Ametek TAYLOR HOBSON FORM TALYSURF PGI NOVUS Manual

FORM TALYSURF®
PGI NOVUS
OPERATOR GUIDE
FORM TALYSURF®
www.taylor-hobson.com © Taylor Hobson Ltd. 2023.
English

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This is Taylor Hobson’s safety & installation information
guide for the Form Talysurf®PGI NOVUS.
All the specifications in this document are correct at
time of production and are subject to change.
Please contact Taylor Hobson for further information.
Part No. K505-565
FORM TALYSURF®PGI NOVUS
Introductory operator guide

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Contents
Introduction .................................................................................4
Start up procedure ..................................................................... 5
Metrology 4.0 software .............................................................6
User interface.......................................................................................................7
Selecting the stylus.........................................................................................16
Calibration..................................................................................18
Single bias calibration....................................................................................18
Dual bias calibration......................................................................................20
Calibration procedure - good and bad results ..............................23
Calibration artefacts......................................................................................24
Measurement .............................................................................26
2D measurement............................................................................................26
3D measurement............................................................................................28

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Introduction
Form Talysurf®PGI NOVUS instruments are modular, high precision
instruments for the measurement of surface texture, form and diameter.
They offer the right balance of capability, automation and capacity for
virtually every application and budget with specific options for the
bearings and optics industries.
All instruments use Taylor Hobson’s renowned Phase Grating
Interferometer (PGI) gauge offering several options for range and
resolution dependent on measuring requirements. All instruments are
designed primarily for the measurement of surface texture and form and
other recognised metrology functions as determined by Taylor Hobson.
All installation and servicing should be carried out by a Taylor Hobson
accredited service engineer.
The use of these instruments for any other purpose than a metrology
measuring instrument is not warranted byTaylor Hobson. Be aware of all
relevant safety regulations.

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Start up procedure
Note
Please follow the optimised start up procedure to ensure quick and
easy start up of PGI NOVUS and Metrology 4.0:
1. Switch on PGI NOVUS mains supply via switches located on the rear
and side of the instrument.
2. Turn on PC.
3. Load Metrology 4.0 software by double-clicking on the shortcut icon
located on the PC desktop - DO NOT log on at this point.
4. Press the power button located on the joystick.
5. Enter login details and click ‘Logon’ to load Metrology 4.0.Then follow
the on-screen instructions.
Instrument with free
standing base and frame
Instrument with
surround options
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Metrology
4.0

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Metrology 4.0 software
Metrology 4.0 incorporates all features that are crucial in measurement
and analysis.The software has the added ability of having its own fully
automated 3D instrument view which allows a true visualisation of the
measurement platform on a computer screen.
The software platform is split up into 3 distinct sections: Instrument,
Analysis and Production Interface.
This operator guide will focus on all of the main features that make up
the ‘Instrument’ section of Metrology 4.0.This includes topics such as
measurement, calibration, controlling the axes and programming routines.
Instrument view
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1. Instrument ribbon
2. Real time display
3. Measurement window
4. Real time profile
5. Measurement toolbar
6. Instrument status bar
7. Axes control toolbar
8. Instrument section
9. Analysis section
10. Production interface section
11. Park and stop command
12. Custom layouts

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Change/select bias of
the PGI Gauge
Part co-ordinate system
(PCS)
Gauge calibration
Show TV view (real time
display)
Lift/lower force
calibration
Clear data (profile)
Contact - move stylus
into contact with part
Control - all instrument
axes and stages
Clear all PCS
Stylus force calibration
Show measurement
chart
Gauge settings - set
options for the gauge
Programming editor
Side view of instrument
Plan/top view of
instrument
Front view of instrument
3D/perspective view of
instrument
Scale the view to fit the
entire instrument
Scale the view to fit
all currently displayed
profiles
Scale the view to fit
all currently displayed
profiles and the stylus tip
User interface
Instrument ribbon

