Manual Avançado Calypso

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Calypso 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Advanced 
Course 
Training 
Manual 
December 2001 
 
Software-Rev. 
3.2, 3.4 
 
September 2002 
 
Software rev. 3.6 
Contents 
Calypso Advanced Course 
 
This manual is protected by copyright. No part of its contents may be copied, reproduced, 
translated, further processed by electronic means, or passed on without the express 
consent of Carl Zeiss 3D Metrology Services GmbH. 
 
We reserve the right to alter the contents of this manual as required! 
 
 Carl Zeiss 3D Metrology Services GmbH. All rights reserved. 
 
Software-Revision: 3.6 
Edition: 09/2002 
 
Printed in Germany 
 
4tth Edition, September 2002 
 
 
Carl Zeiss 3D Metrology Services GmbH 
Heinrich-Rieger-Str. 1 
73430 Aalen 
 
e-mail address 
hopp@zeiss3d.de 
 
 
 
 
 
 
 
 
Special information on this edition: 
 
The text and graphics contained in this training manual lay no claim to completeness or 
correctness. 
 
 
Please notify your instructor of any flaws or insufficiencies you may discover in the 
following sections. 
 
Your cooperation will help us improve Calypso training for further course participants. 
 
Since the software described here is constantly being revised deviations from the 
procedures described here may occur at a later point in time. 
 
Please take this point into consideration when working with Calypso in the future. 
 
 
 
Calypso Advanced Course 
 The way to become a Calypso Specialist 
 
 
 
 
Contents 
Calypso Advanced Course 
 
 
Prerequisites 
 Calypso Basic Training 
 4 - 6 weeks practical experience on the CMM or 
 Knowledge of another measuring software 
package 
 
This course: 
 deals with more Calypso functions 
 is a 4 day course 
 is recommended to be taken at a Training Center 
 starts at 8:00 a.m., ends at 4:00 p.m. with a break from 
12:15 – 13:00 
 offers handouts where necessary, you should bring your 
own copy of the Calypso User Manual 
 
 
 
Day 1 Comprehension ↓ Comprehension ↓ 
Review 
 Questions from Basic Training 
 Questions from praxis 
 Probe Qualification ☺ 
 Automatic probe qualification 
 Gauge calibration 
 Special probes 
disk probe, cylinder probe, inclined probe 
 
Special Alignment ☺ 
 Base system using offset plane 
 Alignment with iteration 
 RPS with loop 
 3D best fit with a loop 
 Characteristics Editor: 
Change coordinate system 
 
 
 
 
Day 2 Comprehension ↓ Comprehension ↓ 
Testing Forms ☺ 
 Scanning 
 Filters 
 Outliers 
 Form plots 
 Measuring Force (option) 
CAD ☺ 
 Offline programming 
 CAD file types 
 Healing 
 Extracting 
 CAD modification 
 
Special features and constructions ☺ 
 Recall of points from 
polyline, circles, cylinders 
 Rectangle, Slot, circle on cone, 
radius point, sphere point 
 average feature, 
Min/Max coordinates 
 Evaluation constraints 
 
 
 
 
 
Customer Training 
Calypso Advanced Training 
Carl Zeiss 3D 
Metrology 
Services 
GmbH 
 Name: Company: 
Contents 
Calypso Advanced Course 
 
 
Day 3 Comprehension ↓ Comprehension ↓ 
Extended programming functionality ☺ 
 Pattern: linear and round 
 Formula 
 Loop 
 Break condition 
 Bore pattern 
 Conditional branching 
 
Exercises on 
Advanced programming functions ☺ 
 
 This subject area lends itself to further exercises – 
also offline – using records 
 
 
Day 4 Comprehension ↓ Comprehension ↓ 
Autorun 
 Palet measurment 
 Serial measurement 
 Privileges 
 
Records ☺ 
 Userdefined record 
 Userinformation at CNC-Start 
 Exporting results 
Program optimization ☺ 
 Order to run from feature list 
 Sub-Groups 
 Miniplan 
 Block edges 
 
Day 5 Comprehension ↓ Comprehension ↓ 
Discussion 
 Special customer measuring problems 
 Programming work pieces you have brought to the 
training 
 Editing measuring tasks 
 Furthering your knowledge of new functions 
 
Further Training Courses 
 Introduction to Curve Metrology 
 Introduction to PCM 
 
Review 
 Trainer assesses course 
 Participants assess course 
 
 
 
 
Special training courses or workshops are offered for 
advanced Calypso program options: 
 
 
 
Curve Option, 3 days 
PCM Option, 3 days 
CAM Import Filter Option, on request 
Workshop on User Defined Printout, 1 day 
Workshop on Programming Strategy, 1 day 
 
 
 
 
Contents 
Calypso Advanced Course 
 
 
 
List of Contents 
 
Worksheet 1: Probe Qualification 
 
1.1: Automatic Probe Qualification 
The automatic probe qualification will help you to become familiar 
with handling probes. 
1.2: Gage Calibration 
Recalibration of a stylus on a plug or ring gage. Prerequisite for 
high accuracy measurements and for calibration of special probes 
in the following section. 
1.3: Special Probes 
Qualification of disk and cylinder probes which have to be 
recalibrated on a gage. 
 
Worksheet 2: Special Alignments 
2.1: Base alignment with Offset Plane 
The offset plane as feature and use as alignment element 
2.2: Change Axial Alignment 
Selecting the axial alignment when orientating the axial alignment 
of the workpiece different from that of the machine 
2.3: Startsystem 
2.4: Iterative Alignment 
Single points on the practice cube are calculated to features. 
These form a coordinate system. The iteration is executed with 
loops. 
2.5: RPS Alignment with Loop 
Special alignment for sheet metal measurement 
2.6: 3D Best Fit with Loop 
2.7: 3D Fit to a Curved Pipe 
2.8 Changing a Coordinate System with the Editor 
2.9 Rotation on a Straight Line through the Origin 
 
Worksheet 3: Form Elements / Scanning 
3.1: Basics about Filters and Outliers 
3.1.1: Filters 
3.1.2: Outliers 
3.1.3: Minimum circumscribed and maximum inscribed elements / 
Tangential elements 
3.2: Form element with the help of an example 
 Definition of scanning paths 
 Scanning settings 
 Filters 
 Outliers 
 Tangential elements 
 Default Measurement Strategy 
 Minimum circumscribed and maximum inscribed elements 
 Exercises 
3.3 Flatness with a Reference 
Contents 
Calypso Advanced Course 
Worksheet 4: CAD 
 
4.1: Offline Programming 
CAD File Types 
Healing 
Extracting 
CAD Modification 
4.2: Measurement Strategy 
Default Values 
Creating a Grid 
 
Worksheet 5: Special Features and Constructions 
 
5.1 Recall Feature Points from Polyline 
5.2 Recall Feature Points from Circles 
5.3 Recall Feature Points from Cylinder 
5.4 Recall Feature Points from Curve 
5.5: Slot, Rectangle 
Circle on Cone 
Radius points, Angle point, 
 Mean value 
Contour point 
Min/Max coordinates 
Minimum/Maximum 
5.6: Limiting Degrees of Freedom 
5.7: Form Characteristics, DIN Surface Form 
 
Worksheet 6: Advanced Programming Functions, 
Formula, Loop 
 
6.1: Circular Pattern, Linear Pattern 
Measurement of 6 holes as circular pattern 
6.2: Radius from Diameter with Formula 
The radius is calculated from the diameter value of a circle using 
a formula 
6.3: Probing positions 
Measure hole and refer further probings to the center point 
6.4: Break Condition 
The CNC run is cancelled if the values are too large 
6.5: LOOP on result (SIGMA) Break Condition with Loop 
Characteristic with repetition if values are bad 
6.6: Bore Pattern 
True Position using bore pattern 
6.7 Linear pattern with formula 
6.8 Calculation of the depth of a groove 
6.9 Conditional Branching 
Contents 
Calypso Advanced Course 
 
Worksheet 7: Auto Run 
 
7.1: Pallet Measurement 
7.2: Series Measurement 
 
Worksheet 8: Printout 
 
8.1: One-line Printout 
8.2: User Defined Printout 
8.3 Exporting Results 
 
 
Worksheet 9: Probe Route Optimization 
 
9.1: Probe route optimization with probe head predeflection 
 
 
 
 
Worksheet: Menu Design 
Calypso Advanced Course 0 - 1 
 Worksheet: Menu Design 
 
Redesigning, saving and loading toolbars 
 
 
 
Calling up the editor 
 
Using the Toolbar Editor, you can decide which symbols 
should be shown in whichreal cylinder. 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
Calypso Advanced Course 5 - 9 
 
 
 
 
 
 
As usual recall surface lines lying opposite to 
one another as 2D line. These lines can be 
checked for parallelism as they have been 
recorded along the actual direction. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
5 - 10 Calypso Advanced Course 
Calypso Advanced Course Worksheet 5: Special Features 
Calypso Advanced Course 5 - 11 
 Worksheet 5.4: Recall Feature Points from Curve 
 
 
 
Note: This evaluation can only be carried out if the “Curve” option is known. 
As this subject is covered in the “Curve Measurement” training course, it does not need to 
be examined in depth. 
 
The recall of curve points is mentioned here for the sake of completeness and because of 
the interesting application options. 
 
 
 
Job: Extract points from a curve and calculate a geometric feature from these. 
Here the curve is measured on the top of the cube. Then approx. 10 of the curve 
points are used to calculate a circle. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
 5 - 12 Calypso Advanced Course 
 
Calypso Advanced Course Worksheet 5: Special Features 
Calypso Advanced Course 5 - 13 
 
 
Worksheet 5.5: Special Features 
 
 
 
(Slot, rectangle, circle on cone, sphere point) 
 
 
Job: Becoming familiar with new features on the practice cube 
 
 
Slot: 
 
1. Define a base alignment on the practice 
cube: 
 
Primary datum: “Plane_top” 
Secondary datum: “Plane_front” 
Zero pt in X: “Circle1” 
Zero pt in Y: “Circle1” 
Zero pt in Z: “Plane_top” 
 
2. Define the safety cube. 
 
Caution: there is no automatic feature 
recognition for the following features. 
 
3. Move the “slot” feature from the toolbox to 
the Features page. 
 
4. Open the feature and probe with at least 5 
probing points: 
 
• First probe two points on one side of 
the slot. 
• Probe one point in the summit of a 
curve. 
• Probe one point on the other side of 
the slot. 
• Probe one point in the summit of the 
second curve. 
• You can probe the other points where 
you want. 
 
Output the characteristics for the length, width 
and angle. 
 Think which axis the angle refers to. 
 
 
 
 
 
 
Circle1
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
5 - 14 Calypso Advanced Course 
 
 
Rectangle: 
 
As there is no rectangle on our practice cube, 
we have to construct a rectangle over the bore 
pattern on the lower left. 
 
Proceed as follows: 
 
1. Move the “rectangle” feature from the 
toolbox to the Features page. 
You have to probe the “rectangle” feature 
with at least 8 points. These probing points 
must be distributed so that each side is 
probed with two points. 
 
2. Probe 8 single points in the holes. 
Distribute the points as shown in the figure 
on the right. => 
 
3. Open the “rectangle” feature and recall the 
8 points to the feature (Feature Point 
Recall). 
 
4. You have to enter the value for the depth of 
the shaft manually in the Length input box. 
In this exercise the value is –20. 
 
Caution !!! 
Don’t forget to set the clearance plane 
correctly for the individual points, otherwise a 
collision will occur. 
 
5. Safety groups have to be defined for the 
points 2-3, 4-5 and 6-7: 
• Open the “CNC” pull down menu. 
Under “Navigation”, “Define Safety 
Group”, open the relevant window.
• Create three new safety groups 
and close the window with “OK”. 
• Assign the points to the 
corresponding safety groups (Tip: 
use the Feature Editor). 
 
6. Output the characteristics for the length, 
width and angle. 
Think which axis the angle refers to. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
Calypso Advanced Course 5 - 15 
 
 
Circle on Cone: 
 
1. Move the “Circle on Cone” feature from the 
toolbox to the Features page. 
 
2. Open the feature and probe the circle on 
the cone with at least three probing points. 
 
3. Enter the “Cone angle” manually. 
In this exercise the value for the cone angle 
is 20°. 
After you have confirmed the input with 
ENTER, you can see in the CAD window 
how the vectors (yellow arrows) of the 
individual probing points align themselves. 
Now the radius correction can be calculated 
correctly and the circle is output with its 
real diameter. 
 
4. Output the characteristic for the diameter. 
 
 
Radius, sphere and angle point: 
 
With the radius, sphere and angle point 
features, you can select the radius correction, 
which applies in order to be able to define the 
contact point correctly for the single point 
measurements in various situations. 
 
