Table of Contents
1 About This Guide..................................................................................................................................5
1.1 Purpose ........................................................................................................................................ 5 1.2 Scope ..........................................................................................................................................5 1.3 Audience .....................................................................................................................................5 1.4 Prerequisites ...............................................................................................................................5 1.5 Warranty ......................................................................................................................................6 1.6 Disclaimer of Liabilities ................................................................................................................6 1.7 Copyright and Trademark Information .........................................................................................6 1.8 Related Production Information ...................................................................................................6
2 Environmental and Safety Information...............................................................................................7
2.1 Environmental Considerations.....................................................................................................7 2.2 Safety Considerations .................................................................................................................. 7
3 KMR Mx200 System..............................................................................................................................9
3.1 Overview ......................................................................................................................................9 3.2 Features and Capabilities ..........................................................................................................10 3.3 KMR Mx200 Components and Features ...................................................................................10 3.3.1 X-Y Stage ..........................................................................................................................10 3.3.2 USB Camera with Image Measurement Software ............................................................10 3.3.3 MetLogix Mx200 Digital Read Out and Software ..............................................................11 3.3.4 Zoom Optics with Auxiliary Lens .......................................................................................11 3.3.5 Lighting Control .................................................................................................................12 3.3.6 Operator Controls and Interfaces......................................................................................12
4 System Specifications .......................................................................................................................13
4.1 Performance Specifications .......................................................................................................13 4.2 Hardware and Mechanical Specifications..................................................................................13 4.3 Camera Specifications ...............................................................................................................14 4.4 Optical Specifications ................................................................................................................14 4.5 System Controller Specifications ...............................................................................................14 4.6 MetLogix Mx200 Unit Specifications..........................................................................................15 4.7 Monitor Specifications ..............................................................................................................15 4.8 Electrical Specifications ...........................................................................................................15
5 Unpacking and Installing the System...............................................................................................17
5.1 Planning the Placement of Equipment ......................................................................................17 5.2 Components Included with the System .....................................................................................17 5.3 Unpacking the System ...............................................................................................................18 5.4 Removing the Red Shipping Tabs .............................................................................................19 5.5 Installing and Setting Up the System.........................................................................................20 5.6 On-Site Functional Test, Calibration and Training ....................................................................22 5.6.1 Contacting Starrett Kinemetric Technical Support ............................................................23
6 Operating the System ........................................................................................................................25
6.1 Powering On the System ...........................................................................................................25 6.2 Controlling the KMR System......................................................................................................26 6.3 Adjusting Focus .........................................................................................................................27 6.4 Setting Magnification .................................................................................................................27 6.5 Setting Illumination ....................................................................................................................27 6.6 Using and Adjusting the Camera ...............................................................................................27
6.7 Fixturing Parts and Skew Control ..............................................................................................29 6.8 Accessing the KMR System Camera ........................................................................................30 6.9 Using the Mx200 to Measure a Sample Part .............................................................................31
7 Measurement Strategy .......................................................................................................................33
7.1 Zoom Optics Measurement Strategy .........................................................................................33 7.2 Illumination Strategy ..................................................................................................................33 7.3 Magnification and Focus Strategy .............................................................................................33
8 System Maintenance ..........................................................................................................................35
8.1 Daily Inspections........................................................................................................................35 8.2 Weekly or Monthly Maintenance ...............................................................................................35 8.3 Zoom Optics Alignment Verification ..........................................................................................35 8.3.1 Zoom Optics Parfocality and Focus ................................................................................36 8.3.2 Zoom Optics Parcentricity ...............................................................................................36 8.3.3 Zoom Optics Squareness ................................................................................................37 8.4 Verifying the System Calibration ...............................................................................................37 8.5 Cleaning.....................................................................................................................................38 8.5.1 Cleaning External Surfaces.............................................................................................39 8.5.2 Cleaning Optics ................................................................................................................39 8.5.3 Cleaning Mechanical Parts..............................................................................................39 8.6 Spare Parts and Accessories ...................................................................................................40
9 Glossary ..............................................................................................................................................41
1 About This Guide
1.1 Purpose
This guide provides instructions on how to install, configure, and operate the Starrett Kinemetric Engineering KMR Mx200 Video Inspection System.
1.2 Scope This guide provides detailed information on the features and capabilities of the KMR Mx200 system. This guide also provides high-level information related to unpacking and installation. KMR systems are intended to be installed by SKE Technical Service specialists or qualified third-party personnel. In addition, this guide also provides information on operating and maintaining the KMR system.
1.3 Audience
This guide is intended for end-user customers, SKE Technical Services specialists, and authorized SKE technicians.
1.4 Prerequisites
You should have some knowledge of metrology systems and be familiar with customary system administration and field service practices.