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Change stylus bias
The PGI NOVUS has the option to be fitted with a dual bias gauge. If this
option has been configured, then measurements can be taken in ‘Normal’
or ‘Reverse’ bias.To select between each bias, click on the ‘Change bias’
icon and use the drop-down box to select the desired direction.
Instrument control - move types
Moving the axes to arrive at different positons around the measurement
platform can be done with the use of the ‘Control’ option.‘Move to
position’,‘Move by distance’ and ‘Continuous move’ options are available
to be selected from the control window.
The instrument control dialog box can be displayed
by selecting the Control icon in the Positioning section
of the Instrument tab. Once this has been clicked, the
control window will appear.
1. Continuous - This move requires the operator to click and hold the
icon.This will move the respective axes by the set speed for as long as
the operator holds the icon down.This is availble for all axes.
2. Move to position -This move lets the operator move to a desired
location in the current coordinate system.These are known as absolute
positional moves.The operator would type in the desired position and
the instrument will move at the set speed to that location.
3. Move by distance - This is used to move the instrument by set distances
at a set speed.The operator can type in the move distance they wish
and the instrument will move. Please note positive and negative are
accepted with this function.
Continuous negative
move in X-axis
Continuous positive
move in X-axis

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Continuous negative
move in Y-axis
Tilt - continuous negative
move
Rotary - Rotate anti-
clockwise continuously
Lift/lower - continuous
negative move
Move to position in
Y-axis
Tilt - move to position
Rotary - move to
position
Lift/lower - move to
position
Lift/lower - park
Continuous positive
move in Y-axis
Tilt - continuous positive
move
Rotary - Rotate
clockwise continuously
Lift/lower - continuous
positive move
Move by distance in
Y-axis
Tilt - move by distance
Rotary - move by
distance
Lift/lower - move by
distance
Continuous negative
move in Z-axis
Move to position in
Z-axis
Continuous positive
move in Z-axis
Move by distance in
Z-axis
Move to position in
X-axis
Move by distance in
X-axis

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X-stage (X2)
Second rotary stage (θ2)
Second Y-stage (Y2)
The icons for secondary stages will be displayed in grey. An example of
‘Move to position’ is shown below.
Instrument control - inputs
• Speed - The speeds for each axes can be set independently. Look through
the drop-down list for available speeds or type in a value (as long as it is
within the minimum and maximum limits of the system).The units for the
value are shown to the right of the box.The speed that is set will be used
for all moves.
• ‘Move to position’ value - Type ‘1’ into a ‘move to position’ value textbox
and the respective axis will move to 1 mm with the speed that was
previously set.
• ‘Move by distance’ value - Type ‘-6.5’ into a ‘move by distance’ value
textbox.This will move the respective axis in it’s negative direction by a
distance of 6.5 mm.
Instrument control - vectored move
It is possible to move more than one axes at one time.
This can be achieved using a ‘vectored move’.
A ‘vectored move’ takes the inputs of all absolute values for the available
axes and moves to them inside one routine.The axes will all move with
the associated set speeds.The vectored move can be initiated by clicking
on the icon.
• Reset moves - To delete the inputs that have been
made prior to a vectored move and revert back to the
instantaneous coordinates. Click on the reset icon.This
will put all relative moves back to the default value of 0
and all of the absolute positions back to where they are
at that particular instance in time.

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TV view and measurement chart
Both the TV view and measurement chart show the measurement in
real time through the on-screen profile.This is most beneficial if any dirt,
marks or obscurities are seen, as the measurement can be stopped at any
point, without any loss of data.
The functions can be accessed by clicking on the
designated icons. Image below shows the TV view
in use while a measurment is conducted.
The measurement chart can be floated to another screen if required.
Programming editor
Metrology 4.0 software has the built in functionality to create, load and
run bespoke measurement and analysis programs to automate the
measurement process. Programs can also include variables to further
enhance the functionality of routines.
Create new program
Save
Edit the program Lock the program
Open an existing
program
Open the program text
editor

