Lion Precision SpindleCheck 1.1 User manual

INSTRUCTION
MANUAL SpindleCheck 1.1

M017-7450.003 SpindleCheck 1.1 Manual ii
This instruction manual details the operation of the
Lion Precision SpindleCheck Spindle Qualification
System. Please contact us if you have any
questions or suggestions on how we can be of
greater service to you.
Lion Precision
651-484-6544
[email protected]
www.spindlecheck.com
www.lionprecision.com
Software Version: 1.1
Manual Version: M017-7450.003

Table of Contents
APPROVALS AND SAFETY CONSIDERATIONS..................................................IV
INTRODUCTION.......................................................................................................... V
FUNDAMENTAL CONCEPTS.............................................................................................V
TESTS PERFORMED BY SPINDLECHECK...........................................................................V
ADDITIONAL CAPABILITIES OF SPINDLECHECK...............................................................V
STANDARDS AND REFERENCES......................................................................................VI
ASSISTANCE..................................................................................................................VI
SOFTWARE INSTALLATION.................................................................................VII
SPINDLECHECK SOFTWARE..........................................................................................VII
SOFTWARE BASICS................................................................................................VIII
SELECT MODE OF OPERATION .....................................................................................VIII
BASIC NAVIGATION ......................................................................................................IX
QUADRANT DISPLAYS...................................................................................................XI
SPINDLECHECK CONFIGURATION.................................................................... XII
GENERAL CONFIGURATION .........................................................................................XIII
CALIBRATION CONFIGURATION...................................................................................XIV
DIAGNOSTICS...............................................................................................................XV
SPINDLECHECK SENSOR COMMUNICATION...................................................................XV
SPINDLECHECK HARDWARE.............................................................................XVI
SENSOR SYSTEM ELECTRONICS ..................................................................................XVII
PROBE CONNECTIONS ................................................................................................XVII
SENSOR SYSTEM PROBES ............................................................................................XIX
INDEX SPACER .............................................................................................................XX
PROBE NEST ................................................................................................................XX
PRECISION TARGET PIN...............................................................................................XXI
MAKING MEASUREMENTS AND READING PLOTS..................................... XXII
UNDERSTANDING AND INTERACTING WITH PLOTS ......................................................XXII
SETUP FOR MAKING MEASUREMENTS .......................................................................XXIII
RUNNING TESTS........................................................................................................XXVI
RESPONSE TIME AND SCREEN UPDATES ....................................................................XXVI
SPECIFICATIONS................................................................................................XXXII
APPENDICES.......................................................................................................XXXIII
GLOSSARY..................................................................................................................XL

Lion Precision •St. Paul, Minnesota 55128-7082 USA
Telephone: [phone] •Fax: [phone] •www.lionprecision.com
Copyright © 2016 All Rights Reserved •Document # M017-7450
Approvals and Safety Considerations
The SpindleCheck sensors and electronics are compliant with the following standards:
Safety: 61010-1
EMC: 61326-1, 61326-2-3
To maintain compliance with these standards, the following operating conditions must be
maintained:
●All I/O connecting cables must be shielded and less than three meters in length
●Use the included CE approved power supply. If an alternative power supply is
used, it must have equivalent CE certification and provide safety isolation from
the mains according to IEC60950 or 61010.
●Sensors must not be attached to parts operating at hazardous voltages in excess
of 33VRMS or 70VDC
Use of the equipment in any other manner may impair the safety and EMI protections of
the equipment.

M017-7450.003 SpindleCheck 1.1 Manual v
Introduction
The SpindleCheck is a hardware and software package for measuring the dynamic
performance of machine tool spindles.
Fundamental Concepts
SpindleCheck uses noncontact, capacitive sensors to measure error motions as changes in
position of a precision target pin installed and rotating in the machine spindle.
The pin includes a copper strip used to trigger a once-around index pulse. This index sets
a reference for angular location of the spindle to align measurements from multiple
rotations.
The measurements are collected and analyzed by the SpindleCheck software. The results
of the live measurement or archived measurement file are presented on polar and linear
plots with calculated values of standard error motion measurements.
Tests Performed by SpindleCheck
SpindleCheck performs the following tests as described in ISO, ANSI/ASME, and JIS
standards:
●Radial rotating sensitive direction
●Radial fixed sensitive direction
●Axial error motion
●Thermal stability
●Temperature variation error
●FFT Analysis
Additional Capabilities of SpindleCheck
●Oscilloscope display
●Analog meter display

