M e t r o l o g y MANUAL. ComGage Software. Document-No. : D2F Edition : May 2004 Copyright : IBR. Messtechnik GmbH & Co.

Transcription

1 M e t r o l o g y MANUAL Software Document-No. : D2F Edition : May 2004 Copyright : IBR Messtechnik GmbH & Co. KG

2 Contents 1. Introduction... : 3 2. Features... : 3 3. General information about ( working with )... : 4 4. Installation of... : 5 5. Start of... : 6 6. User Login... : 6 7. Getting started... : Selection of the Language... : Selection of the Data Directories... : Connections... : Display Elements... : User Management... : Reference information ( operators, machines, batch numbers, etc )... : Automatic start... : Convert... : Create one Test Scheme 8.1 Programming of the test scheme head... : Programming of the article reference information... : Programming of the characteristics ( Drawing data )... : Programming of the characteristics ( Statistics )... : Programming of the characteristics ( Reference information )... : Programming of the test steps ( Sequence Control )... : Programming of the test steps ( Digital Outputs )... : Programming of the test steps ( Additional settings )... : Programming of the test steps ( Screen )... : Programming examples... : Start the Test Schemes ( measuring )... : Additional Test Scheme Menus 10.1 Duplicate... : Delete... : Create one Test Order... : Start the Test Orders ( measuring )... : Additional Test Order Menus 13.1 Close... : Print... : Analysis... : Convert... : Delete... : Adjustment Windows 14.1 Mechanical Adjustment of inductive probes... : Important conditions to use... : 53 2

3 1. Introduction is an universal Software for the Metrology and statistical process control in the Production. The software allows the test of components with several characteristics. Additionally by statistical functions the software delivers information for controlling production processes. 2. Features υ Connection of all gauges and sensors via IBR Instruments υ Test orders for saving and analysing of measured values υ Test schemes for defining the characteristics of the component υ Inclusion of reference information ( machines, operators, bath numbers, ) in test orders and schemes υ Simultaneous opening of several test orders or test schemes for taking measured values on different production lines υ On each component up to 128 characteristics can be defined υ Free definition of gauges with mathematical functions ( like sin, cos, tan, min, max, ) υ Static and dynamic measuring modes υ Many possibilities for the definition of the measurement display ( visual design of the display ) υ Statistical displays ( like Control Charts, Histograms, Statistical Data, Run Charts, ) υ Automatic and manual saving of measured values υ Automatic and manual switching over between characteristics and display windows υ Zero adjustment and calibration of gauges ( on air-gauging ) υ Opening a window for doing the zero adjustment and gauge calibration of the characteristics in steps opened by function key, foot switch, time or number of measured components υ Reference Check for testing the fixture υ Control functions by digital inputs and outputs υ Converting measured values to different formats ( Q-DAS, Excel, ) υ Analysis of measured values with print-outs 3

4 υ User management ( for giving rights to the different users ) 3. General information about ( working with ) is programmed with C++ only using standard API functions. This allows a optimum speed, less usage of resources and the possibility to generate a Windows CE version of. In addition to universal measuring routines and online SPC functions for the production an easy understandable shell, multiple languages ( European and Asian ), operation only by a small keyboard and less usage of PC resources ( for working on small Windows CE PCs i.e. Pocket PCs ) were important points for the development of. The programming in is visual. The layout and colours can be defined without limitations always seeing the result or information on the screen. In you can mainly programme two groups of files : a) Test Scheme : A test scheme contains the definition of the component with its characteristics ( nominal size, tolerances, ). Additional it contains the definition how to measure ( measurement sequences, static / dynamic measurements, probe mixings, ) and the design of the display. On a test scheme no measurement data can be saved. b) Test Order : A test order is created for an amount of components ( of the same type ), which must be checked. On a test order you must select a test scheme ( which defines all parameters for the test of the component ) and input the number of components you want to check. The measurement data of one test order can be saved, converted ( Excel, QS-Stat, ), analysed and printed. On test schemes and test orders you can select your reference information ( machines, operators, batch numbers, ). The programming of test schemes and orders is described in the following part of the manual. The software consists of 4 modules : 1.) IBR_TSH ( Test Scheme Handler ) for creating test schemes. 2.) IBR_TOH ( Test Order Handler ) for creating, analysing, printing and converting test orders 3.) IBR_WGL ( Window Gauge Library ) for measuring 4.) IBR_SPC ( Statistical Process Control ) for online statistics and analysis of measured data 5.) IBR_PLC ( Programmable Logical Control ) for controlling of digital inputs and outputs Example for the usage of the 5modules in a company : In a company there are a PC in the supervisor office ( for creating test schemes, test orders and analysis of the measured values ) and 5 measuring PCs with online SPC. On the supervisor PC the modules : IBR_TSH, IBR_TOH and IBR_SPC are needed. On the 5 measuring PCs the modules : IBR_WGL and IBR_SPC are needed. The integrated user management allows to deactivate some menus for different users. ( i.e. the menus for creating test schemes and test orders can be deactivated for the operators in the production ) files : *.tsf Test scheme files *.rto, *.cto Test order files *.tod Measuring data file.rif Reference information.usr User setup 4

5 *.sch Display Element designs 4. Installation of Hardware requirements : Software requirements : Pentium 500 Windows 95/98/ME/NT/2000/XP 64 MB Ram Windows CE 10 MB Hard disk Installation from CD : 1. Please insert the CD IBR Software for Metrology and SPC in your CD-ROM. 2. Go to Start / Run and enter <Letter of CDROM-Drive>: \ \ _Inst Start installation by clicking on the OK-Button. 3. Now input the destination directory for the Software ( INSTALLATION DIRECTORY ). Start installation by clicking on the OK-Button. 4. After the installation you can start working with. Installation from Internet : 1. Download the file COMGAGE.zip from the web side under Downloads \ Software and unzip the file. 2. Start the unzipped installation file _Inst.exe. 3. Now input the destination directory for the Software ( INSTALLATION DIRECTORY ). Start installation by clicking on the OK-Button. 4. After the installation you can start working with. 5

