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 Conventions ................................................................................................................... 5 1.6 Disclaimer of Liabilities................................................................................................... 6 1.7 Warranty ......................................................................................................................... 6 1.8 Copyright and Trademark Information ........................................................................... 6 1.9 Related Product Information .......................................................................................... 7
2 Environmental and Regulatory Specifications .................................................................... 9
2.1 Operating Environment Specifications ........................................................................... 9 2.2 Calibration Environment Specifications ......................................................................... 9 2.3 Regulatory Compliance .................................................................................................. 9 2.3.1 EMC Standards .................................................................................................. 10 2.3.2 Safety Standards................................................................................................ 10 2.3.3 Safety Considerations ......................................................................................... 10
3 The HDV500 System ............................................................................................................. 13
3.1 Overview ...................................................................................................................... 13 3.2 Features and Capabilities ............................................................................................ 13 3.3 HDV500 System Components ..................................................................................... 14 3.3.1 Lens Options ....................................................................................................... 15 3.3.2 MetLogix M3 Software......................................................................................... 16 3.3.3 Operator Controls and Interfaces ........................................................................ 17 3.3.4 Automatic and Manual System Operations ......................................................... 18 3.3.5 Rotary Stage Option ............................................................................................ 18
4 System Specifications .......................................................................................................... 21
4.1 Performance................................................................................................................. 21 4.2 Mechanical ................................................................................................................... 21 4.3 Illumination ................................................................................................................... 22 4.4 Optical .......................................................................................................................... 22 4.5 Operator Controls......................................................................................................... 23 4.6 Electrical ....................................................................................................................... 24 4.7 Computer and Software ............................................................................................... 24 4.8 Rotary Stage Option ................................................................................................... 24
5 Installing and Setting Up the System.................................................................................. 25
5.1 Planning the Placement of the System ........................................................................ 25 5.2 Moving and Uncrating the Equipment .......................................................................... 26 5.3 Removing the Stage Locks .......................................................................................... 27 5.4 Installing the Y-Axis Stage Cover................................................................................. 29 5.5 Mounting and Connecting the Video Monitor............................................................... 30
6 System Operations ............................................................................................................... 31
6.1 Using Automatic System Operations ........................................................................... 31 6.2 Using the Manual System Operations.......................................................................... 31 6.2.1 Using the Joystick to Control Operations ............................................................ 31 6.2.2 Using the Keyboard and Mouse Controls............................................................ 33 6.2.3 Adjusting the Keyboard ..................................................................................... 34 6.3 Controlling Power to the System.................................................................................. 34 6.3.1 Powering Up the System ..................................................................................... 35 6.3.2 Powering Down the System ................................................................................ 36 6.4 Verifying Basic M3 Software Operations ..................................................................... 36 6.5 Installing the Lockout Device ....................................................................................... 37 6.6 Removing and Replacing the Lenses .......................................................................... 38 6.7 Using the Communication Ports................................................................................... 40 6.8 Verifying the Setup of the System................................................................................ 40 6.9 On-Site Installation, Calibration, and Training .......................................................... 41 6.9.1 Contacting Starrett Kinemetric Technical Support .............................................. 42
7 Understanding the Measurement Strategy......................................................................... 43
7.1 Telecentric Lens Magnification Strategy ...................................................................... 43 7.2 Zoom Optics Magnification Strategy .......................................................................... 43 7.3 Focus Strategy ............................................................................................................. 43 7.3.1 Measurement Accuracy and Depth of Field..................................................... 44 7.4 Lighting Strategy .......................................................................................................... 44 7.5 Understanding Optics Squareness .............................................................................. 45 7.5.1 Checking Optics Squareness ............................................................................ 45 7.6 Other Performance Factors.......................................................................................... 45
8 System Maintenance............................................................................................................. 47
8.1 Performing Daily Inspections ....................................................................................... 47 8.2 Performing Weekly or Monthly Maintenance ............................................................... 47 8.3 Replacing the Fuses .................................................................................................... 48 8.4 Maintaining the Fan Filter............................................................................................. 49 8.5 Verifying Calibration ..................................................................................................... 50 8.5.1 Calibration Validation Procedure ...................................................................... 50 8.6 Cleaning the System .................................................................................................... 52 8.6.1 Cleaning External Surfaces ............................................................................... 52 8.6.2 Cleaning the Optics............................................................................................ 52 8.6.3 Cleaning Mechanical Parts................................................................................ 53 8.7 Applying Lubrication ..................................................................................................... 53 8.8 Accessing Components within the System .................................................................. 53 8.9 Spare Parts and Accessories....................................................................................... 56
9 Glossary................................................................................................................................. 59
1 About This Guide
1.1 Purpose
This guide provides instructions on how to install, operate, and maintain the HDV500 floor mounted horizontal digital video system. This guide also provides information on the various options and features available with the system.
