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3 Operating Steps

 

3.1 Prerequisites:

  1. IMRMD is mainly used to correct the five-axis RTCP accuracy, so the machine tool must have been manually performed five-axis transformation vector measurement and the five-axis related parameters have been set before using this function.
  2. Make sure that the geometric accuracy of the machine should be within the standard range, and the RTCP deviation is less than 1mm. Excessive deviation can cause collision with the standard ball during the movement of the probe, resulting in measurement failure.
  3. Make sure that the concentricity deviation of the probe and spindle axis is less than 0.005mm.
  4. The standard ball installation form is based on the principle of providing the maximum measurement angle. For VM500U machining center, the B-axis can achieve a measurement range of 0~ 100° when using the tilted ball seat; while only a measurement range of 0 ~ 60° can be achieved when using the vertical ball seat. Generally speaking, the larger the measuring range is, the more accurate the measurement can be.
  5. The probe needs to be calibrated for length and probe diameter.
  6. The operating level of the machine tool should not be lower than "Key Switch 3".

3.2 Hardware installation:

  1. The standard ball holder is fixed to the workbench by T-nut. The fixation must be firm so that the ceramic ball or probe is not damaged by falling off during the measurement process.
  2. The effective stroke of each linear axis after the workbench is turned over should be taken into account when the ball seat is fixing, meanwhile, the ball should be as far away from the center of the workbench as possible.
  3. As the B-axis stroke is -5 to 110°, the ball should be installed towards the direction of maximum B-axis angle to obtain the maximum measurement range.
  4. The probe is fixed to the spindle by means of an HSK shank.

3.3 Newly created cutting edge:

Before starting operation, the machine tool must be in a non-processing state and the system must be in normal condition.

  1. Press the [MENU SELECT] key at the bottom right corner of the screen, then click the [PARAMETER] soft key at the bottom of the screen to enter the [Tool List] screen.
  2. Use the arrow keys to move the cursor and select the probe in the tool table, ensuring that the probe is not on the spindle or mechanical jaws. If it is, return it to the magazine or unload it firstly.

  3. Press the [Tool Edge] soft key on the right, then press [Newly Created Tool Edge] to create a new tool edge D2.

  4. Load the probe to the spindle.
  5. Calibrate the tool edge D1, and refer to SINUMERIK 840D sl Measuring Cycle Manual for the probe calibration method.

3.4 Probe rough alignment:

  1. Switch the machine tool to JOG mode and manually move the Z-axis so that the probe is approximately 2 to 3mm from the surface of the ball, a value corresponding to the IMRMD parameter page RDFA.
  2. Move the X and Y axes so that the probe is visually aligned with the vertical center line of the sphere, with a deviation of less than 1mm as far as possible to avoid triggering an alarm during measurement.

 

3.5 IMRMD operating steps：

  1. Press the [CUSTOM] key, or press the [MENU SELECT] key at the bottom right corner of the screen, then press the screen soft key [CUSTOM].
  2. Press the [5-axis Param] soft key.
  3. Press the [IMRMD >] soft key to enter the IMRMD parameter setting screen.
  4. Set the IMRMD parameters (refer to the parameter description on the back page for details), and after that, press the [Execute >>] soft key on the right then the machine tool will automatically switch to AUTO mode and generate an operating command.
  5. Press the [CYCLE START] key, then the probe starts to move and carry out alignment. The measurement process starts automatically after the alignment is completed.
  6. Each rotary axis measures 3 positions, which vary depending on the type of ball seat selected.
  7. Default measurement position for tilted ball seat: [0°,45°,90°] for the B axis and [0°,120°,240°] for the C axis.
  8. Default measuring position of the vertical ball seat: [0°, 30°,60°] for the B axis and [0°,120°,240°] for the C axis.
  9. After measuring the two rotary axes, the operator will be prompted to press the [CYCLE START] key to start the calculation, and then the system starts to calculate the five-axis transformation vector values and displays the calculation results in tabular form.

  1. The values in the table show the vectorial relationship of the rotary axis with respect to the linear coordinates.
  2. Continue to press the [CYCLE START] key. When the measurement purpose is "measurement only", it will automatically return to the processing interface and the program operation ends.
  3. If the purpose of the measurement is "RTCP correction", the system will display a warning message with code 62315 after pressing the [CYCLE START] key again. Continue to press the [CYCLE START] key, then the new data will be written to the machine data.

3.6 Parameter description:

6.3.1 Parameter interface:

  1. Measuring Purpose:
    • Measuring Only: The measurement results are only displayed and are not written into the machine parameters;
    • RTCP Correction: The measurement results are written into the machine parameters to correct the RCTP deviation;
  2. Ball Seat Types:
    • Oblique Ball Seat: The club is installed at 45° on the ball seat. This method provides a greater measuring range;
    • Straight Ball Seat: The club is installed vertically on the seat;

    • Sphere Moving Mode:
      • Along the Arc: The probe moves around the surface of the ball along a circular path;
      •  Along the Line: The probe moves around the surface of the ball along a standard line path;
    •  Probe Contact Direction:
      • Based on Position: The probe automatically rotates the spindle before each contact with the ball, ensuring that the probe touches the ball in the same direction each time. This method minimizes probe alignment errors.
      • Fixed Direction: The probe does not rotate its direction each time it touches the ball but touches the ball directly.
    • Standard Ball Diameter:
      • The actual diameter of the ball can refer to the size marked on the club. The default is 30mm standard ball and the roundness of the ball should be less than 0.005mm;

    • Measuring Angle α0:

      • The probe touches the surface of the standard ball at an angle , which increases the measuring range when there is an interference between the probe and the club;

       

    • Align Meas. Stroke RDFA:

      • The moving distance the probe approaches the ball in the measuring direction during alignment, which is set by the distance between the probe and the surface of the ball after rough alignment;
    •  Measuring Stroke DFA: 
      • The moving distance the probe approaches the ball in the measuring direction during measurement;

    • Confidence Interval TSA:

      • Confidence area for the measurement results. The TSA contains the maximum allowable angular deviation values;

       

    • Measuring Times:

      •  The number of times the probe measures each point during alignment and measurement.