6 5. Start of The licences for the Software Modules are stored in the dongel ( security key ) for COM-ports, in the IMB-usb connection cable for the IMBus or in the IBRit-rf1-usb radio modules. So please connect first of all the dongel ( security key ) in supply to one of the COM-ports of your PC or connect the IMB-usb cable or IBRit-rf1-usb radio module to one of the USB-ports of your PC. On the same PC-Port it is only allowed to connect IBR-Measuring and Interface instruments. Connect then the IBR interface(s) or measuring instrument(s) according to the instructions given in their instruction manuals. After this switch on the instrument(s). Start now the software. Use the Windows Explorer to go into the -Directory ( i.e. C:\ ) and start the programme.exe. 6. User login On activated user management ( see 7.5 ) you must log in after the start of : On the first startup of there exists only the user : User name = admin Password = admin After a successful login the main window opens. Note : Capitalization of user name and password is not checked. 6

7 7. Getting started On the first start up of the -Software you have to do some important settings for working with the software : 7.1 Selection of the Language You can select the language in the menu Options / Language ( Button : ) On selection of the language a window with a list of the existing languages is opened : Select your language and confirm by OK. 7.2 Selection of the Data Directories In the Menu Options / Data Directories ( Button : ) you can input the directory names, in which the data - used by - are saved : - Directory for saving the test schemes - Directory for saving the test orders and collected measured data - Directory for saving the converted test orders ( Excel-files, QDAS-files, ) - Directory for loading the pictures ( *.bmp files ) - Directory for saving the reference information and user setup Note : You can only input existing directory names. does not create a directory. 7

8 7.3 Connections On clicking on the Menu Options / Connections ( Button : ) you open the window for programming the PC-devices and for the selecting the connected interfaces and measuring instruments. You can programme up to 8 devices ( i.e. device 1 = COM 1 with an IBRit-di8 and device 2 = COM2 with an IBRit-md2c ). Required programme settings : 1. PC-Connection : Selection of the PC-device ( COM 1, COM 2,..., USB,... ) 2. IBR-Instrument : Selection of the IBR-instrument(s) ( IBRit-mc1, -mc4, -md1, -md2 (c) (s), -di8, -de8, -da8, C100, B100,... ) 3. Connection and Gauge / Sensor : In these two column you see which gauge / sensor is connected to which input of your IBR interface or measuring instrument. 4. Setup : With the Setup button you can select on IBRit-mc1, md2 (s) (c), ma1/2 interfaces the gauge / sensor from the IBR I/O catalogue you have connected to the input of your IBR interface. 5. Mea. Step : On IBRit - di8 / de8 / da8 measuring instruments you can programme the measurement steps of the inputs. 6. Service : Menu for the technical support from IBR. Is not needed for normal measuring mode. Note : On a di8 / de8 / da8 Bus you must select for each of the 8 bus addresses the measuring box ( IBRit di8/ de8 / da8 ) you have connected to the bus. 8

9 7.4 Display Elements On clicking on the Menu Options / Display Elements ( Button : ) the window for the definition of the colours of the measurement display and for the individual design of all measurement- and statistical display elements is opened. You get in the main window a preview of the display elements, when you point with the mouse on the button or when the button is selected. The Programming of the Display Elements explains itself and is supported by a preview of the display element in the programming window. ( Below you find some pictures of their setup windows ) Additional you can define, save and delete schemes with the colour palettes and the settings of the display elements. The defined colours and settings of the display elements are copied into each test scheme on inserting the display elements in the test scheme and can be changed afterwards in each test scheme when required. 9

10 7.5 User management On clicking on the Menu Options / User setup ( Button : of users is opened. ) the window for the creation and changing At the bottom of the window with the checkbox User management activated you can generally activate / deactivate the user management. For changing a user please select the user from the list and press the OK button. For creating a new user you need only to input the new user name and press the OK button. After the selection of the user you can : - input the password for the login - select which menus are activated / deactivated for the user - delete the user By the Next > button you save the new settings of the currently programmed user and you can go on with the programming of the next user. 10

11 By clicking on the Menu Options / New login you can log in as another user : Note : Capitalization of user name and password is not checked. The name of the currently logged in user is shown in the status bar : 11

12 7.6 Reference information ( operators, machines, batch numbers, etc. ) On clicking on the Menu Options / Reference Information ( Button : ) the window for programming the reference information tables is opened. Nearly all reference information types but not the batch number and the last 5 user defined reference information types ( see below) are selected from the reference information tables. Only the batch number and the last 5 user defined reference information types can be input in an edit field for them there is no selection from file. 1.) For each data type the place, where the data are requested, can be selected : off - The data type is not used in test scheme - The data type is requested in the test scheme in test order - The data type is requested in the test order on starting a test order - The data type is requested on starting the test order before measuring a part - The data type is requested for every part in measuring mode ( for i.e. a serial number ) 2.) With the Setup Button you can open the window for programming the tables of the selected data type. ( for programming : see next page ) 3.) For the data types you can choose either that the data are selected for the whole component or for each characteristic ( i.e. one characteristic is measured with a calliper and one with a dial gauge ). On you can programme the following data types : - Customer - Operator - Supplier - Shift - Manufacturer - Test Place - Works / Department - Storage Place - Machine - Production instruction - Fixture - Test instruction - Nest - Events ( why a measurement value is out of tolerance ) - Tool - Batch - Material - Action - Test Equipment - 5 user definable data types ( Selection by tables in measuring mode ) - 5 user definable data types ( Direct input by keyboard in measuring mode ) 12

13 Programming the different data types ( tables ) : First of all you must select a data set in the list or create a new one with the New Button. After the selection you can change the settings of the data set or delete the data set with the Delete button. For each data set you can programme : Name ( 90 characters ) Number ( 10 characters ) Note ( 650 characters ) After programming one data set you can save the settings and leave the window by the OK-button. With the Next > button you store the settings and you can go on with programming the next data set. Note : All settings stored by Next > do not get lost when the Cancel button is pressed. 13