1.2 Scope
This guide provides detailed information on the components, features, and specifications of the HDV500 system. This guide also includes operating and maintenance information for the system. High-level information is provided on unpacking and installation. HDV500 systems are intended to be installed by SKE Technical Service specialists or qualified third-party personnel.
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.
1.5 Conventions
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.
1.6 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 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 may 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.
This warranty does not cover damages from such causes as abuse, accident, neglect, fire, flood, electrical surge, or freight damage.
1.8 Copyright and Trademark Information
HDV500 ™ is a trademark of the L.S. Starrett Company. M3 ™ is a trademark of MetLogix, Inc. Windows ® is a registered trademark of Microsoft Corporation.
1.9 Related Product Information
The following documents provide information that is related to the subject of this guide.
MetLogix M3 Video and FOV Inspection Software User’s Guide
This guide provides detailed information on operating the M3 software that is included with HDV system.
HDV500 Floor Mounted Horizontal Digital Video System Unpacking Read Me First Instructions (8856)
This guide provides information to safely unpack the HDV500 system.
2 Environmental and Regulatory Specifications
The following information provides the environmental and safety information for the HDV system.
2.1 Operating Environment Specifications
The following table provides the environmental specifications for the HDV system.
Feature
Specification
Calibration Temperature
20 ± 0.5°C (68 ± 1°F)
Allowable Operating Temp. 18-22°C (64-72°F), non-condensing
Positive pressure in enclosure provided by two fans with air filter
Environmental Protection
2.2 Calibration Environment Specifications
HDV500 systems are factory calibrated under the standard laboratory environmental conditions shown in the following table.
If the system is to be operated under environmental conditions that are substantially different from those provided, 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.
Specification
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
2.3 Regulatory Compliance
The following information provides the regulatory and safety standards for the HDV500 system.
HDV500 metrology and inspection systems have been designed to comply with Council Directives 2006/42/EC - Machinery when installed and operated in accordance with this manual, and to carry the CE mark. HDV500 systems are certified by SKE to be free from hazardous materials per 2002/ 95/EC RoHS.
2.3.1 EMC Standards
The following information provides the EMC standards for the HDV system.
Standard
Description
EN 55011 Class A
Conducted Electromagnetic Emissions
EN 55011 Class A
Radiated Electromagnetic Emissions
EN 61000-4-2
Electrostatic Discharge (Contact)
EN 61000-4-2
Electrostatic Discharge (Air)
EN 61000-4-4
Electrical Fast Transients (Direct Coupled)
EN 61000-4-4
Electrical Fast Transients (Capacitive Coupled)
EN 61000-4-6
Radio Frequency Conducted Immunity (150 kHz-80 MHz)
EN 61000-4-5
Surge (for control computer, et al)
Voltage Dips, Short Interrupts and Voltage Variations Immunity
EN 61000-4-11
2.3.2 Safety Standards
The following information provides the safety standards for the HDV system.
Standard
Description
Safety of Machinery, General Principles for Design (Referenced)
EN 292-1
EN 60204
Safety of Machinery, Electrical Equipment of Machines
EN 12100
Safety of Machinery, Principles for Risk Assessment
OSHA 1910.147
The control of hazardous energy (lockout/tagout)
2.3.3 Safety Considerations
General Safety
HDV systems are designed for safety and proper ergonomics during normal use. Exercise caution when handling or moving the systems to maintain calibration and measurement performance. Disconnect all power sources prior to moving or working on the equipment. Consult SKE if you have any question regarding transporting, using, or maintaining the
systems. Follow standard safety protocols for electrical and mechanical equipment in addition to all guidelines outlined in this manual. Failure to exercise proper safety practices may result personal injury and equipment damage.
WARNING
Exceeding the maximum load capacity of 150 kilograms (330 pounds) significantly reduces accuracies of the system and might damage the mechanical structure.
