Renishaw OTS User manual

OTS optical tool setter
Installation guide
H-5514-8504-02-B
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Renishaw part no: H-5514-8504-02-B
First issued: September 2008
Revised: November 2008
April 2009
© 2008 - 2009 Renishaw plc.All rights reserved.
This document may not be copied or reproduced
in whole or in part, or transferred to any other
media or language, by any means, without the
prior written permission of Renishaw plc.
The publication of material within this document
does not imply freedom from the patent rights of
Renishaw plc.
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i
Contents
Contents
1.0 Before you begin
Disclaimer ..............................................................................................1.1
Trademarks ............................................................................................1.1
Warranty.................................................................................................1.1
Changes to equipment...........................................................................1.1
CNC machines.......................................................................................1.1
Care of the probe...................................................................................1.1
Patents...................................................................................................1.2
EC declaration of conformity..................................................................1.3
FCC declaration (USA)...........................................................................1.3
Safety.....................................................................................................1.4
2.0 OTS basics
Introduction.............................................................................................2.1
Operation................................................................................................2.2
Modes of operation.................................................................................2.3
Configurable settings..............................................................................2.4
OTS dimensions.....................................................................................2.5
OTS specification...................................................................................2.6
Principal application..........................................................................2.6
Overall dimensions............................................................................2.6
Weight...............................................................................................2.6
Operating ..........................................................................................2.6
Batteries............................................................................................2.7
Environment......................................................................................2.7
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OTS installation guide
ii
Contents
3.0 System installation
Typical system with an OMI-2T/OMI-2H............................................3.1
OTS performance envelope with an OMI-2T/OMI-2/OMI-2H.......3.2
Preparing the OTS for use ................................................................3.3
Fitting the stylus, break stem and captive link...................................3.3
Installing the batteries.......................................................................3.4
Mounting the OTS on a machine table..............................................3.5
Positioning the optical module ..........................................................3.6
Stylus level setting ............................................................................3.7
Square stylus only.............................................................................3.9
Calibrating the OTS.........................................................................3.13
4.0 Trigger Logic™
Reviewing the current probe settings................................................4.1
Probe settings record table...............................................................4.2
Changing the probe settings.............................................................4.3
Operating mode ................................................................................4.4
5.0 Maintenance
Maintenance .....................................................................................5.1
Cleaning the probe ...........................................................................5.1
Changing the batteries......................................................................5.2
Battery types.....................................................................................5.3
Routine maintenance........................................................................5.4
Inspecting the inner diaphragm seal.................................................5.5
6.0 Fault finding
Fault finding.......................................................................................6.1
7.0 Parts list
Parts list ............................................................................................7.1
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1.1
Disclaimer
RENISHAW HAS MADE CONSIDERABLE
EFFORTS TO ENSURE THE CONTENT OF THIS
DOCUMENT IS CORRECT ATTHE DATE OF
PUBLICATION BUT MAKES NO WARRANTIES
OR REPRESENTATIONS REGARDING
THE CONTENT. RENISHAW EXCLUDES
LIABILITY, HOWSOEVER ARISING, FOR ANY
INACCURACIES IN THIS DOCUMENT.
Trademarks
RENISHAW® and the probe emblem used in the
RENISHAW logo are registered trademarks of
Renishaw plc in the UK and other countries.
apply innovation™ and Trigger Logic™ are
trademarks of Renishaw plc.
All other brand names and product names used
in this document are trade names, service marks,
trademarks, or registered trademarks of their
respective owners.
Warranty
Equipment requiring attention under warranty
must be returned to your equipment supplier.
No claims will be considered where Renishaw
equipment has been misused, or where
repairs or adjustments have been attempted by
unauthorised persons. Prior consent must be
obtained in instances where Renishaw equipment
is to be substituted or omitted. Failure to comply
with this requirement will invalidate the warranty.
Changes to equipment
Renishaw reserves the right to change equipment
specifications without notice.
CNC machines
CNC machine tools must always be operated by
fully trained personnel in accordance with the
manufacturer's instructions.
Care of the probe
Keep system components clean and treat the
probe as a precision tool.