Information that Requires Special Attention
This guide uses the following three conventions to present information that requires special attention: a warning, a caution, or a note.
A warning looks like this:
WARNING
Warning information is printed in a box. Warnings direct your attention to operating or maintenance procedures or practices that must be followed correctly to prevent personal injury, loss of life and, possible, hardware or software damage.
A caution looks like this:
Caution
Caution information is printed in a box. Cautions provide information that helps to prevent accidental hardware or software damage.
A note looks like this:
Note : Pay special attention to the information printed in italics that follows the Note: heading. Notes provide additional information that is important to the surrounding text.
1.5 Warranty Starrett Kinemetric Engineering, Inc. products carry a one-year (from date of purchase) warranty against defects in material and workmanship (parts and labor) subject to factory inspection. Parts not manufactured by Starrett Kinemetric Engineering, Inc. (for example, computers, monitors, etc. ) carry the original manufacturers’ warranty. Starrett might also process warranty for these parts. Starrett Kinemetric Engineering, Inc. will repair or replace, at our option, any part or parts, which we find defective in workmanship or material. We will warranty repaired or replaced parts for the balance of the original warranty period or 90 days whichever is longer. This warranty will not apply to defects resulting from modifications made by the customer or improper use of the system or its components. If applicable, parts returned to the factory will be repaired at no charge. UPS Ground freight will be paid by Starrett. Freight other than UPS Ground can be requested and additional fees may apply. Freight other than UPS Ground can be requested and additional fees may apply. This warranty does not cover damages from such causes as abuse, accident, neglect, fire, flood, electrical surge, or freight damage. 1.6 Disclaimer of Liabilities The L.S. Starrett Company shall have no liability or responsibility to the customer or any other person or entity with respect to any liability, loss or damage caused or alleged to be caused directly or indirectly by this documentation, or the hardware and software described in it. This includes, but is not limited to, any interruption of service, loss of business or anticipatory profits, or consequential damages resulting from the use or operation of hardware or equipment. 1.7 Copyright and Trademark Information TrueChrome Metrics is a trademark of Tucsen Photonics Co., Ltd. Metlogix, is a registered trademark of Metlogix, Incorporated. Android is a registered trademark of Google LLC.
1.8 Related Production Information
The following documents provide information that is related to the subject of this guide.
MetLogix Mx200 User’s Guide
This guide provides detailed information on operating the Mx200 software that is included with KMR system.
KMR200 Video Inspection System Unpacking Read Me First Instructions (1000 0082)
These instructions provide the information how to properly unpack the KMR systems.
2 Environmental and Safety Information
This section provides the environmental and safety information for the KMR system.
2.1 Environmental Considerations
The KMR system is factory calibrated under the standard laboratory environmental conditions shown in the following table.
Calibration Environment
Specification
Requirement
Ambient Temperature
20°C ± 0.5°C (68°F ± 5°F)
Humidity
40-60% RH
Temperature rate of change
0.5°C (1°F) per hour
Operating Environment
KMR system can be safely operated under the following environmental conditions:
Environmental Condition
Operational Requirement
Ambient Temperature
20°C ± 3°C (68°F ± 5°F)
Humidity
< 90% RH
If the system is to be operated under environmental conditions that are substantially different from those in the previous table, the system should be recalibrated under the expected conditions. You should also consider the material characteristics of the parts under inspection, for example, coefficients of thermal expansion. Numerical compensation might be required when measuring parts under conditions different from those controlling the stated dimensional specifications for these parts. Before performing critical parts measurements, allow the system to warm up and temperature stabilize for 30 minutes.
2.2 Safety Considerations
General Safety
The KMR system is designed for safety and proper ergonomics during normal use. Exercise caution when handling or moving the system to maintain calibration and measurement performance. Disconnect all power sources prior to moving or working on the equipment. Consult SKE if you have any questions regarding transporting, using, or maintaining the system.
Electrical Safety
The KMR system does not contain hazardous AC line voltages, as these are contained on the input side of the system’s AC adapters, which are UL listed. Even at these low voltages,
there is the potential of electrical component damage caused by accidental short circuits. For maximum electrical safety and minimal risk to the equipment, adhere to the following guidelines: • Ensure that the power receptacles for the AC adapters are properly grounded 3-prong polarized 100-240VAC for use in North America or appropriate safety-rated receptacles for use outside of North America. • Do not operate the systems with housings open except for service by a factory trained technician. • Keep liquids away from the systems, and do not operate the equipment in excessively humid conditions, as water can cause short circuits.
• Keep metal filings away from the systems, as such debris can cause short circuits.
