ROTALIGN-Ultra Straightness ALI 209-848!08!06 1.13 G

Dear Customer,

If you hav e any suggestions for improvement or corrections(not only to this manual, but also to software or hardware),please drop us a line! We would be glad to make improve-ments wherever possible. We look forward to hearing from you!

PRÜFTECHNIK Alignment SystemsDocumentation DepartmentFax: +49 (0)89/99616-100eMail: [email protected]

Edition April 2006Straightness firmware v.1.13ALI 9.848.G

Operating Instructions

Overview:

Part 1ROTALIGN® UltraSystem operating instructions

Part 2ROTALIGN® UltraShaft alignmentoperating instructions

Part 3ROTALIGN® UltraFlatness operating instructions

Part 4ROTALIGN® UltraStraightness operating instructions

Straightness

application withROTALIGN® Ultra

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Ultra Straightness 04.06

1-2

Foreword

The straightness measurement application is now available inROTALIGN Ultra, the third generation ROTALIGN. This manual is asupplement to ROTALIGN Ultra system operating instructions, ALI9.845.G, and discusses only the details specific to straightnessmeasurement. Please acquaint yourself with the ROTALIGN Ultrapart 1 instructions first.

ROTALIGN Ultra follows the modular platform concept of its prede-cessor, with the added attraction of concise navigation and abun-dance of on-screen help making straightness measurement easierthan ever before. The system’s transflective and scratch resistantbacklit colour screen displays high quality images under variouslighting conditions. Intelligent power management helps conservebattery power. ROTALIGN Ultra offers both USB and Bluetoothtechnologies. ROTALIGN Ultra has increased computing power andfunctionality so that several applications can be loaded at once, andmore complex programs can be considered.

The straightness firmware is used in numerous applications includingthe measurement of machine beds, slideways and even papermachine rolls.

We hope this information is presented in a clear readable form andshould give insight to the subject straightness measurement.

Ismaning, GermanyJanuary 2006

PRÜFTECHNIK Alignment Systems

Foreword

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06Contents

Contents

Foreword ....................................................................................... 1-2

Contents ........................................................................................ 1-3

Chapter 1: Introduction ................................................................. 1-41.1 ROTALIGN Ultra straightness packages............................... 1-41.2 ROTALIGN Ultra straightness 2D package ALI 4.020 .......... 1-41.3 ROTALIGN Ultra straightness 2D long range package ALI 4.020–L ......................................................................... 1-71.4 Straightness 2D add-on package for ROTALIGN Ultra Shaft ALI 4.007 ............................................................................. 1-81.5 Additional ROTALIGN Ultra straightness packages ............. 1-81.6 Straightness packages using the laser unit ALI 6.910 (alsoreferred to as 'long range') ........................................................ 1-81.7 Safety notes ........................................................................ 1-91.8 CE compliance and laser safety ........................................... 1-9

Chapter 2: Straightness measurement ........................................... 2-1Typical straightness applications include: ............................. 2-1

2.1 Operating principle ............................................................. 2-12.2 Understanding the working of the sliding bracket forstraightness ............................................................................... 2-2

2.2.1 Measurement plane position ........................................ 2-22.2.2 Identifying the correct position to mount the receiver . 2-3

2.3 Setup................................................................................... 2-42.3.1 Mounting laser and receiver ......................................... 2-42.3.2 Bracket mounting ......................................................... 2-42.3.3 Connecting the receiver ............................................... 2-52.3.4 Switch on ROTALIGN Ultra computer ......................... 2-6

2.4 Dimensions ......................................................................... 2-72.4.1 Set up measurement locations ..................................... 2-7

2.5 Editing measurement locations ......................................... 2-102.5.1 Adding new measurement points ............................... 2-102.5.2 Editing individual positions ........................................ 2-122.5.3 Editing offset values ................................................... 2-152.5.4 Defining state of line position .................................... 2-172.5.5 Deleting points ........................................................... 2-18

2.6 Laser beam adjustment principle ...................................... 2-202.6.1 Laser adjustment procedure ....................................... 2-20

2.7 Taking measurements ....................................................... 2-232.7.1 Sign convention ......................................................... 2-252.7.2 Using auto-routing in measurement ........................... 2-25

2.8 Measurements options ...................................................... 2-272.9 Evaluating results ............................................................. 2-41

2.9.1 Interpreting results ..................................................... 2-412.9.2 Context menu items ................................................... 2-42

2.10 The live move mode........................................................ 2-49

Index ........................................................................................... 2-54

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Chapter 1: Introduction

1.1 ROTALIGN® Ultra straightness packages

Straightness with ROTALIGN Ultra is available either as a stand aloneor an add-on to other applications. Straightness measurements arecarried out using either the ROTALIGN laser ALI 3.610 or theLEVALIGN laser ALI 6.910. The two fundamental packages are theStraightness 2D with ROTALIGN Ultra ALI 4.020 and the Straightness2D long range with ROTALIGN Ultra ALI 4.020–L. Please contactyour local PRÜFTECHNIK Alignment Systems representative fordetails of other available straightness packages.

