CALYPSO

Option 14
UMESS Control data
Converter

Operating Instructions
Read this first! • Please read these operating instructions before starting up the
coordinate measuring machine.
• For your own safety, please keep all relevant accompanying docu-
ments always ready at hand.

All rights pertaining to changes in the CMM and its options, the pro-
gram packages and the pertaining documents reserved.
This manual must not be circulated or copied, or its contents utilized
and disseminated, without our express written permission. Persons
misusing this manual are subject to prosecution.
All rights reserved, especially in cases of granting a patent or register-
ing a utility model.
This manual is subject to modification. All rights pertaining to changes
in the CMM and its options reserved.
All product names are registered trademarks or trademarks of the cor-
responding proprietors.

Carl Zeiss CALYPSO: Operating Instructions

Business Group Revision status: 4.6
Industrial Metrology Ltd. Date of issue: 07/07
D-73446 Oberkochen Order No.: 61212-2840202
Preface
The CALYPSO program consists of a base module and additional
options for special purposes. You can customize the scope of program
to fit your requirements.
These operating instructions describe an option of CALYPSO and are
based on the assumption that the user is familiar with the operating
instructions for the base module of CALYPSO.

NOTE The additional CALYPSO options are described in separate manuals.

hss

Reference information about the windows and dialogs can be found

in the interactive reference in the CALYPSO Online Help.

Supplementary literature
Simply Measure – And what you should know to do it right,
A metrology primer
Carl Zeiss, Industrial Metrology Division,
Order No.: 612302-9002

Text conventions and symbols

Text conventions The following text conventions and symbols are used in this manual:

Example Description
Features Text element of the graphics screen display.
Comment The Comment button on the screen.
C:\windows\w.ini The w.ini file in the windows directory on the
C:\ drive.
For this section... A highlighted passage containing important
information.
➤„Preface“ auf This is a cross reference. If you view this book
Seite -1 on the screen, you can jump to the specified
point by clicking the reference.
Plan → CNC-Start The CNC-Start command in the CNC-Start
→ CNC-Start submenu of the Run menu.
Ctrl-a Press the Ctrl key and the letter a simulta-
neously.

61212-2840202 Operating Instructions Preface

Symbols Three special icons are used in this book; they always contain impor-
tant information. The icons appear in the margin, beside the associ-
ated text.

hss
! Danger!
Special care is necessary in this case. The warning triangle warns the
user about potential danger of injury.
Failure to comply with the warning could result in injury to the user.

hss
! Important!
This symbol calls attention to a situation that could result in incorrect
measurements, disruptions in the measurement process, collisions or
damage to the equipment and the workpiece.

NOTE This symbol represents important and helpful additional information.

hss

Preface 61212-2840202 Operating Instructions

Contents
Kapitel 1 UMESS control data converter
Basics about the conversion of control data . . . . . . . . . . . 1-2

Converting UMESS control data . . . . . . . . . . . . . . . . . . . . . 1-4

Preparing conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Converting control data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Evaluating the conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Functional scope of the UMESS control data converter . . 1-8

Converted functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
New nominal values (DI 1459) in CALYPSO . . . . . . . . . . . . . . . 1-9
UMESS position tolerances in CALYPSO . . . . . . . . . . . . . . . . . . 1-9
UMESS geometry features in CALYPSO . . . . . . . . . . . . . . . . . 1-10
Geometry macros in CALYPSO . . . . . . . . . . . . . . . . . . . . . . . . 1-11
PCM measurement library macros . . . . . . . . . . . . . . . . . . . . . 1-11
UMESS constructions in CALYPSO . . . . . . . . . . . . . . . . . . . . . 1-12
UMESS coordinate systems in CALYPSO . . . . . . . . . . . . . . . . . 1-12
Not converted functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

61212-2840202 Operating Instructions Contents 1

Contents 2 61212-2840202 Operating Instructions
 Chapter

1 UMESS control data converter

.................................................................................................................................
The UMESS control data converter option is used to create a CALYPSO
measurement plan on the basis of UMESS control data.

This chapter contains:

Basics about the conversion of control data . . . . . . . . . . . . . . . . . 1-2

Converting UMESS control data . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Functional scope of the UMESS control data converter . . . . . . . . . 1-8

61212-2840202 CALYPSO Operating Instructions 1- 1

UMESS control data converter

Basics about the conversion of control data

The UMESS control data converter option is used to create a CALYPSO
measurement plan on the basis of UMESS control data.
To do so, you convert the UMESS control data to a text file, load this
file into the converter and generate a CALYPSO measurement plan.

UMESS control data

UNIX

Text file

UMESS control data

converter

CALYPSO
measurement plan

The new measurement plan can be further processed like any

CALYPSO measurement plan.
The UMESS control data converter generates a log file during conver-
sion and stores it in the ...\calypso\home\om directory. Control data
lines that have not been converted are listed in this file.

