 13 mm
100 mm (1)

50 mm
EO Standard 0.10 N 24 mm
100 mm (1)

Note 1 - Carbon Fiber Styli

TP7M Strain Gauge Probe:

Mounting Autojoint, Multiwire

Stylus Mounting M4

Repeatability 0.25 µm (0.000009")

Trigger Force XY2.0 g

Trigger Force Z 15.0 g

The TP7M is based on strain gauge technology which provides a higher accuracy than
standard touch probes. This technology should only be used on DCC style CMMs where
the contact speeds can be controlled and constant. Requires the use of the PI7-2 probe
interface.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH6M PH10M

28
SP25M Scanning Probe System:

Mounting Autojoint

Mounting Magnetic/Optical

Resolution <0.10 µm (<0.00004")

Stylus Length 20mm - 200mm

The SP25M scanning probe system has a compact 25mm diameter body that supports
scanning and touch trigger probe configurations. There are 4 scanning modules to support
various length styli and one TP20 touch probe adapter to data point capturing.

The SP25M system works with the UCC2 CMM Controller which provides full scanning
and touch point operations. This system can be mounted on any Probe Head that supports
the Autojoint with multiwire.

Additional accessories include various changing racks to fit your needs.

Fixed Head Manual Indexing Heads Motorized Indexing Heads

PH6M PH10M

SP25M Scanning and Touch Probe Modules:

29
CMM Style: DCC

The SP25M system has 4 scanning modules that provide a

variety of stylus length, plus one TP20 touch probe adapter
module to perform standard data point capturing.

Body
Length Max Stylus Len.

SM25-1 26.25 mm 20 mm - 50 mm

SM25-2 33.85 mm 20 mm - 75 mm

SM25-3 48.05 mm 20 mm - 100 mm

SM25-4 63.05 mm 20 mm - 200 mm

TM25-20 16.95 mm Module Dependent

MP100 MultiProbe, Video and Touch Probe:

Mounting Direct, Helmel Mount

Auto Zoom 44x - 288x

Digital Crosshair Generator

Color Video

LED Ring Illumination

The MP-100 Video Probe is intended for use with manual CMMs, and provides an
accurate means of measuring 2D features, such as printed or etched images like circuit
boards, where tactile probes are not effective. It is normally used to measure features in
the XY plane, and is positioned manually by means of the locks and fine adjustment
knobs. Positions are entered via the keyboard or footswitch.

The system includes a high resolution color camera, flat panel monitor, 6:1 motorized
zoom lens, variable intensity LED ring light, a multifunctional crosshair generator, a
control console, mounting shank, and cables.

As an added benefit, the MP-100 includes support for the standard Renishaw PH6 probe
head and includes support for touch probes such as the TP2, TP200 and TP20. This
will save having to remove one to use the other.

30
5.4 To select a stylus that will enhance your inspection, we recommend:

Stylus ball size and length:

A ball stylus, when used during the inspection process produces a single point of contact with
your artifact. Variations in surface condition affect repeatability. To counter this, it is
recommended to use as large a ball stylus as possible.

Furthermore, identify the shortest possible combination of stylus and extension that will still
allow you access to all features being inspected. The longer the probe system, the greater the pre-
travel length before the trigger occurs. In some cases, the relationship between the ball size and
shank size can impede the depth the stylus can go into smaller features. Care must be taken to
prevent the shank from contacting your part during the inspection process. This condition is
exaggerated when using small ball size and long extensions.

Some inspection processes require long reaches to make contact on a feature, otherwise most
features have short access distances. To counter this, it is recommended to utilize stylus change
racks where the touch probe can switch stylus configurations to optimize the inspection results.

Chapter 6

Intrinsic CMM Accuracy

31
 6.1 Intrinsic Accuracy means that the CMM accuracy specifications are met by
virtue of the physical and mechanical precision and repeatability of the machine
structure, geometry and scales. You can measure accurately with just the Digital
Readout and hard probes, or with dial or electronic indicators. The machine is
constructed and assembled to be straight, square, stable and has accurate measuring
scales.

a CMM can be constructed and assembled less conscientiously, and may be

physically straight and square to only a few or even many thousandths of an inch.
This would be a terrible CMM, but it can be fixed. By use of a laser or other
instruments the specific inaccuracies of the machine can be measured and detected
throughout the machine volume. The volume can be gridded or "mapped" by
software, and corrections can be made for any position in the volume. Thus,
measurement results can be compensated for, and accuracy can be produced. There is
nothing inherently wrong with this electronic error compensation provided it is not
used as a quick fix to cover up machine deficiencies.