• Do not operate the equipment around volatile or flammable solvents, as local electrical heating could cause ignition. • Disconnect power, or do not plug in the power cord, if hazardous conditions exist such as a damaged or frayed power cord, a damaged or improperly grounded power receptacle, equipment exposure to liquid spills or excessive moisture, or impact damage. Have the system inspected by authorized personnel before operating. There are no fuses or user-serviceable items in the systems. The system should only be opened by a factory-trained service technician.
3 KMR Mx200 System
This section provides the following information:
An overview of the KMR system
•
• A description of the features and capabilities of the KMR system
• A description of the major components of the KMR system
3.1 Overview The KMR Mx200 system is part of the Starrett Kinemetric Engineering (SKE) KMR family of video microscope systems. The KMR systems are modular, versatile, and affordable inspection and vision metrology systems. These systems are intended for receiving inspection, quality assurance, training, manufacturing assembly, research, and documentation. The KMR series is ideal for environments requiring easy setup and a range of magnifications. The KMR Mx200 system is a cost-effective measurement solution that does not require Windows or other operating system software. The system is ideal for customers that require a secure environment while maintaining seamless inspection and measurement capabilities.
Z Column
14-inch Monitor
LED Ring Light
Mx200 DRO
Manual Z Travel
System Controller
X-Y Stage with Manual Travel
Wireless Mouse
Figure 1. KMR System Overview and Components
3.2 Features and Capabilities
The KMR system includes the following features and capabilities:
• 6.5:1 magnifying zoom optics with six detents
• A manual 100 x 200 millimeter (3.9 x 7.9 inch) X-Y stage with digital encoders.
125mm of Z travel
•
• An HDMI camera with powerful built-in measurement capabilities
• USB mouse to interface with camera software
• MetLogix Mx200 software with a digital readout display
• A 14-inch low profile monitor with digital zoom capability
• System Controller that provides light and power control
LED backlight and ring light
•
• Built-in color restoration and image acquisition
3.3 KMR Mx200 Components and Features
This section provides information on the options available with the KMR system.
3.3.1 X-Y Stage
The system includes a manual 100 x 200 millimeter (3.9 x 7.9 inch) X-Y stage with digital encoders. The stage is made from precision machined aluminum. Surface mounting holes allow customer-designed fixtures for part support.
Figure 2. KMR X-Y Stage
3.3.2 USB Camera with Image Measurement Software
The KMR system includes a USB 2.0 2 megapixel (MP) camera. The camera provides 30fps (frames per second) data transfer at an uncompressed resolution of 1920X1080. Embedded with the camera is the TrueChrome measurement software. The software enables you to perform image capture processing, measurement, save, and export functions through the mouse directly. TrueChrome Metrics provides powerful measurement functionalities including, freehand line, rectangle, polygon, circle, angle, point-line distance, circumference, and area. Three different length units of millimeter, centimeter, and micrometer are provided to meet various measurement requirements in different applications.
3.3.3 MetLogix Mx200 Digital Read Out and Software
The Mx200 is a metrology readout and software for performing two axis measurements. User interaction with the software is through the color touchscreen or soft keys and function keys on the rubberized keypad. The Mx200 software includes the following key features and capabilities: • Features and Constructions : Supporting industry standard feature measurement and popular construction types. Toggle feature construction sub-types quickly with the change feature type button. • Geometric Tolerancing and Part Programming : Apply popular geometric tolerance controls to measured and constructed features using the Metlogix tolerance system. Apply nominal and tolerance limits quickly, and view results accurately, in the large and easy to read data views. • Report, Print, and Export : Choose from one of three report formats; CSV, Standard, or Tolerance. Report contents can include a report title, time and date stamps, and all feature measurement result data. Reports can be exported as text or CSV data files.
Figure 3. MetLogix Mx200 DRO
3.3.4 Zoom Optics with Auxiliary Lens
The KMR system includes 6.5:1 magnifying zoom optics with six detents.
Figure 4. Zoom Optics Assembly with Ring Light
3.3.5 Lighting Control
KMR systems include LED-based lighting control. Light is emitted by ultra-bright LEDs mounted directly in the ring light and collimated sub-stage light. The lighting is controlled using the System Controller.
3.3.6 Operator Controls and Interfaces
Low Profile Monitor
The KMR system includes a 14-inch monitor with dual USB Type-C ports with charging. The monitor also features mini HDMI port and a 3.5mm headphone jack for plug-and-play connectivity to additional devices.
Figure 5. 14-Inch Monitor
Mx200 Digital Read Out (DRO)
The Mx200 includes a color touchscreen that can be used to interact with the device. Or the readout can then be operated by using the soft keys and function keys of the rubberized keypad.
System Controller
The KMR System Controller enables you to control power and lighting for the system.
Figure 6. System Controller
Mouse
The wireless mouse is used to capture images, processing, and measurement through the image processing software.
