CALYPSO

Option 7
OVCMM Measuring
uncertainty definition

Operating Instructions
The design and delivered components of the CMM, its options, the pro-
gram packages, and the relevant documentation are subject to change.
This manual must not be circulated or copied, or its contents utilized and
disseminated, without our express written permission. Persons misusing
this manual are subject to prosecution.
All rights reserved, especially in cases of granting a patent or registering
a utility model.
This manual is subject to modification. All rights pertaining to changes in
the CMM and its options reserved.
All product names are registered trademarks or trademarks of the corre-
sponding proprietors.
Although utmost care has been taken in preparing the information given
in this manual, we cannot assume any liability for its completeness and
correctness, except in case of willful intent.

CALYPSO
Version 2018
Operating Instructions
2018-04-17
61212-2771502
Table of contents
Preface

Information about these operating instructions ... Preface

1

Configuration of safety instructions ................... Preface 3

Chapter 1 OVCMM Measuring uncertainty definition (option)

Introduction: OVCMM measurement uncertainty defini-

tion (Option).....................................................................  1-2

Basics of OVCMM ...........................................................  1-3

Basic principle of OVCMM ................................................................  1-3
Uncertainty of measuring results .......................................................  1-4
Influencing variables..........................................................................  1-4
Cooperation in determining influencing variables ..............................  1-5

Configuring the OVCMM.................................................  1-6

Steps for configuring the OVCMM ....................................................  1-6
How to determine the stylus characteristics for the OVCMM .............  1-6

Using the OVCMM .........................................................  1-10

Procedure when using the OVCMM ................................................  1-10
Activating the OVCMM ...................................................................  1-10
Results of the OVCMM ...................................................................  1-12

Alphabetic index

61212-2771502 CALYPSO 2018 Table of contents 11

22 Table of contents 61212-2771502 CALYPSO 2018
Preface
Information about these operating instructions
The CALYPSO program consists of a base module and additional options
for special purposes. You can customize the scope of program to fit your
requirements.
These operating instructions describe an option of CALYPSO and are
based on the assumption that the user is familiar with the operating in-
structions for the base module of CALYPSO.

NOTE
The additional CALYPSO options are described in separate manuals.

Reference information about the windows and dialogs can be found in

the dialog reference in the CALYPSO Online Help.

Simply Measure – And what you should know to do it right, A metrol-

ogy primer
Carl Zeiss, Industrial Metrology Division,
Order no.: 612302-9002

Text conventions The following text conventions are used in these instructions.

Example Description
Features Text element of the graphics
screen display.
Comment The Comment button on the
screen.
<machine name> Variable text or dummy for a
name.
C:\windows\w.ini The w.ini file in the windows di-
rectory on the C:\ drive.
For this section... A passage containing important
information.

61212-2771502 CALYPSO 2018 Preface 1

Information about these operating instructions

Example Description
➤ Preface [⇨ Preface-1] This is a cross reference. When
viewing this manual on the
screen, you will be guided to the
indicated text passage by clicking
the reference.
Plan " CNC-Start " Run The Run command in the CNC-
Start submenu of the Plan
menu.
CTRL+A Press the CTRL key and the letter
A at the same time.

Icons Three special symbols containing important information are used in this
manual. The icons appear in the marginal column next to the respective
text.
You will find a detailed explanation of the safety instructions under Con-
figuration of safety instructions.

22 Preface 61212-2771502 CALYPSO 2018

 Configuration of safety instructions

Configuration of safety instructions

Safety instructions indicate a personal health hazard. We distinguish
three different levels: Danger, warning and caution. All three safety in-
structions are marked with the same warning symbol. The designation
of the safety instruction is shown beside the symbol. The safety instruc-
tions used are described below.

Configuration of a safety instruction

A safety instruction may have the following components:
– Warning symbol and designation of the safety instruction (signal
word): Danger, warning or caution.
– Source and cause of the danger
– Consequences for the user due to non-observance of the safety in-
struction
– Required measures to be taken by the user to avoid possible conse-
quences
– A measure may cause an intermediate result.
– At the end of all measures, a final result may be caused.

