1. apply innovation Slide 1 Renishaw touch-trigger probing technology Rugged and flexible solutions for discrete point measurement on CMMs Issue 2

2. apply innovation Slide 2 Questions to ask your metrology system supplier Are my measurement applications best inspected with discrete points? –if so, should I use a scanning probe or a touch-trigger probe? Will I benefit from the flexibility of an articulating head –access to the component –sensor and stylus changing What are the lifetime costs? –purchase price –what are the likely failure modes and what protection is provided? –repair / replacement costs and speed of service

3. apply innovation Slide 3 Renishaw touch-trigger probing - our objectives robustness –compact and rugged –crash protection –extended operating life flexibility –probe changing –stylus changing –articulation cost effectiveness –innovative hardware –simple programming for lower running costs –robust designs and responsive service for lower lifetime costs

4. apply innovation Slide 4 Renishaw touch-trigger probing systems Articulating heads Trigger probe design Touch-trigger probe applications Probe and stylus changing Metrology of trigger probes

5. apply innovation Slide 5 Probing applications - factors Manufacturers need a range of measurement solutions. Why?  machining processes have different levels of stability:  stable form :  therefore control size and position  discrete point measurement  form variation significant :  therefore form must be measured and controlled  scanning

6. apply innovation Slide 6 Probing applications - factors Manufacturers need a range of measurement solutions. Why?  Features have different functions:  for clearance or location  form is not important  Discrete point measurement  for functional fits  form is critical and must be controlled  Scanning Measured values Best fit circle Maximum inscribed (functional fit) circle

7. apply innovation Slide 7 Discrete point measurement Ideal for controlling the position or size of clearance and location features Data capture rates of 1 or 2 points per second Avoids stylus wear Touch-trigger probes are ideal –lower cost, small size and great versatility Scanning probes can also be used –passive probes can probe quickly –active probes are slower because the probe must settle at a target force to take the reading

8. apply innovation Slide 8 Discrete point measurement Speed comparison Touch-trigger probes are ideal for high speed discrete point measurement Scanning probes can also measure discrete points quickly, and provide higher data capture rates when scanning

9. apply innovation Slide 9 Touch-trigger probing operation Trigger probes measure discrete points... a trigger probe is in one of two states: –seated when the stylus is not in contact with the part –unseated when the stylus is touching the part a trigger signal is generated when the probe changes from seated to unseated the trigger signal latches the machine position to record the location of the surface feature geometry is computed from a best fit of discrete surface points

10. apply innovation Slide 10 Touch-trigger probing characteristics Versatile wide range of probes –sensors that range in size from the small, industry-standard TP20, to larger, high accuracy sensors like the TP7M –probes suitable for use on manual and motorised heads and for quill mounting Ultra-compact TP20 High accuracy TP7M Quill mounted TP800

11. apply innovation Slide 11 Touch-trigger probing characteristics Versatile stylus changing –fast and automated stylus changing without re-qualification sensor changing –allows for a range of probes on your CMM, each suited to a specific measurement task Sensor changing Stylus changing

12. apply innovation Slide 12 Touch-trigger probing characteristics Flexible part access articulating heads –flexible reorientation of inspection sensors for better part access extensions –compact sensors can be mounted on long extension bars for access to deep features

13. apply innovation Slide 13 Touch-trigger probing characteristics Robust and crash resistant rugged design –simple and robust mechanism crash protection –magnetic kinematic mount allows stylus module to detach when over travelled Magnetic mount for stylus module Robust kinematic mechanism

14. apply innovation Slide 14 Touch-trigger probing characteristics Cost effective simple and affordable low lifetime costs –advance replacement service at discounted price Service Centre Renishaw Inc

15. apply innovation Slide 15 Renishaw touch-trigger probing systems Articulating heads Trigger probe design Touch-trigger probe applications Probe and stylus changing Metrology of trigger probes

16. apply innovation Slide 16 Touch-trigger probe technologies Resistive simple compact rugged Strain-gauge solid-state switching high accuracy and repeatability long operating life Piezo three sensing methods in one probe ultra-high accuracy quill mounted