4 System Specifications
The following table provides the specifications for the KMR system components.
4.1 Performance Specifications
The following information provides the performance specifications of the KMR system.
Feature
Specification
Measurement range (X-Y)
200 x 100 mm (7.9 x 3.9 inches)
Z travel
125 mm (5 inches)
Resolution
0.5 µm (0.00002 inch)
Accuracy
± (4µm + L/50)
Metrology means
X and Y encoders
4.2 Hardware and Mechanical Specifications
The following table provides the hardware and mechanical specifications of the KMR systems.
Feature
Specification
Unit Dimensions
545 x 460 x 445 mm (21.5 x 18 x 17.5 inch)
Metrology base
Precision aluminum
Motion Control
Manual X, Y, Z
Stage capacity
10 Kg (22 lbs)
Substage illumination
LED illumination
Surface illumination
LED ring light
Operator controls
Touch screen DRO, wireless optical mouse
Optics mount
Fixed mount 2.0 megapixel camera
The following figures provide the dimensions of the KMR system.
Figure 7. KMR System Dimensions
4.3 Camera Specifications
The following table provides the camera specifications for the KMR system.
Feature
Specification
Resolution
2 MP
•
1920X1080 uncompressed resolution
•
Frame Rate
30 fps (frames per second) data transfer
•
Data interface
USB 2.0, SD, HDMI
•
Optical port
•
Standard C-mount
•
4.4 Optical Specifications
The following table provides the optical specifications for the KMR system.
Feature
Specification
Optics
6.5:1 zoom
Optical magnification on CMOS
0.7X to 4.5X
Total magnification on monitor
25X to 155X
CMOS sensor
1/2.8 inch (2MP)
Working distance
3.47 in (88mm)
Field of view height (along X-axis)
1.02mm to 6.60mm
Field of view width (Y axis)
1.78mm to 11.43mm
4.5 System Controller Specifications
The following table provides the specifications for the System Controller.
Feature
Description
AC power
Voltage requirement 120/240 VAC
Power Control
On/Off switch
Lighting Control
Ring light dimmer switch
•
Profile light dimmer switch
•
HDMI input
HDMI connection from the System Controller to the KMR unit. DB9 power cable connection from System Controller to the KMR unit.
DC input
4.6 MetLogix Mx200 Unit Specifications
The following table provides the specifications for the MetLogix Mx200 unit.
Feature
Specification
Color graphic 1080P monitor
Display
286mm wide x 51mm deep x 162 mm high
Dimensions
Operating system
MLX Android ™
Software
MetLogix
Color graphics
Yes
Optical edge detection
No
Touchscreen operation on digital readout
Yes
X-Y measurements
Yes
Point, line, angle, distance, radius, diameter measurement JPEG image capture and exporting with camera software
Yes
Yes
Exporting
To Excel, text file
4.7 Monitor Specifications
The following table provides the specifications for the monitor.
Feature
Specification
Screen size
14.0 inches
Panel type
IPS
Resolution
1920x1080
Contrast Ratio
1200:1
250 cd/m 2
Brightness
Input interfaces
Mini HDMI, Type-C full function
Output interface
3.5mm headphone jack
4.8 Electrical Specifications
The following information provides the power requirements for the KMR Mx200 system.
Feature
Specification
Power supply location
Inside system controller
Voltage requirement
120/240V AC
Power requirement, KMR unit
300W peak, 200W typical
5 Unpacking and Installing the System
This section provides information on installing the KMR system:
• Planning the placement of the equipment
Components including with the system
•
Unpacking the system
•
Removing the red shipping tabs
•
Installing and setting up the system
•
• Obtaining on-site functional testing, calibration, and training
5.1 Planning the Placement of Equipment
When planning the placement of the KMR system, refer to the following recommendations:
• Ensure a clean operating environment to minimize the accumulation of dirt on the optics and on precision mechanical parts, such as lead screws and encoder scales. • Ensure the planned installation location has the proper electrical requirements. Refer to “Electrical Specifications” earlier in this document for detailed information. • Select an installation location where the temperature can be controlled to within 20°C ± 0.5°C (68°F ± 5°F), which is the calibration temperature of the system. • It is recommended (but not essential) the system be placed on a level work surface using a bubble level for verification. • Allow 60 centimeters (24 inches) to right or left side of the metrology unit to position the monitor. • Allow additional clearance of 30 centimeters (12 inches) on both sides is recommended for general access. Refer to “System Specifications” earlier in this document for the detailed information on the dimensions of the system.