M017-7450.003 SpindleCheck 1.1 Manual vi
Standards and References
●ANSI/ASME Standard B5.54-2005, Methods for Performance Evaluation of CNC
Machining Centers
●ANSI/ASME B5.57-2012, Methods for Performance Evaluation of CNC Turning
Centers
●ANSI/ASME B89.3.4-2010, Axes of Rotation, Methods for specifying and testing
●ISO230 Part 3 (2001), Test Conditions for Metal Cutting Machine Tools, Evaluation
of Thermal Effects
●ISO230 Part 7 (2005), Geometric Accuracy of Axes of Rotation
●JIS B 6190-7, Test Code for Machine Tools Part 7, Geometric Accuracy of Axes of
Rotation
Assistance
For assistance with the installation and operation of the SpindleCheck system, please
visit our web site at: www.spindlecheck.com or contact us at:
Lion Precision
563 Shoreview Park Road
St. Paul, MN 55126
[email protected]
651-484-6544
www.lionprecision.com
www.spindlecheck.com

M017-7450.003 SpindleCheck 1.1 Manual vii
Software Installation
SpindleCheck Software
Minimum Requirements
Windows 7 (32 or 64 bit), Windows 8
2 GB Ram; 1 GB Free Disk Space (minimum)
1 GHz Processor
1 Available USB port (2.0 or higher); 1024 x 768 Minimum Screen Resolution
Installation Procedure
The SpindleCheck program is installed in the \PROGRAM FILES (X86)\LION
PRECISION\SPINDLECHECK directory on your hard disk. If you install the SpindleCheck
software a second time using the same subdirectory, the previous installation will
automatically be uninstalled first.
To use the SpindleCheck flash drive:
1. Insert the Lion Precision SpindleCheck flash drive in an available USB port.
2. View the contents of the flash drive.
3. Run SpindleCheckInstall.exe
4. Follow the directions of the installation programs.
5. Once the installation has copied all files, restart the computer.
6. After restarting, run the program by selecting the icon on the desktop, or by
selecting Start > All Programs > SpindleCheck > SpindleCheck.exe.
The flash drive also contains demo data files and other valuable documents related to
spindle measurement and improving machined part quality. These files are stored in the
My Documents > Lion Precision > SpindleCheck > Docs.

M017-7450.003 SpindleCheck 1.1 Manual viii
Software Basics
Select Mode of Operation
When the program is launched (Start > SpindleCheck ), the initial splash screen requires
you to choose an operating mode:
●Measure
●Load Data File
“Measure”
Select this option only if the SpindleCheck electronics are connected to the computer.
“Load Data File”
This mode only produces static displays of files loaded for viewing. It can be used for
viewing and analysis of saved test data without the SpindleCheck electronics connected
to the computer.
SpindleCheck can also view files from the Spindle Error Analyzer (SEA), but will only
display the data available in SpindleCheck; it will not display data from channels 4 (X2)
or 5 (Y2) or any of the tests not included in SpindleCheck.
The SpindleCheck electronics do not need to be connected to view saved data files.

M017-7450.003 SpindleCheck 1.1 Manual ix
Basic Navigation
The SpindleCheck software uses several simple conventions that make the software easy
to use.
●Menus display lists of selectable options.
●Buttons execute functions or gain access to features.
●Panels display fields of information.
●In configuration windows, white background fields are inputs, while gray
background fields are only indicators
Top Menu and Status Bar
Top Menu
File
Live Display: Connects to the SpindleCheck electronics and begins to collect
measurements according to configuration parameters.
Load Data File: Loads saved rotational test data for display. Data files have .lda
extensions.
Load Thermal File: Loads saved thermal test data for display in the thermal window.
Thermal files have .lts extensions.
Save Data File: Saves the current rotational test data to a file. Thermal data is
automatically saved while the thermal test is in progress.
Print Screen: Prints the current screen to a printer, PDF, or print preview. When printing,
window backgrounds are changed to light gray for better printing results.
Exit: Exits the program
Configuration
Show Configuration: Displays configuration windows in all four quadrants. This will
always display configuration windows in all four quadrants, even if a test window was
previously selected for one of the quadrants.
Save Configuration: Saves the current configuration settings to the current file name.
Save Configuration As: Saves the current configuration settings to a new file name.
Load Configuration: Loads an existing configuration file.
Probe Meter: When connected to the electronics, the full screen Probe Meter is
displayed. This is useful for probe placement during setup and for seeing low frequency
machine structural movements when the spindle is not rotating.
Return to Test Displays: Returns test displays to all four quadrants. This selection will
always display test windows in all four quadrants, even if a configuration window had
been previously displayed in one of the test quadrants.

