HVR100 Benchtop Digital Video Vision System User Manual
Starrett Kinemetric Engineering 26052 Merit Circle, Suite 103 Laguna Hills, CA 92653, USA www.starrettkinemetric.com Phone: (949) 348-1213 Fax: (949) 582-8040
Table of Contents
1. PREFACE........................................................................................................................................5
1.1 Introduction...........................................................................................................................5 1.2 Safety Symbols & Terminology ...........................................................................................5 1.3 Warranty ...............................................................................................................................6 1.4 Regulatory Compliance .......................................................................................................6 1.5 Disclaimer of Liabilities ........................................................................................................7 1.6 Copyright and Trademark Information ................................................................................7
2. PRODUCT DESCRIPTION.............................................................................................................9
2.1 Overview...............................................................................................................................9 2.2 HVR100 Configurations .......................................................................................................9 2.3 System Specifications........................................................................................................10
3. HVR100 SYSTEM COMPONENTS .............................................................................................13
3.1 Manual Illumination and Lens Control ..............................................................................14 3.2 Keyboard Usage and Wireless Mouse .............................................................................15 3.3 Electrical Power .................................................................................................................15 3.4 Operational Values ............................................................................................................16 3.5 Safety Considerations........................................................................................................17
4. INSTALLATION ............................................................................................................................19
4.1 Installation Overview..........................................................................................................19 4.2 Planning Placement of the System ...................................................................................19 4.3 Moving the System ............................................................................................................20 4.4 Unpacking the System.......................................................................................................21 4.5 Setting Up the System PC.................................................................................................23 4.6 Setting Up the Metrology Unit ...........................................................................................23 4.7 Verifying the System is Operational ..................................................................................23 4.8 On-site Functional Test, Calibration and Training ............................................................23
5. SYSTEM OPERATIONS ..............................................................................................................25
5.1 System Controls.................................................................................................................25 5.2 Powering the System On and Off .....................................................................................28 5.3 Switching the System from the Vertical to Horizontal Position........................................28 5.4 Switching the System from the Horizontal to Vertical Position ........................................29 5.5 Access to Electronics.........................................................................................................29
6. MEASUREMENT STRATEGY .....................................................................................................31
6.1 Measurement Accuracy and Depth of Field .....................................................................31 6.2 Lighting and Illumination Strategy .....................................................................................32 6.3 Parts Fixturing ....................................................................................................................33 6.4 M3 Software Operation......................................................................................................33
7. SYSTEM MAINTENANCE............................................................................................................35
7.1 Daily Inspections ................................................................................................................36 7.2 Weekly Inspections ............................................................................................................36 7.3 Cleaning .............................................................................................................................36 7.3.1 Cleaning External Surfaces ...............................................................................................36 7.3.2 Cleaning Optics..................................................................................................................37
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7.3.3 Cleaning Critical Mechanical Parts ...................................................................................37 7.3.4 Recommended Spare Parts ..............................................................................................37
8. GLOSSARY ...................................................................................................................................39
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1. PREFACE
1.1 Introduction
Thank you for purchasing an HVR100 Digital Video Vision System. We are pleased that your search has led you to Starrett Kinemetric Engineering, a subsidiary of the L.S. Starrett Company. This manual is intended to maximize your satisfaction with your system and ensure the most in operating performance. Feel free to contact Starrett Kinemetric Engineering at any time. We value your feedback and your satisfaction as a customer.
1.2 Safety Symbols & Terminology
The following symbols and terms are used in this manual to call attention to important safety issues. Heed these notices carefully to avoid personal injury or damage to the system.
Symbol or Term
Meaning
CAUTION : Failure to heed the message may result in personal injury or equipment damage.
WARNING : Dangerous voltage. Risk of electrical shock. Failure to observe this warning might result in equipment damage, personal injury or death. WARNING : Disconnect equipment from power source. Failure to observe this warning might result in equipment damage, personal injury or death. CAUTION : Pinch Point - Keep hands clear. Failure to observe this warning might result in minor to severe personal injury or equipment damage. Immediate hazard which could result in severe personal injury or death.
DANGER
WARNING
Hazard or unsafe practice which could result in personal injury.
CAUTION
Hazard or unsafe practice which could result in equipment damage or minor injury.
Note
Information that is helpful in properly operating the equipment.
