Welcome 1. History 1 2

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1 WELCOME WELCOME TO THE PRODUCTTRAINING Welcome 1 HISTORY 1928 MAX WYLER started the activities in Winterthur by taking over the product range of precision spirit levels from the former company Franz Hoen, Buelach Switzerland 1970 Development and introduction to the market of the first electronic inclination measuring instrument, the NIVELTRONIC, in co-operation operation with TESA Switzerland Development and introduction to the market of the electronic inclination measuring instruments, the Minilevel classic A10 and the Leveltronic classic A Development of the handheld instrument CLINOTRONIC 1991 Establishing the holding company WYLER INTERINVEST AG by H. Hinnen & R. Morlet. This new company takes over the complete shares of the WYLER AG 1993 Receiving the accreditation as SWISS CALIBRATION OFFICE SCS / ISO 9002 / SN EN as an international recognized calibration laboratory of highest standards 1995 Development and introduction to the market of the digital inclination measurement sensor ZEROTRONIC and the Software DYNAM History 1 2 1

2 HISTORY 1996 Development and introduction to the market of the electronic inclination measuring instruments, the Minilevel NT and the Leveltronic NT 2000 Development and introduction to the market of the new generation of spirit levels called SPIRIT 2000 Development of radio modules for the electronic measuring instruments for wireless data transmission 2000 Development and introduction to the market of the Software LEVELSOFT PRO 2004 Development of the 2 dimensional precision inclination sensors with automatic reversal measurement ZEROMATIC 2/1 and 2/ Development and introduction to the market of the electronic inclination measuring instruments BlueSYSTEM, with BlueLEVEL, BlueMETER and BlueTC 2005 Development and introduction to the market of the new Software MT-SOFT for definition of machine tool geometry 2007 All the shares of WYLER AG were taken over by Heinz Hinnen History 2 INFORMATIONEN ZUR FIRMA WYLER AG Additional information about WYLER AG Staff: approx. 45 employees Patents: t Various patents valid in Switzerland and in most of the industrialized countries all over the world Production: Climate controlled production facilities / Calibration laboratory SCS WYLER AG CH-8405 WINTERTHUR SWITZERLAND WYLER AG 2

3 IMPRESSIONEN Our facilities PRODUCT RANGE Precision spirit levels and CLINOMETERS Electronic inclinometers and measuring instruments Inclination measuring sensors and measuring software Prduct range 3

4 PRODUCT RANGE High quality granite measuring and setting plates from DIABAS High quality granite measuring and setting straight edges and setting squares from DIABAS High quality granite measuring and setting straight edges and setting squares from DIABAS Prduct range 2 ORGANISATION WYLER AG Management WYLER AG Hinnen Heinz President R&D + Engineering Jaray Martin Vice-President Sales & Marketing Finance Bruno Isabella R&D Dr. Gassner Martin Projects Herzog Elias Projects Müller Ernst QS / SCS Pfeifer Hans Peter R&D Schönbächler Alois Admin Trachsler Heinz Purchasing Bachmann Kai R&D Popp Toralf Marketing Jaray Martin Assembly Götte Max Elektronic Knecht Marcel Workshop Bretscher Walter Special Projects Breu Peter 4

5 SALES REGIONS 4.5% 1.2% 3% 3.1% 1.5% 1.5% 23.6% Switzerland Various OEM Germany 3.4% France Great Britain 5.8% Netherlands Sweden Italy Rest Europe 11.2% USA India 17.4% Japan South Korea Taiwan China Sales Region 2.2% 3.6% 3.3% 3.2% 17.9% Rest Asia Rest SALES PRODUCTGROUPS % 7.3% 28.6% 48.2% 7.5% 6.5% 1.1% % 17.0% 0.5% 0.2% Precision Spirit Levels Granite plates Maschines of granite Electronic instruments Calibration 73.3% Service / Repair Sales Products 5

6 GESCHICHTE Homepage with the newest information: Applications Productline Actual Manuals Software, SW Updates and Demo-Versions New products Product specifications Distributors worldwide Training dates Visits per month Ø: approx Pages per month Ø: approx Homepage: wylerag wyler@wylerag.com Homepage WYLER INCLINATION MEASUREMENT - HYSTORY AND DEVELPMENT The inclination measurement was used already in ancient times - for the construction of buildings - for the creation of simple city maps - for the navigation at sea. The use of new materials and working methods allowed the development of new and more accurate inclination measuring instruments 1727 the first Sextant was built according to Isaac Newtons designs 1760 the first Theodolit was made by the physic Dollond Theodolit from W. & S. Jones Sextant Sir Isaac NEWTON Especially in the Quality Assurance the inclination measurement is applied in various different forms An inclination measuring instrument is used for: - measuring an angle - measuring the flatness of a line, e.g. of a machine guide way - measuring a flatness surface profile - long term monitoring of objects The classic spirit level is, due to the higher requirements of precision, resolution and sampling time, reliability as well as data storage and protocoling more and more replaced by electronic inclination measuring instruments The latest development clearly tends towards inclination measuring sensors bound in networks with the possibility of data transmission over short and long distances and collected in appropriate units such as computers and display units (Levelmeter) History 6

7 MISSION AND OBJECTIVES OF WYLER AG Missions 1 CUSTOMER SATISFACTION IS OUR MOST IMPORTANT OBJECTIVE QUALITY HAS A HIGH PRIORITY STRENGTHEN OUR LEADERSHIP POSITION IN THE MARKET FOR PRECISION-LEVELS AND - MEASURINGINSTRUMENTS DEVELOPMENT OF NEW PRODUCTS AND TECHNOLOGIES WHICH WILL BE WELL PERCEIVED BY OUR CUSTOMERS AND PARTNERS SUPPORT AND STRENGTHEN OUR SELLING PARTNERS ALL OVER THE WORLD. THE PREFERRED PLACE FOR MANUFACTURING IS SWITZERLAND PROVIDE A FULL RANGE OF QUALITY SERVICES AND PRODUCTS FROM THE ANALYSIS TO THE IMPLEMENTATION IMPROVE THE COOPERATION BETWEEN THE VARIOUS DEPARTMENTS WITHIN OUR COMPANY STRENGTHEN THE COMMUNICATION WITH OUR PARTNERS, CUSTOMERS AND SUPPLIERS BY EFFECTIVE INFORMATION ENSURE THAT ALL EMPLOYEES AND THE ORGANISATION ARE ABLE TO MAINTAIN WYLER'S COMMITMENT TO QUALITY AND PRODUCTIVITY ENVIRONMENTAL PROTECTION IS AN IMPORTANT PART OF THE COMPANY S TASKS MISSION AND OBJECTIVES OF WYLER AG Missions 2 7

8 SALES STRATEGY YESTERDAY TODAY TOMORROW EVOLUTION PRODUCTS SOLUTIONS Evolution 1 SCS-ACCREDITATION / ACCREDITATION NUMBER: 044 Type of dimension Length (flatness) Angle Angle Angle of 90 degrees Measuring range up to 12.5 m 2 ± 20 mm/m 360 Measuring bases Granite angles Precision ( L) µm ( *E) µm/m E = measured value in µm/m 1 Arcsec 5 (7) µm/m ( *SL) µm Recognized by EUROPEAN ACCREDITATION of LABORATORIES / EAL SCS Lab 8

9 CERTIFICATES WYLER AG Declaration of conformity WYLER Certificate SCS-Certificate Certificates QUESTIONS ABOUT INCLINATION MEASUREMENT 1. You made a reversal measurement and received the following values: Measurement A: +032 µm/m Measurement B: +026 µm/m - What is the zero deviation of the instrument? - What is the absolute inclination of the surface? 2. Define the unit "1 Rad" 3. How many µm/m will give 1 Arcsec? 4. What is the basic difference between an analogue and a digital measuring instrument? 5. Using a spirit level with a sensitivity of 20 µm/m on a surface. When inclining the surface, the bubble of the vial moves from one graduation mark to the next. How much was the inclination in µm/m? 6. What is the principal difference between a measurement with ONE instrument only and a differential measurement (using two instruments, one as a measuring and one as a reference instrument)? Questions 9

10 PRODUCTLINE WYLER AG HIGH PRECISION SPIRIT LEVELS INCLINATION MEASURING INSTRUMENTS AND -SYSTEMS Posters INTRODUCTION IN INCLINATION MEASUREMENT Intro Inclination Measurement 10