M017-7450.003 SpindleCheck 1.1 Manual x
Help
Manual: Opens a PDF view of this manual.
Typical Mounting: Displays an image of a typical setup.
Lion Support: Contact information and online resources for support in operating
SpindleCheck.
About: Revision level and other information about the software.
Status Bar
The Status Bar is to the right of the Top Menu. It contains information about the data
currently being viewed. That data will be different for viewing data from a file compared
to viewing live data streaming from the SpindleCheck sensor electronics.
Run/Pause: This button is only visible when the electronics are connected, AND the
index probe is detecting rotation. SpindleCheck defaults to Run mode when a rotation is
detected and the button will display “Pause.”
Clicking Pause will immediately freeze the screen with the last 32 revolutions of data and
change the Status Bar color to yellow. This mode can be used for closer examination of
the data and for saving a data file. When Paused, the button will change to “Run.”
Clicking Run resumes the process of collecting measurement data from the device and
displaying it.
Version (v.): The current version of the SpindleCheck software. When viewing a file, the
Version field displays the version of software in use when the data was collected.
Date/Time: Displays the current date and time while displaying live data. Displays the
date and time the data was collected when viewing a file.
Machine ID: Displays the current text in the Machine ID field of the General
Configuration panel.
Operator Name: Displays the current text in the Operator Name field of the General
Configuration panel.
Status Bar Color
The Status Bar background color indicates the overall system status.
Green: Computer is connected and communicating with the sensor electronics.
Yellow: Computer is connected and communicating but it is “Paused.”
Orange: Probe Meter is displayed full screen and no other measurement data is being
collected.
Red: Error mode. Either communication with the sensor electronics has been interrupted
(check connections and power) or there has been a program error.
White: Viewing files or otherwise idle.

M017-7450.003 SpindleCheck 1.1 Manual xi
Quadrant Displays
SpindleCheck displays four quadrants on your screen. Each quadrant displays a selected
view of the current data or configuration information. The current data may be live data
from the sensors or saved data from a previous measurement.
Each quadrant has a menu bar (Quadrant Menu) which begins with Display. Use the
Display menu to select which panel to display in that quadrant. If a selected panel is
already being displayed in a different quadrant, that panel will move to the selected
quadrant and the display’s previous quadrant will be replaced with a Notes screen.
Active Quadrant
Some functions like keyboard shortcuts execute functions in the “active” quadrant which
has a darker title bar. Quadrants are activated by clicking anywhere in the quadrant.
Notes Screen
Screen-prints are often used to document spindle tests. It is helpful to have machine
information displayed on the screen when the screen is printed.
To display a Notes quadrant, select Display > Notes in a quadrant.
Click in the text box to enter text. To change the displayed image, select View > Select
Graphic from the Notes screen’s tool bar.
Maximizing Displays to Full Screen
Initially, each display uses one quarter of the screen (quadrant). Select View > Maximum
Size to fill the entire screen, or double click the right mouse button over the display to be
maximized.