If a CMM measures accurately with error comp, and meets specification, then why
worry whether the machine is intrinsically accurate? Here are some points to
consider :

• The uncompensated accuracy of a CMM is an indication of the quality of the

underlying product. It is much more difficult to produce a CMM with uncompensated
volumetric accuracy of .0005" than .005", obviously. To achieve it, each component
must be made to exacting standards, and checked closely. Extreme care must be taken
in assembly so that axes are set perfectly straight and square to each other. Every
bearing must be tested and hand selected, and the same applies to the measuring
scales. Mounting surfaces, guide ways, or both may have to be hand lapped to
produce the necessary precision. With every element subjected to severe scrutiny, and
the ultimate assembly tested throughout every position along the length of travel
repeatedly, only a product of the highest quality can make it to the shipping dock.

• A lesser machine can be assembled with less precise, even lower quality
components, by far less skilled people. It can be assembled without great concern for
its raw performance or precision, because everyone involved in the process
understands that at the end of the line, any flaws or inaccuracies, even poor
component or assembly quality, can be "fixed" with a laser, computer and software.
therefore, must be a "better" machine than the equivalent CMM claiming only .0005"
accuracy, even though the later machine offers intrinsic mechanical accuracy.

CMM Maintenance
The necessity of a clean air supply for air bearing machines has already been covered.
This problem is nonexistent with mechanical bearing units.

32
Some people are concerned about chips. Our latest designs enclose all ways under
covers or bellows to protect them against dirt, dust, oil and chips. The economical
Checkmaster is equipped with wipers. Should a chip find its way in and cling to the
bearing or way, it will make itself known immediately and can be removed quickly.
That same chip can find its way just as well between the air pad and way of an air
bearing machine, and is much more likely to do serious and costly damage there than to
our machine.

As traditional QC decentralizes, CMMs are migrating to the shop floor where some
regular preventive maintenance is important. The simplicity and reliability of
mechanical bearings becomes even more advantageous here. Mechanical bearings are
extremely accessible and can easily be cleaned or oiled when necessary. Air pads are
less accessible, require more caution and skill and take longer to perform preventive
maintenance.

The Helmel CMM construction is an elegantly simple and uncluttered concept designed
for ease of assembly and therefore ease of service.

Fig6.1 Flat Bearing Design

An example is the gravity loaded V-and-Flat design, see figure 1, employed in the X-
axis of all models and certain Y-axes. This approach has been used successfully in
machine tools for over 100 years. It never needs adjusting. Again: improved reliability
and less service!

33
 Fig6.2

Please compare this to a typical air bearing system as shown in figure 2. Imagine
adjusting all those pads by means of a threaded stem and a jam nut, keeping an eye on
the delicate air gap and squareness at the same time.

Operating costs should also be considered. An air bearing CMM will consume $500.00
to $2,000.00 worth of compressed air each and every year, over and above the
installation cost of the air supply line and filter system. This cost is non-existent with
Helmel machines.

Uses

They are often used for:

34
(1) Dimensional measurement

(2) Profile measurement

(3) Angularity or orientation measurement

(4) Depth mapping

(5) Digitizing or imaging

CONCLUSION
Extended research and practical application have shown that CMMs can be very
powerful
tool for calibrating measuring standards and instruments. They shall be, however,
always
used together with calibrated standards of measurement. The most universal
traceable high
precision standard for such use is laser interferometer. Application possibilities have
been
tested but not yet fully applied in our laboratory. Some uncertainty estimation
models have
already been developed and environmental conditions put fully under control.
However,
many research possibilities, especially those related to the uncertainty of
measurement, are
still open. Further work will be focused into development of measuring setups for
laser
application including special flat mirror optics. Additional probing systems with
better

35
repeatability will be tested, too. It is also planned to develop measuring software for
calibrating lots of measuring standards - especially setting rings. One of the most
important
standards to be calibrated on the CMM is step gauge, which is widely used in
industry and
calibration laboratories.

Reference

• Wikipedia, the free encyclopedia.

• http://brownandsharpe.com/vision-metrology-solutions.

• www.helmel.com.

36
37