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1.3 Warranty
Starrett Kinemetric Engineering products carry a one-year warranty from date of purchase against defects in material or workmanship (parts and labor), subject to factory inspection. Starrett Kinemetric Engineering will repair or replace, at its option, any part or parts found to be defective in material or workmanship. Starrett Kinemetric Engineering warrants repaired or replaced parts for the balance of the original warranty period or 90 days, whichever is longer. Parts returned to the factory under warranty will be repaired at no charge. Freight charges to the factory will be paid by the customer. Return freight charges to the customer will be paid by Starrett. This warranty does not cover damages from such causes as abuse, accident, neglect, fire or freight damage. It does not apply to defects resulting from modifications made by the customer or improper use of the system or its components.
1.4 Regulatory Compliance
The HVR100 system has been inspected, tested, and evaluated by independent test laboratories and is declared to comply with Council Directives 2014/30/EU. Accordingly, these systems are entitled to bear the CE Mark. The Product Safety, EMC Testing and Evaluation reports can be provided upon request.
EMC Test Standards
Standard
Specification
EN 61326-1:2013 CISPR 11:2003+A1:2004 +A2:2006
Radiated and Conducted Emissions
EN55011 Class A
Conducted Electromagnetic Emissions
EN55011 Class A
Radiated Electromagnetic Emissions
IEC 61000-4-2:2009
Electrostatic Discharge Immunity
IEC 61000-4-5:2006
Power Line Surge Immunity
IEC 61000-4-4:2012
Electrical Fast Transients Burst Immunity
EN 61000-4-6:2009
RF Common Mode Immunity
IEC 61000-4-3:2006 +A2:2010
Radio Frequency Immunity
IEC 61000-4-8:2010
Power Frequency Magnetic Field Immunity
IEC 61000-4-11:2004
Voltage Dips and Short Interruptions Immunity
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Safety Standards
Standard
Specification
Safety of Machinery, Electrical Equipment of Machines
EN 60204-1:2006+A1:2009
EN 12100
Safety of Machinery, Principles for Risk Assessment
1.5 Disclaimer of Liabilities
Starrett Kinemetric Engineering shall have no liability or responsibility to the customer or any other person or entity with respect to any liabilit y, 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.
1.6 Copyright and Trademark Information
HVR100™ is a trademark of Starrett Kinemetric Engineering. M3™ is a trademark of MetLogix, Inc. Windows ® is a registered trademark of Microsoft Corporation.
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2. PRODUCT DESCRIPTION
2.1 Overview
The HVR100 is a fixed-stage benchtop digital video vision system that can be oriented both vertically and horizontally. The HVR100 has a large field of view, providing optical accuracy better than .010 mm (.0004-inches)**. The system comes with a 5-megapixel digital video camera and includes a telecentric lens for micron-level resolution and measurement.
Note: ** Measurements were made using a 25mm fiducial on glass circle, .750-inch gauge block, and a .621-gauge pin with appropriate shape correction.
The HVR100 is a manually operated system. The Z-axis of the telecentric lens is controlled by a wire-controlled pendant. The system features a high-strength frame, a 24-inch touch-screen monitor with a system PC, wireless keyboard, wireless mouse and MetLogix M3 vision metrology software with the M3 DXF/FOV option pack.
The M3 software includes the following features:
• Provides the ability import DXF CAD files over a network and make automatic 2D go-no- go comparisons to an engineering design by using video edge detection (VED), with no need for the screen overlays that would be required with a vision system. 2D geometric functions include points, lines, circles, arcs, rectangles, distances, slots, angles and skew. • Displays a live video image of the part plus geometry tools and digital readings. The image of the part can be resized using pan and zoom, and measurements can be taken by simply tapping a feature on the screen. HVR100 systems are rugged machines that are equally suitable in a quality lab or on the shop floor. The maximum workload capacity of the system is 20 pounds. The computer, M3 controller, and electronics are located inside the housing, resulting in a clean design with minimal external wiring. The housing is designed to minimize the entry of oil and dust particles in machine shop environments. Two high-speed data cables carry all signals between the metrology unit and system PC. Superb metrology performance is provided by a high-resolution video camera and telecentric lens that enable accurate field-of-view (FOV) measurements.
2.2 HVR100 Configurations
The HVR100 system can be conf igured in both vertical and horizontal system positions. This dual conf iguration provides the best features of a vision metrology system in one system. Switching from one conf iguration to another is accomplished quickly and easily with minimal configuration changes.