11 INTRODUCTION IN INCLINATION MEASUREMENT What is INCLINATION? E 2 E 1 E 2 90 Absolute inclination INCLINATION α = ANGLE α between lines g 1 and g 2 resp. g 3 which have to be in line with a vertical plane INCLINATION α, eg. in [degrees / Arcmin / Arcsec] [Rad], [mrad], [µrad], [mm/m], [µm/m] E 1 90 vertical reference line Relative inclination g 2 : horizontal zero-line E 1 : horizontal plane E 2 : vertikal plane Intro Inclination Measurement INTRODUCTION IN INCLINATION MEASUREMENT Relative- and Absolute Measurements In the inclination measuring technology we distinguish between and Intro Inclination Measurement 11

12 INTRODUCTION IN INCLINATION MEASUREMENT Relative measurements Examples: Relative measurements are used when the actual position of the measuring object is not relevant Flatness of a granite surface plate Flatness of a platform Relevant is the difference of the inclination between one measurement and the following measurement Intro Inclination Measurement INTRODUCTION IN INCLINATION MEASUREMENT Relative measurements Alignment method: End points 2.79 µm Step length = 180 mm ISO µm Maximaler Fehler =15,5 µm Linear regression Manual analysis according to the method End points : Maximum error (straightness) in relation to the step length: 180mm = 15.5 µm x = 2,79 µm 1000mm 2.77 µm Intro Inclination Measurement 12

13 INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Examples: Absolute measurements are used when the actual position of the measuring object is relevant Monitoring of objects, such as bridges, dams, etc. Calibration of industrially used robots, radar systems, etc. Measurements of machines tools, particularly in the comparison of elements which hare measured independently from each other (e.g. horizontal guide way in relation to vertical spindle, etc. ) Relevant is the actual position of the measuring object in space Intro Inclination Measurement INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Reversal measurement to define the exact horizontal ZERO POSITION (ZERO OFFSET) Measurement X Measurement X Reversal measurement direction X direction X Zero point deviation Inclination of surface instrument (ZERO-Offset) in direction X X + X X - X = = 2 2 Intro Inclination Measurement 13

14 INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Reversal measurement to define the angular error of the instrument Angular error of the instrument = C + D 2 A + B 2 Master Intro Inclination Measurement INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Software MT-SOFT (Machine Tool Inspection Software) Type of measurement: Absolute position and flatness of a rotary table Program module for measuring circles Intro Inclination Measurement 14

15 INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements ZEROTRONIC sensors ZEROMATIC Leading technology for the long term monitoring in X- and Y axis The newly developed biaxial high precision sensor with automatic reversal measurement ZEROMATIC. Continuous availability of measuring values in X- and Y axis. Periodic reversal measurement for the compensation of deviations of the absolute Zero of the two sensors. ZEROTRONIC sensors The digital inclination sensor with high resolution with excellent temperature stability insensitive against shocks no influence of strong electro-magnetic waves or electric fields on the measuring precision ZEROMATIC, the most precise biaxial inclination sensor ZEROTRONIC sensors Intro Inclination Measurement POSSIBLE APPLICATIONS WITH INCLINATION MEASURING SYSTEMS STRAIGHTNESS GERADHEIT INCLINATION NEIGUNG SQUARENESS RECHTWINKLIGKEIT PARALLELISM PARALLELITÄT FLATNESS EBENHEIT MONITORING ÜBERWACHUNG Symbols 15

16 APPLICATIONS Dams Bridges Calibrating instruments MEASUREMENT ADJUSTMENT MONITORING with INCLINATION MEASUREMENT Radar units Industrial used robots Buildings Highspeed printing machines Applications Flatness of measuring and setting plates Machine tools APPLICATIONS Straightness - Measurement of straight edges made of granite - Measurement of guide way on machine tools - Checking on air planes (unstable conditions) - Deformations due to changing forces applied Measurement of straightness on straight edges made of granite Measurement of straightness on guide way of a machine tool Parallelism - Measurement of guide way on machine tools - Measurement of geometry of machines - Adjustment of printing machines - Adjustment of platforms Adjustment of high speed printing machines during assembly Applications 2 16

17 APPLICATIONS Inclination - Adjustment of all kind of objects - Rotation measurement on machine tools - Measurement of geometry on cars, trucks, trains, radar stations, - Monitorung and measuring of objects like e.g.: -Dams - Bridges - Buildings - Pallet transportation, storage platforms Monitoring of dams Monitoring of bridges Flatness - Flatness of measuring and setting plates in laboratories ato and on the shop floor - Flatness of tables of machine tools - Flatness of connecting surfaces of assemblies and subassemblies Flatness measurement of a measuring and setting plate Flatness measurement of the table of a machine tool Applications 3 APPLICATIONS Squareness - Measurement of guide ways of machine tools - Measurement of master squares - Measurement of angular deviation between spindle and other elements of a machine tool Measurement of flatness and squareness of a master square Applications 4 17

18 OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS / VIAL SYSTEM R = 5 200m Ground vial for precision spirit levels radius = meter Height arc based on 80mm = µm Bent vial (low cost version) radius = meter R = 0.5 1m Spirit Levels 1 OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS / VIAL SYSTEM U out Outer Electrode U 0 Elektrolyte-Vials Electrolyte vials are made of glass similar to precision vials but filled with a liquid that is electrically conducting. By inclining the vial the outer portions of the vial (electrodes) will be more or less covered ed by the liquid. The electrolyte vial will supply a voltage proportional to the inclination. CLINOMETER CLINOMETER with built-in precision vial A clinometer has a precision vial combined with a precision mechanical device allowing a +/-180 scale positioning. The mechanical disk can be adjusted by using a micrometer until the precision vial shows an absolute horizontal value. On the large scale and on the micrometer scale the angle can be read to a precision of 0.3mm/m Spirit Levels 2 18

19 OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS / ELECTRONIC SYSTEMS 1. INDUCTIVE MEASURING SYSTEMS nivelswiss (NIVELTRONIC 50) Range II: Range I: +/ mm/m +/ mm/m Excellent zero point stability Measuring principle: The electronic inclination measuring instruments use a friction free suspended pendulum. At the end of the pendulum a ferrite core is fastened which is penetrating a double winded coil fed by alternating current (principle of an inductive probe). The output voltage is directly related to the instrument s inclination. Inductive systems OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS / ELECTRONIC SYSTEMS 2. CAPACITIVE MEASURING SYSTEMS 1: Electrodes based on ceramic 2: Pendelum Capacitive measuring systems These electronic levels are based on the pendulum properties of a friction free supported disc of mass. A frequency is supplied to two ceramic and copperplated electrodes, which together with the pendulum disc supported in the shielded and dust proof gap between them, build a differential capacitor built of 2 ceramic and copper plated electrodes deliver the angular signal. This unit is encapsulated and protected from outdide electronical influence. C 1 C 2 Capacitive Systems Analogue Systems Digitale Systems MINILEVEL / LEVELTRONIC / LEVELMATIC ZEROTRONIC / CLINOTRONIC BlueSYSTEM with wireless transmission and capacitive measuring system ZEROTRONIC Sensors with capacitive measuring system Capactive systems 19

20 OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS 3. ANGULAR MEASUREMENT WITH LASER Target laser The system consists of a laser sender and a laser receiver unit. The sender unit is high stabilility semi conductor laser prcisely adjustable with a mechanical device to the target. The receiver unit is a 10x10mm PSD (Position sensing detector), an opto electronic device with a complete amplifying and computing electronic based on a DSP (digital signal processor) Laser Interferometer The measuring system consists of a laser with detector, an angular interferometerreflector and a reflector. The laser beam is split in the interferometer and runs from there on in two different paths. (Measuring beam and reference beam) On the return way the two beams will be superimposed to one beam again. The difference in path distance leads to a difference in return time and therfore a phase difference is the result. This phase difference results in a interference that can be measured. Laser OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS 4. OTHER INCLINATION MEASUREMENT SYSTEMS / PART 1 Opto-electronical principle A liquid horizontal surface is the basic reference. Changing the objects position automatically ti results in changing the reflection of the sensors optical beam on the liquid s (horizontal) surface. The reflection is dtected by a photo detector in two axis (X and Y) Clinometer with optical readout Clinorapid (Clinometer with pendulum) Communicating water level Servo-Clinometer Opto 20

21 OVERVIEW OF INCLINATION MEASUREMENT SYSTEMS 4. OTHER INCLINATION MEASUREMENT SYSTEMS / PART 2 Sextant Autocollimator Theodolite (Geodesy) Sextant PRECISION SPIRIT LEVELS Horizontal Spirit Level Precision Spirit Level with magnetic inserts Precision Frame Spirit Level Clinometer Precision spirit levels 1 21