Before you begin
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OTS installation guide
1.2
Before you begin
EP 0695926
EP 0974208
EP 1130557
EP 1373995
EP 1397637
EP 1425550
EP 1503524 B
EP 1701234
EP 1734426
EP 1804020
JP 2994401
JP 2004-522961
JP 2004-530234
JP 2005-502035
US 5150529
US 5669151
US 6472981 B2
US 6839563 B1
US 6860026 B2
US 6941671 B2
US 7145468 B2
Patents
Features of the OTS probe, and other similar
Renishaw probes, are the subject of one or
more of the following patents and/or patent
applications:
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1.3
Before you begin
CFCC DECLARATION (USA)
FCC Section 15.19
This device complies with Part 15 of the
FCC rules.
Operation is subject to the following two
conditions:
1. This device may not cause harmful
interference.
2. This device may accept any interference
received, including interference that may
cause undesired operation.
FCC Section 15.105
This equipment has been tested and found to
comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC rules.These limits
are designed to provide reasonable protection
against harmful interference when the equipment
is operated in a commercial environment.This
equipment generates, uses, and can radiate
radio frequency energy and, if not installed
and used in accordance with the instruction
manual, may cause harmful interference to radio
communications.Operation of this equipment
in a residential area is likely to cause harmful
interference, in which case you will be required
to correct the interference at your own expense.
FCC Section 15.21
The user is cautioned that any changes or
modifications not expressly approved by
Renishaw plc, or authorised representative
could void the user’s authority to operate the
equipment.
EC DECLARATION OF
CONFORMITY
Renishaw plc declares that the product:-
Name
Description
OTS
Optical tool setter
has been manufactured in conformity with the
following standards:-
BS EN 61326-1:2006
BS EN 60825-12:2004
Electrical equipment
for measurement,
control and
laboratory use - EMC
requirements -
Part 1: General
requirements
Immunity to Table 2
- industrial locations.
Emissions to Class A
- industrial locations.
Safety of laser
products -
Part 12: Safety of
free space optical
communication
systems used for
transmission of
information
and that it complies with the requirements of
the following directives: -
2004/108/EC
2006/95/EC
Electromagnetic
compatibility
Low voltage
The above information is summarised from the
full EC Declaration of Conformity. A copy is
available from Renishaw on request.
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Safety
Information to the user
Handle and dispose of batteries in accordance
with the manufacturer's recommendations. Use
only the recommended batteries. Do not allow the
battery terminals to contact other metallic objects.
The OTS has a glass window, handle with care if
broken, to avoid injury.
Information to the machine supplier/
installer
It is the machine supplier's responsibility to
ensure that the user is made aware of any
hazards involved in operation, including those
mentioned in Renishaw product literature, and
to ensure that adequate guards and safety
interlocks are provided.
Under certain circumstances, the probe signal
may falsely indicate a probe seated condition. Do
not rely on probe signals to halt the movement of
the machine.
Information to equipment installer
All Renishaw equipment is designed to comply
with the relevant EEC and FCC regulatory
requirements.It is the responsibility of the
equipment installer to ensure that the following
guidelines are adhered to, in order for the product
to function in accordance with these regulations:
• any interface MUST be installed in a
position away from any potential sources
of electrical noise, i.e.power transformers,
servo drives etc;
• all 0V/ground connections should be
connected to the machine 'star point' (the
'star point' is a single point return for all
equipment ground and screen cables).
This is very important and failure to adhere
to this can cause a potential difference
between grounds;
• all screens must be connected as outlined
in the user instructions;
• cables must not be routed alongside high
current sources, i.e. motor power supply
cables etc, or be near high speed data
lines;
• cable lengths should always be kept to a
minimum.
OTS installation guide
1.4
Before you begin
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2.12.1
OTS basics
Introduction
The OTS is a tool setter probe with optical signal
transmission, suitable for use on small to large
machining centres.It is designed to resist optical
interference, false triggering and shock.
OTS types
The OTS is available in two versions, one with
½ AA batteries and the other with AA batteries.
This allows the use of a common battery type for
both the OTS and the spindle probe.
i.e. OTS with ½ AA batteries with an
OMP40-2/OMP400.
or
OTS with AA batteries with an OMP60.
Both versions work in conjunction with any
modulated spindle probe.
Modulated transmission
To minimise the effects of light interference, the
OTS operates using modulated transmission, and
must be used with a modulated receiver.