 
Sphere point: 
 
For the sphere point, the measured value is 
corrected in the direction of the connecting line 
between the probe ball center point and the 
defined center point. 
 
1. Move the “Sphere point” feature from the 
toolbox to the Features page. 
 
 
 
 
2. Open the feature and enter the midpoint 
and radius of the sphere (see figure). 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
5 - 16 Calypso Advanced Course 
 
 
3. With the definition template option, probe a 
point. Now the actual radius of the sphere 
and the coordinates of the probing point are 
output. 
 
4. Output the characteristic for the radius. 
 
 
You should have now created the following 
characteristics: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Let the complete measurement plan run in the 
CNC mode. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
Calypso Advanced Course 5 - 17 
 Worksheet 5.6: Evaluation Constraints 
 
 
 
Job: A measuring problem, which frequently occurs, is the measurement of a small circle 
section. 
The center point of the circle to be measured is often defined. I.e. the coordinates 
are defined with e.g. the X value and Y value. 
A circle is calculated from the probing points; its diameter represents a 
characteristic. 
 
Or the radius is defined and the center point coordinates are requested. 
 
Both versions are shown here. 
You can carry out the exercise on any work piece; this example uses a support. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
5 - 18 Calypso Advanced Course 
 
Clamp the support; define a base alignment and the safety cube. You can carry out this 
exercise on the CAD model. 
 
Make four probings on the circle to be measured. 
 
 
 
 
 
 
 
 
 
Enter the nominal values correctly. 
 
 
 
 
 
Define X, Y and D as well as a radius 
measurement. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
Calypso Advanced Course 5 - 19 
 
 
 
Run the program and create a compact printout. 
 
In the following, you will change the evaluation and create a compact printout for comparison. 
We recommend you save these printouts. 
 
 
Compact printout for the “normal” Gauß circle 
 
 
 
 
Constrain the degree of freedom: 
Evaluation 
Evaluation Constraints. 
 
 
 
 
 
 
Using the “Evaluation Constraints” 
function with the circle you can 
define the vectors for X, Y and Z or 
the radius. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
5 - 20 Calypso Advanced Course 
 
 
 
Constrain the X, Y degrees of 
freedom: The actual values of the 
circle are “fixed” on the nominal. 
 
 
 
 
 
 
 
 
 
Constrain the radius degree of 
freedom; the radius is “fixed” on the 
nominal. 
 
 
 
 
 
 
Carry out various evaluations and observe the compact printout. 
 
 
 
X, Y valueconstrained: 
 
 
 
 
Radius constrained: 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
Calypso Advanced Course 5 - 21 
 
Representation in the custom printout with 
• Gauß circle without constraint 
• Circle with constraint of X and Y 
• Circle with constraint of radius 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Features 
5 - 22 Calypso Advanced Course 
 
 
Calypso Advanced Course Worksheet 6: Advanced Programming Functions 
Calypso Advanced Course 6 - 1 
 Worksheet 6: Advanced Programming Functions 
 
 
With formulas and loops you have numerous ways of making CNC programs flexible. 
These exercises will help you to become familiar with this topic. 
 
Note that the use of parameters follows on directly from the use of formulas, conditions and 
loops. 
Further training is required for the parameter coded measuring runs topic. Loops and condition 
functions are also used here. 
 
 
1. Rotational pattern, Linear pattern 
Measurement of 6 holes as rotational pattern 
2. Radius from diameter with formula 
The radius is calculated from the diameter value of a circle using a formula 
3. Probing positions 
Measure hole and refer further probings to the center point 
4. Break condition 
The CNC run is cancelled if the values are too large 
5. LOOP on result, Break condition with loop 
Characteristic with repetition if values are bad 
6. Bore pattern 
True Position using bore pattern 
7. Linearteilung und Formel 
8. Calculation of the depth of a groove 
The depth of a groove is measured on a shaft 
9. Conditional branching 
A cycle should branch into different program variants dependent of the presence/absence 
of a hole 
 
Calypso Advanced Course Worksheet 6.1: Rotational pattern, Linear pattern 
6 - 2 Calypso Advanced Course 
Worksheet 6.1: Rotational pattern, Linear pattern 
 
 
 
Job: Measure 6 holes as rotational pattern. 
By specifying a rotational pattern, the measuring run for a circle is extended to all 6 
circles of the pattern. 
 
 
 
 Load CAD model 
 Define the alignment 
 Generate a rotational pattern for 6 circles 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 6.1: Rotational pattern, Linear pattern 
Calypso Advanced Course 6 - 3 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
1. Load CAD model 
 
CAD 
 Load “Welle_1.sat” 
 
Load the part as usual; create the alignment with suitable features. 
 
CAD 
 Modify Chart Settings 
 Silhouette on 
 
 
Note: 
Make sure the origin from the CAD model is 
placed in a suitable location. 
 
 
 
 
2. Origin of the model: 
 
CAD 
 Modification 
 Transformation 
 Nominal vectors 
 
 
Z= 20.0000 
 
 
If you enter 20.000 in Z for “Translation”, the 
model is then moved by this value. The origin will 
lie on the height of the plane with the holes. 
 
 
 
 
Calypso Advanced Course Worksheet 6.1: Rotational pattern, Linear pattern 
6 - 4 Calypso Advanced Course 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
1. Create base alignment 
 
Probe the surface with the holes, a plane for primary datum and ZP. 
Circle on the diameter 32 for origins in X/Y. 
Secondary datum with the first 10 mm circle 
MPH: 
The base system should be defined with features, which do not have any circle segments, 
polylines or grids. Therefore new features have to be generated/probed here. 
 
 
 
2. Define features 
 
Probe cylinder with 32 mm diameter. 
Measure plane on the surface with the 6 holes with polyline 
(these features will be used in a later exercise). 
 
MPH: here a plane can be generated with polylines and where necessary intermediate 
positions. 
 
 
Define circle 
 
 
 
 
 
Enter nominal values 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
3. Create pattern 
 
Nominal Input 
 Pattern 
 
 
 
 
Calypso Advanced Course Worksheet 6.1: Rotational pattern, Linear pattern 
Calypso Advanced Course 6 - 5 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Select Rotational Pattern 
 
 
 
 
 
 
 
 
This CAD is displayed once you have 
filled in the page and concluded with 
. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Define Circle Segment: 
Circle 
 Strategy: 4 points from 0° to 360° 
 
Generate Diameter as characteristic: Select D 
 
 
The circle in the features list is displayed as follows: 
 
Circle 2 is made up to 6 individual circles 
 
Calypso Advanced Course Worksheet 6.1: Rotational pattern, Linear pattern 
6 - 6 Calypso Advanced Course 
 
 
 
View as characteristic: 
 
 
 
 
 
 
View of Custom Printout 
Calypso Advanced Course Worksheet 6.2: Radius from Diameter 
Calypso Advanced Course 6 - 7 
 Worksheet 6.2: Radius from Diameter 
 
 
Job: The radius is calculated from the diameter value of a circle using the formula 
option. 
 
 
Procedure: 
 
1. Existing measurement plan 
 
2. Measure hole as circle with enough points for a form check, close circle 
 
3. Take another circle from the toolbox 
 
4. Open second circle, 
Nominal Definition 
 Recall One Feature 
 
5. Select the first circle 
 
Note: 
With the “Recall” function, a copy of the 
first circle is created. This copy has yellow 
highlighted nominals to identify it as 
theoretical feature. 
 
These yellow nominals are the actuals 
(measured values) of the first circle. 
The formula can now access these 
nominals. 
 
6. Using the right mouse button, click on the 
nominal for “D” and select “Formula”. 
 
 
7. Enter the following formula: 
 
 
 
 
 
 
Note: 
In this formula window, inputs are possible corresponding to the prescribed syntax. All 
features and characteristics can be accessed. 
The return value is the result of the formula, which can also be displayed first with the 
“Calculate” button. 
 
8. Create the “D” characteristic from the second circle. 
This characteristic is entered with the diameter icon, but is actually a radius. Renaming 
ensures clarification. The nominal should also be entered correctly in the characteristic as 
the current actual has been accepted during the generation. 
Calypso Advanced Course Worksheet 6.3: Probing positions 
6 - 8 Calypso Advanced Course 
Worksheet 6.3: Probing positions 
 
 
Job: Measure hole and refer further probings to the center point 
 
 
 
 Measure hole 1 as the center point of the bore pattern. 
 Probings in holes 2-5 should be defined relative to hole 1. 
 If for example circle 1 were offset by 0.5 mm, the probings in the other holes should also 
be offset. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 6.3: Probing Positions 
Calypso Advanced Course 6 - 9 
 
Procedure: 
 
1. Measuring the center hole results in circle 3, for example. 
 
2. Insert another circle in the list from the toolbox: Circle4 
 
3. Open Circle4 and assign the nominals with formulas as shown below. 
 
 
 
 
 
 
1. In Strategy, assign the circle a Circle Auto Path with 4 probings. 
 
2. Copy the circle 3 times and change the formula corresponding to the nominals of the other 
holes. 
 
3. Form the diameter characteristics and start the run. 
 
4. CMM with trigger probe head: If the bore pattern itself is relatively accurate, the retract path 
can be lessened to save time. 
 
Calypso Advanced Course Worksheet 6.3: Probing positions 
6 - 10 Calypso Advanced Course 
Notes: 
Calypso Advanced Course Worksheet 6.4 : Break Condition 
Calypso Advanced Course 6 - 11 
 Worksheet 6.4: Break Condition 
 
Job: Cancel a CNC run because the values are too large 
 
 
1. Existing measurement plan 
 
2. Measure the hole as circle with sufficient points for a form check 
 
3. Roundness as characteristic 
 
4. Run program to collect points 
 
5. Set the break condition 
Click the “ Roundness” feature 
right mouse button: Condition 
 
This window opens: 
 
Click on Post condition 
 
The formula window is opened 
Enter formula – see below. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
6. Start this CNC run. 
Createvalues, which are wrong in order to check the break criterion. 
Calypso Advanced Course Worksheet 6.4 : Break Condition 
6 - 12 Calypso Advanced Course 
 
Calypso Advanced Course Worksheet 6.5: Break Condition based on Deviation 
Calypso Advanced Course 6 - 13 
 Worksheet 6.5: Break Condition based on Standard Deviation 
 
 
Job: This exercise demonstrates the use of the LOOP function. Here the loop is used 
to repeat the measurement of a feature based on a result (e.g. Sigma standard 
deviation) 
 
 
1. Open a measurement plan and establish 
a base alignment. 
2. Measure another plane (Plane4) taking 
one point in each corner. 
Normally a diameter is used to check the 
form. We are using a plane for testing the 
function better. 
3. Using the right mouse button open the 
formula in the Z nominal input box. 
4. In the Formula window enter the 
following: 
0+(LOOP1*0) 
This formula establishes the loop counter 
LOOP1 in the feature. The first zero in 
the formula represents the nominal 
dimension; the next part is the actual 
loop counter. This counter multiplied by 
zero will always be zero. 
 
 
5. After clicking OK create a characteristic for the Z location. 
 
 
Worksheet 6.5: Break Condition based on Deviation 
6 - 14 Calypso Advanced Course 
 
6. Select the Z dimension characteristic for the plane, click on this with 
the right mouse button and select Loop. 
7. Click Insert and enter the maximum loop program cycles (5 
in End). 
 
 
8. Using the right mouse button, click in 
the Break Condition field and select 
Formula. 
9. Enter the following formula in the 
formula field: 
getActual("Plane4").sigmaso 
that the following holes are measured. 
 
1, 2, 5, 6, 7 
 
 
 
 
You can try out this exercise 
on other work pieces. 
 
 
 
Calypso Advanced Course Worksheet 6.7: Linear Pattern and Formula 
Calypso Advanced Course 6 - 25 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Linear pattern with formula 
 
 
 
Create another circle, e.g. Circle2 
 
 
 
 
 
 
 
Set a formula for the Y value 
 
 
 
 
 
 
 
 
 
Enter values as shown on the right. 
 
 
 
 
Think of a suitable measuring strategy. 
 
 
 
Create characteristics. 
 
 
Group the characteristics together so 
that a loop can be inserted over these 
characteristics. 
 
 
 
 
 
 
Check the incrementation of the Y value in the 
printout. 
 
 
What solution can you think of for the “2nd 
row”? 
 
Adapt the run on the measuring machine. 
Calypso Advanced Course Worksheet 6.7: Linear Pattern and Formula 
6 - 26 Calypso Advanced Course 
 
 
Notes 
 
Calypso Advanced Course Worksheet 6.8:Groove Depth 
Calypso Advanced Course 6 - 27 
 Worksheet 6.8: Calculating the depth of a groove 
 
Job: Calculate the depth of a groove on a shaft. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
The depth of the groove cannot be measured 
directly. 
Probings in the base of the groove are possible, 
but not probings at the highest position on the 
vertical axes. 
 