Packages

ALI 4.200 ROTALIGN Ultracomputerincluding standALI 4.201 andrechargeablebattery ALI 4.603

ALI 3.600 ROTALIGNreceiverincluding dust capALI 3.606

1.2 ROTALIGN Ultra straightness 2D packageALI 4.020

ALI 4.811 Straightness casewith Ultra insert(Contents not included)

ALI 3.610 ROTALIGN laserincluding 9Vbattery and dustcap ALI 3.607

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ALI 3.581-5 Receiver cable, 5 m

ALI 4.502-2 ROTALIGN UltraUSB cable (PC), 2 m

ALI 4.503 ROTALIGN UltraUSB cable (peripheraldevices), 0.3 m

SYS 3.651 Battery charger

ALI 4.501 Magnetic footadapter

ALI 6.953 Distance sleevesConsists of 8 offsetranging from 2 mm to200 mm

ALI 3.588 Tape measure

ALI 6.952 Magnetic footaccessoriesConsists of an offsetadapter, 3 foot postsand two 100 mmsupport posts

Packages

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ALI 13.701 CD AlignmentREPORTER CD

ALI 4.745 ROTALIGN Ultra straightness firmwareregistration certificate (not shown)

ALI 2.905 Lens cleaning cloth (not shown)

ALI 9.845.G ROTALIGN Ultra pt.1 (not shown)

ALI 9.848.G ROTALIGN Ultra pt.4 (this manual)

ALI 9.364.DG ROTALIGN Ultra product sheets (not shown)

ALI 9.965.DG LEVALIGN product catalog (not shown)

ALI 4.451 SET ROTALIGNUltra FWupdate USBmemory stick

ALI 3.198 Sliding bracketfor straightness

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ALI 13.700 CD AlignmentCENTER CD(not shown)

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0 0739 1055 Allen key for locking the 2.5 mm allensocket (not shown)

0 0739 1056 Allen key for locking the 3 mm allensocket (not shown)



1.3 ROTALIGN Ultra straightness 2D long rangepackage ALI 4.020–L

Contents of the 2D long range package include:

ROTALIGN Ultra computer ALI 4.200Computer stand (mounted) ALI 4.201ROTALIGN Ultra rechargable battery * ALI 4.603Battery charger SYS 3.651(US/UK)ROTALIGN receiver with dust cap ALI 3.600LEVALIGN laser including battery ALI 6.910Receiver cable, 5 m / 6 ½’ ALI 3.581-5ROTALIGN Ultra USB cable (PC), 2m ALI 4.502-2ROTALIGN Ultra USB cable (peripheral devices), 0.3 m ALI 4.503Lens cleaning cloth ALI 2.905Straightness case with Ultra insert (long range) ALI 4.813Tape measure ALI 3.588ROTALIGN Ultra FW update USB memory stick ALI 4.451 SETROTALIGN Ultra straightness FW registration certificate ALI 4.745Alignment REPORTER CD ALI 13.701 CDAlignment CENTER CD ALI 13.700 CDROTALIGN Ultra part 1 operating instructions ALI 9.845.GROTALIGN Ultra part 4 operating instructions ALI 9.848.GROTALIGN Ultra product sheets ALI 9.364.DGLEVALIGN product catalog ALI 9.965.DGMagnetic foot adapter ALI 4.501Sliding bracket for straightness ALI 3.198Magnetic foot accessories ALI 6.952Distance sleeves (offsset shims) ALI 6.953Allen key (2 mm) - for laser battery compartment 0 0739 1054Allen key, 2.5 mm 0 0739 1055Allen key (3 mm) - for laser assembly head 0 0739 1056Allen key, 4 mm 0 0739 1057Allen key, 5 mm 0 0739 10589 V battery 90109

*The rechargeable battery is installed inside the computer.

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1.5 Additional ROTALIGN Ultra straightnesspackages

Additional straightness packages to suit most needs are available.These include:

ALI 4.007-B ROTALIGN Ultra straightness 2D compact packagewith Bluetooth®

ALI 4.020-B ROTALIGN Ultra straightness 2D package withBluetooth® package

ALI 4.020-BL ROTALIGN Ultra straightness 2D long range packagewith Bluetooth®

ALI 4.017 Straightness 2D add-on package for LEVALIGN Ultra(single plane flatness)

ALI 4.037 Straightness 2D add-on package for BORALIGN Ultra

For all additional packages and content details, please contact yourlocal representative or PRÜFTECHNIK Alignment Systems( www.pruftechnik.com).