14 7.7 Automatic Start In Menu Options \ Automatic Start the automatic start of test schemes or test orders on starting or by Barcode Reader can be activated. The selection of a test scheme or test order in the measuring mode can be done by : Keyboard ( keys : 0 9 ), Foot switch, Mea. input or Barcode reader. Test Orders & Start by COM1..4 On Start or on clicking on the Menu File / Test Order / Start you are requested to select a test order by the Barcode Reader : The used Barcodes must be created in the Format : CODE128 and contain the test order name. Test Orders & Automatic Start on Start After the Start all selected test orders are started and you can collect your measuring values When the assigned Mea. Input Mxx detects a measuring value changing then the belonging test order is automatically started. The measuring input can be selected by the button. When the assigned Foot switch Txx is pressed then the belonging test order is automatically started. The foot switch can be selected by the button. Test Schemes & Start by COM1..4 On Start or on clicking on the Menu File / Test Scheme / Start you are requested to select a test scheme by the Barcode Reader. The used Barcodes must be created in the Format : CODE128 and contain the test scheme name. Test Schemes & Automatic Start on Start After the Start all selected test schemes are started. When the assigned Mea. Input Mxx detects a measuring value changing then the belonging test scheme is automatically started. The measuring input can be selected by the button. When the assigned Foot switch Txx is pressed then the belonging test scheme is automatically 14

15 7.8 Convert started. The foot switch can be selected by the button. In the menu Options \ Convert the automatic conversion of measuring values in measuring mode can be activated. File format Selection of the Data format, in which the conversion shall occur : QDAS Format ( File name : Test order name.dfq ) Excel Format ( File name : Test order name.xls ) Special Format ( File name : Test order name.txt A UDI Script for SPC Light from Lighthouse is available on request ) Automatic conversion of the measuring data after leaving the measuring mode The conversion occurs after leaving the measuring mode Automatic conversion of the measuring data on storing a data set in measuring mode The conversion occurs while measuring Conversion Time Point on converting a data set in measuring mode You can select, that all measuring data are converted on saving ( Convert all values directly ) or that all measuring data which cannot be deleted anymore are converted ( Convert only undeletable ). 15

16 8. Create one Test Scheme In a test scheme the part, its characteristics and the measuring sequence are defined : υ In the test scheme the article number, the part name and the part-reference information ( operator, machine, batch, ) are input. υ Up to 128 characteristics can be created : Characteristic Name Nominal size and tolerances Probe Mixing ( with mathematical functions, like sin, cos, tan, Min, Max, ) Measuring modes ( for static, dynamic [ Min, Max, TIR, Mean ], measurements ) Master values for Zeroadjustment or automatic Gauge-Calibration ( for air gauging ) Sample Size Settings for the statistics ( Plausibility limits, distribution form,... ) υ Up to 128 test steps can be created : Free design of the display windows with Numeric displays, Column displays, Analogue meters, Control charts, Histograms,..., Lines, Texts, Pictures Assignment of the foot switches, function keys, digital inputs and free definable conditions ( with mathematical operators, logical operators, trigometrical functions, timers,... ) to the executable functions ( i.e. saving of measuring values, deleting of measuring values, adjustment, ) Setting of digital outputs 8.1 Programming of the test scheme head ) the window for pro- By clicking on the menu File / Test Scheme / Create & Change ( Button : gramming the Test Scheme is opened : At first you have to enter the Article Number. If you enter an existing Article Number you can modify the existing test scheme, otherwise you create a new test scheme. 16

17 To the article number a directory entry can be added. This directory entry is a relative to the data directory ( see 7.2 ) and must already exist. does not create any directory. [ Example : Machine 1\Art-1234 The test scheme Art-1234 is created in the directory Machine 1 ] In the test scheme the following settings can be programmed : 1) Article name ( Name of the part, i.e. Cylinder, Bore, ) 2) Article reference information ( Additional data of the test scheme, i.e. manufacturer, distributor, customer, operator, batch,.... The selection of the article reference information is described under the point : 8.2. ) 3) Characteristics Drawing data ( The drawing data of the characteristics consists of the standard data of the characteristics, like i.e. name, nominal size and tolerances, master values, probe-mixing, The programming of the drawing data is described under the point : 8.3. ) 4) Characteristics Statistics ( The statistical data consists of the settings for the statistical analysis of the characteristics. The programming of the statistical data is described under the point : 8.4. ) 5) Characteristics Reference information ( The programming of the characteristic reference information is described under the point : 8.5. ) 6) Test steps Sequence ( Programming of the control of test steps, i.e. How is the saving of the characteristics in the current test step called? The programming of the sequence control is described under the point : 8.6. ) 7) Test steps Digital Outputs ( Programming of the output values of the digital outputs in the particular test steps. The programming of the test steps is described under the point : 8.7. ) 8) Test steps Additional settings ( The programming of the additional settings is described under the point : 8.8. ) 9) Test steps Screen ( Design of the display window for the particular test steps. The programming of the screens is described under the point : 8.9. ) 17

18 8.2 Programming of the article reference information Reference information In the window a data set must be selected or input for all reference information of the test scheme. The reference information types of the test scheme are selected under 7.6. Creation date Creation date of the test scheme Created by Name of the operator, who has created the test scheme Note Free edit field for documentation 18

19 8.3 Programming of the characteristics ( drawing data ) For programming the drawing data of a characteristic the following window is opened : 1.) Characteristic name : Name of the characteristic 2.) Unit : Selection of the Unit. In the list you find the standard units. Special units ( ) you can define by the Setup-Button. For a special unit you can input an offset and factor ( i.e. for converting F to C the factor is 5/9 and the offset is 160/9 ). 3.) Nominal size (of the characteristic ) 4.) Tolerances ( of the characteristic ) 5.) Measurement inputs : Formula of the gauge see below 6.) Measurement mode : Measurement mode for calculating the measurement result ( i.e. static, dynamic ) see below 7.) Master values : Input of the master values. For a zero adjustment the input of 1 master value is necessary, for a gauge calibration ( i.e. air gauging ) the input of 2 masters is necessary. 19