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2.3 System Specifications
Performance
Feature
Specification
Focus Range, Z (front-back)
165.1 mm (6.5 inches)
Maximum Object Height
152.4 mm (6 inches)
Stage Load Capacity
20 lbs
Mechanical
Feature
Specification
Mounting Location
Benchtop
Height
1016 mm (40 inches)
Width
432 (17 inches)
Depth
432 (17 inches)
Monitor Dimensions
565 x 975 x 64 mm (24 x 38.4 x 2.5 inches)
Height of Center of Monitor
0 to 250 mm (0 to 10 inches), adjustable
Basic Stand
Billet machined frame
Stage Material
Aluminum
Housing Material
Aluminum
Stage Area
349.25 x 165.1 mm (13.75 x 6.5 inches)
Shipping Weight
206 pounds (93.4 kilograms)
Shipping container dimensions
121.9 x 66.0 x 78.7 cm (48 x 26 x 31 inches)
Illumination
Feature
Specification
Surface Illumination
190 mm (7.5 inches) diameter LED ring light mounted around body of lens
Profile Illumination
120 mm (4.7 inches) collimated LED backlight
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Optical
Feature
Specification
609.6 mm (24 inches) diagonal monitor, backlit LED, 1920x1080 pixels
Operator Display
Monitor Display Area
279.4mm x 241.3 mm (11 x 9.5 inches)
Monitor Pixel Size
0.36 x 0.36 mm (0.014”)
Sentech monochromic, 5 megapixels (2448 x 2058) on 2/3- inch array
Camera Type
Camera Interface
USB 3.0 cable
Optics Mount
Fixed
Working Distance
255 mm
Telecentric Lens Magnification
.090X
Telecentric Lens Field of View
92.7 mm x 76.2 mm (3.65 x 3.0 inches)
Screen magnification
3X
Visual Resolution on Monitor
1920 x 1080 pixels
Optical Distortion
-.026%
Telecentric Depth of Field (split 1/3 front, 2/3 back)
25 mm
Telecentric Lens FWD
255 mm
Optical accuracy **
.010 mm (.0004-inches) or better
Note: ** Measurements were made using a 25mm fiducial on glass circle, .750-inch gauge block, and a .621-gauge pin with appropriate shape correction.
Operator Controls
Feature
Specification
Computer Interface
24-inch color monitor, wireless keyboard and wireless mouse
Lens movement
Wire-controlled pendant that controls the speed and direction of telecentric lens moving on the Z-axis.
Power
On/Off switch that powers the HVR system on and off.
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Internal Power Supply
Feature
Specification
Voltage Requirement
120/240V AC
Frequency
50-60 Hz
Maximum current
1.3A
Output
24V, 60W, 2.5A
External Power Supply
Feature
Specification
Power Supply
“Brick” type AC adapter, 100/240 VAC for the PC
Voltage Requirement
120/240V AC
Power Requirement, Main Unit
40W
Power Requirement, Monitor
60W typical
Computer & Software
Feature
Specification
Computer Hardware
System PC
Network Interfaces
Ethernet (1 GB/sec), Wi-Fi, 6 USB 2.0 ports, 2 USB 3.0 ports
Windows ® 10 Professional
Operating System
Application Software
MetLogix M3 Version 2 software with FOV/DXF option pack
Comparison to CAD files
DXF CAD file import, automatic comparison to CAD files
Geometrical Constructs
2D geometries
Operator Controls
Computer touch-screen, wireless keyboard, wireless optical mouse
Applications
Feature
Specification
Video Inspection
Yes
Dimensioning
Video edge detection (VED)
Geometric Constructs
Yes
Image Annotation
Yes
Image Archiving
Yes
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3. HVR100 SYSTEM COMPONENTS
The following figures illustrate the key components of the HVR100 system.
Telecentric lens and LED ring light
•
24” touch- screen monitor
•
255 mm of Z-axis travel
•
Fixed stage
•
Keyboard
•
I/O Control Panel
•
Wireless mouse
•
Ergonomic workstation
•
•
HVR100 System Components (Vertical Position)
Level pads
•
Rear pivots
•
HVR100 System Components (Horizontal Position)
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3.1 Manual Illumination and Lens Control
The focus position of the telecentric lens is controlled by a wire-controlled pendant. The pendant is connected to the I/O control panel on the right side of the system with a DB9 connector. The pendant includes functionality to control both speed and position of the lens. See the figure below.
Position lever
•
Speed control
•
Wire-Controlled Pendant
Control
Function Tasks
Speed selector
• Move the selector up (=) to set the speed to Fast. • Move the selector to the middle position (O) to set the speed to Normal. • Move the selector down (—) to set the speed to Slow. • Push the lever to the Up position to move the lens up in the vertical direction. • Push the lever to the Down position to move the lens down in the vertical direction.