17. apply innovation Slide 17 Kinematic resistive probe operation

18. apply innovation Slide 18 Kinematic resistive probe operation probe in seated position All kinematics in contact Motion of machine stylus makes contact with component contact force resisted by reactive force in probe mechanism resulting in bending of the stylus Reactive force Contact force stylus assembly pivots about kinematic contacts, resulting in one or two contacts moving apart trigger generated before contacts separate Contacts separate Pivots about these contacts machine backs off surface and probe reseats

19. apply innovation Slide 19 Kinematic resistive probe operation Electrical switching electrical circuit through contacts resistance measured contact patches reduce in size as stylus forces build Kinematic attached to stylus Kinematics bonded to (and insulated from) probe body Current flows through kinematics Contact patch shrinks as stylus force balances spring force Resistance rises as area reduces (R =  /A) Close-up view of kinematics: Elastic deformation Section through kinematics:

20. apply innovation Slide 20 Kinematic resistive probe operation Electrical switching resistance breaches threshold and probe triggers kinematics are still in contact when probe triggers –stylus in defined position current cut before kinematics separate to avoid arcing Force on kinematics Resistance Trigger threshold Trigger signal generated Force on kinematics when stylus is in free space

21. apply innovation Slide 21 Factors in measurement performance Pre-travel stylus bending under contact loads before trigger threshold is reached pre-travel depends on F C and L trigger is generated a short distance after the stylus first touches the component F C x L = F S x R L and F S are constant  F C is proportional to R

22. apply innovation Slide 22 Factors in measurement performance Pre-travel variation - ‘lobing’ trigger force depends on probing direction, since pivot point varies –F C is proportional to R therefore, pre-travel varies around the XY plane Top view High force direction: Pivot point Low force direction: Pivot point R 1 > R 2 F C1 > F C2

23. apply innovation Slide 23 Factors in measurement performance Pre-travel variation - ‘lobing’ trigger force in Z direction is higher than in XY plane –no mechanical advantage over spring –F C = F S kinematic resistive probes exhibit 3D (XYZ) pre-travel variation –combination of Z and XY trigger effects –low XYZ PTV useful for contoured part inspection Test data: ISO 10360-2 3D form TP20 with 50 mm stylus: 4.0  m (0.00016 in)

24. apply innovation Slide 24 Factors in measurement performance Probe calibration pre-travel can be compensated by probe calibration a datum feature (of known size and position) is measured to establish the average pre-travel key performance factor is repeatability Limitations on complex parts, many probing directions may be needed low PTV means simple calibration can be used for complex measurements if PTV is significant compared to allowable measurement error, may need to qualify the probe / stylus in each probing direction

25. apply innovation Slide 25 Factors in measurement performance Typical pre-travel variation XY plane

26. apply innovation Slide 26 Factors in measurement performance Repeatability the ability of a probe to trigger at the same point each time –a random error with a Normal distribution –for a given probe and probing condition, repeatability is equal to twice the standard deviation (2  ) of the Normal distribution –95% confidence level that all readings taken in this mode will repeat within +/- 2  from a mean value Hysteresis error arising from the direction of the preceding probing move –maximum hysteresis occurs when a measurement follows a probing moves in opposite directions to each other in the probe’s XY plane –hysteresis errors increases linearly with trigger force and stylus length –kinematic mechanism minimises hysteresis

27. apply innovation Slide 27 Factors in measurement performance Ranked in terms of importance repeatability –key requirement of any trigger probe –fundamental limit on system measurement performance –hysteresis contributes to measurement repeatability pre-travel variation –can be calibrated, provided all probing directions are known –measurement accuracy will be reduced if probe used in un-qualified direction and PTV is high –increases rapidly with stylus length hysteresis –small error factor for probes with kinematic mechanisms

28. apply innovation Slide 28 Renishaw touch-trigger probing systems Articulating heads Trigger probe design Touch-trigger probe applications Probe and stylus changing Metrology of trigger probes

29. apply innovation Slide 29 Kinematic resistive probe technology Simple electro-mechanical switching resistive probes use the probe kinematics as an electrical trigger circuit pre-travel variation is significant due to the arrangement of the kinematics

30. apply innovation Slide 30 Kinematic resistive probe characteristics Extremely robust Compact –good part access –suitable for long extensions Good repeatability –excellent performance with shorter styli –low contact and overtravel forces minimise stylus bending and part deflection Universal fitment –simple interfacing Cost-effective Finite operating life –electro-mechanical switching

