Setting up the workpiece with graphical support (#159 / #1-07-1)
Application
Use the Set up the workpiece function to determine the position and misalignment of a workpiece with only one touch-probe function and save it as a workpiece preset. During setup, you can probe curved surfaces.
The control supports you additionally by showing the setup situation and possible touch points in the Simulation workspace by means of a 3D model.
Related topics
- Touch-probe functions in the Setup application
Touch probe functions in the Manual operating mode (#17 / #1-05-1)
- Generating an STL file of a workpiece
- Simulation workspace
- Setting fixtures with graphical support (#140 / #5-03-2)
Integrating fixtures into collision monitoring (#140 / #5-03-2)
Requirements
- Touch Probe Functions software option (#17 / #1-05-1)
- Tip
If you are using a HEIDENHAIN touch probe with EnDat interface, then the Touch Probe Functions software option (#17 / #1-05-1) is automatically enabled.
- Model Aided Setup (#159 / #1-07-1) software option
- Touch probe properly defined in the tool management:
- Sphere radius in parameter R2
- Workpiece touch probe calibrated
- NC program with BLK FORM workpiece blank definition or STL file of the workpiece blank
Description of function
The control compares the positions of the probe points on the actual workpiece with a 3D model of the workpiece.
The more the 3D model corresponds to the actual workpiece, the higher the possible workpiece setup accuracy.
You have the following options for defining the 3D model:
- BLK FORM in the NC program
The control creates the 3D model using the workpiece blank definition.
- STL file of the workpiece with up to 300 000 triangles
The scope of the Set up the workpiece function depends on the Adv. Function Set 1 (#8 / #1-01-1) and Adv. Function Set 2 (#9 / #4-01-1) software options as follows:
- Both software options enabled:
You can tilt before setting up and incline the tool while setting up in order to probe even complex workpieces (e.g., shaped parts).
- Only Adv. Function Set 1 (#8 / #1-01-1) is enabled:
You can tilt before setting up. The working plane must be consistent. If you move the rotary axes between the touch points, the control will display an error message.
- Tip
If the current coordinates of the rotary axes and the defined tilt angles (3D ROT window) match, the working plane is consistent.
- None of the two software options is enabled:
You cannot tilt before setting up. If you move the rotary axes between the touch points, the control will display an error message.
Tilting the working plane (#8 / #1-01-1)
Extension of the Simulation workspace
In addition to the Probing function workspace, the Simulation workspace offers graphical support for setting up the workpiece.
- The Set up the workpiece function with the Simulation workspace open
When the Set up the workpiece function is active, the Simulation workspace displays the content below:
- Current position of workpiece as viewed by the control
- Probed points on the workpiece
- Possible direction of probing by means of an arrow:
- No arrow
Probing is not possible. The workpiece touch probe is too distant from the workpiece or the workpiece touch probe is positioned within the workpiece, as seen by the control.
In this case you can correct the position of the 3D model in the simulation, if required.
- Red arrow
Probing in the direction of the arrow is not possible.
- Tip
Probing on edges, corners or heavily curved workpiece areas fails to deliver precise measuring results. This is why the control blocks probing in these areas.
- Yellow arrow
Probing in the direction of the arrow is possible to a limited extent. The probing is performed in a deselected direction or could cause collisions.
- Green arrow
Probing in the direction of the arrow is possible.