Position Lever
The light levels are controlled through slides within the M3 software. Refer to the M3 software documentation for additional information.
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3.2 Keyboard Usage and Wireless Mouse
The HDV100 wireless keyboard is used for programming, data entry, and program operation. The system also includes a wireless mouse to control program operation. • Power to the wireless mouse is provided by a single AA battery. Have spare AA batteries on hand. • Power to the wireless keyboard is provided by two AAA batteries. Have spare AAA batteries on hand.
3.3 Electrical Power
HVR metrology unit includes an internal power supply. The unit accepts 100/240 VAC (50/60 Hz) power for worldwide use. The maximum combined current draw is 1.3A. Ensure that the power outlet is rated for at least these currents. The I/O panel on the unit includes a receptacle for a standard C13 power cord The HVR system PC is powered by a “brick” type AC adapter (19.5 VDC output). The adapter accepts 100/240 VAC power for worldwide use. The maximum combined current draw is 4.6A at 120 VAC or 2.3A at 240 VAC. The power adapter is normally placed on the floor. Before doing so, verify that the floor will not be flooded or hosed down for cleaning. If there is danger of contact with water on the floor, place the adapters in a higher, protected location.
System PC Power Supply
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3.4 Operational Values
HVR100 systems are factory calibrated under the standard laboratory environmental conditions shown below:
Specification
Calibration Requirement
Ambient Temperature
20°C ± 0.5°C (68°F ± 1°F)
Humidity
40-60% RH
Temperature rate of change
0.5°C (1°F) per hour
HVR100 systems 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
Calibration Temperature
20 ± 0.5°C (68 ± 1°F)
Allowable Operating Temp.
18-22°C (64-72°F), non- condensing
If the system is to be operated under environmental conditions that are substantially different from those shown above, the system should be recalibrated under the expected conditions. Users should also consider the material characteristics of the parts under inspection, in particular 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.
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3.5 Safety Considerations
Meaning
System or Term
General Safety
HVR systems are designed for safety and proper ergonomics during normal use. Exercise caution when lifting, handling or moving the system to avoid personal injury and to maintain equipment calibration and measurement performance. Disconnect all power sources prior to moving or working on the equipment. Consult Starrett if you have any questions regarding transporting, using or maintaining this system. HVR systems do not contain hazardous AC line voltages, as these are contained on the input side of the system AC adapters, which are UL listed. The supplied voltages are 24 VDC to the metrology unit and 19.5 VDC to the PC. 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, follow the guidelines below: • Ensure that the power receptacles for the AC adapters are properly grounded. 3-prong polarized 120V AC types for
Electrical Safety
use in North America or appropriate safety-rated receptacles for use outside of North America.
• Do not operate the system with the housing open except for service by a factory trained technician. • Keep liquids away from the system and do not operate the equipment in excessively humid conditions, as water can cause short circuits. • Keep metal filings away from the system, 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 system. The system should only be opened by a factory-trained service technician. The HVR100 system weighs 106 pounds. Switching the system from the vertical to horizontal position requires two people. Do not attempt to move the system without proper assistance.
Mechanical Safety
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4. INSTALLATION
4.1 Installation Overview
Starrett Kinemetric Engineering Vision Metrology and Optical systems are normally installed by a factory-trained technician who also provides operator training. The following information covers basic hardware installation if an installer is not available.
Installation on the system requires the following overall steps:
• Planning placement of the system
Moving the system
•
Unpacking the system
•
Setting up the system PC
•
Setting up the metrology unit
•
• Verifying the system is operational
4.2 Planning Placement of the System
Prior to unpacking the system, refer to the following guidelines to ensure an adequate operating environment is established.
A clean operating environment is recommended to minimize the accumulation of dirt on the optics and on precision mechanical parts, such as lead screws and encoder sca les.
HVR systems are designed to be installed on a benchtop at a height of approximately 85 cm (33.5 inches), which is the height of Starrett’s ergonomic workstation. A level work surface, as checked with a bubble level, is recommended, but is not essentia l. Allow 60 cm (24 inches) to right or left side of the metrology unit to position the system PC. An additional clearance of 30 cm (12 inches) on both sides is recommended for general access. Allow a minimum of 5 cm (2 inches) behind the unit for air flow, as the electronics compartment only uses convective air cooling. Refer to the following figure for dimensions of the HVR100 metrology unit. Completely opening the hinged door at the back of the metrology unit for service access requires an additional 50 cm (20 inches) of space. The metrology unit can be moved as needed for service.