22 PRECISION SPIRIT LEVELS Type 56 Type 52 Various Spirit Levels Type 45 Various Clinometers Type 78 Type 57 Type 53 Type 76 Type 79 Type 73 Type 74 Type 62 Type 47 Various Circular Spirit Levels Precision spirit levels 1 PRECISION SPIRIT LEVELS TWIST and standard dimensions of prsmatic bases Adjustment Nullpunkt Adjustment Twist The user has the possibility to adjust the ZERO as well as the TWIST thanks to a simple adjustment system. Standard dimensions of prismatic bases for shafts measurement Length of base Possible shaft diameter What does TWIST mean? L A B Ø 100 mm 100 mm 150 mm 200 mm 250 mm 300 mm 500 mm 30 mm 32 mm 35 mm 40 mm 45 mm 50 mm 60 mm 21 mm 22 mm 24.5 mm 28 mm 31.5 mm 35 mm 42 mm Ø mm Ø mm Ø mm Ø mm Ø mm Ø mm Ø mm Precision spirit levels 1 22

23 PRECISION SPIRIT LEVELS WYLER TYPE SPIRIT Most important advantages of the new concept: 1. Simple adjustment system 2. Excellent view on the vial 3. Modern design 4. Tested according to DIN standards 5. Stability of twist 6. Comfortable handling All bases of the high sensitivity spirit levels (up to 50 µm/m) are manually precision scraped!!! Precision spirit levels 2 WHAT IS INCLINATION? The definition ANGLE is the difference between two straight lines g1 and g2 in a flat plane. An angle will be created at the cross section between the two lines g1 and g2. ANGLE α between lines g1 and g2g The INCLINATION is a specific angle related to the angle a created between the line g3 and a horizontal line g4, whereas the horizontal lline g4 lies in the intersection between a vertical plane E2 and the horizontal (reference) plane E1, which must be absolutely horizontal. INCLINATION α between a line g3 and the zero line g4, e.g. in [Deg/Min/Sec] or [Rad] g4: horizontal zero-line E 1: horizontal plane E 2: vertikal plane Angle Inclination 23

24 MOST COMMON UNITS USED IN INCLINATION MEASUREMENT / DESCRIPTION OF AN ANGLE α Height H=1µm Base length B = 1m Angle α, e.g. in xx xx xx or in mrad or Height H refering to a base length B, e.g. mm/m or µm/m Multiply height H and base length B with factor 1000 Result: 1µm/m = 1mm/km 1 µm/m WHAT IS A POSITIVE, RESPECTIVELY A NEGATIVE INCLINATION? A positive inclination is, when the line respectively the plane, in the measuring direction is inclined. The negative inclination is therefore when the line or plane is declined Positive negative 24

25 APPLICATIONS / SPECIFICATIONS Legend of the symbols used Straightness Parallelism Squareness Large inclination Small inclination Flatness Product group Applications Measuring range Sensitivity Signal-output Horizontal Spirit level ±0,060mm/m up to ±3,0mm/m 20µm/m up to 1,0mm/m Frame Spirit level ±0,060mm/m up to ±3,0mm/m 20µm/m up to 1,0mm/m Clinometer ±180 1 Arcmin Applications and Specifications 1 APPLICATIONS / SPECIFICATIONS Legend of the symbols used Straightness Parallelism Squareness Large inclination Small inclination Flatness Product group Applications Measuring range Sensitivity Signal-output Electronic instrument with inductive system for small angles 1: ±0,750mm/m 2: ±0,150mm/m Measuring range 1: 1 Division: 50µm/m Measuring range 2: 1 Division: 10µm/m ±0,24V analogue Electronic instrument with capacitive system for small angles ±20mm/m ±1µm/m Digital-output: up to up to RS485 ±200mm/m ±10µm/m depending depending on Type on Type Applications and Specifications 2 25

26 APPLICATIONS / SPECIFICATIONS Legend of the symbols used Straightness Parallelism Squareness Large inclination Small inclination Flatness Product group Applications Measuring range Sensitivity Signal-output Electronic instrument with capacitive system for large angles ±10 Deg ±30 Deg ±45 Deg depending on Type approx 5 Arcsec depending on Type Digital-output: RS232 Electronic inclination sensors with capacitive system for small and large angles ±1 Deg ±5 Deg ±10 Deg ±30 Deg ±60 Deg depending on Type ±1 µm/m up to ±30 Arcsec Depending on sampling rate and meas. range Digital-output: RS485 Applications and Specifications 3 INTERNATIONAL UNIT SYSTEM (SI) Figure, resp. dimension Power Unit SI-Preset 0, , , , , ,001 0,01 0, of Trillion Atto of Billiard Femto of Billion Piko of Milliard Nano / Mikro /1000 Milli /100 Zenti /10 Dezi 10-0 One 10 1 Ten Deka 10 2 Hundered Hekto 10 3 Thausand Kilo 10 6 Million Mega 10 9 Milliarde Giga Billion Tera Billiarde Peta Trillion Exa Unit System 26

27 SINE, TANGENT AND ARCUS IN ACCORDANCE WITH ANGLES Rad = = * PI tg α α arc α Important: 1 µrad = 1 µm/m is valid for small angles only sin α sin α tg α arc α α = 0,5 α = 45 0, , , , ,00 0,78540 Sine, tangent MOST COMMON UNITS USED IN INCLINATION MEASUREMENT XX XX' XX' XX'' XX, X µm/m XXX mrad Degrees and Arcmin Arcmin and Arcsec 1 µm equivalent to 1/1'000'000 m 1 mrad equivalent to 206,26 Arcsec Display Minilevel "NT" in units like µm/m (mm/m) and Arcsec Units for +CLINO PLUS+ / CLINO 2000 XX XX' X,XXXX XX,XX XX'XX'' XX,XX mm/m,xxxx mm/m XX,XX mrad Units 27

28 ELECTRONIC INCLINATION MEASUREMENT IN GENERAL Purpose of the instrument: Transformation of a mechanically measured value into an electronic signal Existing Systems: - Inductive Systems (Niveltronic) - Capacitive Systems (Minilevel, Leveltronic, Zerotronic, Clinotronic) - Resistive Systems (e.g. by means of vials based on electrolysis) - Laser Capacitive Sensors: An inclination of 1 µm/m causes a pendulum movement of 10 up to 20 nm Thickness of a hair approx. 50 up to 70 µm (Measuring the thickness of a hair as an excercise) EXERCISE Thickness hair EXERCISE: DIAMETER OF A HAIR Instrument: MINILEVEL 1µm/m Base length: 150mm Thickness hair 28

29 ELECTRONIC INCLINOMETERS WYLER AG / OVERVIEW ZEROMATIC (2-dimensional precision inclination sensor with automatic reversal measurement) NIVELTRONIC ZEROTRONIC-Sensor +CLINOTRONIC PLUS+ Measuring instruments BlueSYSTEM-Series with wireless data transmission Measuring instruments NT-Series with wireless data transmission Electronic instruments overview ANALOGUE AND DIGITAL MEASURING SYSTEMS Analogue measuring system Digital measuring system Measuring value: Voltage Output in mv / unit (digit) Measuring value : Frequency Output frequencies f1 and f2 Format RS485 MINILEVEL classic LEVELTRONIC classic NIVELTRONIC LEVELMATIC MINILEVEL NT LEVELTRONIC NT BlueSYSTEM CLINOTRONIC 15 CLINO 2000 ZEROTRONIC ZEROMATIC 2/1 + 2/2 Analogue Digital 29

30 LINEARITY Linearity Angle Measured characteristic Nominal characteristic maximum error of linearity Angle DIN 2276 Measured value below half the measuring range Maximum error 1% of the measured value, at least 0,05% of the measuring range For measured values above half the measuring range Maximum error f max = 0,01 (2 x I M v I - 0,5 x M r ) M v : Measured Value M F : Measuring Range Linearity INCLINATION MEASURING INSTRUMENTS OF ANALOGUE AND DIGITAL TECHNIQUE Intro analogue technique 30

31 ANALOGUE / DIGITAL MEASURING PRINCIPLE Analogue measuring principle FORM OF THE PENDULUM Variables depending on the measuring range - Thickness of pendulum µm - Angle of spiral (length) e.g. Pendulum with 360 Pendulum 31

32 SINE, TANGENT AND ARCUS IN ACCORDANCE WITH ANGLES tg α α arc α Important: 1 µrad = 1 µm/m is valid for small angles only sin α sin α tg α arc α α = 0,5 α = 45 0, , , , ,00 0,78540 Sine MOVEMENT OF THE PENDULUM DEPENDING ON THE INCLINATION X = Gravitation of pendulum Y = sin α x X Z = movement of pendulum Y α X Z X 0,0030 (Z) sin α 10 1,0 0,8 0,6 0,4 0,2 (Z) sin α Grad 0, Sine of angle in a range from Arcmin Arcmin Sine of angle in a range up to 90 degrees Movement pendulum 1 32