Personal health hazard

DANGER
A »danger« indicates an imminent risk to life and limb.
Non-observance of this safety instruction when the described risk oc-
curs causes death or serious injuries.
Example: Electric shock due to high electric voltage.

WARNING
A »warning« indicates a possible risk to life and limb.
Non-observance of this safety instruction when the described risk oc-
curs may cause death or serious injuries.
Example: Risk of severe crushing of the body caused by heavy loads.

CAUTION
A »caution« indicates a personal health hazard.
Non-observance of this safety instruction when the described risk oc-
curs may cause slight to moderate injuries.
Example: Risk of minor crushing of the limbs caused by small loads.

61212-2771502 CALYPSO 2018 Preface 33

 Using the OVCMM

System configuration

File Pages

Measuring method

Settings for measuring uncertainty data VCMM Travel paths

Elements
OVCMM VCMM
Methods
Point density
Measuring uncertainty data active Output trace Point masking
SCAN Limits
Conditions for work environment Nominal value

Condition active Start angle

Form Datum
Condition Optics
MMC / LMC
Navigator
Definition of stylus influence Simulation
VCMM
Standard definition Man. Run

Advanced definition

Simulation
Prismo-Ultra RDS-CAA RDS RST Rotos

OK Cancel Apply

2 Activate the OVCMM option and activate the Measuring uncer-

tainty data active check box.
3 If the work of the OVCMM is to be entered in a log file, tick the In-
spection outputs check box.
This can be useful for tests and checks performed by ZEISS Service.
4 In the Environmental conditions group, tick the Conditions ac-
tive check box.
5 In the Conditions selection list, select the relevant specific environ-
mental condition.
6 Save and close with OK.
The OVCMM is now active. It will be started automatically after the next
CNC run and will take the selected conditions into account for the un-
certainty calculation.
Note: Do not forget to deactivate the OVCMM after the CNC run and
output of the printout, as it will otherwise become active again after ev-
ery CNC run and will repeat its calculations.

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OVCMM Measuring uncertainty definition (option)

Chapter

1 OVCMM Measuring uncertainty

definition (option)

This chapter contains:

Introduction: OVCMM measurement uncertainty definition (Option) .......... 1-2
Basics of OVCMM...................................................................................... 1-3
Configuring the OVCMM ........................................................................... 1-6
Using the OVCMM................................................................................... 1-10

61212-2771502 CALYPSO 2018 1-1

Introduction: OVCMM measurement uncertainty definition (Option)

Introduction: OVCMM measurement

uncertainty definition (Option)
With the OVCMM (Offline Virtual Coordinate Measuring Machine), the
possible deviations from the real value and thus the measuring uncer-
tainties of the results of a measurement plan can be defined with more
detail. Important influencing variables that may affect the result are ana-
lyzed to this end.
Determining the measuring uncertainty with the OVCMM is a CALYPSO
option. You can license this functionality and have it enabled in your sys-
tem if you want to use it. Contact your ZEISS Service for more informa-
tion.
The OVCMM must be configured by ZEISS Service. ZEISS Service will also
support you in handling this option.

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 Basics of OVCMM

Basics of OVCMM
Basic principle of OVCMM
Using the OVCMM, CALYPSO can determine the possible deviations
from the real value for all characteristics of a measurement plan, i.e., it
uses the method of the virtual CMM to determine the characteristic-spe-
cific measuring uncertainty and output this in a printout.
Benefits of the OVCMM The measuring uncertainty calculation using the virtual CMM has the fol-
lowing advantages:
– It is objective and in line with standards.
– It is performed automatically and requires, contrary to other meth-
ods, no special knowledge on the part of the user.
– It is not excessively time-consuming.
– It matches the complexity of connected uncertainty components oc-
curring during measurements on CMMs.
– Its high degree of automation allows to meet the requirements of
the various measuring jobs performed by CMMs.