Electrical Safety
HDV systems do 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 120V AC types 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.
• Disconnect all power sources prior to moving or working on the equipment.
• 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, 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. • Control unexpected hazardous energy by using the detachable IEC (International Electrotechnical Commission) plug lockout device available with the system. The lockout device works as a block to prevent power going to the socket by simply plugging into the socket and twisting. To install the lockout device, refer to “Installing the Lockout Device” in Section 6 of this document.
Mechanical Safety
The HDV system has moving components and pinch points. Do not place hands and mechanical items near pinch points. Failure to observe this warning could result in personal injury and equipment damage.
3 The HDV500 System
This section provides the following information for the HDV500 system:
An overview of the HDV500 system
•
• A description of the feature and capabilities of the HDV500 system
• A description of the major components of the HDV500 system
3.1 Overview
The HDV500 is a large horizontal digital video system that includes a 500-millimeter (20 inch) of stage travel, 150 kilogram (330 pound) load capacity, and a large 1067 millimeter (42 inch) diagonal video monitor. The HDV system provides a uniquely designed interchangeable lens mounting system to a hi-resolution 5 mega-pixel digital video camera. In addition, the CNC- capable system includes the powerful MetLogix M3 vision metrology software with the M3 DXF/FOV option pack.
3.2 Features and Capabilities
Key features and capabilities of the HDV system include the following:
• Delivers a rugged system that is equally at home in a quality lab or on the shop floor. The housing is made of welded steel. The stage is made of machined nickel-plated steel and has two dovetail slots to allow the clamping of parts and fixtures. Maximum workload capacity is 150 kilograms (360 pounds). Linear glass scales provide 0.5 µm (0.00002 inches) of resolution to read stage motion. • Includes a 5-megapixel digital video camera that is available with a choice of three telecentric lenses for micron-level resolution and measurement distortion as low as 0.002% across the field of view (FOV) for accurate measurements. The system is also available with 6.5:1 zoom optics. The lenses are mounted by means of a bayonet fitting and can be changed by the user in a matter of seconds. • Includes a motorized CNC system, where motion and illumination are under computer control. Manual operation for setup and individual measurements is provided by means of a joystick. • Includes MetLogix M3 vision metrology software with the M3 DXF/FOV option pack. With this software, the HDV500 can 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 an optical comparator.
• Easy to use operator controls including joystick, wireless keyboard and mouse, and 42-inch touch screen monitor.
• Optional CNC rotary stage that provides increased radial load stability and moment load rating.
• Includes a computer and M3 controller that are located inside the housing, resulting in a clean design with minimal external wiring. The housing is maintained at a positive pressure by two filtered fans to minimize the entry of oil and dust particles in machine shop environments.
3.3 HDV500 System Components
The following information describes the key components of the HDV system. Refer to the following figure for the locations of these components.
42-inch Monitor
Joystick
Wireless Mouse
Interchangeable Lens
Wireless Keyboard
Stage
Access Doors
Figure 1. System Component Overview
3.3.1 Lens Options
Telecentric Lens Options
Telecentric optics allow high accuracy, high throughput measurements within their field of view. For the highest throughput, select a telecentric lens with a field of view that encompasses the entire part to be measured. Or work at higher magnification, in which case M3 software will seamlessly combine FOV measurements with encoder readings from stage motion. The HDV500 system comes with a bayonet mount which allows telecentric optics to be changed by the user in seconds.
The following telecentric lenses are available with the system:
• 0.24X magnification with a 35 x 29 millimeter (1.4 x 1.1 inch) field of view
• 0.16X magnification with a 54 x 45 millimeter (2.1 x 1.8 inch) field of view
• 0.11X magnification with a 76 x 64 millimeter (3.0 x 2.5 inch) field of view
Zoom Lens
The HDV500 system includes the option for 6.5:1 manual zoom optics, with continuous zoom from 0.7X to 4.5X. Like the telecentric lens, the zoom optics are also bayonet mounted that can be changed by the user in seconds. Utilize zoom optics to measure large parts which would not fit into a single FOV, also for smaller parts where extremely high magnification is required.