20 Measurement inputs It is possible to switch over between the display of measurement inputs and the display of characteristics. In the formula of the gauge mixing the measurement inputs and the results of other characteristics can be combined. In the formulas the following inputs can be used : Address Input Mx Measurement Input x Cx Current measuring value of characteristic x Cx_File Last measuring value from file of characteristic x Cx_USL If the mea. value of characteristic x > USL, then Cx_USL = 1 Cx_UCL If the mea. value of characteristic x > UCL und x < USL, then Cx_UCL = 1 Cx_ok If the mea. value of characteristic x inside the tolerances, then Cx_ok = 1 Cx_LCL If the mea. value of characteristic x > LSL und x < LCL, then Cx_LCL = 1 Cx_LSL If the mea. value of characteristic x < LSL, then Cx_LSL = 1 In the formulas the following operators can be used : Operator Function Example + Addition of inputs, characteristics and numbers M1+M Subtraction of inputs, characteristics and numbers M1-M2+1.1e-4 * Multiplication of inputs, characteristics and numbers M3*0.5+M2*M1 / Division of inputs, characteristics and numbers M2/3 ^ x power by y ( i.e. 2^3 = 2*2*2 = 8 ) M2^(1/2) Sin() Sinus ( unit : degree ) Sin(M2) Cos() Cosines ( unit : degree ) Cos(M2) Tan() Tangens ( unit : degree ) Tan(M2*3+M1) asin() Arc Sinus ( unit : degree ) asin(m2) acos() Arc Cosines ( unit : degree ) acos(m2) atan() Arc Tangens ( unit : degree ) atan(m2) exp() Exponential Function ( ^ x ) exp(m1) log() Natural Logarithm log(m1) abs() Absolute Function abs(m1) Pi Pi (=3,14) Sin(Pi) Min(;;;) Minimum of all objects in the list Min(M1;M2;M3;M4+M5) Max(;;;) Maximum of all objects in the list Max(M1;M2;M3;M4+M5) Avr(;;;) Average of all objects in the list Avr(M1;M2;M3;M4+M5) Tir(;;;) (Maximum Minimum) of all objects in the list Tir(M1;M2;M3;M4+M5) SD(;;;) Standard deviation of all objects in the list SD(M1;M2;M3;M4+M5) Example for a formula : 45e-5 + sin( 5*M1/M2 )*cos( 4*M3 ) ( C2+M3+4.5 )^( 1 / 2 ) + Min( sin( C1 );cos( M2 )/3;M2+M3;5 ) 20

21 Measurement mode a) Static measurement measures and calculates continuously the result of the characteristic. The display is updated continuously. b) Dynamic measurement Measurement mode for finding the Minimum, Maximum, TIR and Mean of a dynamic measurement. Min Searching the smallest measurement value Max Searching the biggest measurement value TIR Searching the TIR Value ( Max-Min ) MEAN ( (Max+Min)/2 ) Calculation of the Mean value ( (Max+Min)/2 ) Mittelwert ( (X1+...+Xn)/n ) Calculation of the Mean value ( Adding all measurement values and dividing by the number of values ) c) Gauge Triggered Only these measurement values are shown, which are transmitted by data key of the gauge. This mode is especially for hand gauges, on which the measurement values of the hand gauge should be sent by the data key on the hand gauge d) Grading Mode Classification of the measurement results in linear and in non linear classes : 21

22 8.4 Programming of the characteristics ( statistics ) 1.) Type of analysis : Selection of the characteristic type : Variable Characteristic Assigning of a physical size, i.e mm Nominal Characteristic i.e. number of defective pixel on a TTF screen,... Attributive Characteristic i.e. the part is red, green, blue,... 2.) Sample size ( for the measurement of a characteristic. ) Note : On a 100% Control a display of a control chart or Cp / Cpk is not possible 3.) Plausibility limits : If a measurement value is on the saving outside of the plausibility limits, then the operator is asked, whether the measurement value should be saved or not. 4.) Norm for the standard deviation : Selection of the norm for calculating of the standard deviation ( ISO9000 / OS9000 ). Is only needed for control charts and for Cp / Cpk. 5.) Distribution type : Not available at this time 6.) Message output On a value outside the specification limits ( USL / LSL ) : For the measuring mode the display of a message can be activated, when the measurement value is outside the specification limits on saving it. 7.) Message output On a value outside the controlling limits ( UCL / LCL ) : For the measuring mode the display of a message can be activated, when the measurement value is outside the controlling limits on saving it The controlling limits are input in the window for the drawing data ( see 8.3 ). 8.) Message output On a value outside the controlling limits of a control chart : For the measuring mode the display of a message can be activated, when the measurement value is outside the controlling limits on saving it The controlling limits are calculated in the control charts which are in the same step. 22

23 8.5 Programming of the characteristics ( reference information ) Reference information In the window a data set must be selected or input for all reference information of the characterisics. The reference information types of the characteristics are selected under 7.6. Note Free edit field for documentation 23

24 8.6 Programming of the test steps ( Sequence control ) In this window to the particular functions ( Save the characteristics, Delete measuring values,... ) foot switches, function keys, digital inputs and events are assigned, by which they are executed. As functions it is provided : Save the characteristics : By the function key F1 or by the hand / foot switch T2 or by the digital input I4 all selected characteristics are saved in the test step. Note : If the characteristics are not saved, because they are i.e. outside the plausibility limits then it is not switched to the next step. Delete measuring values For deleting measuring values of the selected characteristics function keys, foot switches can be selected. 24