1.6 Straightness packages using the laser unitALI 6.910 (also referred to as 'long range')

Straightness applications will be carried out using either RO-TALIGN laser ALI 3.610 or the LEVALIGN laser ALI 6.910. Thesafety notes and CE compliance relating to ALI 3.610 and ALI6.910 are to be found in ROTALIGN Ultra part 1 ALI 9.845.G andROTALIGN Ultra part 3 ALI 9.847.G respectively. Please refer tothe aforementioned operating instructions for details.

Note

1.4 Straightness 2D add-on package forROTALIGN Ultra Shaft ALI 4.007

Contents of the compact package include:

Case with insert for straightness add-on package ALI 3.197ROTALIGN Ultra straightness FW registration certificate ALI 4.745Alignment REPORTER CD ALI 13.701 CDAlignment CENTER CD ALI 13.700 CDROTALIGN Ultra part 4 operating instructions ALI 9.848.GLEVALIGN product catalog ALI 9.965.DGMagnetic foot adapter ALI 4.501Sliding bracket for straightness ALI 3.198Distance sleeves (offsset shims) ALI 6.953Allen key, 2.5 mm 0 0739 1055Allen key, 3 mm 0 0739 1056Allen key, 4 mm 0 0739 1057Allen key, 5 mm 0 0739 1058

Packages

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06Safety notes

ATTENTION

WARNING!

1.7 Safety notes

The equipment described in this manual is to be used only inindustrial environments for straightness measurements. Care must betaken to ensure that the parts are not subjected to mechanicalknocks. The equipment must be operated only by properly trainedpersonnel. No liability will be assumed when components or operat-ing procedures as described in this manual are altered withoutpermission of the manufacturer.

This manual is to be used in conjunction with ROTALIGN Ultra part 1ALI 9.645.G (System Operating Instructions), and ROTALIGN Ultrapart 3 ALI 9.647.G (Flatness Operating Instructions) if using theLEVALIGN laser ALI 6.910.

Safety symbolsThe following symbols are used in this manual in order to draw thereader's attention to especially important text, such as that regardingpossible dangers or useful operating tips.

This symbol denotes general information and tips regarding thestraightness application using ROTALIGN Ultra.

This symbol denotes information which must be followed in orderto avoid damage to equipment.

This symbol denotes information which must be followed in orderto avoid personal injury.

Note

1.8 CE compliance and laser safety

Straightness measurements are carried out using either theROTALIGN laser ALI 3.610 or the rotating laser LEVALIGN ALI 6.910in conjunction with the ROTALIGN Ultra computer ALI 4.200.

The ROTALIGN Ultra computer ALI 4.200 and the ROTALIGN laserALI 3.610 fulfill the EC Guidelines for electric devices (73/23/EWG)and electromagnetic compatibility (EMC) (89/336/EWG), and havebeen tested to the scope of:

• EN 61326 Edition 2004-05 • EN 61000-4-2 Edition 2001-12

• EN 61000-4-3 Edition 2003-11 • EN 61000-4-4 Edition 2002-07

• EN 61000-4-5 Edition 2001-12 • EN 61000-4-6 Edition 2001-12

• EN 61000-4-11 Edition 2001-12• EN 50022 Edition 2003-09

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CE compliance

Declaration of conformity

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• DIN EN 55022 Edition 2003-09 • prEN 50140 Edition 1993

• EN 55011 Edition 1991 • ENV 50141 Edition 1993

• EN 50082-2 Edition 1995 • ENV 50204 Edition 1995

CE compliance

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Chapter 2: Straightness measurement

This chapter describes straightness measurement procedures usingeither the ROTALIGN laser ALI 3.610 (also used in shaft alignment)or the rotating laser LEVALIGN ALI 6.910 in conjunction withROTALIGN Ultra.

Straightness

EIN AUS

Laser

Receiver

Magneticfoot adapter

Sliding bracketfor straightness

Workpiece

Typical straightness applications include:• Measuring straightness of long machine beds• Checking for runout on moving slides, tables and stages• Measure bend and straightness in tracks and guide rails• Shaft and drive alignment• Positioning bearings and shaft supports over long runs• Monitoring surface deflections and bending in long structures• Aligning long rail and track sections• Measuring deflections on rams, actuators, and extrusion presses• Checking roll flatness and crown profiles• Lathe and spindle alignment• Other measurement of linear deflections

2.1 Operating principle

The ROTALIGN Ultra alignment system uses a visible laser beam todetermine the straightness of linear workpieces. The laser emitter ismounted at one end of the workpiece or on an independentreference, and then aimed at the receiver. Both the laser and thereceiver are adjusted to ensure the receiver detects the laser.