33 MOVEMENT OF THE PENDULUM DEPENDING ON THE INCLINATION X = Gravitation of pendulum Y = sin α x X Z = movement of pendulum α X Z Y Movement of the pendulum in direction Y, e.g. MINILEVEL: For an inclination of 1µm/m nm Movement pendulum 2 REVERSAL MEASUREMENT Measurement A Measurement B Interpretation of the results: Reversal measurement 33

34 WYLER SOFTWARE FOR GEOMETRICAL MEASUREMENTS LEVELSOFT PRO Line / Straightness Parallels with/without twist Flatness (WYLER Standard and U-Jack) Rectangularity Levelsoft PRO WYLER SOFTWARE FOR GEOMETRICAL MEASUREMENTS LEVELSOFT PRO Measurement of partial surfaces Measurement of circular abjects Measurement of flat surfaces elements with cut out sections Partial surfaces 34

35 WYLER SOFTWARE FOR GEOMETRICAL MEASUREMENTS LEVELSOFT PRO Analysis of the measuring results by means of Software / LEVELSOFT PRO Line / Straightness Parallels with/without twist Rectangularity Flatness (WYLER Standard and U-Jack) Levelsoft PRO BASICS ON LINE- AND STRAIGHTNESS MEASUREMENT Influence of temperature: t in µm At temperature t difference of f1d degree Celsius between the upper and dthe lower side of a plate of 1m length results already in a deformation of the plate of 6 to 7 µm Choice of measuring base: Ideal measuring base: Flat steel base with dust groves Measuring step length: Length of the base Optimal step length Recommended step length 110 mm 90 mm mm 150 mm 126 mm mm 200 mm 170 mm mm SPECIAL BASIS Levelsoft PRO 2 35

36 BASICS ON MEASURING DIRECTION Measuring direction EXERCISE: MEASURING A LINE (as preparation for flatness measurement) SW WYLER according to ISO1101 Example: Sensitivity of the instrument: Base length: Step length: 1 µm/m 200 mm 180 mm =13,5µm based on 1000mm Maximum error: 13,5 µm x 180 mm 1000 mm = 2,43 µm (reduced to the step length of 180 mm) Measuring a line 1 36

37 EXERCISE: MEASURING A LINE Moving direction µm Remark: When using the WYLER-Software for measurement the effective value will be read in -4µm based on 1000mm 180 mm 1000 mm Measuring a line 2 ADJUSTMENT OF MEASURING RESULTS The following methods of adjustments are used: Adjustment according to: - End points method - ISO Linear regression Example: Measurement of a line Linear Regression 9.5µm ISO µm End point 10µm Adjustment methods 37

38 FLATNESS MEASUREMENT WITH WYLER INCLINOMETERS AND SOFTWARE SURFACE GRID WYLER Length: 1200 mm Width: 800 mm Maximum error: 4,0 μm Closure error: 0,3 μm Graphic display of profile As an option the connection to a PC is available: Options: - Leveladapter - Measurement-Software Operating Systems: WIN 95/98 / Win NT / WIN2000 / WIN XP Engineer Set consists of -2 BlueLEVELS - BlueMETER - Cable Levelsoft PRO BlueSYSTEM-Family / BlueLEVEL BlueMETER The latest generation of inclination measuring instruments and systems The most important features of the new BlueSYSTEM family are: All instruments of the BlueSYSTEM-family are available with or without wireless data transmission. All instruments without wireless data transmission can be upgraded later. Compact and modern design which is optimised for precision measurement Wireless data transmission according to the international system Bluetooth Standard Large LCD digital display integrated in a turnable handle (display can be turned upside down) Every instrument has its own unique adress for identification The measurement can be initiated from every instrument with an INFRARED ZAPPER There are three sensitivities available: BlueLEVEL 1µm/m: Measuring range ±20mm/m BlueLEVEL 5µm/m: Measuring range ±100mm/m BlueLEVEL 10µm/m: Measuring range ±200mm/m All instruments with the following interface: RS232 / RS422 / RS485 Powered by standard 1.5 V - batteries, Type C Fulfills the strict CE requirements BlueSYSTEM 1 38

39 BlueSYSTEM-Family / BlueLEVEL BlueMETER TECHNICAL DATA FOR RADIO Communication serial ports SENDER / RECEIVER Batteries BlueLEVEL / BlueMETER / BlueT/C: Frequency Modulation RS232 / RS422 / RS485, asynchr., 7Bits, 2 Stopbits, no parity, 9600 Baud ISM-Band / 2,4000-2,4835 GHz FHSS (Frequency Hopping Spread Spectrum) Used Net-structure Point to point / Point to multi-point RF Output power Max. +17 dbm / Class 1 Sensitive level Receiver -80 dbm BlueLEVEL BlueMETER 2 x 1.5V, Size C Alkaline 2 x 1.5V, Size C Alkaline Standard configuration of an ENGINEER SET BlueSYSTEM: 1 BlueLEVEL horizontal version BlueLEVEL with flat base of hardened steel, 150 mm, with dust grooves, sensitivity 1 µm/m 1 BlueLEVEL angular version BlueLEVEL with angular base of cast iron, 150mm, both faces prismatic, suitable for measurements on horizontal and vertical surfaces and shafts, contact faces hand scraped, sensitivity 1 µm/m 1 BlueMETER Complet System for initiating the transmission of measuring data via infrared 2 Cables, 2.5 m each 2 BlueLEVEL with BlueMETER BlueSYSTEM 2 technical data BlueSYSTEM-Family / BlueLEVEL BlueMETER Possible configurations: Two BlueLEVELs with a BlueMETER without wireless data transmission, connected to a PC/Laptop via cables Two BlueLEVELs with a BlueMETER with wireless data transmission, connected to a PC/Laptop BlueSYSTEM 3 configurations 39

40 BlueSYSTEM-Family / BlueLEVEL BASIC BlueMETER BASIC TECHNICAL SPECIFICATIONS Sensitivity 1 µm/m 0.2 Arcsec 5 µm/m 1 Arcsec 10 µm/m 2 Arcsec Display range ± 10 mm/m ± 50 mm/m ± 100 mm/m Limits of error <0.5 Full-scale (DIN 2276) max. 1% of measured value Limits of error >0.5<Full-scale (DIN 2276) max. 1% of (2 x measured value x Full-scale) / Digital output RS232 / RS422 / RS485, asynchron, 7 DataBits, StopBits, no parity, 9600 bps Batteries BlueMETER BASIC: Batterien BlueMETER BASIC: 3 x 1.5 V Alkaline, Size C or/oder 3 x 1.2 V NiMH, Size C Standard configuration of an ENGINEER SET BlueSYSTEM BASIC: 1 BlueLEVEL BASIC horizontal version BlueLEVEL with flat base of hardened steel, 150 mm, with dust grooves, sensitivity 1 µm/m 1 BlueLEVEL BASIC angular version BlueLEVEL with angular base of cast iron, 150mm, both faces prismatic, suitable for measurements on horizontal and vertical surfaces and shafts, contact faces hand scraped, sensitivity 1 µm/m 1 BlueMETER BASIC Complet System for initiating the transmission of measuring data via infrared 2 Cables, 2.5 m each All instruments of the BlueSYSTEM BASIC-family are available with or without wireless data transmission. 2 BlueLEVEL BASIC with BlueMETER BASIC BlueSYSTEM 2 technical data BlueSYSTEM-Family / BlueLEVEL BASIC BlueMETER BASIC Possible configurations: Two BlueLEVEL BASIC with a BlueMETER BASIC without wireless data transmission, connected to a PC/Laptop via cables Two BlueLEVEL BASIC with a BlueMETER BASIC with wireless data transmission, connected to a PC/Laptop BlueSYSTEM 3 configurations 40