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HVR100 Metrology Unit Dimensions
4.3 Moving the System
HVR systems are shipped in a wooden shipping crate. Use a forklift or pallet cart to move the crate within the building to the final location where the system will be installed. Exercise care in handling the unopened shipping crate, as excessive force or a drop might damage its contents.
HVR100 Shipping Container
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4.4 Unpacking the System
The HVR100 system arrives in one crate that includes all components of system including the system PC and monitor. The metrology unit arrives in the horizontal position.
Unpacking Tools
The following items are required to uncrate and install an HVR system:
• Battery powered drill with Phillips bit (to remove the top of the crate)
• Bubble level (optional, to level workbench or workstation)
Other common hand tools
•
The metrology unit includes a permanent handle at the top of the unit (see the figure below) and two handles at the base of the unit. The threaded handles at the base of the unit can be removed or left on the system to facilitate possible later lifting. Specifically, the handles can be used to rotate the system from the vertical to horizontal position. See the “System with Carrying Handle Attached” figure in Section 5 of this document.
Unpacking Instructions
To unpack the system refer to the following figures and perform the following steps:
The HVR100 system weighs 106 pounds. Do not attempt to move the system without proper assistance.
1. Using a drill with a Phillips screw bit, remove the screws that attach the top of the crate. 2. With the crate now open, use the drill to remove the four woodscrews that secure the wood crossbeam holding the metrology unit in place. 3. With a person on each side of the metrology unit, use the handles to lift the unit in place. 4. Unpack the remaining components in the crate including the system PC, monitor and supporting hardware.
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HVR100 System in Shipping Container
Top handle
•
Metrology Unit Top Handle
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4.5 Setting Up the System PC
Note: This manual includes information specific to a Shuttle system PC. In some instances, the HVR system might include a system PC from another vendor.
To set up the system PC, refer to “System Controls” figure in Section 5 and perform the following steps: 1. Connect the USB cable from the top of the system PC to the I/O panel on the HVR metrology unit. 2. Connect an additional USB cable from the top of the system PC to the I/O panel on the HVR metrology unit to support the camera signal. 3. Connect the power supply cable to the underside of the system PC. 4. Connect the monitor cable from the monitor to the underside of the system PC. 5. Ensure both the wireless keyboard and wireless mouse are equipped with batteries. 6. Press the on/off switch on the back of the mouse to turn on the mouse. 7. Press the on/off switch on the top of the keyboard to turn on the keyboard. 8. Power on the system PC. Ensure that the system PC boots up properly. 9. Verify that the preinstalled M3 software is functioning properly. Refer to the M3 software documentation for additional information.
4.6 Setting Up the Metrology Unit
To set up the metrology unit, refer to “Metrology Unit I/O Control Panel” figure in Section 5 and perform the following steps: 1. Ensure both USB cables from the system PC have been connected to the I/O panel. See “Setting Up the System PC” earlier in this section. 2. Connect the power cable to the I/O panel. 3. Connect the remaining end of the power cable to an appropriate power outlet. 4. Connect the DB9 connector for the pendant to the I/O panel. 5. Power on the unit by pressing the Power On/Off switch to the “I” position.
4.7 Verifying the System is Operational
To verify the system is operational, perform the following steps:
1. Launch the M3 software from the system PC. 2. Place a sample part on the system stage.
3. Do a single measurement on an artifact whose dimensions are comparable to those that will be measured. Verify that the measured dimensions are within the HVR’s specifications.
4.8 On-site Functional Test, Calibration and Training
All Starrett vision metrology systems are calibrated at the factory prior to shipment; however, it is possible that components might have moved during shipment. A complete functional test and calibration are recommended following physical installation. Professional system installation is normally provided by Starrett or by an authorized Starrett dealer for all new systems sold in North America. Installation includes equipment setup, on-site calibration and on-site operator training. While professional installation i s a
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separately-quoted line item, it is highly recommended and is purchased by most users.
As part of its setup services, Starrett oversees the equipment’s in-plant transportation to its permanent location and uncrating. Starrett then performs the physical setup and electrical connection, followed by a completed functional checkout. This typically takes 1/2 day for an HVR 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 an HVR system. On-site basic operator training is provided following calibration. This typically takes 1/2 day for an HVR system. Many customers choose to augment basic training with additional hands-on training, where new operators program actual 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 all users get hands-on time. Starrett’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.
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5. SYSTEM OPERATIONS
5.1 System Controls
HVR100 System
On the right side of the HVR100 system is an I/O panel that includes the following controls. See the figures that follow.