5.2 Components Included with the System
The following information provides the components that are included with the system:
Component
Description/Quantity
KMR metrology system
1
14-inch monitor
1
MetLogix Mx200 unit
1
Power cables
• DB9 cable from System Controller to KMR unit (1 qty) • Power cable from System Controller to AC power source (1 qty) • 12V power supply for Mx200 readout (1 qty)
Additional cables
HDMI (1 qty)
•
X and Y encoder cables (2 qty)
•
Component
Description/Quantity
Miscellaneous items
Wireless mouse
•
Starrett mouse pad
•
SD card for image storage
•
5.3 Unpacking the System
Tool Requirements
The following items are required to uncrate and install an KMR system:
• Battery powered drill with Phillips bit (to remove top and sides of shipping crate)
Metric hex wrench
•
Procedure
The KMR system is shipped in a single wooden crate. To unpack the system, refer to the following figures and perform the following steps: 1. Locate the fourteen screw locations that are marked in red on the crate. Refer to the following figure. 2. Using a power screwdriver, remove the eight Phillips screws from the lid and the six Phillips screws from the front side of the crate.
Figure 8. KMR Crate with Screw Locations in Red
3. Carefully remove the contents of the crate from the open side. The monitor and Mx200 DRO are included in separate boxes.
4. Verify that your system is complete as listed in the previous table.
Figure 9. KMR System Crate with Lid and Front Side Removed
5.4 Removing the Red Shipping Tabs Starrett Kinemetric X-Y stages use metal tabs to prevent movement during shipment. Painted red for easy identification, these are intended to be removed once the equipment has been placed in its final position.
1. Locate the red shipping tabs on the system. Refer to the following figure.
• Two tabs are located on the front of the system.
• One tab is located on the back left side of the system.
Figure 10. Red Shipping Tabs Front and Side of System
2. Using a metric hex wrench, remove the two M4 socket head cap screws that secure the tab.
3. Store the tabs and their mounting screws for a possible later move of the equipment.
5.5 Installing and Setting Up the System
To install and setup the system, perform the following steps:
1. Ensure the shipping tabs have been removed from the system and all components have been removed from the individual boxes. Refer to the previous section.
1. From the System Controller column, attach the Mx200 DRO to the bottom VESA mount.
2. From the System Controller column, slide the monitor onto the top VESA mount.
3. Attach the HDMI cable coming from the System Controller column to the side of the monitor. Refer to the following figures. 4. Attach the power cable to the USB type-C port on the side of the monitor. Refer to the following figures.
USB Type-C Port for Power Cord
Figure 11. Monitor Control Panel
Figure 12. HDMI and Power Cable Connections
5. Connect the Mx200 unit as follows. Refer to the following figures.
a. Attach the Mx200 12V power supply connector (positive tip) to the power input port on the Mx200 readout. Refer to the following figure. b. Connect the remaining end of the power supply 2-wire line cord cable to a stable 110/220 AC power source. c. Attach the X and Y encoder cables to the inputs on the back of the unit. The input is labeled X or Y accordingly. Refer to the following figures.
Figure 13. Mx200 Encoder and Power Connections
Figure 14. Mx200 Encoder Connections
6. Connect the HDMI cable from the System Controller to the KMR system column.
7. Connect the DB9 power cord from the System Controller to the KMR system column.
8. Plug the power cord from the System Controller to an AC power outlet.
HDMI cable connection to KMR unit
DB9 power cable to KMR unit
AC power connection
Figure 15. System Controller Rear Panel with Cable Connections
HDMI Cable
DB9 Power Cable
Figure 16. KMR Unit Connections
5.6 On-Site Functional Test, Calibration and Training All SKE vision metrology systems and optical comparators are calibrated at the factory prior to shipment; however, it is possible that components may have moved during shipment. A complete functional test and calibration are recommended following physical installation. Professional system installation is available for all KMR systems and is quoted as a separate line item. As part of its setup services, SKE oversees the equipment’s in -plant transportation to its permanent location and uncrating. SKE then performs the physical setup and electrical connection, followed by a completed functional checkout. This typically takes 1/2 day for a KMR system. The system is then allowed to temperature stabilize overnight. On-site calibration normally takes place on the day following setup. Calibration uses NIST- traceable glass grids and gage blocks. Calibration typically takes 1/2 to 1 day for a KMR system. On-site basic operator training is provided following calibration. This typically takes 1/2 day for a KMR system. Many customers choose to augment basic training with additional hands- on training, where new operators program parts of the type on which they will be working. Training is with the new equipment and is limited to 1 to 3 people, so that these can all get hands-on time. SKE’s objective is to create “ power users, ” who can then train other users when needed.
Installation services in North America (USA, Canada and Mexico) are provided by professional service technicians operating out of the Laguna Hills, CA, headquarters of Starrett Kinemetric and its regional sales offices. Outside of North America, installation services are provided by Starrett subsidiaries in Brazil (for South America), Scotland (for Europe and Africa), China (for Mainland China), and Singapore (for Southeast Asia), and Australia.