The method of the virtual CMM

In order to determine the uncertainties, CALYPSO uses the method of
the virtual CMM to calculate an uncertainty range for each individual
measurement.
In the case of complex measured values (construction, theoretical ele-
ment), this range consists of the uncertainties from the entire measure-
ment chain. For this, the OVCMM considers the influencing variables
and deviations of all measuring jobs involved in the measurement, i.e.,
including the alignment and references.
CNC run The OVCMM determines the measuring uncertainties in accordance with
GUM, ISO 14253 and ISO 15530. To this end, the CNC run for all char-
acteristics of a measurement plan is simulated.
The result of this simulation corresponds to the dispersion range of a
measurement of 128 workpieces with a random variation of the known
influencing factors.
A range is then calculated that is representative for the measurement re-
sults. Finally, the resulting variance is used to ascertain the uncertainty
for each characteristic and to output it in the printout.

61212-2771502 CALYPSO 2018 1-3

Basics of OVCMM

Uncertainty of measuring results

Measuring uncertainty Measuring results are afflicted with uncertainties resulting from the im-
perfectness of the CMM, the environmental conditions and the measur-
ing process. This means a result is complete only if it is accompanied by
a specified measuring uncertainty. This is summarized in the following
formula:
Y=y±U
Here, Y is the value to be measured, y is the measured and possibly cor-
rected measuring result and U represents the measuring uncertainty. No
exact value is specified for Y in the equation, only a range in which Y
lies.
Uncertainty of coordi- Coordinate measuring machines are extremely universal measuring ma-
nate measurements chines for practically any workpiece. This is why coordinate measuring
machines have a great many sources of inaccuracy, whose mutual over-
laps are difficult to analyze.
The uncertainty of a coordinate measurement depends on the relevant
measuring job: How many and which measurements are included in the
result? How are the individual measurements linked? Which is the mea-
surement strategy applied to the geometry features?

Influencing variables
The following influencing variables are taken into account by the
OVCMM:
– Systematic residual deviations of the CMM geometry
– Fluctuations of the geometry deviations due to temporal and spatial
temperature gradients
– Direction-dependent systematic residual deviations of the stylus sys-
tem
– Random deviations of the probing system
– Uncertainty caused by thermal workpiece expansion
– Uncertainty in qualification of the stylus diameter
– Uncertainty in qualification of the styli within a stylus system
– Roughness of the workpiece surface
– Uncertainty of the standards used for connection to the international
SI units
The following influencing variables are not automatically taken into ac-
count:

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 Basics of OVCMM

– Measurement deviations due to operator influence

– Deformation of the workpiece due to clamping
– Deformation of the workpiece due to probing forces
– Temperature gradients in the workpiece
– Shape influence of the workpiece
These influencing variables must be set manually and individually taken
into account if it can be assumed that each influence makes a significant
contribution to the measuring uncertainty in each job.

Cooperation in determining influencing

variables
Use of the virtual CMM method requires interaction between a number
of parties: the manufacturer, a calibration lab and the user.
What does Carl Zeiss The most important systematic errors of a CMM must be determined in
do? advance.
The specific errors for each CMM type (geometry, effect of ambient in-
fluences on the geometry, dynamic effects) have been determined by
Carl Zeiss and recorded in a device file.
What does the accred- An accredited laboratory (e.g. Carl Zeiss Service) measures your CMM
ited laboratory do? with great precision and creates the database of the OVCMM. To this
end, geometry deviations in the entire measuring range are recorded us-
ing perforated-plate measurements in different positions.
Depending on the specific environment of your CMM and your require-
ments for use, the laboratory generates for your CMM and its specific
purpose one or more “ambient conditions” as a basis for the OVCMM.
What do you do? To ensure the device accuracy, you measure calibrated workpieces or
gages at regular intervals (e.g. weekly).
To take into account the uncertainty influences of the styli used, the
OVCMM must know the stylus characteristics. You can determine these
stylus characteristics by probing the reference sphere.
When you set up a new measurement plan and each time the influenc-
ing variables change, start the simulation using the OVCMM.

61212-2771502 CALYPSO 2018 1-5

Configuring the OVCMM

Configuring the OVCMM

Steps for configuring the OVCMM
In order to use the OVCMM in CALYPSO, you must configure it first. To
do so, determine the stylus characteristics for the stylus (styli) used and,
if appropriate, select the ambient condition.

NOTE
The ambient conditions of your CMM must have been determined by
ZEISS Service or a different accredited laboratory and entered in the
OVCMM.