25 Change to test step x By the function key F4 or by the hand / foot switch T2 or by the digital input I8 it is changed to the selected test step. It can be selected a fix test step Sx or it can be changed to the next test step in the list. Repeat last test step Selection of the foot switch, function key, for repeating the last test step, in the case that because of a measuring error ( i.e. part was inserted in the fixture wrongly ) a new measurement of the last step is necessary. Adjustment of the characteristics By the function key F1 or by the hand / foot switch T1 or by the digital input I1 all selected characteristics are adjusted in the test step. Note : If it is waited for the inserting of the 2 nd master on a gauge calibration, then the saving of Characteristics or switching to another step is not possible. Dynamic measurement on / off By the function key Ctrl+F10 or by the hand / foot switch T2 or by the digital input I2 the dynamic measurement of characteristic 3 is started / stopped in the test step. Note : If a dynamic measurement is running, then the saving of Characteristics, adjusting of Characteristics or switching to another step is not possible. Call sub sequence / Return from sub sequence Calling a sub sequence for i.e. adjusting of gauges or for showing SPC windows. If it is returned form a sub sequence returns to that step, from which the sub sequence was called. 25

26 Add additional functions By the New-Button up to 50 functions can be added : The functions ( i.e. saving of characteristics,... ) can be created several times. For example the characteristics C1..C3 can be saved with F1 and the characteristics C5...C7 can be saved with F2 or you can change with F1 to step S2 and with F2 to step S4. Additional to the function keys, hand / foot switches and digital inputs Events can be selected for executing the functions : Test step was started - The function is executed on the start of the test step, when changes into the test step. It is possible with this event to start i.e. a dynamic measurement, when changes into the test step. Char. x dyn. Measurement... - If the dynamic measurement of characteristic x is stopped, then the assigned functions are executed. It is possible with this event to save i.e. the result of the dyn. Measurement when the dynamic measurement is stopped. Char. x Value is collected - If a value from characteristic x is sent ( i.e. by data key of the gauge ) then the event is raised. It possible to save directly the received value. Formula - Free Input of a condition for executing the function. ( see below ) 26

27 Formula editor ( for inputting >If-Then< conditions ) It is possible to switch over between the display of the measurement inputs, the display of the characteristics, the display of the foot switches and the display of the digital inputs. The inputted formula consists always of logical conditions : x>y, z=1,.... These logical conditions can be combined by Boolean operators. If the logical conditions of a formula are fulfilled then the assigned function ( see above ) is executed. As logical operators are available : Operator Funktion & And conjunction between 2 conditions Or conjunction between 2 conditions = The condition is fulfilled, if both Parameter are equal <> The condition is fulfilled, if both Parameter are unequal < The condition is fulfilled, if Parameter 1 is smaller than Parameter 2 > The condition is fulfilled, if Parameter 1 is bigger than Parameter 2 >= The condition is fulfilled, if Parameter 1 is equal or bigger than Parameter 2 <= The condition is fulfilled, if Parameter 1 is equal or smaller than Parameter 2 Example for a formula : (x>5 & y<=3) z=1 In the formulas the following inputs can be used : Address Input Mx Measurement Input x Cx Current measuring value of characteristic x Cx_File Last measuring value from file of characteristic x Cx_USL If the mea. value of characteristic x > USL, then Cx_USL = 1 Cx_UCL If the mea. value of characteristic x > UCL und x < USL, then Cx_UCL = 1 Cx_ok If the mea. value of characteristic x inside the tolerances, then Cx_ok = 1 Cx_LCL If the mea. value of characteristic x > LSL und x < LCL, then Cx_LCL = 1 Cx_LSL If the mea. value of characteristic x < LSL, then Cx_LSL = 1 Tx If a pressing of the foot switch Tx is detected, so Tx = 1 is set Tx_State Current state of foot switch Tx ( 0=foot switch is not pressed / 1= foot switch is pressed ) Ix If the setting of the digital input Ix is detected, so Ix = 1 is set Ix_State Current state of digital input Ix ( 0=not set / 1=set ) F1... F12 If a pressing of the function key Fx is detected, so Fx = 1 is set F1_State... F12_State Current state of function key Fx ( 0= Function key is not pressed / 1= Function key is pressed) 27

28 In the formulas the following operators can be used : Operator Function Example + Addition of inputs, characteristics and numbers M1+M Subtraction of inputs, characteristics and numbers M1-M2+1.1e-4 * Multiplication of inputs, characteristics and numbers M3*0.5+M2*M1 / Division of inputs, characteristics and numbers M2/3 ^ x power by y ( i.e. 2^3 = 2*2*2 = 8 ) M2^(1/2) Sin() Sinus ( unit : degree ) Sin(M2) Cos() Cosines ( unit : degree ) Cos(M2) Tan() Tangens ( unit : degree ) Tan(M2*3+M1) asin() Arc Sinus ( unit : degree ) asin(m2) acos() Arc Cosines ( unit : degree ) acos(m2) atan() Arc Tangens ( unit : degree ) atan(m2) exp() Exponential Function ( ^ x ) exp(m1) log() Natural Logarithm log(m1) abs() Absolute Function abs(m1) Pi Pi (=3,14) Sin(Pi) Min(;;;) Minimum of all objects in the list Min(M1;M2;M3;M4+M5) Max(;;;) Maximum of all objects in the list Max(M1;M2;M3;M4+M5) Avr(;;;) Average of all objects in the list Avr(M1;M2;M3;M4+M5) Tir(;;;) (Maximum Minimum) of all objects in the list Tir(M1;M2;M3;M4+M5) SD(;;;) Standard deviation of all objects in the list SD(M1;M2;M3;M4+M5) Example for a formula : 45e-5 + sin( 5*M1/M2 )*cos( 4*M3 ) ( C2+M3+4.5 )^( 1 / 2 ) + Min( sin( C1 );cos( M2 )/3;M2+M3;5 ) > 1000 There are additional the following Special functions for the formulas available : Specialfunction Description Timer Timer ( time interval, num. of calls ) The Timer is initialised on the start of the measuring step and raises the event after the time is over. time interval Time Interval after which the timer event raises [ in msec ] num. of calls Number of calls of the timer 0 = Special case : The timer event raises infinite times 1 = The timer event raises one time 2 = The timer event raises two times. GlobalTimer GlobalTimer ( time interval, num. of calls ) The Timer is initialised on the start of the test scheme / test order and raises the event after the time is over. ( serves for a call of i.e. a timer forced calibration ) time interval Time Interval after which the timer event raises [ in msec ] num. of calls Number of calls of the timer 0 = Special case : The timer raises infinite times 1 = The timer event raises one time 2 = The timer event raises two times. PartCounter PartCounter ( reset size ) The Part Counter counts the measured parts since the start of the test scheme / test order. When the counter reaches the reset size then the counter is reset. ( serves for a call of i.e. a forced calibration ) reset size Number of parts till the counter is reset 0 = Special case : The counter is never reset 1 = The counter is reset after one part 2 = The counter is reset after two part. 28