Twin probe system with an OMI-2T/
OMI-2H
A twin probe system can accommodate a spindle
probe with a tool setter probe or twin tool setter
probes or twin spindle probes, see Optical start
configuration page 2.4.
The OTS can be user configured to use one of
three coded start commands, named Probe 1,
Probe 2 and Probe 3.
NOTE:
Currently no interface is compatible with Probe 3.
Single probe system with an OMI-2T/
OMI-2/OMI-2H/OMI-2C
A single OTS can be used with an OMI-2T/
OMI-2/OMI-2H/OMI-2C receiver.
Trigger Logic™
All OTS settings are configured using the Trigger
Logic™ technique.
Trigger Logic™ (see Section 4 - Trigger
Logic™) is a method that allows the user to view
and select all available mode settings in order to
configure a probe to suit a specific application.
Trigger Logic™ is activated by battery insertion
and uses a sequence of stylus deflection
(triggering) to systematically lead the user
through the available choices to allow selection
of the required mode options.
Current probe settings can be reviewed by
simply removing the batteries for a minimum of 5
seconds, and then replacing them to activate the
Trigger Logic™ review sequence.
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OTS installation guide
2.2
OTS basics
Operation
Achievable set-up tolerances
The tolerances to which tools can be set depend
upon the flatness and parallelism of the stylus tip
setting. A value of 5 µm (0.0002 in) front to back
and side to side is easily achievable over the flat
portion of the stylus tip, and 5 µm (0.0002 in)
parallelism is easily achievable with the axes of a
square tip stylus.This setting accuracy is sufficient
for the majority of tool setting applications.
Recommended rotating tool feed rates
Cutters should be rotated in reverse to the
cutting direction. Renishaw tool setting software
calculates the spindle speed and axis feed rates
automatically using the following information.
First touch – machine spindle rev/min
Rev/min for the first move against the probe
stylus:
Diameters below 24 mm, 800 rev/min is used.
Diameters from 24 mm to 127 mm, rev/min is
calculated using a surface speed of 60 m/min
(197 ft/min).
Diameters above 127 mm, 150 rev/min is used.
First touch – machine feed rate
The feed rate (f) is calculated as follows:
f = 0.16 × rev/min f units mm/min
(diameter set).
f = 0.12 × rev/min f units mm/min
(length set).
Second touch – machine feed rate
800 rev/min, 4 mm/min (0.16 in/min) feed rate.
Operation
The tool is driven in the machine Z axis for tool
length measurements and broken tool detection.
Rotating tools are set in the machine’s X andY
axes for tool radius offsets.
Screw adjusters allow the stylus to be aligned
with the machine’s axes.
Software routines
Software routines for tool setting are available
from Renishaw for various machine controllers
and are described in data sheet H-2000-2289.
In addition data sheet H-2000-2298 lists available
Renishaw software programs. Both data sheets
can be downloaded from
www.renishaw.com/mtp
Stylus
ZX/Y
Rotate tool in reverse direction
for diameter setting
X
Y
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2.3
OTS basics
Modes of operation
The OTS can be in one of three modes.
Stand-by mode:where the OTS is waiting for a
switch-on signal.
Operational mode:The OTS is ready for use
in the operational mode, it is activated using the
switch-on method described on page 2.4.
Configuration mode: where Trigger Logic™ may
be used to configure the following OTS settings.
• Optical start configuration
• Enhanced trigger filter setting
• Optical power
Configuration mode factory settings are given on
page 2.4.
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OTS installation guide
2.4
OTS basics
Configurable settings
Switch-on method
Typically optical probe systems turn on in less
than 0.5 seconds.Please refer to the interface
user's guide for full details.
Optical start configuration
The user can configure the OTS to either
Probe 1, Probe 2 or Probe 3 identification, see
Changing the probe settings page 4.3.
The OTS is factory set to Probe 2 so that it can
be used in a system with modulated spindle
probes.
Typically the OTS is used in Probe 2.
A twin tool setter application would require that
one of the OTS probes is reconfigured to Probe 1.
A triple probe application would require one of the
probes to be reconfigured to Probe 1 and another
to Probe 3.
Switch-off method
A timer automatically switches the probe off 90
minutes after the last trigger if not turned off by an
M code.
NOTE:
After being switched on, the OTS must be on for
1 second minimum before being switched off.