Visit http://www.starrettmetrology.com for more details and to request services.
5.6.1 Contacting Starrett Kinemetric Technical Support
To contact Starrett Kinemetric for additional services, training, or technical support issues, visit www.starrettmetrology.com. From the Starrett Kinemetric service site you can the following:
• Request technical support through our ticketing system.
Register your system.
•
Download User Manuals.
•
• Access our Starrett Kinemetric Knowledge Base for answers to frequently asked questions.
• Learn more about the installation, service, and training services available.
6 Operating the System
This section provides the following information on operating the KMR system:
Powering on the system
•
Using the system controls
•
• Setting focus, magnification, and lighting for the system
Using parts fixturing
•
Accessing the KMR camera
•
6.1 Powering On the System
The power on the KMR system, perform the following steps:
1. Ensure power cables are plugged into an appropriate AC power outlet.
2. Press the power button on the front of the System controller.
Figure 17. System controller Power Button
3. Press the power button on the left side of the monitor. Refer to the previous figure.
4. Press the Power button located in the bottom left corner of the Mx200 keypad.
Allow Mx200 boot sequence to complete.
Figure 18. Powering On the Mx200 Unit
6.2 Controlling the KMR System
The following table provides the information on how to control the KRM system. Refer to the following figure to the control locations.
Function
Method
X-axis travel
Left side hand wheel
Y-axis travel
Right side hand wheel
Z axis travel
Z column hand wheel
Lighting control
Profile/Ring light: Turn the dimmer knob to the right to increase the light. Turn the knob to the left to decrease the light.
Z-axis hand wheel
X-axis hand wheel
Y-axis hand wheel
Figure 19. KMR Unit System Controls
Figure 20. System Controller Lighting Controls
6.3 Adjusting Focus
To adjust the focus of the KMR system, raise and lower the optical head using the Z axis hand wheel. Following are guidelines for setting focus:
• The object to be viewed will be in best focus at a specific height.
• Use the two large knobs on the side of the Z-column for height adjustment.
• Focusing is most sensitive at the highest magnification.
6.4 Setting Magnification
Set magnification by turning the knurled adjustment in front of the zoom optics to one of its six detent positions. Following is additional information on magnification: • With parfocal zoom optics used the KMR system, the image will stay in focus regardless of magnification. • You might want to set focus at highest magnification, then reduce magnification and increase the field of view.
• The system is calibrated for all six zoom detent positions.
6.5 Setting Illumination
KMR systems with dedicated zoom optics are shipped with LED substage illumination that is optimized for these optics. No action is required by the user. Use the Profile or Ring light dimmer knobs on the System Controller to increase or decrease lighting from the profile or ring light.
6.6 Using and Adjusting the Camera
The following provides basic information on the using and adjusting the camera.
Default Settings
The HDMI camera included with the system includes numerous options and settings. The following options are set by default.
Auto Exposure: Off
•
Crosshairs: On
•
Accessing Camera Settings
To access camera settings and operations, do the following: • Move the cursor to the left of the screen to display the Capture and Setting icons. Refer to the following figure. • Move the cursor to the right of the screen to display the shortcut buttons. Refer to the following figure.
• Right click to enter the calibration and measurement module.
Adjusting Camera Settings
To adjust the default camera settings, access the Setting menu. Additional options include exposure rate and color options. Refer to the previous figure.
Camera Operations
Refer to the following figure and corresponding table for a description of the camera functions.
Number
Function
Description
1
Scale bar
Toggle the scale bar on the picture On or Off.
2
Coordinate
Obtain the coordinates of the selected points.
3
Line
Horizontal and vertical line measurement.
4
Freehand Line
Obtain the freehand line length.
5
Rectangle
Measure rectangle perimeter and area. Selectable to have the data of radius, perimeter, or area. • Center point: Use center point and point to draw a circle. • Two point: Draw a circle according to the diameter. • Three point: Use three point to draw a circle. • Selectable to have the data of radius, perimeter, or area.
6
Circle
Number
Function
Description
7
Polygon
Measure polygon perimeter or area. Selectable to have the data of perimeter or area.
8
Perpendicular
Measure the perpendicular length.
9
Concentric circles
Obtain the diameters of two concentric circles.
10
Bicircle
Obtain the distance between two circles’ center points .
11
Angle
Measure an angle.
12
Setting
• Set the measurement width, color, and font color. • Magnifier On/off: Switch on/off the magnifier. When the magnifier is switch on, the cursor located area will be zoomed in and placed at the corner to help accurately locate the measurement point. Select to export the measurement results to an Excel or text file. The exported results will be saved to an SD card. Enables the user to create 10 groups of calibration files in the calibration table and to select 10 groups of files to do measurement.