The receiver uses a semiconductor position detector to preciselymeasure both the horizontal and vertical positions of the beam. Thereceiver is moved along the workpiece, and any changes of the laserbeam position in the receiver gives a measure of straightness.

The laser beam is not intended to be the absolute reference. The set-up should be such that the laser beam always strikes the detectorthroughout the entire length being measured.

Different brackets allow this principle to be used on a wide variety ofapplications, including straightness measurement of rolls on papermachines and rolling mills.

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ltra Straightness 04.06

2.2 Understanding the working of the slidingbracket for straightness

2.2.1 Measurement plane positionThe physical position of the measurement plane is close to the back ofthe receiver housing as shown below.

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The optical (not physical) position of the measurement plane isdifferent due to the effect of the lens.

4.5 mm

4.5 mm 20 mm

Understanding the sliding bracket

Physical measurementplane

The optical measurement plane is inline with the middle contact pointon the base plate of the slidingbracket.

middle contact point

base plate

The optical measurement plane (shown as the dotted line in thefigures) is located approximately 4.5 mm behind the housing of thereceiver, or 20 mm from the center of the support posts as shownbelow.

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2.2.2 Identifying the correct position to mount the receiverThe possible errors due to the offset between measurement plane andmeasurement contact point can be minimized depending on theposition where the receiver is mounted on the sliding bracket forstraightness. If for any reason the receiver inclines during measure-ment, the error is magnified by a factor depending on the distance ofthe receiver from the inclination fulcrum.

In the above configuration, thereceiver is mounted on thesliding bracket such that thecenter support point falls on thesame plane as the measurementplane.

Should the bracket incline, erroris minimized.

In this configuration, the mea-surement plane does not fall inline with the center supportpoint and therefore errors dueto inclination are amplified.

In the above configuration, thereceiver is mounted close to thebase plate. This minimizes errorsshould the sliding bracketincline.

In the above case the error isamplified as the receiver hasbeen mounted at a longerdistance to the base plate.

Understanding the sliding bracket

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Setup

2.3.2 Bracket mounting3. Place the sliding bracket ALI 3.198 onto the machine as shown

below. Ensure that the three of the support studs on the bottom ofthe bracket plate rest firmly on the surface to be measured.

4. Position the laser assembly (laser mounted on the magnetic foot)at least 500 mm / 20" away from the nearest measurementlocation. With the laser switched on, the beam should strike thereceiver dustcap.

EIN AUS

Custom-made brackets can also beused in conjunction with theALI 3.199 adapter.

2.3 Setup

The standard description below could vary depending on theapplication and the laser unit used.

2.3.1 Mounting laser and receiverThe laser ALI 3.610 mounts on the magnetic foot ALI 4.501 at oneend of the workpiece. The receiver ALI 3.600 is mounted onto thesliding bracket ALI 3.198, which is moved along the workpiece fromone measurement location to the next.

1. Ensure that the yellow knobs on both the laser and the receiver areloosened enough to let you slide the housings onto the supportposts.

2. Tighten the yellow knobs to lock the components onto the posts,then remove the dust cap from the laser.

Note

The adapter ALI3.199 is part ofthe magneticfoot

ROTALIGN laserALI 3.610

Magnetic footALI 4.501

ReceiverALI 3.600

Sliding bracketfor straightnessALI 3.198

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Setup

2.3.3 Connecting the receiver5. If not already done, insert the angled end of the receiver cable

ALI 3.581-5 into the receiver socket, noting the keyway orienta-tion, and screw the plug fitting into place.

The angled plug should be permanently left connected to thereceiver, even during storage in its case, as this will help avoiddamage to cable pins, plugs and sockets.

Match the double-sided arrow head on the plug to the red markingon the socket to ensure proper plug orientation; otherwise the pinsinside the plug may be damaged.

To disconnect, grasp the ribbed collar of the plug on the receivercable ALI 3.851-5 and carefully pull it out of the ROTALIGN UltraRS 232 sensor socket.

ATTENTION

6. Plug the quick fit straight end of the receiver cable ALI 3.581-5into the eight-pin socket at the top of the ROTALIGN Ultracomputer. Note the keyway indicating proper plug orientation. Agentle push is required until the plug clicks into place.

ATTENTION

If using the RF Bluetooth moduleALI 4.621 for wireless data trans-mission, please refer to the Blue-tooth guide 0 0594 1184.