An alternative would be the “slot” feature. Here you 
can evaluate the depth of the hole, but this 
dimension is dependent directly upon the probing 
strategy. 
 
 
 
 
Calypso Advanced Course Worksheet 6.8: Groove Depth 
6 - 28 Calypso Advanced Course 
 
Using a formula solves this problem: 
 
The diameter or the radius of the shaft is easy to determine. 
In addition to this, the space axis with zero dimension is located in the center of the shaft. 
 
By probing a Z point, you will get a value, which you can subtract from the radius. 
 
Try this simple application without 
further instructions. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 6.9: Conditional Branching 
Calypso Advanced Course 6 - 29 
6.9 Conditional branching 
 
 
 
 
 
 
 
Job: 
 
A program is to be developed, whereby one or another 
part of a CNC cycle is run dependent on the presence or 
absence of a hole 
 
 
In detail: 
A characteristics group includes a check of the top circle 
segment diameter. 
A second group checks the roundness and position of the 
cylinder on the front side of the cube. 
 
 
The measurement plan therefore consists of two groups. 
 
 
Calypso Advanced Course Worksheet 6.9: Conditional Branching 
6 - 30 Calypso Advanced Course 
Design the measurement plan using Conditions according to the above guidelines. 
 
If the condition is true (correct): 
Hole present -> measure the top circle segment. 
 
If the condition is false (incorrect): 
hole absent -> measure the cylinder. 
 
Under no circumstances should both 
be measured! 
 
The corresponding graph could look like 
this: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
As Calypso should branch dependent on a hole, this must be “checked” with a probe point. 
 
 
 
If the Z value is near to zero (or at least > -1), so there is no hole: the cylinder must be 
measured 
 
Otherwise the Z value is around –8 and the hole can be measured as a circle. 
 
 
 
Calypso Advanced Course Worksheet 6.9: Conditional Branching 
Calypso Advanced Course 6 - 31 
The following steps: 
 
1. Generate a probe point in the hole 
2. Caution – danger of collision! If there is no hole, the machine will travel at high speed 
up to 2 mm in front of the anticipated probing. 
 
3. Create the characteristic “Z value” from this point. This Z value is checked from the 
Conditions as follows. 
 
4. Make the Circle Segment group the first entry in the measurement plan. 
 
 
5. Assign a condition to the Circle Segment group with a right mouse click. 
 
 
 
 
6. Insert the custom printout 
illustrated. 
 
 
 
 
 
 
 
 
 
 
 
 
7. Now the program initially 
checks the point. 
 
8. Then the condition is applied in the Circle Segment group. If the outcome is “no”, the 
circle segment is not measured. Only the cylinder measurement is carried out in this case. 
 
9. If the condition is satisfied (“yes”), the circle segment is measured and subsequently also 
the cylinder. This, however, should be avoided. 
 
10. A check must also be carried out before the Cylinder group, which results in the exact 
opposite of the first check. 
 
 
 
11. Test the cycle by covering the hole with a coin. 
Caution – danger of collision! 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 6.9: Conditional Branching 
6 - 32 Calypso Advanced Course 
 
 
Worksheet 7: Auto-Run Interface 
Calypso Advanced Course 7 - 1 
 Worksheet 7: The Auto-Run Interface 
 
 
 
The “Auto-Run” function enables you to carry out two different types of runs: 
 
 
 
1. Pallet measurement: 
Several identical parts are measured in succession on a pallet. 
 
This requires an exact work fixture, as the same measurement plan is offset by X and 
Y values of the clamping positions. 
 
 
 
2. Series measurement: 
Several different parts are measured automatically in succession. 
 
Different measurement plans are run through one after the other. 
 
 
 
 
 
The function works with a special user interface which lets Calypso run in the background. 
This interface is intended for users who only have user rights to start programs. 
The user rights should be set explicitly in Autorun for each user; these do not influence the 
user rights in Calypso. 
 
 
 
Worksheet 7: Auto-Run Interface 
7 - 2 Calypso Advanced Course 
1. Pallet mode 
 
1.1 Preparations 
 
 Create a complete measurement plan for the part to be measured. 
 Create a base alignment on the pallet itself. 
To do this, use a separate measurement plan. A base alignment from three 
single points each with the origins in X, Y and Z may suffice. 
 Define distances between positions on the pallet in X and Y, clamp workpieces on 
pallet. 
 
 
1.2. Setting up the pallet mode 
 
Close all measurement plans. 
 
Open the Auto-Run Interface: 
 
CNC 
 Autorun 
 
The Auto-Run Interface window is opened. 
 
1.Give the layer a new name: 
 
Layer 
 Rename 
 Palette1 
 
 
2.Insert a pallet: 
 
Edit 
 Pallet 
 Enter 
 
 
1.3. Enter pallet parameters (right mouse 
button) 
 
⇒ Pallet alignment=base alignment of 
the pallet (see Preparations) 
⇒ Pallet name 
⇒ Distances between positions on the 
pallet in X and Y 
⇒ No. of rows in X and Y. 
⇒ (Exercise example: Input of the 
thread bores of the granite table 
each with three rows: 200/3, 200/3) 
 
 
Worksheet 7: Auto-Run Interface 
Calypso Advanced Course 7 - 3 
 
 
 
 
 
 
 
 
 
 
 
1.4. Insert measurement plan: 
 
Right mouse button on pallet icon or: 
Edit 
 Pallet 
 Insert measurement plan 
 e.g. click on “Shaft2” measurement 
plan 
 
 
 
 
 
1.5. Define run loop: 
 
Right mouse button on pallet icon or: 
 
Edit 
 Pallet 
 Define Run Loop 
 
Enter the number of runs: 
Right mouse button, Insert 
Here from 1 to 4, Step 1: 
Means the first four positions will be measured. 
 
Alternatively you can select the occupied positions 
directly in the pallet icon. 
 
 
 
 
 
1.6. Define measurement plan parameters: 
 
Right mouse button on pallet icon or: 
 
Edit 
 Pallet 
 Measurement plan 
parameters 
 
Enter: 
⇒ Base alignment 
⇒ Speed 
⇒ Custom Printout 
etc. 
 
 
 
 
 
 
 
 
1.7. Start pallet measurement 
Press start button 
 
Calypso Advanced Course Worksheet 7: Auto-Run Interface 
7 - 4 Calypso Advanced Course 
 
 
 
 
 
 
 
 
 
 
 
 
 
2. Series measurement 
 
2.1 Preparations 
 
 Create complete measurement plans for the parts to be measured. 
Each measurement plan has its own base alignment. 
 
 
2.2. Set up the series measurement 
 
Close all measurement plans 
 
Open Auto-Run Interface: 
 
CNC 
 Autorun 
 
The Auto-Run Interfacewindow is opened. 
 
1.Give the layer a new name: 
 
Layer 
 Rename 
 Pallet 
 
2.3. Insert measurement plans 
 
Edit 
 Edit measurement plan 
 
Select a measurement plan from the list. 
 
 
2.4. Enter parameters 
 
Select a measurement plan each time. 
 
Edit 
 Measurement plan 
 Enter CNC start parameters 
 
 
 
 
2.5. Start the programs 
 
Click on the measurement plans which you want to start. The measurement plans are 
selected, you will see a frame. 
For further selection use the Strg button. 
 
The measurement plans are run through in the order they are selected. 
Click on “Order” if you want to change this. 
 
 
Calypso Advanced Course Worksheet 7: Auto-Run Interface 
Calypso Advanced Course 7 - 5 
 
 
 
3. Layer change 
 
 
You can create several layers and change between these layers in the auto-run mode: 
 
 
Select the icon: 
 
or 
 
Edit 
 Layer 
 Enter layer 
 
Select the layer you want. 
 
 
This icon is added to the layer: 
 
 
 
 
 
 
 
 
By double-clicking or by using the right mouse button, 
you can jump to another layer. 
This branching must be created for each layer you 
want. 
The same applies for switching back. 
 
 
Calypso Advanced Course Worksheet 7: Auto-Run Interface 
7 - 6 Calypso Advanced Course 
 Add your own pictures to the auto-run interface 
 
Example of a customized interface: 
There is an image stored for each CNC run. 
A background image can also be defined. 
 
These functions are activated by clicking the right mouse button on the background or on the 
run. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
The images must be available in *.bmp, *.jpg or *:gif format. 
See the User Manual for a detailed description. 
 
 
 
Exercises: 
 
1. Design your own user interface 
 
2. Create a new user, who only has limited user rights. 
 
 
 
 
Worksheet 8.1: One-line Custom Printout 
Calypso Advanced Course 8 - 1 
 Worksheet: One Line Custom Printout 
 
 
Job: The default custom printout consists of one section with icons and several 
lines. 
For extensive measurement plans, this leads to several pages of printout. 
What you can do here is reduce this to one line per characteristic. 
 
Note: 
To change the printout, you must be familiar with common graphics programs as well as 
understand the relationship between printout header and feature list. 
 
 
 
 
 
 
Worksheet 8.1: One-line Custom Printout 
8 - 2 Calypso Advanced Course 
 
Procedure: 
 
1. Open the Calypso graphics program: 
Resources 
 Design Custom Printout 
 Characteristic 
 
2. Click on the “Load” (= open folder) icon 
 
Note: 
All printout formats (header, characteristic, feature...) are in a directory under 
C:\om\protform\... When you open this graphics program for the first time the file 
C:\opt\om\protform\default\cffra.gra is always loaded. 
If this file is changed in the “default” folder, the version supplied is destroyed. 
For this reason you must first save it under a different name! 
 
 
3. Overwrite the name as shown below: 
 
 
 
4. Edit the characteristic display as follows: 
Delete the icon, move the entries, set vertical lines. 
 
Worksheet 8.1: One-line Custom Printout 
Calypso Advanced Course 8 - 3 
 
5. If the position of nominal and actual values etc. are moved, the printout header must 
be adapted: 
Load the graphics program for the printout header: 
Resources 
 Design Custom Printout 
 Report Header File Editor 
 
When this graphics program is opened, the following file is always loaded 
“C:\opt\om\protform\default\vphead.gra”. 
 
Here as well you must save the “single line” folder under another name straightaway. 
 
6. Edit according to how the characteristic looks. Title and numerical value must be 
beneath one another. 
 
Note: 
Check how this looks by printing out on the printer. If the first time the titles are not 
correct, then change this till you have what you want. 
 
 
7. Also edit the printout header for follow-on pages: 
Resources 
 Design Custom Printout 
 Report Header File Editor 
 
 When this graphics program is opened, the following file is always loaded 
“C:\opt\om\protform\default\header.gra”. 
This is the printout header for the follow-on pages from page two. 
 
 
 
8. Assign this new printout header to a measurement plan: 
 
Resources 
 Format Custom Printout 
 Output format: one-line 
 
9. The result you will get is illustrated on the next page. 
Worksheet 8.1: One-line Custom Printout 
8 - 4 Calypso Advanced Course 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
You can change the printout header in the same way. To do this load the vphead.gra 
file and edit. 
Worksheet 8.2: User Defined Output 
Calypso Advanced Course 8 - 5 
 Worksheet 8.2: User Defined Output 
 
 
Job: The default custom printout is to be replaced by a printout showing a 
graphics display of the work piece. The characteristics should be on the side 
and refer to the relevant features in the illustration. 
 
Note: 
To change the printout, you must be familiar with common graphics programs as well as 
understand the relationship between printout header and feature list. 
 
 
 
 
 
 
 
 
 
Worksheet 8.3: Log design 
8 - 6 Calypso Advanced Course 
 
Procedure: 
 
1. Create measurement plan with characteristics. 
 
 
 
 
Open the Calypso graphics program: 
Resources 
 Design Custom Printout 
 User Defined Output 
 
 
2. Click on the “Load” icon (=open folder) 
 
Note: 
The printout header formats for the 
user-defined category are found in a 
separate folder. 
 
 
 
 
 
3. Insert picture from screen. 
 
 
 
 
 
Worksheet 8.3: Log layout 
Calypso Advanced Course 8 - 7 
 
5. Note the list of available characteristics. 
By clicking, you enter the characteristics in 
the form and align the features on the side. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
6. Format the page so that it fits the print area of 
your printer. 
File 
 Format 
 
 
 
 
7. Assign characteristic to graphics using arrows. 
 
 
 
 
 
8. Now all that is missing is the 
printout header itself. 
You can generate a new 
header; the simplest way of 
doing this is to copy the 
header of a default printout 
into the form. 
 