How to determine the stylus

characteristics for the OVCMM
All of the styli used for measurement must be qualified by the OVCMM,
as each stylus has its own specific error influences. You measure these
influences by scanning a point pattern on the reference sphere using the
stylus.
For the OVCMM, you can specify how to determine the stylus character-
istics: You can define how the CMM is to measure the stylus characteris-
tics on the reference sphere (e.g. the number of axis intersection points).
Each stylus characteristic is stored under a separate name in the stylus
management. This means you can use stylus characteristics that have al-
ready been determined for a similar stylus system by assigning it that
name.
CALYPSO offers two possibilities to determine stylus characteristics:
– Standard definition: You only enter the name of the stylus character-
istics. The specific values are set by default.
– Advanced definition: You enter the name of the stylus characteristics
and change the default values for probing the reference sphere.

Standard definition
In most cases, determining the stylus characteristics with the standard
definition is fully adequate.

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 Configuring the OVCMM

Determining the stylus characteristic with the standard

definition method
1 Select Extras " Settings " Measurement and click the VCMM
tab in the Measurement Methods notebook.
The notebook page with the Settings for measuring uncertainty
data VCMM opens.
2 Select the OVCMM option and click the Standard definition but-
ton in the Definition of stylus influence group.
The Stylus Influence window will open.

Probe Influence

Name

OK Cancel Help

3 Enter the name of the stylus characteristics and confirm with OK.
The CMM now starts qualifying the stylus.
4 Save and close with OK.

Advanced definition
The advanced definition is used for analysis purposes.

Determining the stylus characteristic with the advanced

definition method
1 Select Extras " Settings " Measurement and click the VCMM
tab in the Measurement Methods notebook.
The notebook page with the Settings for measuring uncertainty
data VCMM opens.
2 Select the OVCMM option and click the Advanced definition but-
ton in the Definition of stylus influence group.
The Stylus Influence: Extended Qualification Mode window
opens.

61212-2771502 CALYPSO 2018 1-7

Configuring the OVCMM

Probe Influence: Extended Qualification Mode

Name

No. of axis
24
Stylus intersection points
Longitudinal intersection plane No. of longitudinal
7
intersection points

No. of repeat points 5

Axis intersection
plane

Reference sphere

Equator

• Measuring points
Multiple Probings

OK Cancel Help

3 Enter the name of the stylus characteristic.

4 Change the default settings for the number of probing points in the
corresponding input field.
5 Click OK to confirm.
The CMM now starts qualifying the stylus.
6 Save and close with OK.

Assigning stylus characteristics

Configuration of the OVCMM has now been completed. In the stylus
system management, you can assign the corresponding stylus character-
istics to the stylus required for the measurement.

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 Configuring the OVCMM

Stylus Data Management

Stylus
ct
Stylus Stylus System ct
Geometry
Quality Stylus Data
Settings Geometry Settings
MasterProbe X 0,0000
Stylus No. 1
Styli available
Geometry ct Y 0,0000 Type St3
Quality
Settings Z 0,0000 Meas. Force [mN] 0,0
Star
Stylus Radius 0,0000 Qualified Yes
Geometry
Quality X Vector 0,0000 Mode Simulation
Settings Y Vector 0,0000 Reference sphere 9999
Z Vector 0,0000 2nd Reference sphere 9999
Shaft Radius 0,0000 CNC permitted No
A Angle 0,0000 CNC qualified No
B Angle 0,0000 Modified Yes
C Angle 0,0000 Geometry Sphere
Taper Angle 180,0000 Stylus Char. pro00000

Stylus Plate Diff.

Quality
Qual. Temperature 20,0000 Rigidity 0,0000
Qual. Date 3.3.09 Sigma 0,0000
Qual. Time 16:40:49 Dyn. Sigma 0,0000

Recalculate Stylus Data Reset Apply

Close

The following fields are provided for this in the stylus system manage-
ment:
– Base Char. in the display area <stylus system name>
– Stylus Char. in the display area Stylus
These two additional fields are only editable if the OVCMM is activated.