13
Save Results
14
Set Scale
15
Exit
Exit the measurement.
6.7 Fixturing Parts and Skew Control Parts must be fixtured securely to prevent part movement during measurement. In addition, proper alignment of the part to the stage can aid in measurement. If the part is off-axis from the stage, X-Y-Z measurements will not correlate as well with the part dimensions. Aligning the part with the X, Y and Z axes of the system will improve dimensional measurements. Orientation errors, or skew errors, can also be removed by creating a reference frame based on the part before taking measurements. Refer to the MetLogix Mx200 User’s Guide for details. The following figure provides the location of the tooling holes on the system. Use these locations to customize the system to your operating requirements.
Figure 21. KMR Top Plate Tooling Holes
6.8 Accessing the KMR System Camera The HDMI camera included with the KMR system is mounted in the KMR unit. The camera includes an SD card (for data storage) and a USB port for the mouse dongle. To access the camera, do the following: 1. Lift the lid at the top of the KMR column. The lid is attached with magnets for easy access and removal.
Figure 22. KMR Camera Access Lid
2. Access the SD card and USB mouse dongle from the top of the camera.
Figure 23. HDMI Camera Top View
6.9 Using the Mx200 to Measure a Sample Part Every machine should have a practice part that is shipped with the machine. This part should also have a printed and dimensioned pdf file included with the machine. Refer to the following figure.
Procedure
To measure a sample part with Mx200 software, do the following:
1. Power on the Mx200 DRO.
Allow Mx200 boot sequence to complete. Once the Mx200’s main DRO view is displayed you can continue with the procedure. 2. Place or clamp part on stage. Part should be clean and free of burrs as much as possible. The part must not move during measurement. 3. Move the stage so the lower left side of the part is in the FOV (field of view) of the camera. 4. Use the lighting controls on the System Controller to adjust the lighting. This part works best with a contrast of black (part view) and white.
5. Get the clearest view of the part using the hand cranks.
6. Select the Simple Crosshair probe option from the Probe menu. Click once the bottom line of the part, then once on the left line of the part.
7. Make a skew and a datum to give the part a reference point for measurement.
8. As you measure the rest of the part, the right side of the screen will begin to populate the geometric shapes that you measure, and create data points to determine critical distances for the part. These are automatically saved once you run the part for measurement. Refer to the following figure.
9. Once you have completed your measurement, the results will be displayed in the following window. Each feature will have a unique set of coefficients. In this example of a circle, the X and Y center position, plus the circle Diameter are displayed.
10. Click on Play from the Program menu. You will be prompted to measure the first feature in your part program. 11. Continue following the onscreen instructions to complete all datum feature measurements. Once the datum has been completely established (skew and zero), the feature graphic will provide directional guidance to each point in the remaining features of the part program.
7 Measurement Strategy The KMR Mx200 is available with 6.5:1 zoom optics with adjustable magnification from 0.7X to 4.5X. As used here, magnification is the image size at the camera CMOS detector place divided by the object size. Since the CMOS size is fixed, each magnification has a corresponding field of view (FOV), which is the CMOS size divided by magnification. The higher the magnification, the higher the resolution, but also the smaller the field of view. 7.1 Zoom Optics Measurement Strategy Zoom optics are ideal to measure large parts which would not fit into a single FOV, also to measure smaller parts where extremely high magnification is required. The lowest zoom magnification setting accommodates parts up to 11.2 x 9.4 millimeters (0.44 inches x 0.37 inches) in the FOV. To measure large parts, locate the edge of interest at minimum magnification, then take the actual measurement at maximum magnification using the system's crosshairs. The zoom optics’ parcentricity feature ensures that a feature will remain at the optical center of the video image throughout the magnification range. In general, higher magnification provides greater resolution and accuracy; however, not all features should be inspected at the highest available magnification. Too high a magnification might make it difficult to discern edges by exaggerating edge defects such as burrs or chips. Try decreasing the magnification until the edge is more clearly identifiable. Also consider factors such as tolerance requirements, manufacturing processes, functional requirements and optical characteristics of the part. Features with loose tolerances might not need to be inspected at high magnification. Select the magnification best suited for the requirements. 7.2 Illumination Strategy Once the image has been properly focused and magnification has been set, adjust light levels as necessary using the light controls on the System Controller. The right lighting is paramount to accurate measurement with any video-based measurement system. Lighting that is too dim will result in a dark, low-contrast image with indiscernible features. Lighting that is too bright might result in a washed-out image and blooming, or oversaturated bright regions that distort features. When adjusting lighting, start with light that is lower than desired, and then increase lighting while viewing the image on the monitor. Maintain constant lighting for consistent results. Always use the same light level while sampling points for a single feature – do not to change light levels during a measurement run. Depending on the part characteristics and the feature being viewed, the right combination of lighting might aid in bringing out a particular feature. Take time to experiment by balancing the available light sources. 7.3 Magnification and Focus Strategy Accurate measurement requires proper focus of the image. With a zoom lens, focusing is most sensitive at highest magnification. A good strategy is to first focus the image at the highest magnification, and then decrease magnification to the desired level. In general, high magnification (or zoom) helps with accurate measurements. However, while high magnification provides high resolution, it does not always provide the highest accuracy, and not all features should be inspected at the highest available magnification. Too high a magnification might make it difficult to discern the edge of a feature by exaggerating edge defects such as burrs and chips. Try decreasing the magnification until the edge is more clearly definable. Also, there is an inverse relationship between magnification and field of view; using a lower magnification might be more convenient.