.11X Lens
.16X Lens
.24X Lens
Figure 2. HDV500 Telecentric Lenses
3.3.2 MetLogix M3 Software
The HDV system includes the MetLogix M3 advanced metrology software. The software includes the following key features:
• Advanced Video Probes : The M3 software includes several probes that provide the ability to capture complex edges, enable instant feature determination and measurement with the single click, and an industry first video touch probe functionality. • Field of View Functions : The field of view Auto Run function plays part programs to perform measurements quickly without operator intervention. Place one or more identical parts in the field of view and the system will identify the part, execute the appropriate program, and report measurement results. • Touch Probe Support : M3 software includes support for multi-sensor video measuring systems equipped with touch probe modules. Expanded 3-D feature geometries are supported through touch probe and video measurement of features in the XY, YZ and ZX planes. Measure planes, cones, cylinders, and spheres in 3-D part space and then view results in the 3-D part view. Part views can be rotated with markups showing feature measurement results. • Multi-Touch Software Control : In addition to the conventional mouse interface, expanded MultiTouch logic allows for one-touch feature measurements as well as versatile panning and zooming of the live video image and the active part view. This capability increases the efficiency of feature measurements, feature data manipulation, and reporting tasks with a simple pinch zoom, swipe pan, or double click. • Advanced Edge Teach: This feature provides improved edge detection performance under a variety of image and lighting conditions. Features with poor edge contrast, or difficult spacing can be captured in a snap using the M3’s manual teach function. • DXF Overlay and FOV Capability : Using the DFX/FOV option pack, you can import DXF files for “comparative style” Go/No -Go feature and part inspection. This includes a live error whisker display for violations of the original DXF tolerance zones. DFX/FOV option pack features include:
Custom DFX crosshair
•
Feature-based video overlays
•
Import DFX overlay
•
Export features to DFX
•
Pattern teach and recognition
•
Live image “freeze
•
For detailed information on the MetLogix M3 software, refer to the MetLogix M3 Video and FOV Inspection Software User’s Guide .
3.3.3 Operator Controls and Interfaces
The following information provides the controls and interfaces of the HDV system.
System PC
The HDV system includes a small form factor system PC where the M3 software is preinstalled and controlled.
Touch-screen monitor
The 42-inch touch screen monitor is used to control the M3 software. The monitor displays a live video image of the part in addition to geometry tools and digital readings. The image of the part can be resized using pan and zoom, and measurements are taken by simply tapping a feature on the screen.
Wireless keyboard and mouse
The HDV500 keyboard is environmentally sealed. It is used for programming, data entry, and program operation. It includes an integral touchpad, which serves the functions of a mouse. The system also includes a wireless mouse.
Swing-out arm mechanism
Touchpad for mouse functions
Right mouse button
Left mouse button
Right mouse button
Figure 3. HDV500 Sealed Keyboard
Joystick
The joystick provides position control of the stage in the X, Y, and Z axes. The joystick includes functionality to stop the system, switch between axis movement, and control speed. The joystick can be used to operate the system manually for quick individual measurements and short runs.
For detailed information on operating the joystick, refer to “System Operations” later in this document.
Figure 4. Joystick and Wireless Mouse
3.3.4 Automatic and Manual System Operations
The HDV system allows fully automatic operation using the M3 software for the following operations:
Illumination
•
Right-left position of the stage (X-axis)
•
Up-down position of the stage (Y-axis)
•
• In-out position of the stage (Z-axis, used for focus adjustment)
The system also allows manual operation for setup, for quick individual measurements, and for short runs.
• Manual control of front and back illumination through sliders on the computer screen using M3 software.
• Manual control of the X, Y, Z axes through the M3 software using the joystick.
3.3.5 Rotary Stage Option
The HDV system includes the option for the APT200 rotary stage. The rotary stage provides significantly increased radial load stability and moment load rating of up to 55.2 newton meters (Nm).
The APT200 rotary stage provides the following features:
• Includes a 182-millimeter diameter circular face
• Includes an axial load rating of 300 newtons (N)
• Minimized runout (wobble) and radial runout of 10 microns
• Provides repeatability to 2.0 arc seconds
• Operates at a maximum speed of 300 rpm
• Includes the option for vertical or horizontal mounting
For detailed information on the rotary stage specifications, refer to “System Specifications” later in this document.
Figure 5. ATP200 Rotary Stage in Vertical Mounting Position
4 System Specifications
This section provides the performance, mechanical, electrical, and component specifications for the HDV500 system.
4.1 Performance
The following table provides the performance specifications for the HDV500 system.