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Run program
Step through program
Verify program
Run program
continuously
Stop program
Save as
Pause program
Run program from step
Record program
Program properties
Run program ‘n’ times
1. New - To start a new program, click the ‘New’ icon. A blank program tab
will appear each time the ‘New’ icon is selected.
2. Open - To load an existing program, tclick the ‘Open’ icon. Browse to the
correct ‘.thprog’ file (default Metrology 4.0 file type).
3. Edit - If a user has access,‘edit mode’ can be selected and changes to
the current program can be made. Click the ‘Edit’ icon (If icon cannot be
seen, then the administrator should change the user’s role to give editing
access). Once in ‘Edit mode’, there are options to delete, cut, copy and
paste program steps along with undo and redo functionality. Program
steps can be expanded to view more information. Click the ‘arrow’, or
alternatively the ‘expand all’ icon.
4. Lock - Click the ‘Lock’ icon to close ‘Edit mode’ and stop any further
editing to the program.
5. Text edit - When in ‘edit mode’, there is the option to edit the text
file associated to the program. Click the ‘Text editor’ icon, to open the
‘.thprog. file in a text editor.

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6. Save/Save as - Save the program by clicking the ‘Save as’ icon. A Windows
explorer menu will appear where a location to save the file can be
defined. Once the program has been saved once, the ‘Save’ icon can then
be clicked save the program.
7. Properties - Properties can be defined by clicking the ‘Properties’ icon
while in ‘Edit mode’. A properties dialog box will appear displaying details
of the current program.
8. Run (various) - A program can be run in various different ways.
Click the ‘Run’ icon to run all of the program steps in chronological order
until completion.
Click the ‘Run continuously’ icon to run the program in a continuous
loop until the user chooses to stop.
Click the ‘Run n times’ icon to run the program in a continuous loop for
the pe-selected number of iterations.
Click the ‘Step through’ to step through the program with a pause
between each line in the program.
Click the ‘Run program from step’ icon to run the program from a
certain position. Click on the desired step to run from and then click the
icon. Alternatively, this process can be done by right-clicking onto the
step and then selecting to ‘Run from here’.
Click the ‘Run program to step’ icon to run the program to a certain
position within the program. Click on the desired step to run to and
then click the icon.
9. Stop - To stop a program whilst it is running, then click the ‘Stop’ icon.
10. Record - To record steps in ‘Record mode’, click the ‘Record’ icon and
then perform the desired functions. Each step will be recorded at the
bottom of the programming code.
Alternatively, choose to ‘Record before here’ by higlighting a particular
step and right-clicking.This will then record any functions above that step.
11. Error - If the program has an incorrect entry, then it will be highlighted
in red and displayed in the error area at the bottom of the program. Any
error will stop the program from being executed.

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Measurement toolbar
The measurement toolbar is used for all types of measurement.The
available measurements will vary depending on the configured instrument.
Conguration ribbon
2D X-axis measurement
Lock/Unlock
Internal diameter
measurement*
User roles
Discontinuous
measurement
Change password
Crest analysis - LS Arc,
highest, lowest and
turning point.
Corrections
Alignment routines*-
internal offset, cylinder,
axial, auto-level etc.
Log out
Instrument configuration
3D Measurement*
User admin
Crest measurement
Configure licence
Select language
*Dependant on system configuration.

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Instrument/system
configurator
Safe reset
Gauge alignment routine
Change lift/lower
tolerance
Configure axis park
settings
Configure the system’s
device performances
Set and calibrate axis
reference positions
Add or remove stylus
Add, edit or remove
calibration artefacts
Center of rotation
Configure the upper and
lower system end stops
Instrument conguration menu
Further icons
Stop the current
instrument operation
Apply saved workspace -
up to 6 layouts available
Save the current
workspace /layout
Tick
Park instrument
Load a workspace from
file
Clear workspace and
close all windows
Exclamation - no
corrections/calibration
applied

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Import part
Reference guide (Help)
Export settings
About Metrology 4.0
Save profile
Preferences
View Licence
Import settings
Load profile
Selecting the stylus
To select a stylus, acces the configuration dialog box.
1. Navigate to the ‘Gauge’ section of the instrument ribbon and click on
the ‘Settings’ icon.
2. This then brings up a
dialog box containing
a stylus drop-down list,
which is populated with
the options available.
3. Select the required styli
and click ‘OK’ or ‘Apply’.