Also consider factors such as tolerance requirements, functional requirements, manufacturing processes, and optical characteristics of the part. Features with loose tolerances might not need to be inspected at high magnification. Experiment to select the magnification that is most suitable for the feature being inspected or measured.
8 System Maintenance KMR systems have been designed for years of superior service. Periodic maintenance as outlined in this section should be performed to maintain the system in peak operating condition.
• Perform a daily inspection to ensure that the system is operating correctly and that proper safety guidelines are being followed.
• Periodically verify basic optical performance.
Periodically perform cleaning.
•
• Schedule regular factory-authorized calibration and maintenance service to preserve proper function and accuracy. • Replace batteries when needed for wireless mouse. Have alkaline AA batteries on hand for the mouse.
8.1 Daily Inspections
On a daily basis, inspect your system for general safety and basic functionality:
• Verify that the work area is clean, dry, and free of debris. Remove any debris or loose items from around the system and metrology stage. • Verify that the electrical power cords are plugged into a grounded power source and are unobstructed.
• Verify that temperature and humidity are within recommended ranges.
• Allow the system to warm up to normal operating temperature before performing critical parts measurements.
8.2 Weekly or Monthly Maintenance
On a weekly or monthly basis (based on experience), do the following:
• Inspect the system for cleanliness. If the system is dirty, refer to “Cleaning” later in this section for more information. • Verify that the stage control mechanisms move freely. If the stage binds, call for service. KMR lead screws use plastic nuts. Do not apply any grease or other lubricant. • Check the system for calibration against a certified chrome-on-glass standard if critical dimensions are to be measured. 8.3 Zoom Optics Alignment Verification The performance of zoom optics should be verified regularly to ensure accurate measure- ments. Parfocality, parcentricity, and squareness verifications are straightforward and can be performed as often as desired. Focus is set during normal operation by changing the distance between the lens and the surface being viewed.
8.3.1 Zoom Optics Parfocality and Focus
Caution
While optical alignment verification can be performed by an operator, optical alignment correction should only be performed by an authorized service technician. If alignment discrepancies are found, contact SKE or your local SKE representative to schedule authorized service.
Parfocality is the optical property that enables the video image to remain in focus as magnification is adjusted from highest to lowest. SKE zoom optics are designed to maintain parfocality throughout their magnification range. To check parfocality, always reference a flat, sharp edge. Do not select a rough or sloping feature. The magnification checker (part number 9123) available from Starrett Kinemetric is an ideal tool to check parfocality.
Checking Parfocality
To check parfocality, perform the following steps:
1. Place the magnification checker or other suitable inspection part on the stage and secure properly.
2. Backlight the image as necessary. Set light levels as needed to avoid blooming.
3. At low magnification, select a flat, sharp edge in the center of the field of view (FOV).
4. Select highest magnification, and carefully refocus the image by physically changing the viewing distance. 5. While observing the feature, slowly adjust the magnification lower. Verify that the feature remains focused as the magnification is lowered. 6. Report any observed discrepancy. If the error is verified, contact your SKE representative for authorized service.
8.3.2 Zoom Optics Parcentricity
Parcentricity is the optical property that enables a feature to remain at the optical center of the video image throughout the magnification range. Like parfocality, parcentricity requires that the feature be first located at highest magnification.
Checking Parcentricity
To check parcentricity, perform the following steps:
1. Place the magnification checker or other suitable inspection part on the stage and secure properly. 2. Select the crosshair image tool and verify that it is at its defined center position. Refer to the Mx200 Software User’s Guide or details on centering the crosshair. The crosshair is to remain at this position during the parcentricity test. 3. Zoom to low magnification and adjust the stage position so that the crosshair is centered on the X-Y axis of the calibration standard (or another suitable feature if the standard is not used).
4. Change to high magnification and refocus the image.
5. Adjust the stage position as needed to re-center the crosshair on the feature.
6. While observing the feature, slowly adjust the magnification lower. Verify that the feature
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