Feature
Specification
Stage Travel, X (left-right) 500 millimeters (20 inches)
Stage Travel, Y (up-down) 200 millimeters (8 inches)
Focus Range, Z (front- back)
75 millimeters (3.0 inches)
Maximum Object Height
250 millimeters (10 inches)
Scale Resolution, X & Y
0.5 µm (0.00002 inches)
Reading Accuracy, X & Y E2 = 3.0µm + L/33 millimeters
Stage Load Capacity
20 kilograms (44 pounds) for negligible deflection, 150 kilograms (330 pounds) max
Helix Angle Skew Adjustment
+5° clockwise, -15° counter-clockwise
Helix Angle Readout
Protractor Vernier scale for 5’ angular resolution
Motion Control
Full CNC control or motorized manual control via joystick
4.2 Mechanical
The following table provides the mechanical specifications for the HDV500 system.
Feature
Specification
Mounting Location
Floor mount
Height to Top of Monitor
1800 millimeters (70.7 inches) (max)
Height to Center of Monitor
1460 millimeters (57.5 inches) typical, ± 90 millimeters (3.5 inches) adjustment range.
Width
1330 millimeters (52.5 inches) (at extremes of stage travel)
Feature
Specification
Depth
1345 millimeters (53 inches)
Monitor Dimensions
565 x 975 x 64 millimeters (22.3 x 38.4 x 2.5 inches)
Height of Center of Monitor
0 to 250 millimeters (0 to 10 inches), adjustable
Stage Material
Steel, machines, nickel plated
Housing Material
Steel, welded, powder coated
Stage Area
820 x 200 millimeters (31.3 x 7.9 inches)
Shipping Weight
770 kilograms (1700 pounds), approximately
4.3 Illumination
The following table provides the illumination specifications for the HDV500 system.
Feature
Specification
Surface Illumination
190 millimeters (7.5 inches) diameter LED ring light mounted around body of lens
Contour Illumination
112 millimeter (4.5 inches) collimated LED backlight
4.4 Optical
The following information provides the optical specifications for the HDV500 system.
Feature
Specification
1067 millimeters (42 inches) diagonal monitor, backlit LED, 1920 x 1080 pixels
Operator Display
Monitor Display Area
930 x 523 millimeters (36.6 x 20.6 inches)
Monitor Pixel Size
0.36 x 0.36 millimeters (0.014 inches)
Industrial camera, USB 3.0, 5 megapixels (2448 x 2058) on 2/3-inch array
Camera Type
Camera Lens Mount
Quick-change bayonet
Telecentric Lens Magnification 0.24X
0.16X
0.11X
34.7 x 29 mm (1.3 x 1.1 inches)
53.8 x 45 mm (2.1 x 1.7 inches)
76.5x 64 mm (3.0 x 2.5 inches)
Telecentric Lens Field of View
Feature
Specification
Magnification on Monitor (1:1 pixel setting in M3 software)
14.7X
9.3X
6.5X
Visual Resolution on Monitor
18 line pairs / mm
13 line pairs / mm
10 line pairs / mm
Repeatability in FOV, 3 Sigma
Optical Distortion (ΔH/H)
0.04%
0.03%
0.02%
Software Corrected Distortion 0.004%
0.003%
0.002%
Telecentric Depth of Field (split 1/3 front, 2/3 back)
16 mm (0.63 inches) 37 mm (1.46 inches)
52 mm (2.05 inches)
Telecentric Lens FWD
150 mm (9.0 inches) 159 mm (6.3 inches)
228 mm (9.0 inches)
Zoom Optics
6.5:1 zoom manual zoom (continuous zoom from 0.7X to 4.5X)
Zoom Magnification at Detents 0.7X
1.0X
2.0X
3.0X
4.0X
4.5X
Zooms Field of View (millimeters and inches)
12x10.1 .47x.40
8.42x7.04 .33x.28
4.21x3.54 .17x.14
2.78x2.35 .11x.92
2.1x1.76 .83x.70
1.87x1.56 .74x.62
102 LP/mm
144 LP/mm
181 LP/mm
202 LP/mm
Viewed Resolution
32 LP/mm 57 LP/mm
Zoom Magnification on Monitor (1:1 Pixel)
58X
81X
161X
242X
324X
363X
Zoom Working Distance
88 millimeters (3.5 inches)
4.5 Operator Controls
The following table provides the operator controls for HDV500 system.