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Setup

2.3.4 Switch on ROTALIGN Ultra computerPress and hold for approximately 1-2 seconds. The opening screenshown below appears:

Use the navigation keys to highlight the 'Straightness' icon. Press to start the application.

If the straightness firmware has not been licenced, on pressing , ahint to enter the registration key through the licence manager willappear as shown below.

Press to access the licence manager.

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Use the navigation keys to highlight 'Straightness'. Press andproceed to enter the registration key for the application in the editingbox. The registration key (license code) is contained in the LEVALIGNUltra straightness firmware registration certificate ALI 4.745.

After successful registration, a green tick appears next to theapplication and straightness can be started.

The required registration key(licence code) is obtained afterfilling out and returning theLEVALIGN Ultra straightnessfirmware voucher ALI 4.735 toPRÜFTECHNIK Alignment Systemsor your local representative.

2.4 Dimensions

2.4.1 Set up measurement locationsAfter starting the straightness application, the screen below appears.Use the navigation keys to highlight action to be carried out. Tocreate a new file, select 'Straightness line'.

Dimensions

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Press to confirm selection. The 'Creating a new line' screenappears.

The screen above shows the locations to be measured as the receiveris moved along the workpiece.

Use the navigation keys to select item to be edited. Enter the requiredvalue using the data entry keys. Press either or to confirmentry.

Alternatively, after selecting item to be edited, press . The editingbox appears. Edit values using the data entry keys, pressing either or to confirm entries.

Use the navigation keys to movethrough the items.

Enter the total length over whichmeasurements are to be made onthe workpiece, then enter thenumber of points to be measuredalong the total length. The comput-er calculates the interval betweenpoints.

Alternatively, 'total length andinterval' or 'interval and number ofpoints' may be entered. The com-puter then calculates the missingentry.

The maximum number of pointsthat can be measured is 100.

Dimensions

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Dimensions

After all fields required to create a new line have been completed out,the highlighting box jumps automatically to 'Proceed'.

Press to confirm selection. An overview screen of the configura-tion appears.

The view can be zoomed in and out using the context menu item'Zoom'. Alternatively use / to zoom in/out.

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2.5 Editing measurement locations

The following steps are to be performed only when necessary.

2.5.1 Adding new measurement pointsa. While in the set-up overview screen use / to select measure-

ment location where a point needs to be added.

Use the navigationkeys to highlight thecontext menu item'Zoom'. Confirm therequired zoom viewby pressing .

b. Press to access the context menu.

Editing line points

To access the context menu press while in the set-up screen.

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c. Use either or to highlight 'Add point'.

d. Press to confirm the new position.

The newly added point is always equidistant from the twoneighbouring measurement locations. If however, a point is addedafter the last measurement point, the distance of the newly addedsegment is equal to the previous last segment. E.g. If in the aboveset-up screen, a measurement point was to be added after point 12,the segment 12–13 would be the same distance as segment 11–12.

After pressing , the measurement location is added withoutfurther confirmation.

Note

Currently highlightedmeasurement location

Previously highlightedmeasurement location

Newly addedmeasurementlocation

Editing line points

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Editing line points

2.5.2 Editing individual positionsa. While in the set-up overview screen use / to highlight the

measurement location required to be edited.

b. Press . The highlighting box appears on the first item that canbe edited (in this case around the distance box).

Alternatively, the highlighting box can be activated from (a) aboveby pressing . From the context menu that appears, use either

or to highlight the context menu item 'Edit point'.

Press to edit the selected measurement point. The screen withthe highlighting box as seen above appears.

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c. With the distance box highlighted, use the data entry keys to editthe distance using the data entry keys.

d. Press either or to confirm the new position. The 'confirmchanging point' dialog window appears.

The editing box opens as soon asany data entry key is pressed.

Editing line points

e. Use the navigation keys to highlight 'Yes' and then press either or to confirm the change.

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h. Press either or to confirm the new name. On confirmation,the new name appears in the 'Name' box.

Editing line points

f. To edit the name of a selected point, use the navigation keys tohighlight the 'Name' box as seen below.

g. Use the data entry keys to edit the name of the individual position.The editing box appears as soon as any data entry key is pressed.

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2.5.3 Editing offset valuesIf the workpiece being measured has different levels, the verticaloffset must be taken care of without moving the laser. This offset iscompensated by applying offset tubes and shims on the receiverbracket assembly.

Distance sleeve (offset shim)

Adapter ALI 6.952

Receiver

Magnetic foot

Editing offset values

a. Access the 'Offset' box as described in steps (a) and (b) in section2.4.2 ('Editing individual positions').

The bracketing arrangement below is only possible with theLEVALIGN laser which is available only in the long range packages. Note

Note that in this configuration, thereceiver is mounted on the magnet-ic foot.