41 PREPARATION FOR FLATNESS MEASUREMENT 1. Cleaning of the surface plate (on the previous day) 2. Place the instruments on the surface plate for acclimatization 3. Connecting the instruments (and Levelmeter) to the computer 4. Turn on the computer (after connecting the instruments) 5. Adjust surface plate to within +/- 50 µm/m with Spirit Level or Leveltronic / Minilevel. Attention: Loosen the safety supports first! 6. Prepare the software programme for the measurement with the necessary data 7. Calculation of the best fit grid and draw it on the surface plate, after that cleaning of the plate again. Free space at edge minimum 1/2 base width. 8. Execute test measurement, line with approx. 20 steps without moving the instrument 9. Start with flatness measurement, check correct sensitivity of MINILEVEL 10. After the measurement apply MICROPOLISH for conditioning the plate Levelsoft PRO Preparations BASICS ON SURFACE FLATNESS MEASUREMENT Influence of temperature: A temperature difference of 1 degree Celsius between the upper and the lower side of a plate of 1m length results already in a deformation of the plate of 6 to 7 µm Surface flatness according to DIN 876 / ISO1101: Flatness of granite surface plates (DIN 876 / ISO1101) Quality Maximum error in µm 00 2 x ( 1 + Length in [m] ) 0 4 x ( 1 + Length in [m] ) 1 10 x ( 1 + Length in [m] ) 2 20 x ( 1 + Length in [m] ) Length: 1200 mm SURFACE GRID WYLER Width: 800 mm Choice of measuring base: Ideal measuring base: Flat steel base with dust groves Maximum error: 4,0 μm Closure error: 0,3 μm Measuring step length: Length of the base Optimal step length Recommended step length 110 mm 90 mm mm 150 mm 126 mm mm 200 mm 170 mm mm Flatness measurement 41

42 BASICS ON SURFACE FLATNESS MEASUREMENT Prerequisite: Max. temp. difference top/bottom = 0.2 C After cleaning: 2 hours drying time Length: 1200 mm SURFACE GRID WYLER Width: 800 mm Grade t 1 in µm (1 + Length in m) 4 (1 + Length in m) 10 (1 + Length in m) 20 (1 + Length in m) Maximum error: 4,0 μm Closure error: 0,3 μm Flatness error of a partial area Size of area Max. tolerance t 2 in µm x 250 mm 3µm 5µm 13µm 25µm Accepted border zone: 2% of width of plate, max. 20mm Basics flatness measurement PREPARATION OF A GRANITE SURFACE PLATE FOR FLATNESS MEASURING Example: Size of granite plate: 1200 x 800 mm Measuring system used:: 1 LEVELTRONIC 1 µm/m, Base length 200 mm 1 LEVELTRONIC 1 µm/m, Base length 150 mm Preparation: 1. Preparation according to special instructions, like e.g. set to level. cleaning, etc. 2. Defining the edge zone (about ½ of the width of base plus 20 to 30 mm) 3. Definition of the measuring step length 4. Drawing the grid on the plate For the example : Baselength: 200mm (recommended step length: mm) Step length: longitudinal 6 x 185 mm + 2 x 45 mm edge transversal 4 x 175 mm + 2 x 50 mm edge Preparation flatness measurement 42

43 FLATNESS MEASUREMENT WITH LEVELSOFT PRO Three possibilities exist for measuring a flatness area of an object Symmetric layout of the measuring area The measuring instrument will be guided on the centerline of the flat base throughout the measuring area of the plate. In this case the grid is layed out symmetrically on the object Asymmetric layout of the measuring area The measuring instrument will be guided along a side of the base throughout the measuring area of the plate. In this case the grid is layed out asymmetrically on the object Asymmetric layout of the measuring area (3-point base) The 3-point base measuring instrument will be guided on the centerline of the contact points throughout the measuring area of the plate. In this case the grid is layed out asymmetrically on the object. Basics flatness measurement FLATNESS MEASUREMENT WITH LEVELSOFT PRO 1. Symmetric layout of the measuring area The measuring instrument will be guided on the centerline of the flat base throughout the measuring area of the plate. In this case the grid is layed out symmetrically on the object Basics flatness measurement 43

44 FLATNESS MEASUREMENT WITH LEVELSOFT PRO 2. Asymmetric layout of the measuring area The measuring instrument will be guided along a side of the base throughout the measuring area of the plate. In this case the grid is layed out asymmetrically on the object Basics flatness measurement FLATNESS MEASUREMENT WITH LEVELSOFT PRO 3. Asymmetric layout of the measuring area (3-point base) The 3-point base measuring instrument will be guided on the centerline of the contact points throughout the measuring area of the plate. In this case the grid is layed out asymmetrically on the object. Basics flatness measurement 44

45 LEVELSOFT PRO / QUALITY AND INTERPRETATION OF A MEASUREMENT Remarks: Determining the maximum error is always according to ISO 1101 Length: 1200 mm SURFACE GRID WYLER Witdh: 800 mm Flatness according to ISO1101 without correction of the closure error The closure error should not exceed 20% to 25% of the max. error Maximum error: 4,0 μm Closure error: 0,5 μm SURFACE GRID WYLER Length: 1200 mm Witdh: 800 mm Flatness according to ISO1101 with correction of the closure error Maximum error: 4,0 μm Index of correction: 0,3 μm Levelsoft PRO Closure error LEVELSOFT PRO / INTERPRETATION OF A MEASUREMENT H in µm Measured flatness of an object Contact points upper plane Plane 1 (upper plane) Plane 2 (lower plane) H [µm] Contact points lower plane H = Distance between the two parallel planes 1 and 2 = Flatness according to ISO1101 in [µm] Draft flatness measurement 45

46 LEVELSOFT PRO / MEASUREMENT OF A 90 ANGLE WITH LEVELSOFT PRO 1. Step: Determining the angular error of the instrument using a master square with parallel sides 2. Step: Measurement of the 90 deg. angle of the object / 4 different possibilities The WYLER LEVELSOFT PRO is leading the way through the different software menus Levelsoft PRO 90 degrees angle LEVELSOFT PRO / MEASUREMENT OF A 90 ANGLE WITH LEVELSOFT PRO Xµm Reference plane 90 Reference line Right angle tolerance according to ISO 1101 Levelsoft PRO 90 degrees angle / draft 46

47 LEVELSOFT PRO / MEASUREMENT OF A 90 ANGLE / ADJUSTMENT METHODS a) Alignment of the reference line according to ENDPOINTS ANGLE / ENDPOINTS 0.5 µm 0.4 µm 0.3 µm 0.2 µm 0.1 µm 0,0 µm ERROR REFERENCE LINE 0.6 µm ERROR 2ND LINE BASED ON ISO µm END POINTS 0.2 µm LINEAR REGRESSION 0.1 µm CORRECTION OF INSTRUMENT -2,58 µm/m The error of the second line is shown according to the various alignment methods: - ISO ENPOINTS - LINEAR REGRESSION Adjustment methods endpoints LEVELSOFT PRO / MEASUREMENT OF A 90 ANGLE / ADJUSTMENT METHODS b) Alignment of the reference line according to ISO 1101 ANGLE / ISO µm 0.4 µm 0.3 µm 0.2 µm 0.1 µm 0,0 µm ERROR REFERENCE LINE 0.5 µm ERROR 2ND LINE BASED ON ISO µm END POINTS 0.1 µm LINEAR REGRESSION 0.2 µm CORRECTION OF INSTRUMENT -2,58 µm/m The error of the second line is shown according to the various alignment methods: - ISO ENPOINTS - LINEAR REGRESSION Adjustment methods ISO

48 LEVELSOFT PRO / MEASUREMENT OF A 90 ANGLE / ADJUSTMENT METHODS c) Alignment of the reference line according to LINEAR REGRESSION ANGLE / LINEAR REGRESSION 0.5 µm 0.4 µm 0.3 µm 0.2 µm 0.1 µm 0,0 µm ERROR REFERENCE LINE 0.5 µm ERROR 2ND LINE BASED ON ISO µm END POINTS 0.0 µm LINEAR REGRESSION 0.1 µm CORRECTION OF INSTRUMENT -2,58 µm/m The error of the second line is shown according to the various alignment methods: - ISO ENPOINTS - LINEAR REGRESSION Adjustment methods lin regression LEVELSOFT PRO / GEOMETRICAL INSPECTION OF MACHINE TOOLS PITCH error New!!! MT-SOFT Software for definition of machine tool geometry ROLL error Levelsoft PRO Pitch + Roll 48

49 LEVELSOFT PRO / GEOMETRICAL INSPECTION OF MACHINE TOOLS Inspection of machine tool table Geometrical inspection of an instable structure Levelsoft PRO machine tool MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY MT-SOFT (Machine Tools Inspection Software) Software for the definition of machine tool geometry MT-SOFT 49