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Using the OVCMM

Using the OVCMM

Procedure when using the OVCMM
You use the OVCMM to determine the uncertainty of the results of a
certain measurement plan. To do so, you usually proceed as follows:
– You activate the OVCMM and set the ambient conditions relevant
for the current measurement.
– Start the CNC run. After the CNC run, the OVCMM is automatically
active and determines the measuring uncertainty.
The determined measuring uncertainties for each characteristic are
output with the printout.
– Then, deactivate the OVCMM. The measuring uncertainties deter-
mined for the current measurement plan do not change from one
CNC run to the next.
It is only when you want to run a changed or new measurement
plan or the influencing variables have changed (e.g. the measuring
location or a physically changed stylus) that it is important to reacti-
vate the OVCMM to determine the characteristic-specific measuring
uncertainties that now apply.

Activating the OVCMM

Before the OVCMM can take effect after the CNC run, you have to acti-
vate it.
If the OVCMM is to consider additional influencing variables (e.g. work-
piece expansion coefficients or temperature changes with a certain
course), you must select the corresponding environmental condition.
Notice: The environmental conditions must have been configured be-
forehand by an accredited laboratory or by your ZEISS Service.
1 Select Extras " Settings " Measurement and click the VCMM
tab in the Measurement Methods notebook.
The notebook page with the Settings for measuring uncertainty
data VCMM opens.

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 Using the OVCMM

System configuration

File Pages

Measuring method

Settings for measuring uncertainty data VCMM Travel paths

Elements
OVCMM VCMM
Methods
Point density
Measuring uncertainty data active Output trace Point masking
SCAN Limits
Conditions for work environment Nominal value

Condition active Start angle

Form Datum
Condition Optics
MMC / LMC
Navigator
Definition of stylus influence Simulation
VCMM
Standard definition Man. Run

Advanced definition

Simulation
Prismo-Ultra RDS-CAA RDS RST Rotos

OK Cancel Apply

2 Activate the OVCMM option and activate the Measuring uncer-

tainty data active check box.
3 If the work of the OVCMM is to be entered in a log file, tick the In-
spection outputs check box.
This can be useful for tests and checks performed by ZEISS Service.
4 In the Environmental conditions group, tick the Conditions ac-
tive check box.
5 In the Conditions selection list, select the relevant specific environ-
mental condition.
6 Save and close with OK.
The OVCMM is now active. It will be started automatically after the next
CNC run and will take the selected conditions into account for the un-
certainty calculation.
Note: Do not forget to deactivate the OVCMM after the CNC run and
output of the printout, as it will otherwise become active again after ev-
ery CNC run and will repeat its calculations.

61212-2771502 CALYPSO 2018 1-11

Using the OVCMM

Results of the OVCMM

If the OVCMM has been activated, it will automatically start after each
CNC run.
The entire measurement plan is then repeated 128 times by the
OVCMM, giving measurement results that each time are differently, but
systematically distorted.
The error analysis includes:
– The results of the highly precise CMM qualification.
– The stylus characteristics.
– The environmental condition you may have selected.
– Additional contributions to measuring uncertainty, for example due
to ambient influences.
The standard measuring uncertainty is calculated as combined uncer-
tainty of all the influencing variables taken into account.
Then, the printout of the CNC run is output with an additional column.
This column shows the uncertainty U of each individual characteristic,
extended by the factor k=2.

NOTE
At present, the base alignment must not be created using a CMM and
the OVCMM Measuring Uncertainty Definition option. Recommended
procedure:
At first, measure the data without activating the OVCMM Measuring
Uncertainty Definition option.
Then perform the simulation in another CNC run without resetting the
results.

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Alphabetic index
M
Measuring results
Uncertainty 1-4
Measuring uncertainty definition
OVCMM 1-2

O
OVCMM 1-2
Activating 1-10
Basics 1-3
Configuring 1-6
Influencing variables 1-4
Interaction 1-5
Results 1-12
Stylus characteristics 1-6
Using 1-10

S
Standard definition
Stylus characteristics 1-6
Stylus characteristics
for OVCMM 1-6

U
Uncertainty of measuring results 1-4

V
Virtual CMM 1-2
Method 1-3
OVCMM 1-2
OVCMM results 1-12

61212-2771502 CALYPSO 2018 Alphabetic index 11

22 Alphabetic index 61212-2771502 CALYPSO 2018