M017-7450.003 SpindleCheck 1.1 Manual xii
Minimizing Displays to a Quadrant
Select View > Normal Size to return a maximized display to its quadrant, or double click
the right mouse button over the display.
SpindleCheck Configuration
SpindleCheck software must be properly configured for proper operation.
Most of the required configuration information is correct as the default values when
SpindleCheck is installed. The only exception may be the Target data. The default values
are for the 20 mm precision target pin. If you are using a different target, you will need to
change the values for target configuration. Also, the target’s serial number will have to be
added to the configuration if you want that number tracked in the data files.
The complete configuration consists of data from four different configuration windows.
Access the configuration windows through Main Menu > Configuration > Show
Configuration to display all configuration windows, or in any individual quadrant select
Quadrant Menu > Display > Configuration > [Selected Configuration Window].
When connected a SpindleCheck electronics, these windows display the current
measurement configurations and can be edited.
When viewing a file, these windows display the configuration information contained in
the file being viewed and cannot be edited.
There are different types of configuration information:
Indicators: These read-only fields display information acquired from the system or
calculated from other fields. They have a lightly shaded background.
Inputs: These may be required or optional input settings that must be manually entered
by the user. Inputs have a white background.
Configuration settings can be saved with Configuration > Save Configuration in the
main menu bar.

M017-7450.003 SpindleCheck 1.1 Manual xiii
General Configuration
Field
Type
Notes
Operator Name
Input
Machine
Input
Configuration
Indicator
In Live View, displays path and file name of
current configuration. Use Configuration >
Save Configuration As to change file
name/location.
When viewing a file, this indicates the path
to the file being viewed; Save is disabled.
Date Format
Input
Dimensional Units
Input
Select Inches or Micrometers
Target S/N
Input
Record the serial number of the precision
target pin or masterball being used for the
test. This number is recorded in the data file
for later reference.
Auto-Calculate
Input
Nonflat targets require correction factors for
accurate measurements. When auto-
calculate is checked (recommended), the
target correction factors are automatically
determined by the target shape and
dimension and probe model.
Target Shape
(X, Y, Z)
Input
Select target shape for each probe channel.
Target Dimension
(X, Y, Z)
Input
Select the diameter of the target for each
probe channel
Target Multiplier
(X, Y, Z)
Input
A multiplier used with capacitive sensor
channels to correct for measurement
changes due to a nonflat target.
Roundness Error
(X, Y, Z)
Input
Optional listing of target roundness errors
(in nanometers) for record keeping. Must be
entered manually.

M017-7450.003 SpindleCheck 1.1 Manual xiv
Calibration Configuration
During live measurements, the calibration configuration window displays calibration
details of the SpindleCheck device currently connected. When viewing a file, it displays
the calibration details of the system used when the file was created.
Calibration information is given for three capacitive channels (X, Y, Z). For SEA files
with more than three channels, only X, Y, Z will be shown.
Field
Type
Notes
Probe Model
Indicator
Probe model calibrated for the channel
Probe S/N
Indicator
Probe serial number
Driver Model
Indicator
Model of the probe driver electronics
Driver S/N
Indicator
Individual driver channel serial number
Near Gap
Indicator
The smallest gap at which the channel is
calibrated
Far Gap
Indicator
The largest gap at which the channel is
calibrated
Last Cal
Indicator
Last time the system was calibrated
Next Cal
Indicator
When the system is due for calibration

M017-7450.003 SpindleCheck 1.1 Manual xv
Diagnostics
The Diagnostics window shows current measurement and diagnostic information coming
from the SpindleCheck device. The Diagnostics window will display some values when
files are being viewed, but is only useful during live measurements.
Field
Type
Notes
Disp. (µm)
(X, Y, Z)
Indicator
The current output in dimensional units
Counts
(X, Y, Z)
Indicator
The current output of each channel in counts
between 6,000-60,000 for live
SpindleCheck
Will show “Volts” when viewing SEA files
Sensitivity
(X, Y, Z)
Indicator
The sensitivity of each channel in
Counts/µm (Volts/µm for SEA files)
Target Multiplier
(X, Y, Z)
Indicator
The Target Correction as selected/entered in
the General Configuration window
Temperature
Indicator
Internal temperature of the SpindleCheck
device in °C
Main 5.5
Voltage
Indicator
DC voltage output of the 5.5 V power
supply
Input Voltage
Indicator
DC supply voltage into the SpindleCheck
device
Main PS5.5
Current
Indicator
Output current of the 5.5 V power supply
RPM
Indicator
Current RPM of the spindle based on Index
probe. If maximum RPM is exceeded,
indicator will be red.
SpindleCheck Sensor Communication
This window offers information regarding the communication between the PC and device
electronics. Lion Precision support may require some of this information during
troubleshooting should there be a communication problem. This information is not
generally useful for normal operation.