NOTE The present version of the converter does not yet allow conversion of
all UMESS functions (➤„Functional scope of the UMESS control data
converter“ auf Seite 1-8). Check your UMESS control program and
revise the CALYPSO measurement plan if necessary.

1-2 61212-2840202 CALYPSO Operating Instructions

 Basics about the conversion of control data

CNC run of converted control data

During the CNC run of a measurement plan created on the basis of
converted UMESS control data, the converted features will always be
processed in the same order as in UMESS, even if you have only set a
selection. This is to ensure correct travel paths.

! Important!
When starting the CNC run, select the entry Use Position Points
Only under Navigate-Feature To Feature.

61212-2840202 CALYPSO Operating Instructions 1-3

 UMESS control data converter

Converting UMESS control data

The conversion of your UMESS control program is performed in three
steps:
– Preparing conversion
– Converting control data
– Evaluating the conversion and revising the measurement plan

Preparing conversion
Before converting the control data, make the following preparations:
– Convert control data to text file
– Define stylus data in CALYPSO
– Define the base alignment in CALYPSO
Convert control data to The control data converter needs a text file as starting basis.
text file
To create the text file:
1 Convert the UMESS control data file under Unix to an ASCII file
using the following command:
CNCBINASC binaryfile asciifile
The control data file “binaryfile” is saved as “asciifile”.
2 Convert the ASCII file under Unix to a text file using the following
command:
ux2dos asciifile > textfile
The converter uses the “textfile” to create a CALYPSO measurement
plan.
Define stylus data in CALYPSO needs the stylus data of the styli used with UMESS.
CALYPSO
To create the stylus data:
1 Create in CALYPSO the stylus systems and styli used with UMESS.
Observe the following naming convention:

Name in UMESS Name in CALYPSO

Configuration 1 Stylus system U1
Combination 2, stylus number 3 Stylus T3K2

2 Qualify the new stylus systems.

1-4 61212-2840202 CALYPSO Operating Instructions

 Converting UMESS control data

Define the base align- CALYPSO needs a base alignment for the workpiece. In UMESS you
ment in have read in a W position (DI 1712) and saved it under a number.
CALYPSO
To create the base alignment:
1 In CALYPSO, create a new base alignment on the workpiece con-
cerned.
2 Save this base alignment and name it with the number defined in
UMESS.

Converting control data

To convert the UMESS control data to a CALYPSO measurement plan:
1 Select File → UMESS Import.
The converter window is displayed.

2 Enter the path and name of the text file with the control data.
The name of the workpiece, the name of the new measurement
plan and the name of the log file will be displayed.
3 Start the conversion by selecting Start conversion.
The conversion is performed. Under Conversion Information you
can see the control data lines.
4 Confirm the end of the conversion.
Under Conversion Information you can now see the log file.

Evaluating the conversion

A CALYPSO measurement plan is stored in the specified directory as
result of the conversion. The measurement plan includes all elements
of the UMESS control data that allowed conversion.

61212-2840202 CALYPSO Operating Instructions 1-5

UMESS control data converter

You can see from the log file which control data has not been conver-
ted.
You can now evaluate the log file and revise the measurement plan in
CALYPSO, if necessary.

Log file
The log file contains all control data lines that have not been conver-
ted, including the masked ones. Additional error messages are mar-
ked in red.
The log file is composed of lines of the form:
0: dialog text
or
No: line text
Denotation:

Dialog text Error message (red) referring to the succeeding control data line
No Number of the control data line that has not been converted
Line text Text of the control data line that has not been converted

Names of the features

The features from UMESS receive the following names in CALYPSO:
– if existing, the result name from UMESS.
– otherwise the address from UMESS.
If the address has been assigned in UMESS several times, only the
last feature with this address will receive the name.
The preceding features will be renamed by preceding them with an
underscore “_”.

Names of the characteristics

The characteristics from UMESS receive the following names in
CALYPSO:
– if existing, the nominal value designation from UMESS.
If the nominal value designation has been parameterized in
UMESS, the parameter will be determined and used as name of
the characteristic. Characteristic names cannot be parameterized
in CALYPSO.
– otherwise, the characteristic name will be composed of the charac-
teristic type and the name of the corresponding feature (e.g.
Diameter_10).

1-6 61212-2840202 CALYPSO Operating Instructions

 Converting UMESS control data

If a characteristic name already exists, a serial number will automati-

cally be added: with “xdes” occurring a second time, the name
“xdes1” will be generated.