29 StableValue StableValue ( Number of the characteristic, begin, end, time, max. jump ) Detection of a stable value. MVChange The event raises, when the value of the Characteristic Number of the characteristic is in the range from begin till end and is stable, that means it jumps less than max jump for time msec. MVChange ( Number of the characteristic, Changing, Time) Detection of a changing value. Example for a formula : Timer(1000,1)=1 The event raises, when the value of the Characteristic Number of the characteristic changes with the size Changing within time msec. 29

30 8.7 Programming of the test steps ( Digital Outputs ) In this window to the digital outputs the output values can assigned on the particular test step. ( i.e. for controlling a machine ) : The digital outputs and their addresses are shown in the window above. For the digital outputs the following values are available : Output Value Output 0 The digital output is not set. 1 The digital output is set. USL of the complete part The digital output is set; if one characteristic is outside of the upper tolerance (USL) UCL of the complete part The digital output is set; if one characteristic is outside of the upper controlling limit (UCL) and no characteristic is outside of USL / LSL Good signal of the complete part The digital output is set; if all characteristics are inside of the tolerances and controlling limits LCL of the complete part The digital output is set; if one characteristic is outside of the lower controlling limit (LCL) and no characteristic is outside of USL / LSL LSL of the complete part The digital output is set; if one characteristic is outside of the lower tolerance (LSL) Characteristic Cx The digital output is set; if the characteristics is outside of the tolerances ( USL / LSL ) Logic function of the output Input of free formula see Formula editor under 8.6 in the example above the output Q8 is set, when both inputs I1 & I2 are set 30

31 8.8 Programming of the test steps ( Additional settings ) Collection type Collect all characteristics in one test step together In the test step all characteristics are generally active, that means all characteristics are saved, are adjusted, together. Automatic recognition between the characteristics in one test step In the test step only one characteristic is active, that means only one characteristic is saved, is adjusted, at one time. The switching over between the characteristics occurs, if the mea. value of one characteristic changes with Hysteresis. Sample plan 100 % Control The test step is called every time. Collection all x of y parts The test step is only called x-times of y-times, that means with this function the collection of uncritical characteristics can be left out, so that these characteristics must not be collected every time. Collection all x Minutes The test step is only called all x minutes, that means with this function the collection of uncritical characteristics can be left out, so that these characteristics must not be collected every time. 31

32 8.9 Programming of the test steps ( Screen ) In this menu the display window for the test step can be defined. 1.) Selection of the Characteristic In the following table you can select the characteristic you want to programme : 2.) Leave the Programming Menu By the EXIT-Button you can leave the menu for programming the display : 32

33 3.) Adding Display Elements By the following buttons you can add one of the display elements. The element belongs to the currently selected characteristic. ( see 1. ) The new Display Element is placed in the middle of the display and can now be moved. The name of the display element type is shown if you point with the mouse on the button. 4.) Moving Display Elements If you click on one of the display elements it get activated. When it is activated you can move it or change its size by the mouse or by the cursor-keys. ( Cursor : Move the element / Shift+Cursor : Change the size ) 5.) Grayed Display Elements The Display Elements of the currently selected characteristic are coloured, all other display elements ( of other characteristics ) are grey. 6.) Change or delete display elements With the right mouse key or with the ENTER-Key you can open the following menu for the activated display element : 33

34 If you want to change the design of the display element, you have to select the menu point Change : Value and SPC displays There are some parameters of the display elements which can be different between the display elements, because they are depending on the characteristic settings. The other settings are colours, sizes, fonts,. Display Parameters Numeric Display - Resolution - Number of Digits Column Display - Zero Point of the Column - Column Range ( A user defined range is possible ) Analogue Meter - Zero Point - Column Range ( A user defined range is possible ) Histogram - Histogram Type ( for Process Control or Process Analysis ) - Number of Classes Run Chart - Number of shown values in the chart - Scrollbar on / off Statistical Data - Selection of the datas ( min, max, cp, cpk, ) which should be shown Combination Display - Resolution - Number of Digits - Number of shown values in the chart Control Chart - Chart Types ( Average Chart [Xq], Median Chart [Xm], Raw Values Chart [X], Deviation Chart [S], Range Chart [R] ) - Calculation of the Controlling Limits ( Shewhart, Acceptance ) - Number of shown values in the chart - Scrollbar on / off On Control or Run Charts you can input a text which is shown in the axis for each value : In this text you can use the following variables : Variable Contents $n Number of the shown value $t Time when the value was collected $d Date when the value was collected $r1 Costumer $r2 Supplier $r3 Manufacturer $r4 Works / Department $r5 Machine $r6 Fixture $r7 Nest $r8 Tool $r9 Material $r10 Test equipment $r11 Operator $r12 Shift $r13 Test place $r14 Storage place $r15 Production instruction $r16 Test instruction $r18 Batch number $r21 - $r30 user definable reference information 1 10 Note : All variables ( except $n ) are only shown when you measure with a test order. 34