31. apply innovation Slide 31 TP20 stylus changing probe Concept direct replacement for TP2 –ultra-compact probe at just Ø13.2 mm TP20 features fast and highly repeatable stylus changing –manual or automatic –enhanced functionality through extended force and extension modules

32. apply innovation Slide 32 TP20 stylus changing probe Benefits reduced cycle times achieved by fast stylus changing without re-qualification optimised probe and stylus performance with seven specialised probe modules easily retrofitted to all Renishaw standard probe heads (M8 or Autojoint coupling) compatible with existing touch-trigger probe interfaces metrology performance equivalent to industry proven TP2 system but with greater flexibility of operation

33. apply innovation Slide 33 TP20 stylus modules Optimal measuring performance seven specialised probe modules allow optimisation of stylus arrangement for best accuracy and feature access in all user applications module attaches to probe body via a quick release, highly repeatable kinematic coupling module range covers all forces supported by TP2 6-way module replaces TP2-6W TP20 probe body

34. apply innovation Slide 34 Comparative module and stylus lengths Reach up to 125 mm (5 in) Soft materials General use Longer or heavier styli Grooves and undercuts

35. apply innovation Slide 35 Strain-gauge probe technology Solid state switching –silicon strain gauges measure contact forces transmitted through the stylus –trigger signal generated once a threshold force is reached –consistent, low trigger force in all directions –kinematics retain the stylus / not used for triggering

36. apply innovation Slide 36 Strain-gauge probe operation Force sensing four strain gauges are mounted on webs inside the probe body –X, Y and Z directions, plus one control gauge to counter thermal drift low contact forces from the stylus tip is transmitted via the kinematics, which remain seated at these low forces gauges measure force in each direction and trigger once force threshold is breached (before kinematics are unseated) Silicon strain gauges mounted on webs (1 out of 4 shown) Kinematics remain seated at low F C

37. apply innovation Slide 37 Strain-gauge probe operation Low lobing measurement trigger force is uniform in all directions –very low pre-travel variation

38. apply innovation Slide 38 Strain-gauge probe operation Lobing comparison plots at same scale Strain-gauge XY PTV = 0.34  m Kinematic resistive XY PTV = 3.28  m

39. apply innovation Slide 39 Strain-gauge probe characteristics High accuracy and repeatability –probe accuracy even better than standard kinematic probes –minimal lobing (very low pre-travel variation) Reliable operation –no reseat failures –suitable for intensive "peck" or "stitch” scanning –life greater than 10 Million triggers Flexibility –long stylus reach –suitable for mounting on articulating heads and extension bars –stylus changing available on some models

40. apply innovation Slide 40 TP7M strain-gauge probe Concept –25 mm (1 in) diameter probe –Autojoint mounted for use with PH10M multi-wire probe output Benefits –highest accuracy, even when used with long styli - up to 180mm long ("GF" range) –compatible with full range of multi-wired probe heads and extension bars for flexible part access –plus general strain-gauge benefits: non-lobing no reseat failures extended operating life 6-way measuring capability

41. apply innovation Slide 41 TP7M performance Specification Test results from 5 probes

42. apply innovation Slide 42 TP7M performance Specification Test results from 5 probes

43. apply innovation Slide 43 TP200 stylus changing probe Concept –TP2-sized probe, with strain gauge accuracy –stylus changing for greater flexibility and measurement automation –2-wire probe output (like TP2) Benefits –long stylus reach - up to 100mm long ("GF" range) –match stylus to the workpiece using high speed stylus changing improve accuracy for each feature no re-qualification manual or automatic changing with SCR200 –compatible with full range of heads and extension bars

44. apply innovation Slide 44 TP200 stylus modules Optimal sensor performance 6-way operation ±X, ±Y and ±Z two types of module: –SF (standard force) –LF (low force) provides lower overtravel force option for use with small ball styli and for probing soft materials detachable from probe sensor via a highly repeatable magnetic coupling –provides overtravel capability suitable for both automatic and manual stylus changing module life of >10 million triggers

45. apply innovation Slide 45 Piezo shock sensing Shock sensing piezo sensors generate a voltage when subjected to pressure piezos can detect the mechanical shock signal generated when the stylus ball impacts the workpiece –they can respond to frequencies higher than those detected by many other sensors –the result is that piezo probes "hear" the stylus ball touch the surface Shock wave travels up stylus and is transmitted through kinematics Piezo ceramic sensor detects shock of impact Stylus changing kinematics