 
 
 
 
Worksheet 8.3: Log design 
8 - 8 Calypso Advanced Course 
 
9. The output must now be modified for the measurement plan, which is opened: 
 
Resources 
 Format Custom Printout 
 
Here the list output is 
deactivated and the user 
defined printout 
activated. If this step is 
not done, then the 
printer will output both 
printouts. 
 
 
 
 
 
 
 
 
 
 
 
 
 
10. Start the run and check the printout. 
 
 
 
Worksheet 8.3: Log layout 
Calypso Advanced Course 8 - 9 
Worksheet 8.3: Log design 
 
 
Job: Several changes to the log are to be carried out in this section. 
As the available options are of a very diverse nature, this section only 
serves as an introduction and, of course, does not show all possibilities. 
 
 
1. Attach a comment to the measurement characteristic 
 
2. Insert a text element in the measurement plan 
 
3. Insert a log header variable in the characteristic 
(PCM function) 
 
4. Save compact log 
 
5. Generate a user-defined log header field 
 
 
 
 
1st Job: Attach a comment to the measurement characteristic 
 
 
Create a measurement plan with useful characteristics and consider both presentation and 
compact logs. 
 
Shown here without a comment, 
the characteristic “diameter” should be assigned a comment. 
 
 
 
Worksheet 8.3: Log design 
8 - 10 Calypso Advanced Course 
 
Select the diameter and right mouse 
click to rename the characteristic. 
 
 
 
 
 
 
 
 
 
 
Enter a commentary text, which should 
comprise at least two lines here as an 
example. 
 
 
 
 
Display of the log after a new run: 
 
 
 
 
 
 
 
 
 
 
 
 
Please note that the length of the characteristic in the presentation log is increasedif the 
comment extends over several lines. 
 
 
Worksheet 8.3: Log layout 
Calypso Advanced Course 8 - 11 
 
2nd Job: Insert text element 
 
Select the text element from the toolbox and insert it at a relevant place in the 
measurement plan. 
 
Important: The appearance of the text is subject to the usual rules for a characteristics-
oriented run. The appearance of the log may influence the text element through selective 
CNC runs or program changes. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Start the CNC run with all measuring characteristics. 
The logs appear as follows. 
 
 
 
 
Worksheet 8.3: Log design 
8 - 12 Calypso Advanced Course 
 
3rd Job: Insert a variable into the log Variable 
 
This job can only be carried out with the “PCM” option. 
 
 
The exercise involves selecting the ”part number incremental” from the log header 
variables, familiar from earlier exercises and inserting them into a characteristic as a 
comment. 
 
Bear in mind that this example only serves to give an idea of the complex options for 
linking variables using formulas. 
Think out your own applications as a means of consolidating the subject. 
 
 
Sequence: 
 
Take the diameter from the 
previous example, open it and 
delete the comment. 
Now click the right mouse in the 
commentary field and select 
“Formula”. 
 
Enter in the formula field: 
 
 
The function "getRecordHead()" reads a variable from the list of log header variables, in 
this case the variable "partnbinc". This is the part number incremental. 
 
 
 
The log now shows the part 
number as a comment. 
 
 
 
 
 
 
 
 
 
 
 
4th Job: Save compact log 
 
The compact log is stored as a text file. 
Name of the text file: "cprotokoll.txt" in the measurement plan directory: 
...calypso\opt\om\workarea\inspections\ 
 
Work out a routine whereby the compact log is automatically saved to another 
directory or onto disk following completion of a CNC run. 
 
 
Worksheet 8.3: Log layout 
Calypso Advanced Course 8 - 13 
5th Job: Generate a user-defined log header field 
 
This function allows you to design the log header with freely defined field names. 
 
 
Preparation: 
 
 
 
Orientate yourself in Explorer: this requires the 
file "userfields.txt" to be edited. 
 
It is found in the directory 
...Calypso\opt\om\protform 
 
and has e.g. the following content: 
 
 
 
 
 
 
 
 
Each individual line defines a new field according to the following rules (also see User 
Manual): 
 
You will, for example, see the following three lines in the file userfields.txt: 
 
u_field1,FELD 1,RE 
u_field2,FELD 2,R 
u_field3,FELD 3,E 
 
 
 
Element Significance 
Name used in the result file, must begin with “u_” 
Description is shown in dialogs 
Display control E = appears in dialog when editing, 
 R = appears in dialog at CNC start, 
 RE = appears in both dialogs 
 
You can generate any number of further filed according to this principle; other fields may 
already be defined in Calypso: 
 
 
u_company,WERK:,RE 
u_run_number,Bearbeitung:,R 
u_examble,BEISPIEL:',E 
 
Worksheet 8.3: Log design 
8 - 14 Calypso Advanced Course 
 
Application: 
 
 
The log header should appear as follows: 
 
 
 
Generate three new fields according to the above pattern: 
 
u_machine,Machine-Number:,RE 
u_shift,User Shift:,RE 
u_username,User Name:,RE 
 
Save the file "userfields.txt". These fields are now available. 
 
Open the log header editor in the normal way. 
 
 
 
 
 
The new fields are now offered. 
 
 
Place these fields in the log header such that the desired 
display appears. 
 
 
 
 
 
 
Worksheet 9: Probe Route Optimization 
Calypso Advanced Course 9 - 1 
 Worksheet 9: Optimizing Probe Routes 
 
9.1 Probe route optimization with probe head predeflection 
 
 
Job: Probe route optimization with probe head predeflection 
 
 
During movement of the CMM, the measuring probe head is predeflected. 
This means that if a collision occurs, the braking path which is possible is increased due to 
this higher deflection path. 
 
This predeflection however may by a hindrance when probing in blind holes or on narrow 
edges. 
 
Example: 
 
Point P1 is to be probed 0.5 mm from the surface P_Ref. 
If P1 is approached directly from the SG-X safety plane, the probe ball may briefly come 
into contact with the surface P_Ref (due to the probe head deflection). 
 
 
Probe route optimization: 
 
• A local coordinate system “P_loc” is formed with P_Ref as origin. 
• The nominal coordinates of P_Ref are increased in the opposite direction to the 
material in –X. This then takes into consideration possible large fluctuations in the 
material. 
• The P1 probing point is approached in the “P_loc” coordinate system. 
• P1 and P_ref are set to a new safety group “SG-X_loc”. (CNC/Navigation/Safety 
Group). The probe is then only retracted to the safety distance. 
• The safety distance of P_Ref must be selected relatively small to P1. 
• If necessary, the speed for P1 and P_Ref can be reduced in the measurement plane 
editor-features page. 
 
Worksheet 9: Probe Route Optimization 
9 - 2 Calypso Advanced Course 
 
Note: 
 
This reduction in speed is only effective for travel movements in the feature from the 
safety distance (not from the safety cube!) 
 
If necessary, you can set additional intermediate positions in the P1 feature before and 
after the probing. 
You must set the intermediate positions so that the travel path part is the greatest in the 
direction of P1. 
Intermediate positions are accepted if the push button in the XY joystick on the control 
panel is pressed when the P1 feature is open. 
 
As an alternative to this, an intermediate position can be created in the P1 feature strategy 
window using the “Intermediate position” icon. 
 
To evaluate P1, the relevant coordinate system must be recalled.order. 
 
 
 
 
 
 
Properties 
 
• easy to operate 
• comprises 2 input windows 
• integrated: all functions have graphic symbols 
• additional search function, format, help, job protocol, 
trash bin, output 
• key administration is always at the extreme right and 
cannot be deleted 
• maximal length same as the space above the workspace 
• one toolbar definable per user 
• saved under one’s own name as...\home\om*.config 
• symbols may be moved from the lower to the upper window with drag&drop 
 
 
See User Manual for further operating instructions 
 
 
 
Exercise: 
 
Define a menu bar according to your notions. 
 
Example: 
 
 
 
 
 
Worksheet: Menu Design 
0 - 2 Calypso Advanced Course 
 
Some application tips: 
 
To insert a symbol at the right end of the toolbar (in front of the key group): Click on Insert 
at the End. 
- or - 
To insert at another place along the toolbar 
Mark the symbol in the upper window and click on Insert Before Selection. 
 
The toolbar in the upper window is expanded accordingly. If there is no more space 
available for the symbol to be inserted, a message will appear. 
To remove a symbol from the toolbar: Mark it in the upper window and click on Remove 
button. 
 
Once the toolbar is to your satisfaction: Save with Save As..., if you want to transfer it to 
the workspace at a later time. 
- or - 
Click on Accept to make the toolbar immediately effective for your workspace. 
 
Close both windows with OK. 
 
 
Keyboard operation 
All functions can also be operated in both windows using the keyboard (Windows 
standard). 
With Enter (= double click), you can insert the marked symbol at the end of the toolbar; 
Strg+Enter (= Strg + double click) inserts a preceding space. 
 
 
Mouse operation (drag&drop) 
You can also drag symbols from the list in the lower window into the toolbar in the upper 
window with the mouse (using drag&drop). 
If you press Strg, a space is inserted before the symbol. If you press Shift at the same 
time, a space is inserted after the symbol. If you press both keys, spaces will be inserted 
both before and after the symbol. 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Advanced Course 1 - 1 
 
 
Worksheet 1: Probe Qualification 
 
 
Contents: 
1. Automatic Probe Qualification 
The automatic probe qualification will help you to become familiar with handling 
probes. 
2. Gage Qualification 
Recalibration of a stylus on a plug or ring gage. Prerequisite for high accuracy 
measurements and for qualification of special probes in the following section. 
3. Special Probes 
3.1. Disk probe 
3.2. "Inclined" probe 
3.3. Cylinder probe 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 2 Calypso Advanced Course 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Advanced Course 1 - 3 
 
 
 
1. Automatic Probe Qualification 
 
 
 
Job: Automatic run of the probe qualification 
 
 
 
⇒ A measurement plan must be created for this purpose. 
⇒ The contents of this measurement plan must deal with the qualification only. 
⇒ The styli must be qualified once before hand manually. 
⇒ CNC-Start window: Navigate using position points only. 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 4 Calypso Advanced Course 
 
 
 
 
 
 
 
 
 
 
 
1. Open the new measurement plan 
2. Insert the Stylus Qualification feature: 
Open the toolbox 
Resources 
 Probe Qualification 
3. You have to take a “Probe 
Qualification” feature from the toolbox 
for every probe. 
4. Assign a probe to every “Probe 
Qualification”. 
 
5. Open the Probe Qualification 
Ref. Sphere position 
Note: The reference sphere position 
must be defined once at the start. 
6. Probe the reference sphere manually; 
the automatic definition is then 
started. 
 
 
7. Close the Probe Qualification. 
8. Start the CNC run: 
CNC-Start window: Use Position Points Only 
9. The qualification is now carried out automatically in the same place as previously where 
the “Position definition” was defined. 
 
The stylus qualification now runs 
automatically for every probe, which 
– has the “Probe Qualification” feature 
and 
– is located in the probe rack. 
 
Otherwise the CNC run stops and 
requests a manual probe change. 
 
 
 
 
 
 
 
 
Caution: 
The “no generation“ mode remains active at the next CNC start, even if another program is 
started! 
Switch back to “automatic” without fail, as otherwise the threat of serious collisions may exist! 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Aufbaukurs 1 - 5 
 2. Gage Qualification 
 
 
Job: Measure with high accuracy a diameter in a specific location in the measuring 
volume. 
 
⇒ The accuracy required cannot be guaranteed with the normal qualification (standard or 
tensor). 
⇒ A calibration standard – plug or ring gage – is assembled at the location in the measuring 
volume and measured with the probe as a circle. The nominal diameter of the calibration 
standard is entered. 
⇒ With this gage qualification, influencing parameters such as bend are recorded. 
 
⇒ These parameters can be kept ready for later measurements. 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 6 Calypso Advanced Course 
 
 
 
 
 
 
1. Record the bending parameters 
 
2. Resources 
 Utilities 
 Gage correction 
 
This is a “normal” circle 
with the “Gage Correction 
Qualification” property. 
(Alternatively, a circle can 
be taken which is given 
the “Gage Correction 
Qualification” property for 
“Evaluation”) 
 
3. Enter D: 100mm 
(for gage 100 mm 
diameter) 
This circle is now given 
the nominal diameter of 
the gage. 
 
4. Measure the circle once in 
the CNC run. 
The circle must be 
measured using the 
scanning method. 
The bending parameters 
are now recorded and can 
be kept ready for other 
circles. 
 
5. Use the bending 
parameters 
Measure circle 
Open circle 
Evaluation 
 Gage Correction 
 
6. Measure and correct another circle with similar diameter 
 
The correction values are taken into consideration. 
 