50 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Together with the inclination measuring instruments of WYLER AG, the software MT-SOFT is the ideal tool for measuring and checking of machine tool components. Based on a SQL database Possible measuring tasks: Machine tool guide ways vertical and horizontal Surfaces Circles Rotating axes Rotating of geometrical elements LEVELSOFT PRO as an integral part Comparison of measured geometrical elements on the same machine, such as e.g. Machine tool guide ways horizontal compared to Spindle axis vertical MT-SOFT: Machine Tools Inspection Software MT-SOFT MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY There are 2 options: I. Test version of MT-SOFT no licence (limited in time) II. Licenced version of MT-SOFT no time limit Installation of MT-SOFT from CD-ROM Unblocking of Software licensed version Testversion no licence by Testversion / no licence limited in time or number of start-ups lincenced version unblocking of chosen set of modules unlimited use purchase Yes / No Yes purchase and unblocking for unlimited use lincenced version unblocking of chosen set of modules No De-installation MT-SOFT 50

51 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY define new measuring template start MT-SOFT prepare measurement load template Setup of measurement task new measurement Preparation Choosing the object to be measured Definition of the jig Definition of the layout Definition for data entry reversal measurement Yes / No single or reference measurem. 1 / 2 axis Description of the measurement De efinition mandatory Carry out measurement Display / Analysis Store and print results MT-SOFT MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY additional languages will follow MT-SOFT 51

52 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Careful choice of coordinate system The program allows (under certain conditions) the integration of elements which have been measured earlier as well as the comparison between elements from separate measurements. This requires though the appropriate positioning within the coordinate system. The relevant entries are used to label the measuring results. Correct labeling allows the correct allocation for later analysis. +X: Tool coordinate X-axis +X : Moving direction table MT-SOFT INTRODUCTION IN INCLINATION MEASUREMENT Relative- and Absolute Measurements In the inclination measuring technology we distinguish between Relative measurements and Absolute measurements Intro Inclination Measurement 52

53 INTRODUCTION IN INCLINATION MEASUREMENT Relative measurements Relative measurements are used when the actual position of the measuring object is not relevant Examples: Flatness of a granite surface plate Flatness of a platform Relevant is the difference of the inclination between one measurement and the following measurement Intro Inclination Measurement INTRODUCTION IN INCLINATION MEASUREMENT Relative measurements Alignment method: End points 2.79 µm Step length = 180 mm ISO µm Maximaler Fehler =15,5 µm Linear regression Manual analysis according to the method End points : Maximum error (straightness) in relation to the step length: 180mm = 15.5 µm x = 2,79 µm 1000mm 2.77 µm Intro Inclination Measurement 53

54 INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Examples: Absolute measurements are used when the actual position of the measuring object is relevant Monitoring of objects, such as bridges, dams, etc. Calibration of industrially used robots, radar systems, etc. Measurements of machines tools, particularly in the comparison of elements which hare measured independently from each other (e.g. horizontal guide way in relation to vertical spindle, etc. ) Relevant is the actual position of the measuring object in space Intro Inclination Measurement INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Reversal measurement to define the exact horizontal ZERO POSITION (ZERO OFFSET) Measurement X Measurement X Reversal measurement direction X direction X Zero point deviation Inclination of surface instrument (ZERO-Offset) in direction X X + X X - X = = 2 2 Intro Inclination Measurement 54

55 INTRODUCTION IN INCLINATION MEASUREMENT Absolute measurements Reversal measurement to define the angular error of the instrument Angular error of the instrument = C + D 2 A + B 2 Master Intro Inclination Measurement MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Analysis of the measuring results by means of Software MT-SOFT (Machine Tools Inspection Software) Circles (Rotary table) Vertical spindle of a machine tool is to be defined in relation to the horizontally positioned table Guide ways of machine tools MT-SOFT 55

56 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Result of the measurement of the bearing point of a rotary table. The flatness of the inner and the outer circular measurement as well as the deviation of both circular flatnesses from the plumbline of the Z-axis is displayed. Program for measuring CIRCLES MT-SOFT 2 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Analysis of the measuring results by means of Software MT-SOFT (Machine Tools Inspection Software) Comparison of a horizontal with a vertical guide way. In order to do so it is required to measure in the absolute mode. 56

57 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Some examples of the measurement possibilities / GUIDEWAYS Machine tool guide ways horizontal and vertical MT-SOFT 3 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Measuring devices (JIGs) for MT-SOFT Example: Two machine tool guide ways right (front) prismatic surface left (rear) flat surface Jig with symmetrical base plate (Position of cross direction at centre of base plate and prismatic guide on one side) Jig with asymmetrical base plate left (Position of cross direction at the beginning of the base plate and prismatic guide on one side) Jig with asymmetrical base plate right (Position of cross direction at the end of the base plate and prismatic guide on one side) MT-SOFT 4 57

58 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Some examples of the measurement possibilities / ROTATING AXIS Rotating axis MT-SOFT 3 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Some examples of the measurement possibilities / PITCH AND ROLL Pitch and Roll MT-SOFT 3 58

59 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Some examples of the measurement possibilities / CIRCLES One or two circular lines MT-SOFT 3 MT-SOFT / SOFTWARE FOR THE DEFINITION OF MACHINE TOOL GEOMETRY Some examples of the measurement possibilities / PARTIAL SURFACES MT-SOFT 4 59

60 LEVELMATIC-SENSOR TYPE 31 WITH ANALOGUE OUTPUT / PRECISION TRANSDUCER LEVELMATIC-Sensor Type 31 Measuring range Linearity Output signal ±2 mrad... ±30 degrees 0.5% FS ± 2 V DC and Levelmeter C25 Levelmatic INCLINATION MEASURING INSTRUMENTS WITH DIGITAL MEASURING PRINCIPLE Part 3 Inclination measurement 60

61 ZEROTRONIC SENSOR DIGITAL Objectives for the development of the new sensor ZEROTRONIC High resolution, high accuracy Low temperature dependency Digital technique; use of microprocessors Measuring range from ± 1 up to ± 60 degrees Measurement under dynamic conditions Display for graphical analysis and on-line monitoring Galvanic disconnection for outdoor applications Objectives ZEROTRONIC ZEROTRONIC SENSOR DIGITAL Design of ZEROTRONIC: - Sensor including pendulum held by Archimedes helical springs - RC - Oscillator - Voltage stabilisator with level-shifter -Digital frequency counter with calibration data memory and asynchronous serial port - Housing and mounting bracket Pendelum - Voltage stabilisator - Digital frequency counter - Calibration data memory - Asynchronous serial port Connector for RS 485 Design ZEROTRONIC Draft Elektrodes Mounting bracket RC-Oscillator Housing gastight WYLER SEAL-TEC R 61

62 ZEROTRONIC SENSOR DIGITAL / OUTPUT DIGITAL + ANALOGUE OUT IN TYPE 2 RS485 F 1 and F 2 [Hz] Calibration data Temp [Hz] Measuring rate ZEROTRONIC TYPE 3 Angle in [Rad] TYPE 3 (Angle calculated RS485 in sensor) Measuring rate [V] / 5.0 [V] V DD [ma] / [V] V DD ZEROTRONIC OUT - IN ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Voltagestabilisator Pendelum Selector Oscillator cy al port Digital frequen counter asynchronous seria (EXT) GND +5V RTA RTB PWM RTS C1 C2 Connector (AUX) Oscillator 62

63 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Sampling time t max = 8 Seconds t min = 10mS (depending on baudrate) U in F out Output frequency Frequeny Counter 12 Bit Example: F= Hz: 1 t 1 = Hz * = 3,7mS F= Hz: 1 t 2 = Hz * = 5,8mS Position SELECTOR 4096: Capacity of the Frequency Counter / 12 Bit ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Principle function of a RC-Oscillator / Part 1 Principle function oscillator 1 63

64 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Principle function of a RC-Oscillator / Part 2 Simplified description of principle function of a Schmittrigger U in Schmitttrigger U out U+ positive threshold U - negative threshold Principle function oscillator 2 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Principle function of a RC-Oscillator / Part 3 High capacity Low frequency Small capacity High frequency U+ positive threshold U - negative threshold Principle function oscillator 3 64

65 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Principle function oscillator 4 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Calibration of a digital measuring system / Part 1 1. Calibration of the system F1/F2 (F1,F2) Number of calibration points: Clinotronic: 21 Zerotronic: free to chose Angle F1/F2 (F1,F2) Angle 2. The calibration points will be stored Calibration 1 65

66 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Calibration of a digital measuring system / Part 2 F1/F2 (F1,F2) 3. Calculation of the individual values between the calibration points by means of interpolation T=40 C T=20 C T= 0 C Calibration point F1/F2 (F1,F2) Angle F1 30 F2 30 Angle Setting of calibration device e.g. -30 degrees 4. Calibration at different temperatures Calibration 2 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Calibration of a digital measuring system / Part 3 T=40 C T=20 C T= 0 C F1/F2 (F1,F2) Angle Calibration Measurement Calibration 3 66