35 Text Elements You can input the text of the text element and select the font and colours. The text elements additional allows the linking of variables ( The variables are always refer to the characteristics the text element belongs to ) : Variable Contents $n Number of measured components $r1 Costumer $r2 Supplier $r3 Manufacturer $r4 Works / Department $r5 Machine $r6 Fixture $r7 Nest $r8 Tool $r9 Material $r10 Test equipment $r11 Operator $r12 Shift $r13 Test place $r14 Storage place $r15 Production instruction $r16 Test instruction $r18 Batch number $r21 - $r30 user definable reference information 1 10 $o1 Article Number $o2 Article Name $o3 Quantity $o4 Creation date $o5 Created by $o6 Article Text i.e. Text in Programming Mode Text in Measuring Mode : There are $n components measured : There are 50 components measured Note : All variables ( except $n ) are only shown when you measure with a test order. Line Elements You can define the thickness and colour of the line Picture Elements You can select your bitmap. ( You can only use pictures in *.bmp format ) With the Delete -Menu Point you can delete the display element. 7.) Managing of the Windows With the Adopt window contents Button the display window of another test step can be copied completely. With the Colour Button you can define the background colour of the window. With the Size Button you can change the size of the drawing area ( Standard, for Pocket PCs (320x240 Pixel), for Handheld PCs (640x240), ) 35

36 8.) Keys In the programming mode there are the following keys : Key TAB SPACEBAR Cursor Shift+Cursor Enter Function Moves the Cursor from Button to Button and Display Element to Display Element Presses one Button Moves one display element Changes the size of one display element Opens the menu for changing / deleting the currently selected display element 8.10 Programming examples Adjustment window For the programming of an adjustment sequence additional test steps must be created for the adjustment sequence. In these test steps the control of the fixture by digital outputs and the adjustment in several steps ( i.e. Step 1 = Adjustment of the characteristics 1 & 2, Step 2 = Adjustment of the characteristics 5-8,... ) can be executed. For calling the adjustment steps the function Call sub sequence ( see 8.6 ) and for leaving the adjustment sequence the function Return form sub sequence ( see 8.6 ) should be used. The adjustment sequence can be started by foot switch / function key... ( see 8.6 ) or can be started by the special functions of the formula ( see 8.6 ) GlobalTimer / PartCounter. Example : PartCounter(10) - After 10 parts the operator is forced to adjust the fixture GlobalTimer( ,0) - After each hour the operator is forced to adjust the fixture 36

37 9. Start the Test Schemes ( measuring ) This menu is created for testing the function of the test scheme before you create the test orders. ( Note : When one Test Order is created, you cannot change its test scheme data any more ) The measured values you have collected in this menu get lost, when you leave it. You start the test scheme by clicking on the Menu File / Test Scheme / Start ( Button : ). After you have pressed the button you must select the test scheme you want to start : In this menu it is possible to start up to 10 test schemes at the same time. After the start of a test scheme one of the keys is automatically assigned to the test scheme by. 37

38 1.) Start an additional test scheme You can start an additional test scheme by clicking on the menu File / Test Scheme / Start ( Button: ). To this test scheme one of the keys 0 9 is automatically assigned. 2.) List of test schemes The started test schemes and their keys 0..9 are shown in following list : The Number before the article numbers ( i.e. [0] ) informs you which key you must press to start measuring with the test scheme. By clicking on one test scheme it is started. 38

39 3.) End of one test scheme By the EXIT-Button you can end the currently measuring test scheme : When all test schemes ended the menu is left automatically. 4.) Buttons With the following buttons you can : - Save all characteristics shown in the window - Delete the last value of all characteristics shown in the window - Do a zero adjustment / gauge calibration of all characteristics shown in the window - Remove the zero adjustment offset and gauge calibration factor of all characteristics shown in the window 5.) Adjustment Buttons With the following button in the menu bar you can open the window for the mechanical adjustment. ( This menu is described under point : 14 ) 6.) Saving values If one measured value you want to save is outside of the plausibility limits then the following window opens. If you click on the No button then the data set is not saved.!!! When this window is opened, does not measure till the window is closed. 39

40 7.) Deleting values If the operator has done an error on measuring, he can delete this wrong value and can repeat the measurement. But he cannot delete more values ( from components ) he measured before. 8.) Zero Adjustment & Gauge Calibration If you press the button, function key or foot key for the zero adjustment, then the zero adjustment or gauge calibration is executed. On Zero Adjustment the value assumes the programmed master value. On Gauge Calibration the value is stored as first master value. The Numeric Display shows alternately Cal and the measured value. When the button, is pressed a second time the calibration is completed. So you must insert on the first key press the first master and on the second key press the second master in the fixture. 40

41 9.) Keys In the measurement mode there are the following keys : Key Function TAB, + Moves the cursor from button to button SPACEBAR, ENTER Presses one button F1, F2,... The functions of the function keys are defined in the test scheme / Moves the window to full screen mode and back to normal mode Cursor Scrolling in the statistical display elements ( with scrollbars ) 0 9 Selection of a test scheme 10.) Full Screen Mode Example for the Full Screen Mode : 41

42 10. Additional Test Scheme Menus 10.1 Duplicate In the Menu File / Test Scheme / Duplicate ( Button : ) you can duplicate a test scheme. At first you must select the test scheme, which you want to duplicate. After this you have to input the Article Number of the new test scheme and at last you can change the test scheme settings Delete In the Menu File / Test Scheme / Delete ( Button : ) you can delete one or more test schemes. 11. Create one Test Order In a test order you input the data of the test order head and select the test scheme of the component, you want to produce and test. ) the window for program- By clicking on the Menu File / Test Order / Create & Change ( Button : ming the test order is opened : At first you have to input the order number. If you enter an existing order number you can modify the existing test order, otherwise you create a new test order. To the order number a directory entry can be added. This directory entry is a relative to the data directory ( see 7.2 ) and must already exist. does not create any directory. [ Example : Machine 1\Order-1234 The test order Order-1234 is created in the directory Machine 1 ] 42