7. Form the characteristic 
Diameter, roundness,..... 
 
8. Important: 
The gage calibration is effective for all measurement plans. 
Therefore: Create a measurement plan just for the gage calibration. 
Stylus dependent: Only the corrected stylus can be used. 
When checking the diameter this should be as near as possible to the ring gage diameter 
and 
when calibrating the gage, its position should be as near as possible to its position for the 
later measurement. 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Advanced Course 1 - 7 
 3. Special Probes 
 
3.1 Disk probe 
 
 
Job: Qualify a disk probe 
 
 
 
⇒ Qualification of the disk probe on the calibration sphere 
⇒ Recalibration on the calibration standard 
⇒ Manual correction of probe data 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 8 Calypso Advanced Course 
 
A disk probe is not a complete sphere but a 
section of a sphere. 
 
 
 
 
When working with the probe there is 
always the risk that probings will be made 
with the edge of the disk and not with the 
flat side. 
 
 
 
 
 
 
 
 
 
 
 
To qualify the probe: 
 
1. Assemble a disk probe 
2. Calibrate “manually” with 8 points in 
2 section heights 
3. Clamp a ring gage or plug gage on 
the table 
4. Create a base system on the ring / 
plug gage 
5. Measure this “calibration standard” 
as circle 
6. Output of the diameter in the default 
printout: 
7. The deviation from the actual 
diameter must now be corrected. 
Open the probe data and edit the 
radius. 
8. Measure the plug / ring gage again 
and view the diameter. 
9. If necessary carry out a correction. 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Advanced Course1 - 9 
3.2 Qualifying an inclined probe 
 
 
 
 
 
 
 
⇒ Qualify the inclined probe as usual 
⇒ Determine the inclination of the shaft with the cylinder feature 
⇒ Recalibrate with the correct vector data 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 10 Calypso Advanced Course 
 
1. Assemble an inclined probe. 
2. Qualify the inclined probe as usual 
on the calibration sphere. When you 
are doing this, make sure you probe 
in the direction of the shaft. 
3. Once you have completed the 
calibration, change to the Features 
page. 
4. Probe eight points at two heights on 
the sphere of the calibration standard 
using the shaft of the probe (see 
photo). 
 
 
 
 
 
5. The software outputs a cylinder with the diameter of the calibration sphere. The 
inclination of the cylinder axis, output via the projected angles A1 and A2, is defined 
using the inclined position of the probe shaft. 
 
 
 
6. Close the cylinder in order to call up 
the Features representation window 
using the corresponding icon. The 
feature must be selected to do this. 
 
7. The Features representation window is opened: 
 
 
 Open the popup menu in the Mode field and select “Change”. 
 Click on the “Angle” option. 
 Click on “Vector”. 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Advanced Course 1 - 11 
 
8. Open the cylinder feature again and make a note of the actual values of the vector 
components Nx, Ny and Nz. 
 
 
9. Change to the “Resources” 
page and open the window for 
the probe definition. 
10. Open the probe 
administration using the 
relevant icon. 
 
11. Edit the values for shaft X, 
shaft Y and shaft Z. Close the 
page and calibrate the stylus 
again in the CNC mode. 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 12 Calypso Advanced Course 
Notes: 
Calypso Advanced Course Worksheet 1: Probe Qualification 
Calypso Advanced Course 1 - 13 
3.3 Qualifying a cylinder probe 
 
 
 
 
 
 
 
⇒ Qualify the cylinder probe in the manual mode 
⇒ Recalibrate on the calibration sphere 
⇒ Manual correction of the probe data 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 1: Probe Qualification 
1 - 14 Calypso Advanced Course 
 
1. Assemble a cylinder probe. 
2. Calibrate the probe manually on 
the equator of the calibration 
sphere with eight points at two 
heights. 
 
 
 
 
3. The software calculates a sphere 
within the cylinder. 
(see drawing) 
 
 
 
4. After you have completed the 
calibration, change to the Features 
page. 
5. Measure a circle on the equator of 
the calibration sphere. 
6. Compare the diameter of the circle 
with the diameter of the calibration 
sphere. 
7. The deviation from the actual 
diameter must now be corrected. 
8. Open the probe data and edit the 
probe radius. (Cf. Qualifying a disk 
probe) 
 
 
 
9. If necessary, repeat this procedure 
several times. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 1 
 Worksheet 2: Special Alignments 
 
1. Offset Plane 
The offset plane as feature and use as alignment element 
2. Change axial alignment 
3. Startsystem 
4. Iterative Alignment 
Single points on the practice cube are calculated to features. 
These form an alignment. The iteration is executed with loops. 
5. RPS 
Special alignment for sheet metal measurement 
6. 3D Best Fit on the Practice Cube with Loops 
7. 3D Best Fit with Loops 
A pipe with 4 bends is shown with the X, Y and Z points of the bend points. The bend 
points are used for the 3D best fit. 
8. Change the coordinate system using the Editor 
Change the coordinate system for several elements simultaneously 
9. Rotation on a straight line through the origin 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 2 Calypso Advanced Course 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 3 
 
 
Worksheet 2.1: Alignment with Offset Plane 
 
 
 
This exercise uses a theoretical plane 50 mm above the 
work piece for the alignment, the primary datum. 
This plane cannot be probed directly but has to be 
defined with 3 points on the cube, which have to be 
corrected in the height. 
 
This Offset Plane is a feature in Calypso and must be 
probed with exactly 3 points. 
 
1. Open new measurement plan. 
 
2. Insert Offset Plane in the measurement 
plan 
open this plane 
 
 
 
3. Probe three single points on the practice cube. 
- Point 1 upper rear. 
- Point 2 in circular slot 
- Point 3 in the slot at the front 
 
 
 
4. The points must be corrected so that a plane is 
created at a height of 
50 mm above the cube. 
5. According to the 
drawing the correction 
values are: 
- Point 1: -50 mm 
- Point 2: -58 mm 
- Point 3: -60 mm. 
 
 The plus/minus sign 
originates from the offset 
height you want and 
determines the dimension by 
which the individual point must 
be corrected. 
 
 
6. Close Offset Plane 
. 
 
See next page 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 4 Calypso Advanced Course 
 
7. In the Offset Plane: 
 
Evaluation 
 Edit 
 
 
Correct the points, make sure 
the plus/minus sign is correct. 
 
 
 
 
 
 
 
 
8. Select other useful features 
for the alignment and probe. 
9. Create the base alignment. 
10. Define the safety cube. 
11. Edit the clearance distance 
and retract distance. 
 
Please note, that each point in the offset plane is probed as in a normal plane with 
the default retract distance (2mm). This is not possible for the points in the slot. 
 
Note: Later in the exercise, the cube is tilted by several degrees. Take this into 
consideration with the probing points and the retract distances for all the features. 
12. Start the run to check the alignment. 
13. Tilt the cube so that you can actually see it is tilted and start the run again. 
 
Note: 
At the CNC start you can choose between the 
“Offset” base system and “Offset(CNC)”. 
 
Offset(CNC) uses the base system determined 
last in the CNC run. 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 5 
 
14. Points to be taken into consideration when correcting the probe points. 
 
 
15. With this alignment, the first run results in an offset plane with an error with the 
“wrong” correction in machine coordinates. 
 
If the alignment is repeated and the 
plane direction of the first run 
accessed, the result improves 
considerably. In a third cycle – with 
the correction direction of the second 
alignment – the error approaches 
zero. 
 
The resource here is a loop. 
 
 
16. When you call up the base 
alignment, click on loop and then on 
Insert. 
Enter the values as shown in the 
illustration. 
 
 
17. Start the run again. 
The base alignment is now run 
through three times. 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 6 Calypso Advanced Course 
 
18. At the end, take a look at the values in the default printout. 
The value “A” is of interest here; it is the total of the shift, rotation and tilt values. 
The value “A” specifies the amount by which the coordinate system has changed 
since the last alignment. 
19. In a later exercise, this value is requested by a break condition. 
20. The illustrations below show the A values in the first, second and third cycle. 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 7 
 
 
Worksheet 2.2: Changing axial alignment 
 
 
Mount a work piece on the measuring machine and create a base system; the work piece 
coordinate system is automatically aligned close to the machine’s coordinate system with 
slight angular variances. 
 
Or load a CAD model; in this case, a zero point and the corresponding alignments are 
preset. 
 
Itmay be necessary to define the work piece in a completely different direction. For 
instance, to show the Z axis of the work piece in the Y direction. 
 
This exercise should illustrate how the base system may be changed in such a case. 
 
Use a work piece and the CMM or a CAD model and work offline. 
 
. 
 
 
 
Here it is important that you have 
to manually change the 
automatic recognition of axial 
alignments. 
 
 
 
 
 
 
Worksheet: Iterative Alignment 
2 - 8 Calypso Advanced Course 
 
The offline programming is shown here as an 
example: 
1. Define a cylinder in the circular slot 
2. Use this cylinder as the primary datum 
(spatial orientation). 
3. Set the axis direction of this cylinder to 
“X-axis”. 
 
Create and enter the other 
elements of the base 
system. 
 
 
 
 
 
 
 
 
4. The secondary datum (rotation in the plane) 
must also be checked manually and corrected 
as necessary. 
 
5. Set the distance 
between the circle and 
axis using the “Special” 
function (rotate to 
distance). 
 
The coordinate system is now defined as in the drawing, the axial orientations are chosen 
arbitrarily. 
 
This type of programming generally calls for special attention when processing further 
elements. The automatism for axial orientation and probing routes is calculated 
accordingly. The conceptualization of the change in position usually requires the user’s 
complete attention. 
Please pay special attention to the definition of the safety cube on the following page. 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 9 
 
Definition of the safety cube for a change in axial position: 
 
Until now, the safety cube was normally achieved by approaching the 
 "rear, top, right” corner and 
 "front, lower, left" corner 
of the work piece. 
 
The “rear, top, right” corner is the point with the high X, Y and Z coordinate values 
 
referenced to the base system. 
 
If the basis system is now rotated, “rear, top, left” are to be interpreted with reference to 
the basis system and NOT according to the machine coordinate system! 
 
A message appears if the corners of the safety cube are entered incorrectly. 
 
 
 
Worksheet: Iterative Alignment 
2 - 10 Calypso Advanced Course 
 
Worksheet 2.3: Start System and Base System 
Calypso Advanced Course 2 - 11 
 Worksheet 2.3: Start System and Base System 
 
 
What does a start system do? 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Practical exercise : 
 
Important: 
A start system is used in 
 
• base systems with scanning elements. 
Scanning elements cannot be manually re-measured! A start system is inserted in 
this case. 
• base systems comprising complex links. 
A system start can be used here to reduce the work of manual calibration. 
 
 
The base system is placed in the center of the upper bore, a start system on the front 
right edge of the cube. 
 
Any CNC program should be started by means of the start system. 
 
Worksheet 2.3: Start System and Base System 
2 - 12 Calypso Advanced Course 
 Method: 
 
 
Measuring the elements for the base system 
 
• plane with 4 points 
• circle with scanning 
technology 
• straight line with two 
points 
 
 
 
Creating the base system in 
the center of the bore: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Measuring the points and creating the start 
system: 
 
 
 
 
Worksheet 2.3: Start System and Base System 
Calypso Advanced Course 2 - 13 
 
 
 
 
 
The start system is selected 
with Preparation – Select 
Base System. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Only fill out the zero points. 
 
Thus, the axis directions 
remain aligned with the 
device axes. 
 
 
 
 
 
 
 
 
 
 
 
 
Create arbitrary measurement 
characteristics in order to enable 
a useful CNC start. 
 
 
 
 
Test the start system with the 
available options “manual 
alignment” etc. 
 
 
 
Worksheet 2.3: Start System and Base System 
2 - 14 Calypso Advanced Course 
 Worksheet 2.4: Iterative Alignment 
 
Alignment using plane with 3 probings at different heights and iteration 
 
 
A coordinate system is generated by means of an offset plane, whereby the offset plane 
has to be generated manually using the formula. 
 
Dieses bedeutet eine grössere Variabilität, da eine beliebige Anzahl von Messpunkten für 
die Offsetebene zur Verfügung stehen können. 
 
 
 
 
 
 
A work piece rests on three points, which are located at different heights. A plane is to be 
defined with these three points, which is declared as primary datum in WCS 2. 
This is the classic calculation for an offset plane. 
An offset plane from the toolbox always consists of exactly three probings, which can be 
corrected, in their height. 
 
In this exercise, an offset plane is to be 
calculated from individual points using the 
formula. 
Advantage: More than three points can be 
used. 
 