Feature
Specification
Computer Interface
42-inch color monitor, sealed keyboard with touchpad, wireless mouse
Other Operator Controls
Two on-off switches, Emergency Stop switch, joystick, wireless mouse
4.6 Electrical
The following table provides the electrical specifications for the HDV500 system.
Feature
Specification
Power Supply Location
Inside main housing
Voltage Requirement
120/240V AC
Power Requirement, Main Unit 300W peak, 200W typical
Power Requirement, Monitor
60W typical
4.7 Computer and Software
The following table provides the computer and software specifications for HDV500 system.
Feature
Specification
Form Factor
Board level computer housed inside comparator enclosure
Computer Hardware
64-bit CPU, Intel Core i7 256 GB M.2 SSD hard drive
Network Interfaces
Externally accessible Ethernet port, 3 USB 2.0 ports
Windows ® 10 Professional
Operating System
Metrology Software
MetLogix M3 Version 3 software with FOV/DXF option pack
4.8 Rotary Stage Option
The following table provides the specifications for the APT200 rotary stage option. See Section 3, “HDV500 System Components” for additional information on the rotary stage. Note : The APT200 rotary stage is an option and does not come standard with the HDV500 system.
Specification (Units)
APT200
Rotational Accuracy (arc-sec)
±2
Load Capacity, Axial (Kg)
30.6
Load Capacity, Radial (Nm)
55.2
Maximum Speed (RPM)
300
Runout (µm)
10
5 Installing and Setting Up the System
This section provides the following information on the HDV system:
• Planning the placement of the HDV system
• Uncrating and moving the system to the desired location
Removing the stage locks
•
Installing the stage cover
•
Setting up the video monitor
•
SKE metrology systems are normally installed by factory-trained technicians who also provide operator training. The following information covers basic hardware installation if an installer is not available. Refer to “ On-Site Installation, Calibration and Training ” later in this section for more information on SKE installation and calibration services.
5.1 Planning the Placement of the System
HDV systems are normally placed directly on a concrete floor in a work area. Following are recommendations for planning the placement of the HDV system:
• Select a location where the temperature can be controlled to within 20°C ± 0.5°C (68°F ± 1°F), which is the calibration temperature of the system.
• Select a location that is free from oil fumes, dust, and debris. Contaminants can coat critical mechanical and optical parts, which require more frequent system maintenance.
• Ensure a grounded 2-phase electrical power outlet is located close to the system.
• Allow enough clearance around the machine as follows:
• Allow at least 200 millimeters (8 inches) to the rear for access, and 600 millimeters (24 inches) or more to the sides.
• The width required for maximum X-axis stage travel is 1330 millimeters (52.5 inches). Consider the longest parts to be measured or inspected, since large parts can overhang beyond right or left sides of the stage.
• Allow room for the staging of incoming and outgoing parts.
Figure 6. HDV500 Dimensions
5.2 Moving and Uncrating the Equipment
WARNING
The shipping weight of the HDV500 system is 1700 pounds (770 kilograms). The system must be moved and positioned by a professional rigger (or rigging company) with specialized skills and equipment to move and position heavy and large machinery.
HDV500 systems are normally shipped in single wooden crate. To uncrate the equipment, refer to the following figures and perform the following steps:
1. Use a reversing battery powered drill with a Phillips bit, remove all wood screws from the top of the crate, then lift off the top.
2. Remove all wood screws from the side panels of the crate, then remove the side panels. This action exposes the HDV500 main unit on the shipping pallet and the 42-inch video monitor, which is shipped uninstalled in the same crate.
Figure 7. Removing the Screws from the Shipping Container
3. Use a wrench to remove the four L-shaped brackets that secure the HDV500 main unit to the shipping pallet.
Figure 8. L-Shaped Bracket
The main unit can now be lifted by the rigging company using the four red bosses which extend from the base.
5.3 Removing the Stage Locks
The HDV system is shipped with X, Y, and Z stage locks to prevent movement during shipment. The stage locks must be removed once the equipment has been placed in its final position.
1. Locate the stage locks using the following information and figures.
• The X-axis lock is located on the left of the stage.
• The Y-axis lock is located under the lens mount.
• The Z-axis lock is located near the X-axis drive motor.