61212-2840202 CALYPSO Operating Instructions 1-7

UMESS control data converter

Functional scope of the UMESS control data

converter
The present version does not yet allow conversion of all elements of
the UMESS control data to a CALYPSO measurement plan.
To find out which elements must be entered subsequently in
CALYPSO, please check the following lists:

Converted functions
The following functions are converted to CALYPSO:
– Old nominal values (DI 1452)
Old nominal values are converted to individual characteristics. The
nominal value designation becomes the name of the characteristic
(see names of characteristics).
UMESS does not contain old parameterized nominal values.
– New nominal values (DI 1459)
New nominal values are converted to individual characteristics.
The nominal value designation becomes the name of the characte-
ristic (see names of characteristics).
– DIN programs
Old and new DIN control data are converted. The nominal value
designation becomes the name of the characteristic (see names of
characteristics).
– Certain form tolerances
DIN roundness, flatness and cylindricity are converted to characte-
ristics.
Straightness cannot yet be converted.
– Certain position tolerances
– Certain geometry features
– Certain geometry macros
– Certain PCM measurement library macros
– Certain constructions
– Certain coordinate systems
– Recall of an address or an alignment (DI 1301)
– Formula (DI 1379)
– Initial state (DI 1608)
An alignment is created (offset 0/0/0).

1-8 61212-2840202 CALYPSO Operating Instructions

 Functional scope of the UMESS control data converter

– Printout header (DI 1610)

An alignment is created (offset 0/0/0).
– Fixed plane (DI 1680)
– Set result counter (DI 1690)

New nominal values (DI 1459) in CALYPSO

New nominal values are converted to individual CALYPSO characteris-
tics. The nominal value designation becomes the name of the charac-
teristic (see names of characteristics).
– If the nominal values are parameterized in UMESS, the characteris-
tics in CALYPSO will also be parameterized. If the characteristic is
an angle (A1, A2, cone angle), the entire parameter will be conver-
ted with rad(parameter) to radian measure.
– The PCM parameter assignments (ASSIGNMENT, ASSIGN TEXT) are
gathered and assigned to the characteristic as input parameter.
– The tolerance classes corresponding to the tolerance modes
“General Tolerances fine, medium, coarse, very coarse” are set in
CALYPSO. The tolerances for all other tolerance modes (e.g. plastic
and casting tolerance) are taken from the control data.

UMESS position tolerances in CALYPSO

Tolerance extensions MMC for features and reference features are
converted as additional characteristics. As to the naming of characte-
ristics see “Names of characteristics”.
In UMESS, MMC does only exist for DIN position, perpendicularity,
coaxiality and parallelism.
If no reference has been specified in UMESS, the current alignment
will be used as reference. This is not always possible in CALYPSO.
Auxiliary elements will be created in such cases.
The following position tolerances are converted:
– True Position
– Concentricity
– Coaxiality
– Symmetry
– Parallelism
– Perpendicularity
– Angularity
The following position tolerances are not converted:
– GDT runout

61212-2840202 CALYPSO Operating Instructions 1-9

UMESS control data converter

– DI 1415 (GDT PAR general) without reference feature

– DI 1425 (GDT Perp general) without reference feature
– DI 1435 (GDT Ang general) without reference feature

Position tolerance Remark

True Position, If no reference has been specified in UMESS, the current alignment
GDT Symmetry will be used as reference in CALYPSO.
Coaxiality If no reference has been specified in UMESS, an error message will be
written to the log file as a reference feature is required in CALYPSO.
In UMESS, MMC exists for the measuring feature and the reference
feature, in CALYPSO only for the measuring feature. In the case of a
reference feature with MMC, an error will be written to the log file.
Parallelism If the feature is a 2-D line, this will be used to additionally create the
auxiliary element 3-D line.
Reason: In CALYPSO, a 2-D line is considered as a plane, in UMESS,
however, as an axis.
Perpendicularity GDT Perp plane/plane (DI 1421), plane/axis (DI 1422):
The results from UMESS and CALYPSO are different as in UMESS half
the form error is added to the CALYPSO result.
Angularity In CALYPSO, the GDT angularity is spatially measured, in UMESS,
however, only in one direction.
An auxiliary element is therefore created for the corresponding
feature, setting the angle that is not used to 0.

UMESS geometry features in CALYPSO

The following geometry features are converted:
– Point
– 2-D Line
– 3-D Line
– Plane
– Circle
– Circle segment
– Sphere
– Cylinder
– Cone
– Ellipse
The torus is not converted.
The following measurement strategies are converted:

1-10 61212-2840202 CALYPSO Operating Instructions

 Functional scope of the UMESS control data converter

– Probing (1103)
– Step CMM with probing (1153)
– Position CMM without probing (1101)
– Position IPT (1111)
– Position (1113)
– Step IP (1151)
– Recall several features (1302)
– Scanning known contour Circle
– Scanning known contour Circle path on plane
– Theoretical features
For other measurement strategies (e.g. the file evaluation) or parame-
terized control data, the feature is created without being completely
defined. An error message is written to the log file.