 
This new WCS should be run through at 
least twice so that the correction of the 
offset probings is created in the correct 
alignment. 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 15 
 
 
 
 
1. Load CAD model of the practice cube. 
 
2. Click on 3 points in the CAD window: 
1st point (P1) on the top surface 
2nd point (P2) in the slot at the front 
3rd point (P3) in the slot at the back 
 
3. Add 2 more points (P4, P5) from the toolbox to 
the list. 
 
4. Open the first of these points (P4) 
Recall one feature: Point 2 
Edit the Z value with the formula: 
correction by 10 mm. 
 
5. Open the second point (P5), recall P3, correction 
by 8 mm. 
 
6. Take a plane from the toolbox and 
define using recall of point 1, 4, 5. 
This plane is the same as the top 
surface. 
 
7. Form the first symmetry point from 2 
probings (P6, P7): front right, front 
left 
 
8. Form the second symmetry point 
from 2 probings (P8, 9): front right – 
front left 
 
9. Calculate 3D line from these 2 
symmetry points 
 
10. Set point 10 at front for Y=0 
 
11. Basissystem erzeugen: 
 
Ebene 1 für Primär 
3D-Gerade für Sekundär 
3D-Gerade für NP in X 
Punkt 10 für NP in Y 
Ebene 1 für NP in Z 
 
 
 
12. Place a loop over this alignment. 
 
13. Sicherheitsquader setzen 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 16 Calypso Advanced Course 
 
 
 
 
 
 
 
 
14. Start the CNC cycle and interpret the results! 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 17 
 
 
Worksheet 2.5: RPS with Loops 
 
This exercise will demonstrate the use of the RPS Alignment function. 
RPS is short for Reference Point System. 
RPS alignment is based on the 3-2-1 rule. The point, space point and intersection features can 
be used with RPS alignment. 
RPS alignments are primarily used for measuring body panels. 
 
1. Open a new measurement plan. 
 
 
2. Probe six individual points on the 
practice cube. 
- Two points on the top plane. 
- One point in the slot. This will make a total 
of three points in the Z-axis. 
- Two points on the front plane. 
- One point on the right side plane. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
3. Call up Base Alignment and 
select RPS Method. 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 18 Calypso Advanced Course 
 
4. Select the features for the base 
alignment: all six points 
 
5. Insert the point data for each 
point and select in which axis 
they are to be constrained. 
 
See table with point data. 
6. Select OK. 
7. Measure a circle and create the 
Diameter characteristic. 
8. Define clearance planes. 
9. Run the program. The six 
points will be taken at the value 
location that was entered 
manually from the table. 
10. Open the Base Alignment. 
 
11. Click on Loop and enter the 
number of cycles 
Select OK. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 19 
 Worksheet 2.7:3D Best Fit on the Practice Cube 
 
This procedure can be used to align work pieces for which no unequivocal restraints are 
defined. The 3D best fit is a method of achieving the best possible fit between any number 
of points or geometrical features and their specified geometry. 
 
In our example we want to construct the eight corners of the practice cube as intersection 
points and, using the procedure described above, fit them until the total of all the errors 
squared is a minimum between nominal and actual points (best fit acc. to Gauß). 
 
1. Open new measurement plan. 
2. Go to the Features page and probe the six 
planes of the cube with the star probe. 
 
 
 
 
 
 
 
 
 
 
 
 
 
3. Open the Tool Box and copy the 
“Intersection” construction four 
times to your measurement plan. 
 
 
 
4. Intersect the planes 
“front” with “right” 
“right” with “rear” 
“rear” with “left” 
“left” with “front”. 
These settings may not correspond to the illustration 
 
on the next page. 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 20 Calypso Advanced Course 
 
5. Four intersection lines are 
created: 
 
 
 
 
 
 
 
 
 
 
6. Now intersect the intersection 
lines with “Plane top” and “Plane 
bottom”. Four penetration points 
are created. Name the 
penetration points with 
Intersection1 to 8. You can see 
the location of the points in the 
illustration on the right. 
 
 
 
 
 
 
7. Eight intersection points are 
created: 
 
 
 
 
 
 
 
 
 
8. Call up the Base Alignment and 
select 3D Best Fit Method. 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 21 
 
9. Select the features for the alignment: all eight intersection points. 
 
10. Specify the nominal position for the intersection points. 
Compare with below: 
 
 
11. Define safety cube. 
12. Define loops for base alignment 
with break condition. 
 
 
13. Note: The break condition must 
be entered using the formula. 
Activate input field and open the 
formula window using the right 
mouse button. 
Close window with OK. 
 
14. Start the measurement plan in 
the CNC mode. 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 22 Calypso Advanced Course 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 23 
 Worksheet 2.6: 3D Best Fit on Tubular Bodies 
 
Best fit with several spatially defined points 
 
Part of exercise without measuring machine 
 
⇒ A pipe with several bends is to be measured. 
⇒ The individual bend points as well as the start and end of the pipe are listed as XYZ 
coordinates in a table. 
⇒ The tolerances for each point are 0.1 mm. 
⇒ The sections are measured as cylinder. 
⇒ The alignment is to be calculated as best fit over all points. 
⇒ Several runs will be required for approximation. 
 
 
 
 
In this exercise, a practice piece will be used with a prepared measurement plan. This 
measurement plan “Pipe 100” already includes the measured features. 
The measurement plan can be put together without the measuring machine. 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 24 Calypso Advanced Course 
1. Precondition: 
 
 
The “rohr100” measurement plan: 
 
 
 
Table of bend points: 
 
 Point X Y Z 
 
 1 0 0 0 
 2 37.3 -35.4 -11.5 
 3 144.5 5.4 -63.1 
 4 245.7 7.7 -106.7 
 5 372.4 24.7 167.8 
 6 397.9 -23.7 184.3 
 
 
Point 1: Intersection of Plane 1 - Cylinder 1 
Point 2: Intersection of Cylinder 1 - Cylinder 5 
Point 3: Intersection of Cylinder 5 - Cylinder 4 
Point 4: Intersection of Cylinder 4 - Cylinder 3 
Point 5: Intersection of Cylinder 3 - Cylinder 2 
Point 6: Intersection of Cylinder 2 - Plane 2 
 
 
These intersections must be created in the following. 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 25 
2. Creating constructions (intersections) 
 
Create an intersection 6 times 
 
Tool Box 
 Constructions 
 Intersection 
 
Here is an example: 
 
 
You can see that previously there were only machine coordinates. The coordinate values 
in the construction are later converted automatically to the base alignment during the best 
fit. 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 26 Calypso Advanced Course 
3. 3D Best Fit 
 
The 3D best fit creates an alignment. This can be the base alignment or an alignment, 
which is needed later. 
 
A base alignment should be created here. 
 
1. Call up Base Alignment: 
 
 
2. A new base alignment with the method: 
3D Best Fit 
 
 
 
 
 
 
 
Here you will also find the loops needed for 
later. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
3. Select the features: 
 
 
 
 
 
 
The relevant features are 
transferred to the mask and have 
to be given the nominals of the 
individual intersections manually. 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 27 
 
The entered data: 
 
 
 
 
 
 
 
 
 
 
 
4. Insert loops: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
After the best fit, the alignment is in the position required: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
In the next step, characteristics are defined from the intersections. 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 28 Calypso Advanced Course 
 
5. Open Intersection1, 
mark X, Y, Z as 
characteristic 
Specify tolerances. 
 
 
 
 
 
6. Repeat for intersections 
2 to 6. 
 
 
 
 
 
 
 
 
 
 
 
 
 
7. For the sake of clarity, combine the 
characteristics of each intersection in a group 
and give the group a new name. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
8. CNC start of all groups as simulation 
 
9. Adapt the program on the measuring machine. 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 29 
Worksheet 2.8: Changing the coordinate system using the 
Editor 
 
The Editor changes the characteristics of objects; the assignment of a coordinate system is 
only one of the characteristics. 
 
 
 
 
 
 
 
 
 
Job: 
Part 1: Assign a new coordinate system to the circles 1-4 (Z, Y values) without opening the 
elements. 
 
Part 2: Carry out the same procedure for defining the evaluation. Set the “Gauss 150” filter for 
all the circles. 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 30 Calypso Advanced Course 
Part 1: 
 
 
Create the program incl. the 2nd 
coordinate system. 
 
 
 
 
 
 
 
 
Assign the new coordinate system 
to the first circle (circle 4 here). 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Select the Editor. 
 
 
 
 
 
 
Simply select “Coordinate 
system”. 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 31 
 
 
 
Now select the 3 other circles (5-7), 
which are also to be transferred to the 
coordinate system. 
 
 
 
Close with OK. 
 
 
 
 
 
 
 
 
 
 
 
The assignment is now concluded. Check the coordinate system in each of the circles. 
 
 
 
 
 
Part 2: 
 
Carry out the same procedure for defining the 
evaluation. Set the “Gauss 150” filter for circle 4 
and apply the same evaluation method. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 32 Calypso Advanced Course 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 33 
 Worksheet 2.9: Base System 
 
Rotation on a straight line through the origin 
 
 
 
 
 
 
 
 
 
 
Practical exercise: 
 
The functions presented here: 
”Rotation on a straight line through the origin” and 
”Rotation at equal deviation” 
are both derivatives of the common “Rotation on a path”. 
 
Practical application should be checked on a case-by-case basis. 
 
The function is investigated in more depth on the following pages. 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 34 Calypso Advanced Course 
 Rotation on a straight linethrough 
the origin 
 
 
 
 
 
 
 
Set the coordinate system on Level 1, zero point 
Z, X in Circle 1 and the direction of the X-axis 
through Circle 2. 
 
 
 
 
Up until now, this would have been a normal alignment, in which an axis direction (X) is given 
by Circle 2. 
Now, not the axis direction, but a straight line is rotated on Circle 2. 
How is this straight line produced? 
In a coordinate system, a point is defined by two values, e.g. X=50, Z=28. 
A straight line is drawn from the origin to this point. 
 
On the work piece, this straight line is now rotated to the actual value of the bore. 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
Calypso Advanced Course 2 - 35 
Further procedure: 
 
Click on “Special” and enter the values in the relevant fields: 
 
 
The function rotates the coordinate system around a given axis, such that the straight line 
placed through the origin intersects the tertiary reference plane. 
This gives rise to the same conditions for the X-values as for the Y-values of the point on the 
straight line and of the tertiary reference. 
 
 
Calypso Advanced Course Worksheet 2 : Alignments 
2 - 36 Calypso Advanced Course 
 
 
 
Worksheet 3: Filters and Outliers 
Calypso Advanced Course 3 - 1 
 Worksheet 3: Form Elements 
 
3.1 Basics about filters and outliers 
 
3.1.1 Filters 
 
Data is mainly filtered in order to segregate the different types of deviation (form 
deviation, waviness and roughness), but is also used for compensating any measurement 
deviations. 
 
Goal: Filtering is used in roughness metrology in separating the long-waved 
components gained in the roughness measurement such as waviness and 
form. 
 In coordinate metrology, the short-wave components defined in the probed 
profile, such as the roughness components which have been recorded 
despite a large probe ball, have to be eliminated. 
 
In Calypso you can choose between two different types of filter: 
 
• Gauß (ISO 11562) 
 
Characteristics: 
Only 50% of the values are accepted with this cutoff wave length. 
 The amplitude of the short wave length is therefore damped by half. 
 
• 2 RC (ISO 4291) 
(R = Resistance; C = Capacitor) 
 
Characteristics: 
75% of the values are accepted with this cutoff wave length. 
The amplitude of the short wave length is therefore damped by a quarter. 
The 2RC filter is a mathematical imitation of a real RC filter. 
 
Each of these two filter types can be subdivided into two different types of filter: 
 
• High-pass filter 
 
Characteristics: 
High frequencies pass the filter, low ones are filtered. 
=> Waviness is filtered out. 
 
• Low-pass filter 
 
Characteristics: 
Low frequencies pass the filter, high ones are filtered. 
=> Surface roughness is filtered out. 
 
 
Worksheet 3: Filters and Outliers 
3 - 2 Calypso Advanced Course 
 
 
*Cutoff wavelength: The cutoff wave length λc is the wavelength of 
 (straightness profile) vibrations in the input signal whose amplitude is let 
through the filter at a specific transmission ratio 
(previously 75%, today 50%). 
 
No. of waves ng: Describes the number of waves per rotation. 
(roundness profile) 
 
Note: Filters are only recommended for high numbers of points 
i.e. for scanned features. 
 There should be at least 7 measured points per wave. 
 