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Note
If the selected stylus has previously been calibrated then it is possible to
restore that last calibration. Please note it is best-practise metrology to
re-calibrate after replacing the stylus to ensure the more accurate results.
Adding a new stylus
To add a new stylus to Metrology 4.0, acces the ‘Gauge’ tab in the
‘Instrument Configuration’ section.
1. Select the ‘Add or remove stylus’ icon.
2. Click ‘New’, navigate to the required .def file and
click ‘Open’.
3. Click ‘OK’ to close the dialog box.
The stylus will now be available to select for use. Please use the ‘Selecting
the stylus’ instructions above.
Removing a stylus
To remove a stylus from Metrology 4.0, acces the ‘Gauge’ tab in the
‘Instrument Configuration’ section.
1. Select the ‘Add or remove stylus’ icon.
2. Click ‘Delete’, then confrim the deletion by
selecting ‘Yes’.
3. Click ‘OK’ to close the dialog box.
The stylus has now been removed from Metrology 4.0.

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Calibration
Single bias calibration
A calibration is required on the gauge to ensure the acurate motion
of the stylus has been corrected.This ensures that the measurement is
accurate and reliable. Automated calibration procedure steps are below:
1. Navigate to the ‘Gauge’ section of the instrument ribbon and click on
the ‘Calibration’ icon.
2. The calibration dialog box will then be displayed. Select a single bias
calibration artefact form the drop-down list. Ccomplete the relevant
options (Explained on Page 19) and click ‘Next’.
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3. Follow the on-screen instructions. Click ‘Next’ to continue through
the calibration procedure.
Note: If auto Y-stage fitted, message
will appear differently.

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1. Calibration artefact - The artefact in use can be selected using the drop-
down list, with information displayed to the right of the list.
2. Stylus - The stylus being used for the calibration can be selected from
the drop down list. Part number and basic information about the stylus
dimensions are displayed within this list.
3. Valid Duration - This feature can be used to warn the operator that the
instrument requires a recalibration, after a defined time.This feature is
optional. Once the defined time period has passed, a warning message
will be displayed when measurements are attempted or the system will
not allow the user to make measurements, as per the preferences set.
4. Auto Crest inY - To ensure an accurate calibration using a hemispherical
standard, the artefact must be measured through its crest. If the system
is fitted with an automatedY-stage then the option to find the crest using
the Y-axis prior to measurement can be selected. If the system does
not have an automatedY-stage then this step will have to be completed
manually prior to carrying out the calibration process.
5. Gauge range - The desired gauge range over which the calibration is
completed can be selected by manually typing the value into this box.
Values which have previously been entered can be selected using the
drop-down box function.
6. Speed - The speed of measurement during the calibration process can
be selected from the predetermined values within the drop down box.
7. Asymmetric calibration - Calibration for small shank styli.
4. When the calibration routine is complete, the results will appear in
the analysis section of Metrology 4.0.

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Dual bias calibration
A calibration is required on the gauge to ensure the acurate motion of
the stylus has been corrected and tip to tip size is calculated.This ensures
that the measurement is accurate and reliable. Automated calibration
procedure steps are below:
1. Navigate to the ‘Gauge’ section of the instrument ribbon and click on
the ‘Calibration’ icon.
2. The calibration dialog box will then be displayed. Select a dual bias
calibration artefact form the drop-down list. Complete the relevant
options (Explained on Page 22) and click ‘Next’.
• Select a combination of ‘Ball 1’ (Upper),‘Ball 2’ (Lower) or ‘Tip to Tip’.
• Select ‘Ball 1’ and ‘Ball 2’ for the arcuate correction procedure.
• If all three options are selected, then the software will instruct
to position the stylus over the 4 mm ‘Tip to Tip’ ball first. A crest
procedure will be completed to work out the crest position.The
arcuate correction procedure will be completed first, followed by the
‘Tip to Tip’ ball procedure last.
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