46. apply innovation Slide 46 Piezo shock sensing Ultra-sensitivity shock travels at speed of sound through the stylus and probe –800 m per second (2,600 ft/sec) –response time is 1.25  sec / mm High performance pre-travel depends on stylus length and probing speed –pre-travel is the same in all directions since mechanical signal path is constant –lobing effect limited to ball sphericity! Shock wave travels up stylus and is transmitted through kinematics Piezo ceramic sensor detects shock of impact Stylus changing kinematics

47. apply innovation Slide 47 Multi-sensor operation Kinematic and strain sensing shock sensing is not 100% reliable –speed sensitive –surface contamination –workpiece hardness –small stylus ball diameters are not reliable shock can be backed by kinematic and strain sensing to confirm triggers generated by shock sensor –life of piezo probes are limited by electro-mechanical elements

48. apply innovation Slide 48 TP800 piezo probe Unprecedented performance quill mounted probe featuring unique multi-sensor design ultra-high accuracy –repeatability specification: 0.25  m with 50 mm stylus 1  m with 250 mm stylus –low trigger force < 1 gf –pre-travel variation << 0.5  m –typical values for 150 mm stylus: 0.15  m repeatability 0.25  m PTV support for very large stylus clusters –350 mm straight –200 mm star

49. apply innovation Slide 49 TP800 piezo probe Application limitations cannot measure small bores –probe works best with larger stylus balls (e.g. 6 mm) –machine may not reach calibrated probing speed without sufficient clearance surface condition is critical –dirt on the surface can reduce shock and prevent a clean trigger –soft surfaces such as plastics do not generate sufficient shock probing speed must be controlled to within 1 mms -1 large probe size prevents use with articulating heads or extension bars

50. apply innovation Slide 50 Trigger probe measurement performance comparison

51. apply innovation Slide 51 Renishaw touch-trigger probing systems Articulating heads Trigger probe design Touch-trigger probe applications Probe and stylus changing Metrology of trigger probes

52. apply innovation Slide 52 Articulation or fixed sensors? Articulating heads are a standard feature of most computer- controlled CMMs –heads are the most cost-effective way to measure complex parts Fixed probes are best suited to small machines on which simple parts are to be measured –ideal for flat parts where a single stylus can access all features

53. apply innovation Slide 53 Renishaw articulating heads Increased flexibility…  easy access to all features on the part  repeatable re-orientation of the probe  reduced need for stylus changing  optimise stylus stiffness for better metrology Reduced costs…  indexing is faster than stylus changing  less expensive than active scanning systems  reduced stylus costs  simpler programming

54. apply innovation Slide 54 Renishaw articulating heads for trigger probing PH10T indexing head 2-wire probes TP20 TP200 PH10M / MQ indexing head Autojoint connector (multi-wire) TP7M & 2-wire probes with PAA adaptors PHS1 servo positioning head infinite range of orientations longer extension bars

55. apply innovation Slide 55 Articulating head applications Flexible probe orientation PH10M offers 7.5° increments in 2 axes - is this enough? prismatic parts –generally few features at irregular angles –use a custom stylus to suit the angle required –fixed scanning probes also need customer styli for such features Knuckle joint needed to access features at irregular angles

56. apply innovation Slide 56 Articulating head applications Flexible probe orientation PH10M offers 7.5° increments in 2 axes - is this enough? sheet metal / contoured parts –many features at different irregular angles –stylus must be perfectly aligned with surface in each case –no indexing head is suitable –fixed probes also unsuitable due to need for many stylus orientations –need continuously variable head (PHS1) Sheet metal Cylindrical stylus must be perfectly aligned with hole

57. apply innovation Slide 57 PH10M indexing head - design characteristics Head repeatability test results: Method: –50 measurements of calibration sphere at {A45,B45}, then 50 with an index of the PH10M head to {A0,B0} between each reading TP200 trigger probe with 10mm stylus Results: Comment: –indexing head repeatability has a similar effect on measurement accuracy to stylus changing repeatability ResultSpan fixedSpan index  [Span]  [Repeatability] X0.000630.001190.00056± 0.00034 Y0.000390.001610.00122± 0.00036 Z0.000450.000810.00036± 0.00014