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b. With the 'Offset' box highlighted, use the data entry keys to enterthe offset value for the individual position.

c. Confirm entry by pressing either or .

The editing box opens as soon asany data entry key is pressed.

The diagram opposite shows theline position 6 with an offsetsymbol.

The offset value entered during set-up is also referred to as manualoffset and is overriden whenever auto offset is active. Auto offset isset in the measurement screen.Note

Editing offset values

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2.5.4 Defining state of line positionDepending on the workpiece being measured, it may be necessary todefine the state of certain line positions. These could either bephysically non-existent or fixed in order to act as reference points.The definition of line positions is carried out in set-up as follows.

a. Access the 'State' box as described in steps (a) and (b) in the'Editing individual positions' (page 2-10).

b. With the 'State' box highlighted, press . The drop down menuappears.

Defining line positions

c. Use either or to highlight the required state and then press to confirm selection.

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Defining line positions

2.5.5 Deleting pointsa. While in the set-up overview screen use / to highlight the

position to be deleted.

b. Press to delete the highlighted measurement point.

d. The position now appears with the corresponding symbol. Thefigure below shows the various options.

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Deleting points

Alternatively, press to access the context menu. Use use either or to highlight the context menu item 'Remove point'.

c. Press to confirm selection. The 'Deleting point' confirmationscreen as shown below appears.

d. Use the navigation keys to highlight 'Yes'. Use either or toconfirm the deletion.All positions to the right of the deleted position are consequentlyrenumbered.

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2.6 Laser beam adjustment principle

Before measurement can begin, the laser must be positioned suchthat the beam strikes the approximate center of the receiver lens overthe entire measurement path. Actual measurements then reflect theexact deviation from this initial beam position.

The system's built-in wizard guides users through the laser beamadjustment procedure. The laser wizard is accessed via the globalmenu. The global menu is opened by pressing twice.

2.6.1 Laser adjustment procedureThe following laser adjustment procedures are for the ROTALIGNlaser ALI 3.610. If using the rotating laser LEVALIGN ALI 6.910,please refer to the 'Flatness operating instructions ALI 9.847.G.

2.6.1.1 Offset adjustment with the receiver located in 'near'position:

The entire laser bracket frame can be loosened on the magneticbracket post, then moved up or down for approximate adjustment.The laser itself can be loosened on its support posts, then moved upor down for fine vertical adjustment. Horizontal adjustment can bemade by moving the entire laser bracket assembly.

Note

If you elect to use the wizard, follow the instructions accurately. Ifnot using the wizard, use the following description.

Note

Laser beam adjustment

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a. With the receiver at the closest measurement position, leave thedustcap on for the moment.

b. Remove the laser dustcap and the switch it on.

Do not stare into the laser beam!

After beam adjustment has been carried out, maximum measure-ment stability can be ensured by switching on the laser at least 30minutes before beginning measurement.

WARNING!

Note

c. Adjust the height of the beam to center it vertically on the receiverdustcap. If the laser and receiver have been roughly positioned toeach other during mounting (see page 2-2), the laser beam shouldstrike the red cap of the receiver. If not, use a white piece of paperto try and locate the beam and readjust it onto the receiver.

ON/OFF switch

d. Offset adjustment: adjust the position of the laser to center thebeam onto the receiver cap.

Vertical adjustmenti) Rough: loosen the support post assembly to allow it to slide upand down on the magnetic bracket post.ii) Fine: Loosen the locking knobs, then slide the emitter along itssupport posts.

Horizontal adjustmentDeactivate the magnetic bracket clamp, then position the entireemitter bracket assembly laterally.

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2.5.1.2 Angular adjustment at the 'far' position:The laser bracket frame can be loosened on the magnetic bracketpost, then swiveled horizontally for rough horizontal angle adjust-ment. The yellow thumbwheels on the laser housing allow fineadjustment of horizontal and vertical beam angularity.

horizontal angle

vertical angle

a. With the receiver at the far end of the measurement path, adjustthe angle of the beam to center it onto the receiver dustcap.

Horizontal adjustmenti) Approximate: Loosen the locking knobs, then swivel the lasersupport assembly horizontally on the magnetic bracket. (Avoidletting the assembly move vertically to retain the previous adjust-ment.)ii) Fine: Turn the yellow thumbwheel on the bottom corner of thelaser housing to adjust the exact horizontal angle of the beam.

Vertical adjustmentTurn the yellow thumbwheel on the top of the laser housing toadjust the exact vertical angle of the beam.

b. Repeat steps 2.5.1.1 and 2.5.1.2 as necessary until the beamremains centered on the receiver cap in both the 'near' and 'far'positions.