Icons and buttons
The Set up the workpiece function contains the following icons and buttons:
Icon or button | Meaning |
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Open the Change the preset window You can select the workpiece preset and the pallet preset and edit values if required. The control shows the number of the active preset to the right of the icon. Tip After the first point has been probed, the control dims the icon. | |
XY Clamping plane | Use this selection menu to define the probing mode. Depending on the probing mode, the control displays the respective axis directions and spatial angles. |
File name of the NC program or 3D model | |
Shifts the position of the virtual workpiece by 10 mm, 0.3937 inches, or 10° in the negative axis direction Tip Shifts the workpiece in mm or inches in a linear axis, and in degrees in a rotary axis. | |
Shifts the position of the virtual workpiece by 1 mm, 0.0394 inches, or 1° in the negative axis direction | |
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Shifts the position of the virtual workpiece by 1 mm, 0.0394 inches, or 1° in the positive axis direction | |
Shifts the position of the virtual workpiece by 10 mm, 0.3937 inches, or 10° in the positive axis direction | |
Status of the direction: | |
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Compensate the active preset | The control saves the determined values in the active row of the preset table. |
Probing mode
The following modes for probing the workpiece are available to you:
- XY Clamping plane
X, Y and Z axis directions as well as spatial angle SPC
- XZ Clamping plane
X, Y and Z axis directions as well as spatial angle SPB
- YZ Clamping plane
X, Y and Z axis directions as well as spatial angle SPA
- 6D
X, Y and Z axis directions as well as spatial angles SPA, SPB and SPC
Depending on the probing mode, the control displays the respective axis directions and spatial angles. In the XY, XZ and YZ clamping planes a toggle switch allows you to deselect the respective tool axis and spatial angle, if required. The control will not take deselected axis directions into account in the setup process and positions the workpiece by considering the remaining axis directions only.
HEIDENHAIN recommends executing the setup process as follows:
- Pre-position a 3D model in the machine’s working space
By default, the control positions the 3D model to the active workpiece reference point. At this point in time, the control does not know the precise position of the workpiece, but of the workpiece touch probe. Pre-positioning the 3D model in accordance with the position of the workpiece touch probe produces values close to the position of the real workpiece.
- Set the first touch points in the X, Y and Z axis directions
If the control can determine the position in one axis direction, it will change the status of that axis to green.
- Determine the spatial angle by setting further touch points
To achieve maximum accuracy when probing the spatial angles, the touch points should be as far apart from one another as possible.
- Increase the accuracies by additional check points
Additional check points at the end of the measuring process improve the matching accuracy and minimize the misalignment between the 3D model and the real workpiece. Perform as many probing processes as necessary until the control displays the desired accuracy beneath the current value.
The error estimate diagram shows for each probe point the distance of the 3D model from the real workpiece.
Error estimate diagram
Every additional touch point gradually restricts the possible positioning of the workpiece and puts the 3D model closer to the actual position in the machine.
The error estimate diagram shows for each probe point the distance of the 3D model from the real workpiece.
- Error estimate diagram in the Set up the workpiece function with transparent columns
The error estimate diagram of the Set up the workpiece function shows the following information:
- Error estimate [mm]
After each probe point, the value shows the greatest estimated distance between the 3D model and the workpiece.
- Mean deviation (RMS)
After each probe point, the value shows the average of all measured distances between the 3D model and the workpiece.
- Deviation [mm]
Using this axis you can determine how large the estimated distance between the 3D model and the probe point on the workpiece is.
- No. of probe point
This axis shows the numbers of the probe points so far.
- Columns
As long as the status of all axes is not green, the control shows transparent columns.
The control recalculates the 3D model after each probe point. This also changes the previous values.
When the columns of the error estimate diagram are no longer transparent, and Error estimate [mm] shows the desired accuracy, the setup process is complete.
The following factors influence the accuracy that can be achieved when measuring workpieces:
- Accuracy of workpiece touch probe
- Accuracy of the machine kinematic configuration
- Deviations of the 3D model from the real workpiece
- Condition of the actual workpiece (e.g., unmachined areas)
Setting up a workpiece
Use the Set up the workpiece function to set the preset:
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Note
- Calibrate the workpiece touch probe at regular intervals
- Enter parameter R2 in the tool management
- The control cannot identify modeling differences between the 3D model and the workpiece.
- Collisions might be more easily detected, if a tool carrier is assigned to the workpiece touch probe.
- HEIDENHAIN recommends probing check points for one axis direction on both sides of the workpiece. As a result, the control will correct the position of the 3D model in the simulation uniformly.
- Use the +, -, *, /, (, and ) keys for calculations in the numerical input fields.