58. apply innovation Slide 58 PH10M indexing head - design characteristics Indexing repeatability affects the measured position of features –Size and form are unaffected Most features relationships are measured ‘in a plane’ –Feature positions are defined relative to datum features in the same plane (i.e. the same index position) Datum feature used to establish a part co-ordinate system –Therefore indexing typically has no negative impact on measurement results, but many benefits

59. apply innovation Slide 59 PH10 series indexing head - design characteristics Light weight 650 g (1.4 lbs) lightest indexing head available total weight of < 1 kg including scanning probe Fast indexing typical indexing time is 2 to 3 seconds indexes can occur during positioning moves –no impact on measurement cycle time

60. apply innovation Slide 60 PH10M indexing head - design characteristics Flexible part access Rapid indexing during CMM positioning moves give flexible access with no impact on cycle times

61. apply innovation Slide 61 PH10M indexing head - design characteristics Autojoint programmable sensor changing with no manual intervention required use scanning and touch-trigger probes in the same measurement cycle Autojoint features kinematic connection for high repeatability

62. apply innovation Slide 62 PHS1 servo head - design characteristics Servo positioning for total flexibility full 360° rotation in two axes for total flexibility of part access –resolution of 0.2 arc sec –equivalent to 0.1µm at 100mm radius servo control of both axes for infinitely variable positioning and full velocity control –speeds of up to 150° per second –5-axis control required

63. apply innovation Slide 63 PHS1 servo head - design characteristics High torque for long reach extension bars of up to 750 mm (30 in) –ideal for auto body inspection –touch-trigger probes only Autojoint for use with SP600M and TP7M Powerful motors generate 2 Nm torque –4 times more than a PH10 –carry probes and extension bars of up to 1 kg (2.2 lbs)

64. apply innovation Slide 64 PHS1 servo head - design characteristics Infinitely variable positioning PHS1’s motion can be combined with the CMM motion to generate blended 5 axis moves

65. apply innovation Slide 65 Renishaw touch-trigger probing systems Articulating heads Trigger probe design Touch-trigger probe applications Probe and stylus changing Metrology of trigger probes

66. apply innovation Slide 66 ACR3 probe changer for use with PH10M 4 or 8 changer ports –store a range of sensors, extensions and stylus configurations Passive mechanism –CMM motion used to lock and unlock the Autojoint for secure and fully automatic sensor changes

67. apply innovation Slide 67 New ACR3 probe changer for use with PH10M Probe changing Quick and repeatable sensor changing for maximum flexibility Video commentary new ACR3 sensor changer no motors or separate control change is controlled by motion of the CMM

68. apply innovation Slide 68 ACR2 probe changer for use with PHS1 Probe module changing flexible storage of probes and extension bars

69. apply innovation Slide 69 TP20 stylus changing MCR20 - passive rack simple design for rapid stylus changes under program control storage for up to 6 stylus modules kinematic stylus changing mechanism –highly repeatable connection between stylus and probe –styli can be stored and re-used without the need for qualification collision protection MSR1 manual rack stores and protects up to 6 modules on manual CMMs MSR1 manual rack MCR20 rack for DCC CMMs

70. apply innovation Slide 70 TP200 stylus changing SCR200 - active rack automated changing for up to 6 stylus modules active rack, but no communications are needed with the CMM controller –operation handled by the PI200 interface 2 operating modes: –TAMPER PROOF ON - protects against accidentally inhibiting probe operation –TAMPER PROOF OFF - for automatic loading or high speed operation full collision protection

71. apply innovation Slide 71 TP800 stylus changing SCR800 - passive rack automated changing for up to 3 or 4 stylus modules passive rack, operated by motion of the CMM adjustable to suit long styli and large star configurations

72. apply innovation Slide 72 Renishaw touch-trigger probing - our offering Robust solutions –compact and rugged sensors –crash protection to avoid damage –extended operating life with solid-state switching The most flexible and productive solution –probe changing –stylus changing –articulation The lowest ownership costs –innovative and affordable hardware –responsive service for lower lifetime costs

73. apply innovation Slide 73 Responsive service and expert support Application and product support wherever you are Renishaw has offices in over 20 countries responsive service to keep you running optional advance RBE (repair by exchange) service on many products we ship a replacement on the day you call trouble-shooting and FAQs on www.renishaw.com/support Service facility at Renishaw Inc, USA

74. apply innovation Slide 74 Questions?