Geometry macros in CALYPSO

The geometry macros for line, plane, circle, sphere, cylinder and cone
are converted to features with defined measurement strategies.

Feature Measurement strategy

Line Line Measurement
Plane Grid
Circle Circle Auto Path
Sphere Sphere macro
Note: Contrary to UMESS, it is not possible to define the number of
points and intersections.
Cylinder Several circle auto paths
Cone Several circle auto paths

PCM measurement library macros

Some PCM measurement library macros are converted to features
with corresponding measurement strategies. If nominal values have
been selected, a characteristic is created for each nominal value (see
new nominal values).

Macro name Feature Measurement strategy

POINT.CAL Point Intermediate position, probing, intermediate position
CIRCLE.CAL Circle Circle Auto Path
SPHERE_6PT.CAL Sphere (6 points) Sphere macro
CYLINDER_1.CAL Cylinder Several circle auto paths, uniform distribution

61212-2840202 CALYPSO Operating Instructions 1-11

 UMESS control data converter

Macro name Feature Measurement strategy

CYLINDER_2.CAL Cylinder Several circle auto paths, non-uniform distribution
CONE_1.CAL cone Several circle auto paths, uniform distribution
CONE_2.CAL Cone Several circle auto paths, non-uniform distribution

Further macros (e.g. plane, line, bore pattern, slot) cannot yet be
converted.

UMESS constructions in CALYPSO

In some cases, auxiliary elements are created for the constructions.
The following constructions are converted:
– Distance (DI 1202)
– Polar (DI 1203)
– Symmetry (DI 1206)
– Intersections of axes in space (DI 1215)
– Piercing point (DI 1217)
– Planar sections (DI 1218)
– Cone addition (DI 1243)
– Space diagonal (DI 1261)
– Perpendicular cylinder (DI 1285)
– Perpendicular distance (DI 1286)
The following constructions are not converted:
– Calculation of rotation and inclination angle (DI 1204)
– Corner point (DI 1216)
– Surface sections (DI 1219)
– Edge point (DI 1220)
– Change reference axis and sense of rotation (DI 1251)
– Projection of a point onto a line (DI 1266)
– Projection of a line into a plane (DI 1267)

UMESS coordinate systems in CALYPSO

Converted features
At the beginning of each CNC run, an alignment with offset (0/0/0) is
created as a precaution.
The following UMESS features are converted to CALYPSO:
– Zero point (DI 1701)
– Rotate Plane (DI 1702)

1-12 61212-2840202 CALYPSO Operating Instructions

 Functional scope of the UMESS control data converter

– Rotate zero point and 1 element (DI 1703)

– Rotate on distance (DI 1705)
– Rotate Space (DI 1706)
– Select space axis (DI 1707)
– Store W-position (DI 1708, 1710)
– Rerotate about angle (DI 1709)
– Axis selection (DI 1711)
– Read W-position (DI 1712)
– Wpos to WS (DI 1713)
– Relative axis selection (DI 1720)
– WP displacement (DI 1723)
– Zero point X (DI 1731)
– Zero point Y (DI 1732)
– Zero point Z (DI 1733)
– 3D transformation (DI 1734)
– 2D transformation (DI 1735)
– W-pos displacement polar (DI 1769)
Not converted The following UMESS features are not converted to CALYPSO:
features
– Preset (DI 1736)
– Alignment acc. to nominals (DI 1740)
– Basic displacement (DI 1722)
– W-pos displacement cartesian (DI 1771)

Not converted functions

The following functions are not converted to CALYPSO:
– Masked control data
– Half-new nominals (NOMINAL C)
If control data lines contain half-new nominals, these will have to
be converted to new nominal values under UMESS UX/LX using
the control data correction, key NOM CONV.
New nominal values are easily converted.
– Reserved nominal lines (RES NOMINAL)
– Reserved addresses (RESERVE ADR)
– Comment in the control data (CTEXT)
– Supplementary coordinates (DI 1262)

61212-2840202 CALYPSO Operating Instructions 1-13

UMESS control data converter

1-14 61212-2840202 CALYPSO Operating Instructions

Index
C T
Conversion Text conventions Preface-1
of UMESS control data 1-2
Converting UMESS control data U
basics 1-2
UMESS control data
run 1-4
converted functions 1-8
not converted functions 1-13
F preparing conversion 1-4
functional scope UMESS control data converter
UMESS converter 1-8 functional scope 1-8

S
Symbols Preface-2

61212-2840202 Operating Instructions Index 1

Index 2 61212-2840202 Operating Instructions