67 ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ Calibration of a digital measuring system / Part 3 / Typical curves of the frequencies of +CLINO PLUS+ Frequency in [Hz] Frequency F1 Frequency F Calibration 4 / frequency clino plus ZEROTRONIC SENSOR DIGITAL / DIGITAL MEASURING PRICIPLE ZEROTRONIC CLINO CLINOTRONIC PLUS+ ELIMINATING OF ZERO-OFFSET Angle eff 45 Angle nominal z.b. 45 ZERO-Offset The ZERO-Offset can be eliminated with a reversal measurement Elimination ZERO OFFSET 67

68 ZEROTRONIC SENSOR DIGITAL / DIGITALES MESSPRINZIP ZEROTRONIC CLINO CLINOTRONIC PLUS+ ELIMINATING OF ZERO- AND GAIN-OFFSET 1. ZERO- and Gain-Offset Max. Offset 2. Eliminating the ZERO-Offset Gain-Offset Angle eff. Angle eff. The ZERO-Offset can 45 be eliminated with a reversal measurement 45 (Zerotronic, Clino45 and Clino2000) Angle nominal e.g. 45 Angle nominal e.g. 45 ZERO-Offset 3. Eliminating Gain-Offset Angle eff. 45 Angle nominal e.g. 45 The GAIN-Offset can be eliminated with a stick calibration (Clino2000 and ZEROTRONIC only) Elimination ZERO-OFFSET and GAIN +CLINOTRONIC PLUS+ Most important features: Digital measuring system Easy to calibrate by the user Various units to select Standard: Measuring range ±45 Options: ±30 and ±10 Sensor cell in SEALTEC-quality Short settling time No loss of calibration date by battery change Standard batteries 1,5V Size AA Connection to RS 485 output of PC Specifications: - Settling time / Display < 5 Seconds - Repetition < 20 Arcsec - Linearity < 2 Arcmin + 1 digit CLINO PLUS 1 68

69 +CLINOTRONIC PLUS+ Exercise: 1. Change and store unit of measurement 2. Eliminating the zero-offset by means of a reversal measurement 3. HOLD function 4. Calibration a) Calibration manually b) Calibration automatically CLINO PLUS 2 / Exercise CLINOTRONIC 2000 The new digital inclination measuring instrument for a great variety of measuring tasks, fulfils all requirements Most important features: - Highest possible precision over the large measuring range of ±45 with integrated temperature compensation - Effortless zero adjustment by using the integrated software and a reversal measurement - Most modern digital electronic components - Fulfils the strict CE requirements (immunity against electromagnetic smog) - Easy to calibrate due to the implemented software guidance and the calibration aids - Most common units available - Standard: Measuring range ±45 Options: ±60, ±30 und ±10 Specifications: - Settling time < 5 seconds - Resolution 5 Arcsec - Limits of error: < 5 Arcsec % R.O. - Data connection: RS232, asynchr., 7 Bit, 2 Stopbits, no parity, 9600 Baud CLINO

70 ZEROTRONIC SENSOR / OUTPUT ANALOGUE Angle = 0 Vcc=5V 0V Output Ø 2.5V Angle = + FS Ø 4.5V Angle = - FS Ø 0.5V F=3.6kHz 100%=277.7µS 10%=27.77µS Analogue Output (PWM) ZEROTRONIC analogue output ZEROTRONIC SENSOR / GENERAL REMARKS Angle 0 degree Angle positive; e.g. +10 degrees Angle negative; e.g. -10 degrees ZEROTRONIC plus / minus 70

71 ZEROTRONIC SENSOR / CONFIGURATIONS ZEROTRONIC-Sensors with T/C (Transceiver/Converter) connected to a Personal Computer ZEROTRONIC-Sensors with T/C (Transceiver/Converter) connected to a Levelmeter 2000 ZEROTRONIC configuration ZEROTRONIC SENSOR / CONFIGURATIONS Configuration with Laptop connected via 2 BlueTC to ZEROTRONIC sensors. BlueT/C used as interface data transmission through cables. Configuration with Laptop connected via 2 BlueTC to ZEROTRONIC sensors. BlueT/C used as interface, data transmission through wireless connection. ZEROTRONIC Sensors connected to a PC or Laptop through one or more BlueT/C. BlueT/C used as interface, data transmission through wireless connection. 71

72 ZEROTRONIC SENSOR / CONFIGURATIONS ZEROTRONIC 2-D IN COMBINATION WITH A LED-CROSS Format of data transfer Transmission data format: asynchron / 7 Bit / 2 Stopbits / no parity ZEROTRONIC configuration LED Cross 2D-AUTOMATIC REVERSAL MEASUREMENT HEAD ZEROMATIC 2/1 + 2/2 Advanced technology in long-term measurement in X- and Y-axis The new developed high precision 2-axis inclination measurement instrument ZEROMATIC The ZEROMATIC is available in two different versions: ZEROMATIC 2/1: Inclination measurement head with one ZEROTRONIC Sensor. Each single measurement is established by a reversal measurement, which delivers the absolute inclination value in both X- and Y-axis. For each measurement the ZERO OFFSET is calculated and compensated. Each measurement sequence, which consists of a complete reversal measurement, gives one set of output data. The user can define the interval between 2 sequences. ZEROMATIC 2/2: Inclination measurement head with automatic reversal measurement with two ZEROTRONIC Sensors. The absolute inclination values in X- and Y- axis can be read continuously. At defined intervals, which can be set by the user, the zero offset is evaluated and compensated through a reversal measurement. The length of the interval is dependent on the required accuracy. ZEROMATIC 2 / 1 ZEROMATIC 1 72

73 2D-AUTOMATIC REVERSAL MEASUREMENT HEAD ZEROMATIC 2/1 + 2/2 Calculation and elimination of any ZERO-OFFSET by means of a reversal measurement ZEROMATIC 2 / 2 ZEROMATIC 2 2D-AUTOMATIC REVERSAL MEASUREMENT HEAD ZEROMATIC 2/1 + 2/2 TECHNICAL SPECIFICATIONS ZEROMATIC / TECHNISCHE DATEN ZEROMATIC 1 Sensor 5 Sensor 10 Sensor Stability of Zero / Nullpunktstabilität Linearity / Linearität Temperatur Error Temperatur Fehler Time for one reversal measurement Dauer einer Umschlagmessung Limits of error Fehlergrenze Limits of error Fehlergrenze ±1 Arcsec ±2.5 Arcsec ±4 Arcsec 0.5% R.O. 0.6% R.O. 0.8% R.O. 0.08% R.O. / C 0.05% R.O. / C 0.02% R.O. / C < 2 minutes < 2 Minuten ZEROMATIC 2 / 2 ZEROMATIC 3 technical data 73

74 Longterm Monitoring of Dams, Bridges and Buildings with ZEROMATIC 2/1 + 2/2 Our sensors ZEROTRONIC and ZEROMATIC are very well suited for long term monitoring of civil engineers constructions like dams, bridges or buildings. Very often such applications require data gathering and data transmission with remote indication and alarming. For such tasks we recommend the use of a DC3 system. DC3 allows the gathering of various types of sensors like GPS receivers, totalstations and inclination sensors. The data is then transmitted by internet, by phone lines or wireless to a central monitoring station. The picture left shows a typical display of a damn which is monitored with the help of a DC3 system. ZEROMATIC 3 technical data ZEROTRONIC SENSOR / FORMAT DATA TRANSFER WYLER RS485 instruments / Characteristic data transfer Asynchronous data transfer Baudrate [Automatic or fix, depending on the instrument] 1 Start Bit 7DataBit 2 Stop Bit DATA transfer 74

75 ZEROTRONIC SENSOR / SOFTWARE-STRUCTURE DYNAM ZEROTRONIC / Software-strukture DYNAM Operating Systems DYNAM Basic-Software - very flexible configured - Parameters like - Display on the monitor - Measuring rate - Selection of filters, and so on are free selectable Additional SW for customer specific applications The complete SW package will be prepared by WYLER according to customers requirements DYNAM 1 ZEROTRONIC SENSOR / SOFTWARE-STRUCTURE DYNAM ZEROTRONIC / Software-strukture DYNAM PANEL the cockpit DISPLAY with actual values Display on the monitor of a measurement with 2 ZEROTRONIC- Sensors and continuous monitoring of all previously measured values ANALYZER which displays all measured measuring values DYNAM 2 75

76 ZEROTRONIC SENSOR / SOFTWARE-STRUCTURE DYNAM ZEROTRONIC / Software-strukture DYNAM ANALYZER Tool to analyse all previously recorded measuring values stored in different files DYNAM 3 ZEROTRONIC SENSOR / SOFTWARE LabVIEW from NATIONAL INSTRUMENTS Measurements and Analyzations with VI s from WYLER for ZEROTRONIC Type 3 LabVIEW 76