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2.7 Taking measurements

a. Remove the receiver dustcap. Place the receiver at the closestmeasurement position. Press to enter the beam adjustmentmode.

The beam position should appear in the displayed detectordiagram as a red dot within the target circle, remaining within thecircle when the receiver is moved to the far end of the measure-ment path. If not, repeat adjustment steps 2.5.1.1 and 2.5.1.2 asnecessary.

b. If the beam appears on the display as shown in the diagram above,you may now proceed with actual measurement.

The measurement in the shownexample has been carried out usingthe RF Bluetooth module ALI 4.621.Please refer to the Bluetooth guide0 0594 1184.

Note

To ensure maximum measurement stability, place the receiverassembly at the most distant position for the first measurement andwork successively toward the closest position to the laser.

c. Move the receiver assembly to the designated most distantposition.

d. Use / to highlight this measurement position on the displayscreen (see diagram overleaf).

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Measurement

f. Use / to proceed to the next position on the line and move thereceiver to the corresponding measurement position.

g. Take the measurement for this point by pressing . The display isupdated to include this new set of readings.

g. Repeat steps (d) and (e) for each remaining measurement point inturn, moving successively closer to the laser emitter.

h. Any measurement may be deleted by using / to mark it, thenpressing .

e. Press to take the first measurement. The (V,H) beam coordi-nates are displayed.

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Measurement –sign convention

2.7.1 Sign conventionAs can be seen from the previous measurement screen, the centredlaser beam lies in the first quadrant. The measured Y value on thedetector surface corresponds to the actual surface value V but with anegative sign. This is explained by the fact that the laser position onthe detector changes in the opposite direction to the actual surfacedeviation. In the example below, the laser beam is centered at thefirst measurement position. At the second position, the surfacedeviation decreases by say 2.00 mm. As the laser beam remainsunaltered, it strikes the detector surface 2.00 mm above the centreposition 0,0, and therefore the detector reading of Y = +2.00 mm,but the actual surface deviation V = -2 mm as shown on the displayscreen.

V = -2 mm

Y = +2 mm

2.7.2 Using auto-routing in measurementa. The auto-routing function enables the intelligent and automatic

selection of the next measurement position. Auto-routing isaccessed from the measurement screen.

b. While in the measuremt screen press . The context menu asshown below appears.

This configuration is based on thelong range (LEVALIGN laser) ver-sion.

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Measurement – auto-routing

c. Use the navigation keys to select 'Auto Routing' /'On', and confirmselection by pressing . For details on 'Auto Routing' please referto the 'Measurement options' on section 2.8

d. Proceed to take measurement for the highlighted line position bypressing . After taking measurement, move the receiver assem-bly to the next measurement position. With auto-routing, thisposition will be assigned automatically.

After line position 11 has beenmeasured, the automatic measure-ment sequence highlights the nextposition - in this case position 10.

The navigation keys ( / ) can be used to override the auto-routing function.

Routing details will be discussed in the next section, 'MeasurementOptions'.

Note

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Measurement options

2.8 Measurements options

The measurement context menu items provide commands thatfacilitate measurement procedures. The context menu is accessed bypressing while in the measurement screen.

1a. The context menu item 'Take point' has the submenu items'Laser' and 'Manual'. Use or to toggle between these twosubmenu items. When 'Laser' is highlighted, the selected point ismeasured when is pressed.

1b. The submenu item 'Manual' can be used to compare readingstaken using conventional methods. Highlighting 'Manual' andconfirming selection using reveals the dialog window withthe H/V value editing box.

After manually entering the H valueand confirming entry by pressingeither or , the V value editingbox appears.

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A 'pencil' symbol ( ) next to a measurement indicates that themeasurement has been entered manually.

The measurement table also shows the composite reading whichis the average of all checked ( ) measurements.

If however all measurements for a given position are unchecked,the position appears with this symbol ( ).

Note

2a. The context menu item 'Measurement Table' is used to access themeasurement table. The table shows a detailed history ofmeasurements for each individual measurement position.

Use either or to highlight 'Measurement Table'. Press to view all measurements taken at the position currentlyhighlighted.

Measurement options

Individual measurements can be checked by simply highlightingthe measurement and then pressing .

Measurementsselected foraveraging

Highlightedposition

Date & time of readingLast 4 serial numberdigits of sensor used

Measured (H,V)beam coordinates

Averagingsetting used

Temperature attime of reading

Composite reading

Manually enteredmeasurement values

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2b. The measurement table context menu allows the checking,unchecking and deletion of measurements. Manually enteredreadings can also be edited.

The submenu items 'Check'/'Uncheck', 'Delete', 'Edit value', 'Fullscreen'/'Details' are accessed by highlighting the respective itemusing either or and then pressing .