Enhanced trigger filter
Probes subjected to high levels of vibration or
shock loads may trigger without having been
contacted.The enhanced trigger filter improves
the probe’s resistance to these effects.
When the filter is enabled, a constant nominal
7 ms delay is introduced to the probe output.
It may be necessary to reduce the approach
speed to allow for the increased stylus overtravel
during the extended time delay.
The OTS is factory set to Enhanced trigger filter
off.
Optical power
Where the separation between the OTS and the
receiver is small, the low optical power may be
selected, see pages 3.2 and 4.3. In this setting
the optical transmission operating range will be
reduced by approximately 40%. Battery life will
also be increased.
The OTS is factory set to standard optical power.
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2.5
OTS basics
Ø65 (2.56)
OTS dimensions
dimensions given in mm (in)
Machine table
Ø62.5 (2.46)
34.5 (1.36)
with disc stylus
33 (1.30)
with square
stylus
½AA 67.8 (2.67) 44.7 (1.76)
Base
Ø54 (2.125)
93 (3.66)
59.25 (2.33)
68.75 (2.71)
Ø51
(2.01)
Two holes for dowel pins
6.13 (0.24)
5.95 (0.23)
equi-spaced on Ø54 (2.125) PCD at 45° to OTS axis
Øx 13 (0.51) deep MIN
Cap head bolt and T nut
M10/M12 (Ø0.50) MAX
Typical bolt length 30 (1.18)
supplied by user
AA 92.5 (3.64)
Cranked horizontal stylus adaptor kit
Disc stylus 72 (2.83) shown
Square stylus 70.5 (2.78)
89.5 (3.52)
76.5 (30.12) shown
Typical bolt length 110 (4.3)
or
125.5 (4.94)
Typical bolt length 150 (5.9)
Raising block
Raising block
19.05 (0.75)
8 (0.31)
8 (0.31)
19.05 (0.75)
Disc stylus
Ø12.7 mm × 8 mm (Ø0.5 in × 0.31 in)
Tungsten carbide 75 Rockwell C
Square stylus
19.05 mm x 19.05 mm (0.75 in x 0.75 in)
Ceramic 75 Rockwell C
Ø12.7 (Ø0.5)
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OTS installation guide
2.6
OTS basics
OTS specification
Principal application: Tool setting on CNC machining centres
Overall dimensions:
½ AA battery type: Length with square stylus 122.00 mm (4.08 in)
AA battery type: Length with square stylus 143.55 mm (5.65 in)
All battery types: Width 60.00 mm (2.36 in)
All battery types: Height 103.25 mm (4.06 in)
Weight:
½ AA battery type: with batteries without batteries
(with disc stylus) 870 g (30.69 oz) 850 g (29.98 oz)
AA battery type: with batteries without batteries
(with disc stylus) 950 g (33.51oz) 900 g (31.75 oz)
Operating:
Signal transmission type: Infra-red optical transmission
Switch-on method: Optical on
Switch-off method: Optical off
Operating range: Up to 5 m (16.4 ft)
Receiver/interface: OMI-2T, OMI-2 or OMI-2H
Sense directions: Omni-directional ±X, ±Y, +Z
Uni-directional repeatability: 1.0 µm (0.00004 in) 2 sigma (2σ) *
Stylus trigger force: 1.3 N to 2.4 N/130 gf to 240 gf (4.5 ozf to 8.5 ozf) §
depending on the sense direction
Stylus overtravel: XY plane +Z direction
±3.5 mm (0.14 in) 6 mm (0.23 in)
* Probe module results valid as tested with a 35 mm (1.38 in) straight stylus
and a velocity of 480 mm/min (1.57 ft/min).
§ Factory set using 50 mm (1.97 in) straight stylus.
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2.7
OTS basics
Typical battery life
Battery type
(x 2) Standby life 5% usage (72 minutes/day) Continuous use
Standard
power mode Low power mode Standard power mode Low power mode
½ AA LTC
(standard) 320 days 140 days 170 days 300 hours 400 hours
AA Alkaline
(standard) 530 days 210 days 250 days 400 hours 550 hours
AA LTC
(optional) 730 days 300 days 350 days 600 hours 800 hours
Lithium Thionyl Chloride (LTC).
AA battery types are also designated as LR6 or MN1500.