77 ZEROTRONIC SENSOR / DATA TRANSMISSION FROM SHORT DISTANCE UP TO SERVERAL KILOMETERS / PART 1 Levelmeter 2000 Transceiver / Converter RS 485 BUS Sensor A RS 485 BUS T/ PC C Sensor B Distance < 15m 2 Sensors s with Levelmeter e ete 2000 With additional T/C s and external power supply more than 2 sensors can be connected Distance < 15m 2 Sensors with Levelmeter 2000 And external power supply With additional T/C s and external power supply ppy more than 2 sensors can be connected 2 Sensors with PC, external power supply and 1 T/C Distance < 2,5m Distance < 15m Up to 31 T/C s with 2 sensors each can be connected ZEROTRONIC short distances ZEROTRONIC SENSOR / DATA TRANSMISSION FROM SHORT DISTANCE UP TO SERVERAL KILOMETERS / PART 2 Transceiver / Converter RS 485 BUS Sensor A RS 485 BUS T/ PC C Sensor B Distance < 2,5m Distance < 1000m Distance < 15m Anschluss: 2 Sensors with PC and 1 T/C as converter RS485/232 1 T/C as transceiver Distance < 2,5m Distance < 1000m Up to 31 T/C s with two Sensors each can be connected Distance < 15m ZEROTRONIC long distances 77

78 ZEROTRONIC SENSOR / CONFIGURATIONS Configuration with Laptop connected via 2 BlueTC to ZEROTRONIC sensors. BlueT/C used as interface data transmission through cables. Configuration with Laptop connected via 2 BlueTC to ZEROTRONIC sensors. BlueT/C used as interface, data transmission through wireless connection. ZEROTRONIC Sensors connected to a PC or Laptop through one or more BlueT/C. BlueT/C used as interface, data transmission through wireless connection. ZEROTRONIC SENSOR / APPLICATIONS A few typical applications for ZEROTRONIC Sensors: Precision inclination measurement on unstable objects like Machine tools Adjustment of moving platforms on boats and vessels Long term monitoring with data collection and -transfer Buildings Construction sites Bridges Dams Tunnels Inclination measurement by driving on a road Various applications Adjustment of printing machines Measurement of profiles (aircrafts, racing cars formula 1, and so on) Applications ZERO 78

79 ZEROTRONIC SENSOR / POSSIBLE CONCEPT FOR DATA TRANSFER Office PC with WYLER-SW DYNAM Field Zerotronic-Sensors Modem Modem Transceiver / Converter Data report Alarm Transmission to another station ZEROTRONIC modem ZEROTRONIC SENSOR / ADJUSTMENT OF PLATFORMS ON BOATS WITH ZEROTRONIC 1. Step: ZERO-SETTING with both sensors 2. Step: Measuring the difference between the two platforms 3. Step: Adjustment of the platform according to the measured deviation until the display shows ZERO ZEROTRONIC platforms 79

80 ZEROTRONIC SENSOR / PROJECTS WITH ZEROTRONIC-SENSORS ZEROTRONIC PROJECT 50 Easy finding of the 90 deg. Deviation when swivelling the spindle from horizontal to vertical. 1. Zero setting by means of reversal measurement on horizontal position of the spindle. saving values (manually or PC) 2. Swivelling spindle 90 deg. 3. Zero setting by means of reversal measurement on vertical position of the spindle. saving values (manually or PC) ZEROTRONIC sensors with Levelmeter Calculating angular difference between the two positions of the spindle by means of pocket calculator or PC. ZEROTRONIC machine tool ZEROTRONIC SENSOR / PROJECTS WITH ZEROTRONIC-SENSORS ZEROTRONIC PROJECT 62 Adjustment of various platforms in large aircrafts during assembly and maintenance Reference plate situated at the forward end of the cargo floor 1. Easy simultaneous zero setting of 4 sensors 2. Angular difference between the pairs of sensors easily visualized on the Levelmeter Differential measurement easily possible at various positions. ZEROTRONIC aircrafts 80

81 ZEROTRONIC SENSOR / PROJECTS WITH ZEROTRONIC-SENSORS Task: Continous measurement of inclination by driving on a road and taking the influence of acceleration into consideration Calculation of the effective inclination β β = β 1 - β 2 β 2 = f (arcsin α) = f {arcsin [f (s, t)]} a: Acceleration [m/s 2 ] (=dv/dt = v = s ) s: Distance [m] f 1, f 2 : Frequencies Sensors ZEROTRONIC EMPA ZEROTRONIC SENSOR / PROJECTS WITH ZEROTRONIC-SENSORS Task: Continous measurement of inclination by driving on a road and taking the influence of acceleration into consideration ZEROTRONIC EMPA 2 81

82 EXPRESS REPARATUR SERVICE - WYLEX EXPTESS REPAIR SERVICE ERS / WYLEX A large number of customers are very dependent on their instruments as they are used daily. They can therefore not do without them for a long period of time. For these cases WYLER SWITZERLAND has created a new service called Express Repair Service, ERS / WYLEX. Employing this service the transport time from the user to WYLER SWITZERLAND and back and thus the complete repair time can be reduced considerably. A simplified description of this service: The customer announces the repair request to the local WYLER partner in his country The WYLER partner will inform the customer about the possibility of the ERS / WYLEX service outlining the advantages and consequences of this service, such as e.g. o reduced total repair time o required acceptance to repair without quote up to 65 % of the price for a new instrument o suitable packing for air transport t o expenses of the ERS / WYLEX In case the customer decides to use the ERS / WYLEX, the customer informs the local WYLER partner or directly WYLER SWITZERLAND providing the necessary data The customer will receive all information and instructions necessary for a smooth handling, the customer has just to pack the product suitably and to fill in a form for the TNT courier service as well as to announce the readiness to the local TNT office for pick-up. Everything else will run automatically Products reaching WYLER SWITZERLAND under this service will be handled with first priority, and the instrument will be returned using the same carrier The invoicing will be through the WYLER partner in your country WYLEX WARTUNGSVERTRAG FÜR WYLER-GERÄTE MAINTENANCE CONTRACT Measuring systems are becoming more and more complex and are therefore subject to continuous supervision in respect of quality and reliability. For this purpose WYLER SWITZERLAND offers the option of a MAINTENANCE CONTRACT with the purchase of new instruments. The MAINTENANCE CONTRACT offers the following services to the customer: Complete inspection and re-adjustment of the instrument / system in a yearly interval as well as remedy of defaults reported by the customer The scope of delivery includes an internationally recognised Calibration Certificate SCS for the entire system confirming the performance after the service intervention. Traceable certificates SCS are issued according our accreditation as a calibration laboratory by the Swiss authorities Highest priority for repair works Technical enhancements and modifications published by WYLER if this is considered suitable Maintanance contract 82

83 WARTUNGSVERTRAG FÜR WYLER-GERÄTE New WYLER Service Concept VISION: Our customers should feel like this: There are no problems with WYLER products, and in the rare case that there is a problem WYLER solves it efficiently and to my full satisfaction We would like to make it as easy as possible for WYLER customers to deal with us. We would like them to feel like WYLER being a local supplier. Wartungsvertrag WARTUNGSVERTRAG FÜR WYLER-GERÄTE New WYLER Service Concept Products under warranty: As of January 1, 2007 WYLER AG will absorb transportation costs to and from Switzerland for products showing errors during the warranty period There are very few WYLER instruments which fail during the warranty period. In order to increase customer satisfaction we would like to make sure that the customer who just invested into a new instrument does not have high costs if the instrument fails. WYLER is only absorbing the transportation cost and the cost to import the instrument into Switzerland. Wartungsvertrag 83

84 WARTUNGSVERTRAG FÜR WYLER-GERÄTE New WYLER Service Concept Products no longer under warranty In order to reduce distance to WLYER we would like to make sure that t a Japanese customer does not pay more than a European customer and that a South American customer has the same short distance to WYLER (in terms of transportation costs) as a Turkish customer. Transportation costs (max amount for the whole world) Clinotronic Plus: CHF 75.- for each way Clino 2000: CHF for each way Single Level (Minilevel / BlueLEVEL): CHF for each way Engineers Set : CHF for each way NivelSWISS: CHF for each way Wartungsvertrag The difference between the above mentioned amount and the real transportation cost will be absorbed by WYLER for the transport to Switzerland. WE THANK YOU FOR YOUR INTEREST IN OUR PRODUCTS WYLER AG, CH Winterthur Thank you Geschichte 84