 
Recommended values for the cutoff wave length: 
 
Mean roughness index Ra in µm Mean peak to valley height Rz in µm λc in µm 
 to 0.025 to 0.1 0.25 
over 0.25 to 0.4 over 0,1 to 1.6 0.8 
over 0.4 to 3.2 over 1.6 to 12.5 2.5 
over 3.2 to 12.5 over 12.5 to 50 8.0 
over 12.5 to 100 over 50 to 400 25 
over 100 over 400 80 
 
 
Recommended values for cutoff vibration number: 
 
Diameter in mm Roundness tolerance in µm 
 to 2.5 2.5 to 5 5 to 10 over 10 
 to 10 150 50 50 50 
over 10 to 50 500 150 150 50 
over 50 to 120 1500 500 500 150 
over 120 to 250 1500 1500 500 500 
over 250 1500 1500 1500 1500 
 
 
 
 
 
 
 
 
3.1.2 Outliers 
 
A measured point is tagged as an outlier if it is further than a defined threshold* from the 
computed Gauß element. 
 
*Threshold = Factor * Standard delta 
 
Outlier inside workpiece: impression in the material 
Outlier outside workpiece: rise in the material 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 3 
 
 
 
 
 
 
 
Reset “Set Default Measurement 
Strategy” 
4 pts, 0 -360° 
 
 
Worksheet 3: Form Elements 
 
3.2 Form element with the help of an example 
 
In this section you will learn: 
• how to define scanning paths 
• how the optimum parameters in Calypso can be set automatically 
• the effect of the scanning speed on the result 
• the effect of filtering 
• all about outliers 
• how to use tangential and minimum features 
• how to use the default measurement strategy 
• how to read the DIN characteristics evaluation 
 
 
 
 
1. Measure a circle in the cylinder on the front of 
the practice cube. 
 
2. Place the “Circle Auto Path” measurement 
strategy in this feature. 
You can also use holes of another workpiece 
for this exercise. 
 
 
 
 
 
 
 
3. Let this feature run once. 
Do not yet change the settings in the Circle 
Auto Path! 
 
4. Open the default printout so you can keep 
checking the results. 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 4 Calypso Advanced Course 
 
Click on Step Width and Expected 
Tolerance. 
 
 
 
 
 
Click on Calculate 
Here you are asked what the feature is 
to be used for. 
As the circle has not yet been assigned 
to an evaluation such as e.g. diameter, 
Calypso needs this information for 
calculating the setting values. 
 
 
 
 
Click on Calculate and then on 
Location, Size and Form, see how the 
speed and step width change. 
 
 
 
 
 
 
 
 
 
 
 
Click on Basic Settings. The 
System Set Up page with which 
you are already familiar is 
displayed. 
 
By making changes in these 
pages, you can change the basic 
parameters. 
 
Make sure that the changes do 
not impair the behavior of the 
measuring machine in the 
scanning mode. 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 5 
 In the next section, three characteristics are linked 
with this circle. Use the circle 
For a location: Z value 
For a size: Diameter 
For a form: Roundness. 
 
A graphics evaluation is possible in the 
Roundness. 
 
 
 
 
 
 
In the Features list select the circle and 
call “Check use ..” with the right 
(middle) mouse button. 
You will see where this is used. This 
step is also available in the 
measurement strategy, the tolerance 
required is also displayed. 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 6 Calypso Advanced Course 
 
 
In the steps which follow, you will change the scanning settings step by step and can create a 
printout for comparison. 
 
 
 
 
The steps: 
 
1. Set the scanning speed to a 
maximum value: for a diameter of 30 
mm e.g. 80 mm/sec. 
 
 
2. Set the scanning speed to a 
minimum value: e.g. 2 mm/sec 
Are there any changes? 
 
Plot the result so you can see this more 
clearly. 
 
 
Discuss the differences in the results 
and application possibilities. 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 7 
 In the next step the result will be filtered. 
 
Make sure the circle has 
been scanned with a slow 
measurement strategy 
(10 mm/sec). 
 
Enter the Roundness and 
click on the circle. In the 
selection menu which 
appears, you can change 
the feature for this 
“Roundness” evaluation 
as your want. 
The original feature 
remains unchanged. 
 
Look at the plot. 
Change the filter several times and observe 
the results: 
 
1. Click on “Filter” and set a filter for 150 
W/U. The roundness is 0.0127 as 
before. 
The default printout explains this 
calculation which at first seems 
incomprehensible:2. Click on "Filter" and set a filter for 50 W/U. 
 
 
 
 
 
 
The filter is basically used to separate the actual 
form from short-wave roughness. 
If sensible filtering is used, the measurement 
results are not falsified. 
 
The size of the filter depends on the customer’s 
specifications. 
 
Now discuss the results and application possibilities. 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 8 Calypso Advanced Course 
 
In the next step outliers are eliminated. 
 
Note: First remove all filter settings 
 
Open the Roundness and click on the circle. 
In the selection menu which is displayed you 
can change the feature for this “Roundness” 
evaluation as you want. 
 
The original feature remains unchanged. 
 
 
1. First set a factor of 3. 
Here all points are removed which lie 
more than three times the sigma 
dispersion value away from the 
computed circle. 
 
 
 
 
 
 
 
 
 
 
 
 
 
2. Click on “Outlier” and set a factor of 2. 
This means that all measured points in 
the circle which are more than 2 times 
the value of the dispersion away from 
the computed circle are not included in 
the evaluation. 
 
3. You can also delete the neighboring 
points around the outlier up to the 
computed circle, this then gives you to a 
large extent a corrected circle. 
 
 
 
For the bore function, outliers “into the 
material” would usually not be significant. 
But they can considerably falsify the 
result. 
Set the outlier elimination 
correspondingly. 
 
Change the outlier several times and observe the results. 
Discuss the results and application possibilities. 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 9 
4. Now add a filter with a filter value of 150 W/U and output the results as a plot. 
 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 10 Calypso Advanced Course 
 
 
 
 
Another possibility is to use tangential 
elements such as Minimum Circumscribed 
and Maximum Inscribed Elements. 
 
Note: Remove all filters and outliers. 
 
 
Selection can also made in the menu for the respective 
feature. 
 
 
The Maximum Inscribed Circle is the largest inscribed 
circle and can be combined well with the “Outlier” and 
“Filter” functions. 
 
Carry out various evaluations. 
 
 
 
 
Observe in particular how the diameter and 
the center point change for the minimum 
circumscribed, maximum inscribed and 
minimum circle. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
In the menu you can select the minimum circle or Tschebycheff evaluation. Compared to the 
Gauss evaluation, note the effect of the outliers here. 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 11 
 
Using the Features Settings Editor you can define parameters for the filter while you are 
creating the feature. 
This is particularly helpful when programming on the CAD model. 
 
Set new values for the filter. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 12 Calypso Advanced Course 
 
Exercise: 
In the Calypso Basic Course, a True Position of a circle was calculated to 2 surfaces. 
 
Carry out this example again and observe the automatic evaluation of the individual features. 
 
 
 
 
DIN characteristics always use the prescribed 
evaluation form such as the minimum circle when 
calculating the diameter. 
Open the default printout and evaluate a few DIN 
characteristics. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 13 
Worksheet 3: Form Measurement 
 
3.3 Form Measurement: DIN Flatness with Reference Length 
 
 
DIN ISO 1101 Flatness with Reference Length can be measured for planes. In contrast to 
DIN ISO 1101 Flatness, here the flatness of sub-rectangles from the plane is measured. You 
can define the size of these rectangles and their degree of overlap yourself. 
You can also set a threshold, which the angle between any individual sub-rectangle and the 
entire plane must not exceed. 
The measurement values obtained from the flatness measurement can be evaluated in 
different ways. 
 
- Flatness in relation to single a sub-plane 
For each rectangle, the difference between the maximum and minimum separation of the 
actual points on the rectangle to the fitted sub-plane of the rectangle is specified. 
 
- - Flatness in relation to the entire plane 
For each rectangle, the difference between the maximum and minimum separation of the 
actual points on the rectangle to the fitted total plane is specified. 
Thus, for every rectangle, you obtain a measurement value for the flatness. For the output, you 
can decide which of these different results should be displayed: 
 
- all flatnesses 
- all flatnesses, which exceed a predetermined tolerance 
- the maximum flatness. 
 
 
 
 
 
Exercise procedure 
 
In this exercise, an area of the exercise cube is measured as a plane and the various DIN 
Flatness functions are evaluated: 
 
1. DIN Flatness and preset plot 
2. DIN Flatness as a progression 
3. DIN Flatness as a CAD plot 
 
4. DIN Flatness in relation to 
⇒ a sub-plane 
⇒ the entire plane 
⇒ output variations 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 14 Calypso Advanced Course 
 
 
Firstly measure the front face of the exercise cube 
with a polyline. 
 
 
Enter a flatness and a flatness with reference into 
the measurement plan. 
 
 
 
 
 
 
 
 
 
 
 
 
Evaluate as before. 
 
 
1. DIN Flatness and preset plot 
 
The plot display can be adapted with “Edit“. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 15 
 
 
2. DIN Flatness as a progression 
 Flatness of line segments 
 
“Progression” is not often displayed and is not 
commonly used for evaluating a polyline. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
3. DIN Flatness as a CAD plot 
 
Proceed as follows in order obtain the adjacent 
view as a plot: 
 
− load CAD model 
− open plane 
− click right mouse in the ACIS window, 
select display actual points 
− close plane 
− open DIN flatness 
− CAD - View – Save View 
− enter name, Flatness1 in this case 
− click on "Graphic" 
− in the upper menu select "CAD view " 
− Select measurement characteristic 
"Flatness1", 
− Click on "Plot" 
 
 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 16 Calypso Advanced Course 
 
 
4. DIN Flatness with reference 
 
Principles: 
 
The plane (Fig. 1) is defined by the spatial point 
E0, the u-axis (u) and the v-axis (v). In the u and 
v directions it has lengths A and B. E0 can lie in 
any corner of the rectangle. 
A rectangle with edge lengths a and b in the u 
and v directions is specified as a tolerance zone. 
 
 
 
 
Starting from E0, this rectangle is shifted “line-
by-line” from the “bottom upwards” parallel to u and v, whereby each rectangle shifted gives 
rise to its own tolerance zone. Fig, 2 shows the sequence of, in this case, 16 tolerance zones, 
which do not overlap (overlap 0%). 
 
 
 
 
 
 
 
 
 
 
 
Fig. 3 shows the same succession of 56 tolerance 
zones in this case, whereby they overlap by 50%. 
The indexing of the tolerance zones is omitted for 
clarity. 
 
 
 
 
 
 
 
 
 
 
All calculations are with reference to the plane comprising all valid measurement points (i.e. 
without overlap or outliers,…) and are based on the selected evaluation method. The 
measurement points can be filtered. 
There are principally two types of evaluation: 
• Case 1: Flatness relative to the sub-plane of each rectangle (corresponds to ANSI or ISO) 
• Case 2: Flatness of each rectangle relative to the entire plane (special application). 
The flatness of a rectangle is the difference between the greatest and smallest deviation (max 
– min) in the rectangle. The edge of a rectangle belongs to the rectangle.Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
Calypso Advanced Course 3 - 17 
 
 
The Input Page: 
 
 
Input parameters: 
 
 
 
 
 
Evaluation type: 
Sub-plane 
 
The sub-plane is calculated for 
every rectangle according to the 
selected evaluation method. 
 
If the sub-plane of a rectangle 
is incalculable (too few 
measurement points, 
measurement points on a line, 
angle between the sub-plane 
and the entire plane greater than a limit angle), the 
flatness of this rectangle must be calculated in the 
same way as flatness in relation to the entire plane, 
and a corresponding note entered in the protocol for 
this sub-plane. 
 
Entire plane 
The greatest and smallest error in each rectangle is calculated in relation to the entire plane, 
from which the flatness of each rectangle is found. If there is no measurement point or only 
one in a rectangle, the flatness of this rectangle is zero and a corresponding note entered in 
the protocol for this sub-plane. 
 
Overlapping rectangles 
The rectangles can either be adjoining or overlapping. The relevant specification lies between 
0% for adjoining and 90% for maximum overlapping. This means that each rectangle is 
shifted by (100% - x%) x edge length, starting from E0, “line-by-line” from the “bottom 
upwards” parallel to u and v. 
 
 
Calypso Advanced Course Worksheet 3: Form Elements / Scanning 
3 - 18 Calypso Advanced Course 
 
Only maximum flatness: 
Only the maximum flatness inclusive of its location. 
 
 
 
 
 
 
All flatnesses outside tolerance: 
The maximum flatness and all flatness inclusive of their locations. 
 
 
 
Visualization of 
the individual 
flatnesses is 
possible by 
clicking in the 
list. 
 
 
 
 
 
 
 
 
 
 
 
 
All flatnesses 
The maximum flatness and all 
flatnesses inclusive of their 
locations. 
 