Figure 9. X-Axis Stage Lock
Stage Lock
Figure 10. Y-Axis Stage Lock
Figure 11. Z-Axis Stage Lock
2. Using a metric hex wrench, remove the screws that secure the lock. Repeat this step for each of the stage locks.
5.4 Installing the Y-Axis Stage Cover
In addition to removing the stage locks, the Y-axis stage cover must be installed on the system. To install the stage cover, perform the following steps and refer to the figures:
1. Locate the Y-axis stage cover that is shipped with the system.
Figure 12. Y-Axis Stage Cover
2. Put the stage cover in the place, directly under the lens, and attach with the screws included.
Figure 13. Y-Axis Stage Cover Screws
Stage cover
Stage screw
Figure 14. Installing the Y-Axis Stage Cover
5.5 Mounting and Connecting the Video Monitor
To mount and connect the video monitor, refer to the following figure and perform the following steps:
1. Mount the 42-inch video monitor, which is held by a commercial articulating arm wall- mount mechanism. Select a mounting height for the system’s principal operator.
Figure 15. Video Monitor with Articulating Arm Wall-Mount Mechanism
2. Make the following electrical connections to the 42-inch video monitor:
a. Insert the power cable.
a. Insert the HDMI video cable into the position marked HDMI 1 IN.
b. Plug in the AC power cable to the back of the main unit.
Figure 16. Video Monitor Cable Connections
6 System Operations
This section provides the following information on operating the HDV500 system:
Using automatic system operations
•
Using manual system operations
•
Powering the system On and Off
•
Verifying basic M3 software operations
•
Installing the lockout device
•
Removing and replacing the lenses
•
Verifying the setup of the system
•
6.1 Using Automatic System Operations
The HDV500 system allows fully automatic operation through the M3 software. For detailed information on automatic system operations refer to the MetLogix M3 Video and FOV Inspection Software User’s Guide .
6.2 Using the Manual System Operations
The HDV500 system also allows manual operation for setup, for quick individual measurements, and for short runs using the joystick, keyboard, and mouse.
6.2.1 Using the Joystick to Control Operations
Caution
Be careful not to knock the joystick unit to the floor, as it can break.
Note : The joystick unit is held by friction in a cradle at the top of the contour illumination post. The joystick can be rotated or removed for hand-held, tethered operation.
The following table provides the functionality of the joystick. Refer to the following figure for the location of the controls.
Control
Function
Emergency stop switch
Press to stop all CNC motion
Button 1
Speed toggle. Located on the top of the joystick. Press once for slow speed for the control. Press again for normal speed. Axis lock. Press for motion along one axis only. Press again to allows diagonal motion.
Button 2
Control
Function
Button 3
Z-Toggle. Press for Z-axis control by the trackball. Press again for Z-axis focus control or Q-axis rotary stage control using the joystick.
Button 4
Go To Here. Press to lock in coordinates when programming.
Button 5
Enter. This button functions the same as the Enter key on a PC keyboard.
Joystick deflect right to left
Moves the Z column from right to left (X-axis control).
Joystick deflect front to back
Moves the stage front to back (Y-axis control).
Joystick rotate
Moves the Z column up and down (Z-axis control) or provides Q-axis control. Rotate for fine tuning X and Y positions, or for fine tuning Z- axis focus as set by Button 3.
Trackball
Figure 17. HDV500 Joystick Unit for Manual Operator Control
6.2.2 Using the Keyboard and Mouse Controls
The HDV500 keyboard and mouse are used for programming, data entry, and program operation. Refer to the following table for functionality. Refer to the following figures for additional information.
Control
Functionality
Keyboard Touchpad
Used to move the cursor, replacing the functionality of a mouse. Slide your fingertip along the surface to move the cursor on the screen.
Two keys below the touchpad Provide left-click and right-click functionality, similar to a mouse. Keyboard swing-out arm Used to adjust the position of the keyboard: left-to-right angle or up-down tilt angle. Wireless mouse Used to move the cursor.
Swing-out arm mechanism
Touchpad for mouse functions
Right mouse button
Left mouse button
Right mouse button
Figure 18. Keyboard
Figure 19. Joystick and Wireless Mouse
6.2.3 Adjusting the Keyboard
The articulated arm that holds the keyboard can be adjusted to best suit your working habits. By default, the keyboard is mounted to the left side of the contour illumination post, but a mounting location to the right side of the post can be specified at the time order. Refer to the following figure for information on the knobs and levers used to adjust the keyboard position.