Control
Function
On/Off switch
Rocker switch controls power to the system. The “l” position is On. The “O” position is Off.
Two USB 3.0 ports
• Connection from the system to PC
• Connection to PC for camera signal
DB9 connector
Connection for pendant that controls the lens
Power connector
Power cable connection to a power outlet
System PC Controls
Note: This manual includes information specific to a Shuttle system PC. In some instances, the HVR system might include a system PC from another vendor.
The system PC includes the following controls. See the “System PC Controls” figure that follows.
Control
Function
Six USB 2.0 ports (2 on the top of the unit, 4 on the underside of the unit)
• Connection from PC to metrology unit
Connection from PC for camera signal
•
Two WiFi antennas
Wireless signal for connection to wireless mouse and keyboard
On/Off switch
Powers PC on and off
HDMI port
Connection to monitor
DC connector
24 VDC power input from power supply
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USB connection to PC for camera signal
•
Power On/Off switch
•
DB9 connector for pendant
•
USB connection to system PC
•
Power connector
Metrology Unit I/O Control Panel
•
Metrology Unit I/O Control Panel with Cable Connections
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24-inch touch screen monitor
•
USB connection from PC to HVR system
•
USB connection for camera signal
•
PC On/Off switch
•
System PC Controls
Communication Ports
The communication ports on the system are connected to the system computer and are supported by the MS Windows operating system. The USB ports are typically used for external data storage devices and computer peripherals, such as printers. The Ethernet port is typically used for connection to a company’s local area network (LAN).
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5.2 Powering the System On and Off
HVR systems have one On/Off switch located on the I/O panel. In addition, the system PC includes an on/off switch located on the top of the unit. Turn the system off when not in use.
Before removing power, first close all computer files and applications, and then shut down the computer using the Windows “Shut down” button. Otherwise computer files could be corrupted by the sudden loss of power.
To power on the system, first apply power to the system PC and then to the metrology unit.
To power on the system PC, perform the following steps:
1. Ensure the system is properly cabled. Refer to the installation instructions in Section 4 of this manual. 2. Press the Power button on the top of the system PC. See the figure above. 3. Wait for the system PC to boot up completely.
To power on the metrology unit, perform the following steps:
1. Locate the On/Off rocker switch on the I/O panel. See the “Metrology Unit I/O Control Panel” figure above. 2. Press the rocker switch to the position marked “l.” “l” is the On position.
The system is now operational.
5.3 Switching the System from the Vertical to Horizontal Position
The HVR100 system weighs 106 pounds. Switching the system from the vertical position requires two people. Do not attempt to move the system without proper assistance.
To switch the system from vertical to horizontal position, perform the followi ng steps:
1. Ensure you have adequate space on the benchtop surface. The horizontal width of the system is 101.6 cm (40.0 inches). 2. Ensure the rear of the unit is free of all cabling. 3. Power Off the system by pressing the On/Off rocker switch to the “O” Off position. 4. With a person on each side of the system rotate the system backward using the rear pivots as a guide. You can also attach the lifting handles located near the I/O panel to help guide the system. See the figure below. 5. Ensure the system is resting on the level pads on the back of the unit. 6. Rotate the stage so that it is parallel to the ground. 7. Power On the system by pressing the On/Off rocker switch to the “l” On position.
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I/O Control Panel
•
Carrying handle
•
System with Carrying Handle Attached
5.4 Switching the System from the Horizontal to Vertical Position
The HVR100 system weighs 106 pounds. Switching the system from the horizontal position requires two people. Do not attempt to move the system without proper assistance.
To switch the system from the horizontal to vertical position, perform the following steps:
1. Ensure you have adequate space on the benchtop surface. The system is 42.16 cm (16.6 inches) wide and 43.43 cm (17.1 inches) deep. 2. Ensure the rear of the unit is free of all cabling. 3. Power Off the system by pressing the On/Off rocker switch to the “O” Off position. 4. With a person on each side of the system pull the system upward using the rear pivots as a guide. 5. Ensure the system is level with the benchtop surface. 6. Rotate the stage so that it is parallel to the ground. 7. Power On the system by pressing the On/Off rocker switch to the “l” On position.
5.5 Access to Electronics
The back of the system is hinged and holds a compartment with all electronics other than the system PC. Removing the knurled hand-screw provides access to this compartment. This is for service access only. There are no user adjustments or controls behind the hinged back.
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6. MEASUREMENT STRATEGY
HVR systems include a .090X telecentric lens. Magnification is the image size at the camera charge coupled device (CCD) detector divided by the object size. For example, a 2.0-inch circle would be .18-inches on the CCD array (2.0 x .090=.18). This value is different than total magnification, which is the size of the object on the monitor.