 
 
 
 
 
 
The working and compact protocol 
documents the values in detail. 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
Calypso Advanced Course 4 - 1 
Worksheet 4: CAD 
 
 
 
Calypso always works together with the CAD window. 
You have already used some of the functions in your work up till now. 
Exercises have already been programmed offline. 
We will now take a closer look at other functions. This can be done on customer work pieces. 
 
1. Offline programming 
CAD file types 
Healing 
Extracting 
CAD modification 
 
2. CAD measuring strategy: Default data 
During the preparation of a measurement plan, part features are created from the model. 
A measuring strategy can be assigned automatically to these features. 
The settings for the measuring strategy are described here. 
 
 
 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
4 - 2 Calypso Advanced Course 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
Calypso Advanced Course 4 - 3 
 Worksheet 4.1: CAD import and preparing IGES, VDA 
 
The purpose of this exercise is to provide an explanation of the Calypso file types as 
well as healing functions. 
 
CAD Model File Types 
Currently Calypso supports the following file types: 
 
ACIS files .sat 
CATIA files .exp 
STEP files .stp 
IGES files .igs 
VDAFS files .vda 
Unigraphics 
ProE .prt> 
 
It is important when importing models, that the file 
extension is correct. Calypso recognizes the file type by 
its extension. 
 
Importing the model 
 
Using the Windows NT explorer, copy the CAD file 
XYZZZ.igs to the directory: …opt\om\cad… 
Open a new measurement plan. 
Define the probe and qualify the styli. For this exercise we will be using the star probe. 
 
 
 
From the CAD pull down menu, select CAD File Load… 
This opens the select window: 
From the Files of Type select IGES. 
Select the file you want XYZZZZ then Open. 
 
The model will be loaded to the Calypso CAD 
window. 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
4 - 4 Calypso Advanced Course 
 Possible errors while importing: 
 
 
If the CAD model does not appear on 
the screen, from the task bar select 
Scheme ACIS Interface Driver 
extension. 
If an error occurred while loading, this 
window provides a list of entities that 
did not load, or causes of the load 
error. 
A log file will also be created with the 
model names. 
Here this is YXZZZZ.log. This file 
contains further information and 
possibly an error list. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Preparing the model 
 
 
 
Once the model has been loaded, click on the 
Render button. 
If the model does not render, some (or all) of the entities were not converted. For these cases, 
Calypso provides a utility called “Healing”. Healing is the process of converting CAD surface 
data to Calypso’s solid ACIS format. 
 
There are three steps to this process: 
 
Simplification 
Stitching 
Build Geometry 
 
 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
Calypso Advanced Course 4 - 5 
 
Example of an incorrectly loaded model: 
 
 
 
Holes after conversion. 
 
 
 
 
 
 
 
 
 
2. Example of an incorrect model 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Open the CAD pull down menu CAD File. 
 
The three options are found here: 
 
Minimal Model Preparation: 
This selection carries out the Simplification. 
 
Autohealing 
This option carries out all three steps. 
Both processes are automatic and do not need additional input from the user. 
 
Step-By-Step Healing 
This selection allows interaction between the user and the healing process. 
In this exercise we will choose Step By Step Healing. 
Calypso Advanced Course Worksheet 4 : CAD 
4 - 6 Calypso Advanced Course 
 
 
Simplification 
 
The healing process starts by attaching an 
accumulation of attributes that will be used 
throughout the various phases of the healing 
process. 
 
The first step “cleans up” the model. 
Inaccuracies, zero-length edges and 
duplicate vertices are removed. 
Incoming models often contain geometry, 
which are not mathematically described. 
Simplification converts these into their 
analytical forms (arc, cylinder, cone, plane) 
wherever possible. 
This calculation requires a tolerance in order 
to have a limiting value for the simplification. 
Attributes are attached to the geometry so 
that they can be easily identified during the 
actual simplification. 
 
Select 
Transformation CAD Model 
 Simplification Start. 
 
 
Stitching 
 
The stitching function provides the means to stitch a set of faces together to form a single 
sheet or solid body. 
Stitching essentially involves the pairing of vertices and edges in the data. 
In the case of a surface model, which lacks topology, such as from IGES, this phase adds 
topology to the model. The analysis phase determines a tolerance to be used when deciding 
whether or not two surfaces should share an edge or vertex. 
 
Select 
Transformation CAD Model 
Stitching Start. 
 
 
Build Geometry 
 
Geometry building heals inaccuracies in the model. In this phase, a series of geometric 
operations are performed to improve the precision of face, edge, and vertex data. These 
operations adjust and correct, where possible, the geometry ensuring that: every vertex lies on 
the underlying curve, every edge (formed by an intersection) lies on two adjoining faces. 
Parametric curves lie on the corresponding faces. 
 
 
 
Do NOT select this option. Close the Transformation CAD Model window with 
 
 
The information on the healing process is from SPATIAL TECHNOLOGY INC. 
To learn more, visit their web site at http://www.spatial.com. 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
Calypso Advanced Course 4 - 7 
 
Converter settings: 
 
 
The converter settings can be matched to the 
quality of the model to improve the import 
functions: 
 
 
 
 
 
 
 
 
 
If the conversion is inadequate, you 
can also activate the function 
“Conversion of incorrectly defined 
geometry”. 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 4 : CAD 
4 - 8 Calypso AdvancedCourse 
 
 
 
 
Worksheet 4.2: Default Measurement Strategy 
Calypso Advanced Course 4 - 9 
 
 
Worksheet 4.2: Default Measurement Strategy 
 
 
Job: The procedure defines the measurement strategy for accepting or 
creating part features when extracting from the CAD model. 
Load the exercise cube as a CAD model 
Then process the default settings: 
CAD 
 Extract 
 Set Default Measurement Strategy. 
 
Default plane settings: 
Click on the Plane button. 
 
 
 
 
 
 
Click on Settings and open the grid. 
 
 
 
 
 
 
 
 
 
 
 
In the following window you can change the grid 
length and grid width with 
 Quantity or 
 Separation. 
 
The edge separation and the meander or line route 
methods are important. 
 
 
Worksheet 4.2: Default Measurement Strategy 
4 - 10 Calypso Advanced Course 
 
 
Example: 
 
Set Step Width to: 2 
If a plane is extracted, there will be a probe point every 2 mm. 
The “Single Points” box has no affect on switching measuring devices 
Set Grid Length to number 5, 
set Grid Width to number 3. 
Set Edge Separation to: 0.5 
A separation of 0.5 mm is maintained to all edges and gaps. 
Set Range to: 
Meander 
the measurement 
sequence proceeds as 
a meander. 
 
 
 
 
 
 
These default settings take effect when a surface is generated on the CAD model: 
 
Click on “Generate Solid Geometry“ and then on the desired surface. 
Open the surface, now the grid is visible. 
 
 
Try another example using the “Distance”. 
 
 
 
 
 
Worksheet 4.2: Default Measurement Strategy 
Calypso Advanced Course 4 - 11 
 
Circle default settings: 
Click on Circle and open the Circle 
section. 
Speed and Step Width are settings 
for measuring probes 
Set Number of Points to 9: 
This will generate 9 points on each 
circle section. 
Set the Probe Radius Factor to 1.5 
Minimum distance to the “end” of a 
cylinder. 
Set the Start Angle to 0 
Starting point for probing. 
Set the Angular Range to 360 
The arc of a circle. Positive values 
indicate counter-clockwise. 
 
 
Cylinder default settings 
Click on the cylinder button and 
open a Circle Auto Path. 
Set Number of Points to: 5 
This will generate 5 points on each 
section of the cylinder. 
Circle Path 
Several options are possible here: 
Probe Radius Factor 
Minimum distance to the edge of a cylinder. 
 
Percent 
Within the restriction of the probe radius 
factor, this places the generated path at a 
percentage of the cylinder’s overall length. 
 
Measuring Height 
Direct input of path location from origin of 
feature. 
 
Number 
Number of equally spaced circle paths. 
 
Worksheet 4.2: Default Measurement Strategy 
4 - 12 Calypso Advanced Course 
 
 
 
Straight line default settings: 
Enter the settings in the same way 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
Calypso Advanced Course 5 - 1 
 Worksheet 5.1: Recall Feature Points from Polyline 
 
 
Recall enables you to carry out more calculations from data already gained from 
previous features. 
 
 
 
 
 
 
Job: Measure a plane with one or several polylines and recall the measured points to the 
“Line” feature in order to carry out a Straightness evaluation. 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
5 - 2 Calypso Advanced Course 
 
This exercise is done on the CAD model. 
 
 
 
Create a base system and safety cube as usual. 
 
 
 
Take a plane from the toolbox and set a polyline with 
3 lines on the right hand side of the cube. 
 
 
 
 
 
 
 
 
 
Enter the “3D Line” twice 
in the measurement plan. 
 
 
 
 
 
 
 
 
 
Open a line and define the nominal input 
with “Recall Feature Points”. 
 
 
 
 
 
 
 
 
 
 
Select the plane; note the buttons, which 
appear in the top bar: 
 
 
 
 
 
 
 
 
First click on the button on the left, the actual points are displayed in the feature as crosses. 
You can now select the ones you want using the button on the right. 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
Calypso Advanced Course 5 - 3 
 
The actual points (!!) are displayed as red 
crosses. 
 
 
Select the scanning path on the left with the 
“lasso”. 
 
 
 
 
 
 
 
 
 
These points are accepted and calculated as 
3D line. 
 
 
 
 
 
Create a second 3D line with another 
scanning path. 
 
 
 
 
 
Evaluate a Straightness for each of the 3D 
lines. 
 
Plot the result. 
 
Try and interpret the plot output. 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
5 - 4 Calypso Advanced Course 
Worksheet 5.2: Recall Feature Points from Circles 
 
 
 
Job: Measure three circles in a hole and recall the measured points in the “Cylinder” part 
feature. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Take a cylinder from the toolbox. 
 
 
 
 
 
 
 
 
Select "Nominal Input – 
Recall Feature Points". 
 
 
 
 
 
 
 
 
Select the three circles. 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
Calypso Advanced Course 5 - 5 
 
 
 
 
With the remaining buttons in the 
header, the actual data from the 
circles can be displayed and 
selected. 
 
 
 
Using the lasso, you can place a box 
around the circles and select the 
actual points. 
 
 
The cylinder you want is then 
calculated and is available as 
calculated feature. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
5 - 6 Calypso Advanced Course 
 Worksheet 5.3: Recall Feature Points from Cylinder 
 
 
 
Job: Measure a cylinder with 2 circle auto paths and with 4 surface lines. Recall the 
points of the surface lines to the “line” feature in order e.g. to carry out a 
straightness evaluation of the cylinder. 
 
 
 
 
 
 
 
Measure a cylinder with eight points; 
define 2 circle auto paths and 4 
surface lines. 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
Define a measuring strategy suitable for the 
measuring machine for the form elements. 
 
 
 
 
 
 
Run the program. 
 
 
You can use a 2D line or a 3D line for the straightness evaluation. 
The 2D line is calculated on the surface of the work piece, the 3D 
line through the probe ball center points. 
 
 
Now consider how usable the various results are for your 
measuring task. 
Calypso Advanced Course Worksheet 5: Special Part Features 
Calypso Advanced Course 5 - 7 
 
Start with the Recall Feature 
Points. 
 
 
 
 
 
 
 
 
There is an important new feature 
here with the Recall Feature 
Points function: 
 
 
You can make the individual 
measuring strategies of the 
cylinder visible and select them 
with the right mouse button. 
 
 
 
 
 
 
 
 
 
 
Path (3) is the first surface line. 
 
 
 
 
 
 
 
You get the 2D line you wanted and you can use this in 
the Straightness evaluation. 
 
The graphical evaluation of the form plot gives you a 
visual impression of the cylinder surface area. 
 
 
 
 
 
 
 
 
 
Note: 
 
The scanning path, which has been evaluated, was made in the direction of the nominal 
cylinder (!!!). 
 
Therefore the evaluation cannot be used here, see also plot. 
 
Calypso Advanced Course Worksheet 5: Special Part Features 
5 - 8 Calypso Advanced Course 
 
 
Consider the following: 
in the nominal cylinder the A1 and A2 
angles are rounded off to the value 
“0”. 
 
Therefore the surface lines are 
scanned in the direction of the axis 
and not in the direction of the “true” 
cylinder. 
 
Here a “pre-alignment” is necessary 
in order to then measure in the 
aligned coordinate system. 
 
 
A typical evaluation could be the parallelism of two lines lying opposite to one another. 
 
It is then possible to see whether the cylinder has taken on a conical form for example. 
 
 
 
 
Start a new exercise by measuring a 
cylinder, here from 2 circles with 
feature point recall. 
 
 
 
 
 
 
 
 
 
 
 
 
 
Create a new alignment with the 
spatial rotation of the first cylinder. 
 
 
 
 
 
In this alignment you now measure the