Locking knob for 1 st swing-out arm
Locking knob for 2 nd swing-out arm
Ball joint for keyboard tilt angle
Locking lever for ball joint (on other side of ball joint)
Figure 20. Adjusting the Keyboard
6.3 Controlling Power to the System
HDV500 systems are equipped with three power switches. Refer to the following figures.
• A rocker switch on the back of the unit adjacent to the 115/ 230V power connector as required for CE certification. This switch supplies power to the two power switches on the front column of the system. Refer to the following figure.
Figure 21. Power Entry Module at Rear of the System
• Two rocker switches on the front column of the system labeled PC Monitor Power and M3 Amp Power.
• The switch labeled PC Monitor Power supplies power to the PC and monitor.
• The switch labeled M3 Amp Power provides power to the remaining components in the system.
For normal operation, the rocker switches should always be in the On position marked “I”. Refer to the following figure.
Figure 22. Power Control at the Front Column of the System
6.3.1 Powering Up the System
To apply power and start the system, perform the following steps:
1. Push the Power switch at the rear of the system (Figure 21) to the position marked “|” (On).
2. Push the PC Monitor Power and M3 Amp Power rocker switches (Figure 22) to the position marked “ | ” (On). This action enables the built-in PC to self-boot and come up in Windows.
3. Launch the MetLogix M3 software by clicking on the M3 icon on the monitor.
4. Proceed to “ Verifying Basic M3 Software Operations ” later in this section for information on initializing the M3 software.
6.3.2 Powering Down the System
Caution
Before removing power, first shut down the computer in software. This ensures that all files are properly closed.
To power down the system, perform the following steps:
1. Close all computer files and applications.
2. Shut down the computer using the Windows “Shut down” button.
3. This action prevents computer files from corruption by the sudden loss of power.
4. After the computer has been properly shut down, push the PC Monitor Power and M3 Amp Power rocker switches to the position marked “O” (Off).
5. Push the rear power switch to the position marked “O” (Off).
6.4 Verifying Basic M3 Software Operations
The following information provides basic instructions for operating the M3 software. For detailed information, refer to the MetLogix M3 Video and FOV Inspection Software User’s Guide included with your system.
To start the M3 software, perform the following steps:
1. Double-click the M3 software icon on the desktop. Refer to the following figure.
This action displays the interface below.
2. Select Start or touch the Start button on the screen. X, Y, and Z-axes are automatically homed.
Once the machine is homed, the screen indicates the machine is homed and there is a green checkmark in the upper right corner of the screen. Touch or click on the screen.
For accurate measurement, this checkmark must be green before proceeding.
6.5 Installing the Lockout Device
An optional component available with the HDV system is a lockout device that is used to control unexpected hazardous energy. The lockout device works as a block to prevent power going to the socket. Note : To purchase the lockout device, refer to “Spare Parts and Accessories” later in this document.
To install the lockout device, refer to the following figure and perform the following steps:
1. Locate the power entry module at the rear of the system. Refer to Figure 23.
2. Install the lockout device onto the power connector.
3. Twist the “key” clockwise to set the device in place.
4. Attach the safety tag to the padlock and insert the padlock into the opening on the lockout device.
5. Remove the key and retain the key in a safe location.
Power entry module (rear of HDV system)
Padlock
Lockout Device
Safety Tag
Figure 23. Installing the Lockout Device
6.6 Removing and Replacing the Lenses
Cautions
• Do not leave the camera unprotected by a lens assembly to minimize dust settling on the sensor surface. • Do not touch optical surfaces. Oil from your hands can permanently damage optical coatings. • Handle the lenses with extreme care. Lenses are breakable and very expensive. • Place unused lens assemblies in a sealed bag or enclosure for dirt protection.
Removing Lens from the System
To remove an installed lens, refer to the follow figures and perform the following steps:
1. Remove the LED ring light that is attached to the lens as follows:
a. Loosen the black knurled nut that holds the electrical cable connector to the main unit and then pull out the cable connector.
b. Pull off the ring light and set it aside. The ring light is magnetized to the lens.
Caution
Use both hands to hold and remove the lens. The lens is spring loaded and will detach from the lens mount with force.
2. With the ring light removed, use both hands to turn the lens a few degrees clockwise, pull it out from its bayonet fitting, and set it aside.
Ring Light Connector
Figure 24. Ring Light
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