6.1 Measurement Accuracy and Depth of Field
The telecentric lens included with the system provides high accuracy, high throughput field-of-view (FOV) measurements. The 0.090 lens accommodates parts up 92.7 mm x 76.2 mm (3.65 x 3.0 inches).
Accurate measurement requires proper focus of the image. When measuring flat parts, always ensure that the stage glass has been leveled.
Always work at best focus. Telecentric lenses have a large focus range, also known as depth of field. Within this range, the instrument is expected to measure wi th an accuracy of approximately 10 microns or better for a one-inch object. The most repeatable results can be achieved by taking the time to adjust focus using digital zoom. Focus is determined by digitally zooming in on the edge of an object and adjusti ng focus until the pixels appear on that edge. This ensures the best and most repeatable measurements are obtained. See the figures below that illustrate poor focus and good focus.
Note:
For best results, view these figures online with a high-resolution monitor. A printed version of these figures does not provide a clear distinction of difference between good and poor focus.
Example of Object with Poor Focus
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Example of Object with Good Focus
6.2 Lighting and Illumination Strategy
Once the image has been properly focused, adjust front and back lighting using the on- screen sliders provided by M3 software. You can also utilize room lighting, or shield the system from room lighting, as appropriate. Correct lighting is paramount to accurate measurement with any video-based measurement system. A clear image with lighting toward the low side is recommended. Lighting that is too low will result in a dark, low-contrast image with indiscernible features. Lighting that is too bright might result in a washed-out image and in hot spots (or blooms) that provide false edges. When adjusting lighting, start with light that is lower than desired, then increase lighting while viewing the image on the computer monitor. Maintain constant light ing for consistent results. Do not to change light levels between points used to measure the same geometrical feature. Depending on the part characteristics and the feature being measured, the right combination of lighting might aid in bringing out a particular feature. Take time to experiment by balancing the available light sources.
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6.3 Parts Fixturing
The part must be fixtured securely to prevent part movement during measurement. Also, proper alignment of the part to the stage can aid in measurement. Orientation errors, or skew errors, can also be removed by creating a reference frame based on the part before taking measurements. See the M3 software manual for details.
The following illustration provides the location of the tooling holes on the system. Use these locations to customize the system to your operating requirements.
HVR100 Tooling Holes
6.4 M3 Software Operation
M3 software operation is outside the scope of this hardware-oriented user manual. Refer to the separate MetLogix M3 software manual for detailed information.
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7. SYSTEM MAINTENANCE
HVR metrology systems have been designed for years of superior service. Periodic maintenance as outlined in this section is considered good practice to maintain your 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 keyboard and wireless mouse. Have alkaline AA batteries on hand for the mouse and AAA batteries for the keyboard.
Wireless Mouse Battery Placement
Wireless Keyboard Battery Placement
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7.1 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.
7.2 Weekly Inspections
On a weekly basis, or if the system has been moved, do the following:
• Verify that the stage control mechanisms move freely. If binding is observed, call for service. The lead screw uses a self-lubricating TFE coating, which is designed to last for the life of the product. Do not apply cleaner or lubricant. • Do a basic calibration check against a certified chrome-on-glass standard, such as Accurite 25mm fiducial. Do a single measurement on an artifact whose dimensions are comparable to those of the parts to be measured and verify that the measured dimensions are within the HVR’s specifications.
7.3 Cleaning
To the degree possible, the system should be kept in a clean environment, away from dirt, dust, oil and debris which could affect system performance or degrade the system’s mechanical and electronic parts. If a clean environment is not available, the machine should be kept as clean and protected as is possible. In harsh environments, preventive maintenance and factory service should be scheduled more frequently to keep the system in top working order.
WARNING: Never pour fluid on the system when cleaning. Do not over- wet cleaning cloth. Excessive moisture can seep into mechanical or electrical parts, damage the equipment and possibly cause an electrical short circuit and physical injury. As a precaution, unplug the system before cleaning. Always unplug the system before using any flammable cleaning fluid.
7.3.1 Cleaning External Surfaces
Wipe down the system with a clean, lint-free cloth moistened (not wet) with plain water or Simple Green ® . Never wipe down with acetone or other harsh solvents, which might damage painted or plastic surfaces. Isopropyl alcohol may be used to clean surface contaminants where Simple Green proves ineffective.