M017-7450.003 SpindleCheck 1.1 Manual xvi
SpindleCheck Hardware

M017-7450.003 SpindleCheck 1.1 Manual xvii
Sensor System Electronics
The sensor system electronics include driver electronics for the capacitive and index
probes, USB port for communicating with the PC, power and ground connections, and
indicators useful during setup.
The electronics enclosure has a magnetic base.
Probe Connections
The Index sensor channel and X, Y, and Z capacitive displacement sensor channels are
color coded. The colored blocks of each channel must match the color-coded rings on
each probe.
Calibration stickers for each capacitive sensor channel (X, Y, Z) are located on the back
of the device. These indicate probe serial numbers and their association with particular
channels.

M017-7450.003 SpindleCheck 1.1 Manual xviii
Index Sensor (Purple)
An index pulse is used to detect rotation. This signal is also used to
align readings from multiple revolutions. The Index sensor uses an eddy
current probe to detect the copper plating on the target pins.
Alternatively, a piece of copper tape can be used if using a target
without the copper plating.
The indicator lights provide feedback regarding the index function.
Signal Strength
The Index probe senses a difference between the copper and steel on the
target. When the spindle is rotating, the resulting AC signal is used to
time the measurements of the rotating spindle. The AC signal must be
sufficiently large to ensure reliable triggers to the system. The closer the
probe is to the target, the greater the signal strength, but the probe must maintain a safe
distance from the rotating target to avoid contact. The INDEX SPACER is provided to
set the ideal gap in most circumstances.
Signal Strength Indicator Conditions
●Green: Good signal strength
●Red: Poor signal strength or no rotation
INDEX
This indicator lights Green when the Index probe is reading the copper strip and is Off
when the Index probe is over the steel.
< 60 RPM
This indicator is Green when the system detects less than 60 RPM and enters “slow”
mode. This requires no action on the operator’s part, but can be informative for
troubleshooting. This indicator can take as long as a few minutes to update when speed
slows from above 60 RPM to below 60 RPM.
NOT READY
The top and bottom indicators light Blue during the 60-90 second initialization period
when power is applied to the SpindleCheck electronics. No communication between the
computer and device is possible during this time.

M017-7450.003 SpindleCheck 1.1 Manual xix
Capacitive Displacement Sensors (X, Y, Z)
The X, Y, and Z Axes each have a separate color-coded capacitive
displacement sensor channel.
X: Blue (Channel 1 on calibration sheet)
Y: Green (Channel 2 on calibration sheet)
Z: Red (Channel 3 on calibration sheet)
Indicator lights are Green when the probe is within its calibrated
range.
The Near or Far light will be Red when the probe is outside of its
calibrated range.
The Near and Far lights will be Blue when the capacitive probe is not
connected.
Sensor System Probes
The system includes four probes: one eddy-current Index probe, and three capacitive
displacement probes for X-, Y-, and Z-Axes.
Capacitive Probes (X, Y, Z)
Noncontact capacitive probes measure the precision target pin as it turns. The probes are
8 mm in diameter, have a total measurment range of 250 µm, and a minimum gap (Near
Gap) of 125 µm.
Calibration sheets and calibration stickers on the back of the electronics housing will list
the specifics of the calibrations. If capacitive probes are damaged, the electronics and
probes must be returned to the factory for probe replacement and recalibration.
Eddy Current Probe (Index)
The eddy-current Index probe provides a once-around
signal to align data for multiple rotations. Its nominal
distance from the target is 0.5 mm (0.02 inch). The tip is
ceramic. Use caution to prevent damage. Replacement probes are available: Part
Number P015-4657.

M017-7450.003 SpindleCheck 1.1 Manual xx
Index Spacer
The Index Spacer is 0.5 mm (0.02 inch) thick and is used to set
the gap between the Index probe and copper plated portion of the
precision target pin.
Replacement Part Number A017-7560.
Probe Nest
The probe nest includes mounting for X, Y, Z probes and an Index probe. An optional
grounding brush (P017-6152) is available. Instructions for grounding brush installation
are in Appendix B.
Adapting Existing Probe Nests
If you have an existing probe nest and want to adapt it to SpindleCheck, you will need to
add an Index Probe Bracket (P017-6157). See Appendix C. You can also add a magnetic
base (P017-6117), see Appendix D.