OTS specification
Batteries:
Battery type (½ AA LTC - standard:Lithium Thionyl Chloride (3.6 V) x 2
Battery type (AA alkaline - standard):Alkaline (1.5 V) x 2
Battery type (AA LTC - optional):Lithium Thionyl Chloride (3.6 V) x 2
Battery reserve life: Approximately 1 week after a low battery
warning is first given.Replace the batteries as
soon as possible
Low battery indication: Blue flashing LED in conjunction with normal
red or green probe status LED
Dead battery indication: Constant red
Environment:
IP rating: IPX8
Operating temperature: 5 °C to 50 °C (41 °F to 122 °F)
Storage temperature: -10 °C to 70 °C (14 °F to 158 °F)
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OTS installation guide
2.8
OTS basics
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3.1
System installation
OTS tool setter probe
Alternative orientations
Cable
Workpiece
CNC
machine
control
PSU3 power supply unit
(optional)
Mounting bracket
Stylus
CNC machining
centre spindle
The spindle mounted inspection probe must use modulated transmission
OMI-2T/OMI-2H
receiver
Typical inspection probe
Typical probe system with an
OMI-2T/OMI-2H
Probe and optical receiver
The OTS probe and receiver diodes must
be in the other's field of view and within the
performance envelope shown (page 3.2).The
OTS performance envelope is based on the
receiver being at 0° and vice-versa.
Natural reflective surfaces within the machine
may increase the signal transmission range.
Coolant residue accumulating on the OTS or
OMI-2T/OMI-2H/OMI-2 windows may reduce
the signal transmission range.Wipe clean as
often as is necessary to maintain unrestricted
transmission.
Operation in temperatures of 0 °C to 5 °C or
50 °C to 60 °C (32 °F to 41 °F or 122 °F to
140 °F) will result in some reduction in range.
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OTS installation guide
3.2
System installation
OTS performance envelope with
an OMI-2T/OMI-2/OMI-2H
(modulated transmission)
OMI-2T/OMI-2/OMI-2H
0°
45°
45° 15°
30°
30°
15°
0°
45°
45°
15°
30°
15°
60°
Typical plot at 20° C (68° F)
Range m (ft)
Switch on/off
Operating - standard power mode
Operating - low power mode
4 (13.1)
3 (9.8)
2 (6.5)
1 (3.3)
60°
60°
60°
75°
OTS
4 (13.1)
3 (9.8)
2 (6.5)
1 (3.3)
5 (16.4)
5 (16.4)
30°
75°
75°
75°
Optical power setting
If two machines are operating in close proximity
to each other, take care to ensure that signals
transmitted from a probe on one machine are not
received by the receiver on the other machine,
and vice versa.
When this is the case, it is recommended that the
low optical power setting on probes is used, and
that the low range setting is used on the receiver.
NOTE:
A single OTS configured to Probe 1
can be used with an OMI-2
Receiver position
To assist finding the optimum position for the
installation, signal condition is displayed on the
OMI-2T/OMI-2/OMI-2H receiver.
Please refer to the receiver User’s Guide.
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3.3
System installation
Preparing the OTS for use
2 mm AF
1.1 Nm
(0.81 lb.ft)
5 mm AF (thin)
2.6 Nm
(1.92 lb.ft)
3 mm AF
2.6 Nm
(1.92 lb.ft)
Support bar
Break
stem
2
1
3
NOTE:
Always hold the support bar in
position to counteract twisting
forces and avoid over-stressing
the stylus break stem.
Captive link
Stylus
Stylus weak link break stem
A stylus weak link break stem is
incorporated in the stylus mounting,
to protect the probe mechanism
from damage in the event of
excessive stylus overtravel or a
collision.
Captive link
In the event of the break stem
breaking, the captive link ties the
stylus to the probe, which prevents
the stylus falling into the machine.
2 mm AF
1.1 Nm
(0.81 lb.ft)
Fitting the stylus, break stem and
captive link

OTS installation guide
3.4
System installation
Installing the batteries
2
1
3
NOTES:
Select suitable battery type, see page 5.3.If
dead batteries are inadvertently inserted into
the probe, the LEDs will remain a constant red,
see page 4.4.
Do not allow coolant or debris to enter the
battery compartment.
When inserting batteries, check that the battery
polarity is correct.
After inserting the batteries the LEDs will
display the current probe settings.
(for details, see Trigger Logic™ page 4.1).
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