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7.3.2 Cleaning Optics
WARNING: Do not touch lens surfaces with your fingertips. Fingerprints might destroy optical coatings over time. Only clean optical surfaces with proper cleaning supplies, and then only when necessary.
If a lens is covered with loose dust, first try blowing off this dust using a can of optical grade (oil-free) canned compressed air. Be careful not to shake the lens, or propellant might blow onto the lens. As alternative, use a lens brush to gently wipe off the dust. If the lens is soiled with greasy deposits which cannot be blown or brushed off , use an alcohol-based commercial lens cleaner and a lens tissue or a lens cloth. These items are available from camera stores. Apply the lens cleaner generously to dissolve the grease, and then blot off the lens cleaner and dissolved grease using minimum motion. Avoid rubbing the lens, since hard particles from the deposit or the lens cloth could scratch the optical coatings. If the greasy deposits do not come off with the lens cleaner, use a stronger solvent such as reagent-grade acetone as a last resort. Gently wipe the lens surface while moving the lens cloth to always present a clean surface to the lens. Wipe in a circular manner moving from the center of the lens toward the outer edge. Do not reuse the lens cloth to avoid redepositing contaminants.
Optical Grade Compressed Air
7.3.3 Cleaning Critical Mechanical Parts
Critical components are covered and are not user serviceable. Should the stage mechanics bind or require service, contact your Starrett representative. The lead screw uses a self-lubricating TFE coating, which is designed to last for the life of the product. Do not apply cleaner or lubricant, which could collect dirt and impair system performance.
7.3.4 Recommended Spare Parts
The only recommended spare part is extra stage glass in case the original breaks or cracks.
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8. GLOSSARY
The following terms might have additional meanings. The definitions that follow are in the context of the HVR metrology systems.
Term
Definition
Accuracy
The maximum error that the system will produce when measuring a true standard.
Axis
A direction which allows movement and along which dimensions can be measured. In the HVR systems, the X-axis is horizontal from left to right, and the Y-axis is from front to back, and the Z- axis is from bottom to top. A condition where the parts of the video image are distorted by oversaturated bright regions, making illuminated regions appear larger than they really are. The alignment of the camera relative to the motion of the metrology stage. If the camera is misaligned (out of square), the image will drift diagonally as the stage position is moved along one axis. (Only applies to systems with X and Y stages.) Charge Coupled Device. The solid-state image sensing element of the video camera. Optical image distortion at the CCD sensor across the maximum field of view. Expressed in percent for the dimensional error along one axis divided by the true dimension. A computer aided design (CAD) data file format developed by Autodesk, Inc. and now also used by other companies for the export and import of CAD data. The condition which provides the sharpest image. Achieved by optimizing the distance between the object and imaging optics. The region of the metrology stage being viewed by the camera and displayed on the video monitor. A video measurement performed in a single field of view without moving the stage or camera. Lighting applied to the object from the same side as the camera so that surface features can be viewed on the video monitor. Lighting applied from the back of the object so as to create a silhouette when the object is viewed by the camera.
Blooming
Camera Alignment
CCD
Distortion
DXF
Focus
Field of View (FOV) FOV Measurement Illumination, Front Illumination, Back
Mag
Abbreviation for magnification.
Magnification, Lens Magnification, Image
In a metrology system, the image size in the CCD plane divided by the corresponding object size. Magnification on monitor. Image size on the video monitor divided by the corresponding object size. Same as lens magnification in a properly adjusted optical comparator.
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Term
Definition
Pixel
A picture element. Term used to describe the individual light detectors of the CCD sensor in the camera and also the individual light emitters of an LCD video monitor. The least significant digit to which a physical quantity can be read. High resolution does not imply high accuracy. Misalignment of the part with respect to the X and Y axes. This will create measurement errors unless the part is repositioned or the deskew feature of the metrology software redefines the measurement axes. Illumination from below the stage glass. Used for profile or silhouette video edge measurements. A space saving personal computer where all electronics, disk drives and I/O connections are in the same enclosure as the video monitor, which is an LCD color touch-screen. A keyboard and mouse are also included. A lens property where the light from the object stays parallel to the optical axis across the entire field of view, thereby eliminating optical distortion. This can only happen if the entrance aperture of the lens is larger than the field of view, requiring a large and expensive lens. See the figure below. Tetrafluoroethylene, a self-lubricating polymer coating used on precision lead screws. Video Edge Detection, a system where a video camera and digital image processing are used to detect edges or other features.
Resolution
Skew
Substage Lighting
System PC
Telecentric
TFE
VED
Object
Telecentric lens
CCD detector
Telecentric Lens
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