43 The next step is the selection of the test scheme. ( Component you want to produce and measure )!!! Attention : When you have created a test order, you cannot do any changing in the test scheme any more. So you should at first test the test scheme, before you create a test order. 1.) Name ( Name of the component, i.e. cylinder, bore, ) 2.) Quantity ( Number of components you have to produce [depends on the order of the customer] ) 3.) Order Text ( Free Text for the documentation of the test order ) 4.) Creation Date ( of the Test Order ) 5.) Created by ( Name of the Operator, who created the test order ) The NEXT-Button stores the settings of the current test order and allows the programming of a next test order. With the button Reference Information you open the window for selecting the reference information assigned to request in the test order : In this dialog window you can at first programme these reference information assigned to the complete component. Therefore please select in the left column by component. After these you can select for each characteristic its reference information, therefore please select in the left column the characteristics. Note : When you have started to collect measurement data with one test order, then you cannot change the reference information of this test order any more. If you want to change the reference information of some types between components you measure, then you must assign to these reference information types the mode on start of a test order. ( see 7.6 ) 43

44 12. Start the Test Orders ( measuring ) This menu contains the measurement mode of. In this menu it is possible to start up to 10 test orders at the same time ( for different production lines ). When one operator has to measure a sample of its components, he can select by the keys 0 9 his test order and can measure his sample. After this a second operator from a second production line can begin to measure by pressing the key of his order. You start the test order by clicking on the Menu File / Test Order / Start ( Button : ). After you have pressed the button you must select the test order you want to start : After the start of a test order one of the keys is automatically assigned by. On the start of on test order, these reference information which are assigned to request on measurement start, can be selected : Documentation for the window : See previous page. 44

45 1.) Start an additional test order You can start an additional test order by clicking on the menu File / Test Order / Start ( Button: ). To this test order one of the keys 0 9 is automatically assigned. 2.) List of test order The started test orders and their keys 0..9 are shown in following list : The Number before the order numbers ( i.e. [0] ) informs you which key you must press to start measuring with the test order. By clicking on one test order it is started. 45

46 3.) End of one test scheme By the EXIT-Button you can end the currently measuring test order : When all test orders ended the menu is left automatically. 4.) Buttons With the following buttons you can : - Save all characteristics shown in the window - Delete the last value of all characteristics shown in the window - Do a zero adjustment / gauge calibration of all characteristics shown in the window - Remove the zero adjustment offset and gauge calibration factor of all characteristics shown in the window 5.) Adjustment Buttons With the following button in the menu bar you can open the window for the mechanical adjustment. ( This menu is described under point : 14 ) 6.) Saving values If one measured value you want to save is outside of the plausibility limits then the following window opens. If you click on the No button then the data set is not saved.!!! When this window is opened, does not measure till the window is closed. If you have activated the Events ( Please see : 7.6 ) and the measurement value is out of range then you must select the event, why the value is out of range : ( Tool is broken, ) 46

47 7.) Deleting values If the operator has done an error on measuring, he can delete this wrong value and can repeat the measurement. But he cannot delete more values ( from components ) he measured before. 8.) Zero Adjustment & Gauge Calibration If you press the button, function key or foot key for the zero adjustment, then the zero adjustment or gauge calibration is executed. On Zero Adjustment the value assumes the programmed master value. On Gauge Calibration the value is stored as first master value. The Numeric Display shows alternately Cal and the measured value. When the button, is pressed a second time the calibration is completed. So you must insert on the first key press the first master and on the second key press the second master in the fixture. 47

48 9.) Keys In the measurement mode there are the following keys : Key Function TAB, + Moves the cursor from button to button SPACEBAR, ENTER Presses one button F1, F2,... The functions of the function keys are defined in the test scheme / Moves the window to full screen mode and back to normal mode Cursor Scrolling in the statistical display elements ( with scrollbars ) 0 9 Selection of a test scheme * Look at, change and delete measuring values 10.) Full Screen Mode Example for the Full Screen Mode : 48

49 11.) Look at, change and delete measuring values With the star-key : * the menu Look at, change and delete measuring values is opened. In this menu you can select the characteristic by PgUp & PgDn. With the Cursor keys Left and Right you scroll in the run chart of the current characteristic and the reference information of the currently selected value is shown. The Cursor keys : Up & Down are scrolling the reference information table. Additionally the most important statistical data and a histogram of the current characteristic are shown. With the Button Change or with the Home-Key the current measuring value can be changed : With the Button Delete Value or with the Del key the current measuring value can be deleted. Note : The Password for changing and deleting is : sval 49

50 13. Additional Test Order Menus 13.1 Close In the Menu File / Test Order / Close ( Button : ) you can close a test order ( when all components are produced ). With these test orders which you have closed you cannot measure anymore, but they can be analysed or converted to different formats Print In the Menu File / Test Order / Print ( Button : ) you can print the measured values of a test order.!!! You need EXCEL for print the data and that is why it can take a few minutes for the print. After the selection of the test order, you select which characteristics shall be printed. At last you have to select the printer Analysis In the Menu File / Test Order / Analyse ( Button : order. ) you can analyse the measured values of a test On the analysis the measurement windows ( without measuring ) are opened in full screen mode. With the PgUp and PgDn keys you can switch over between the windows and select your SPC windows you have define in the test scheme : With the key P you can print the window contents. With the key * the menu Look at, change and delete measuring values ( see above ) is opened. 50

51 13.4 Convert In the Menu File / Test Order / Convert ( Button : order in a different format : ) you can convert the measured values of a test The Output File ( File Name of the converted File ) is shown in the Window. This File Name cannot be changed Delete In the Menu File / Test Order / Delete ( Button : ) you can delete one or more test orders. 51

52 14. Adjustment Windows 14.1 Mechanical adjustment of inductive probes By clicking on the Menu : Adjustment / Mechanical Adjustment ( Button : ) the window for the Mechanical Adjustment of Inductive Probes in the fixture is opened. ( This is necessary because inductive probes are only working optimal near their electrical zero-point. ) Process of adjustment : 1. Selection of the probes which shall be adjusted ( Address ). 2. Inserting of the master piece or a working piece in the fixture. 3. Adjustment of the probes till all bars are in the green range. The green range of the bars is +/-50µm. 52