The submenu item 'Check'/'Uncheck' is used to check/uncheckthe selected measurement, an action that influences the compos-ite reading. Individual measurements can also be checked andunchecked by highlighting the respective measurement usingeither or and then pressing .

The submenu item 'Delete' is used to delete the highlightedmeasurement. On pressing , a dialog window with the hint toconfirm deletion appears. Use or to highlight 'Yes' and thepress either or to complete deletion.

The submenu item 'Check' is used to check/uncheck all measure-ments, an action that also affects the composite reading.

The submenu item 'Edit value' is used to edit manually enteredvalues.

The submenu item 'Fullscreeen'/''Details' toggles the displaybetween the full screen and the details mode.

The 'Check all' function is notpossible if a 'Move' has beencarried, as readings taken beforeand after a move cannot be aver-aged together.

Measurement options

When in the 'Measurement table'screen, pressing either or longenough, selects the next measure-ment position to the left or rightrespectively.

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3a. The context menu 'Auto-routing' has the submenu items 'On','Off' and 'Op..' (options).

In the example opposite, thesubmenu item 'On' appears activeindicating that auto-routing has notbeen selected for the currentmeasurement. Auto-routing isturned on by highlighting 'On'using / and confirming selectionby pressing .

The auto-routing symbol is greyedout showing that auto-routing iscurrently disenabled.

3b. Highlighting 'Op..' (options) using / and confirming selectionby pressing reveals the measurement options dialog window.

3c. The drop down menu has the options 'Left to right' and 'Right toleft'. These options determine the automatic progression ofmeasurement from one position to the next.

The 'Primary move' drop downmenu can only be activated whenauto-routing is checked.

Use the navigation keys to high-light 'Primary move'. Press toreveal the drop down menu. Selectthe direction of progression using

/ . Confirm selection using or .

The auto-routing symbol shows thearrows pointing to the directionwhere the position highlight willnext move to.

Measurement options

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Measurement options

If auto-routing is selected, the next measurement position will behighlighted automatically only after the set measurements perposition have been attained. The measurements are initiated bypressing on each occasion.

The measurement position symbol is shaded out depending on thenumber of measurements taken. As an example, one third of thesymbol will be shaded after the first of three measurements istaken.

During the taking of these measurements, the message 'measure-ment "x" of "y" in progress ...' appears. After "y" measurements havebeen taken, the message "moving focus to point 'b'" appears. Thesucceeding measurement position "b" is then highlighted.

Note

The example opposite is with auto-routing checked and measurementsper point set at 3.

Measurement position 2 will behighlighted after the hint disap-pears.

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4a. The number of measurements to be made per position can alsobe defined from the 'Measurement options' screen.

4b. Use the navigation keys to highlight the 'Measurements perpoint' box. Press to highlight the digit in the box. Use /to set the number of measurements per position. Use or toconfirm frequency of measurement.

5a. The measurement option 'Averaging' is used to adjust thenumber of individual detector readings for averaging into asingle measurement. The greater the number of readings, thelonger each measurement takes. This duration is indicated inseconds on the screen.

Measurement options

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5b. Use the navigation keys to highlight the 'Averaging' box. Press to reveal the drop down menu. Use / to select the desiredaveraging. Use or to confirm the selected value.

6a. If there is an intentional difference in height between two ormore measurement positions, e.g. between a measurementposition on a pump base plate and another, on a motorfoundation, offset shims are placed beneath the receiver tocompensate the depth difference.

If the depth of the step has thesame value offset shim, there is noneed to consider this value in thestraightness calculation, andtherefore the value must not beentered in the instrument software.Note that the shown configurationis based on the long range(LEVALIGN laser) version.

This compensation, if required is entered under the measure-ment context menu item 'Auto offset'. To Access 'Auto Offset',press . The context menu appears.

6b. Use / to highlight 'Auto Offset'/'On', and then press .The editing box appears.

Measurement options

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6c. Use the digit keys to enter the desired vertical offset value.Confirm entry using either or .

6d. Once the vertical offset value (V-Offset value) has been entered,it is used automatically, in the calculations, for all measurementpositions where auto offset has been activated.

If auto offset has been activated, the measurement context menuoffers only the deactivation option 'Auto Offset'/''Off'.

The vertical offset value overrides the manual offset value that mayhave been entered in set-up.

Note

This symbol indicates that autooffset has been activated. In thisparticular example, the auto offsetis 15 mm.

Measurement options

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7a. The workpiece being measured may have a very uneven surfaceor a trough. In such cases, there is the possibility that the laserno longer strikes the receiver at certain measurement positions.Shims may be used to raise the receiver to a height which makesmeasurement possible.

If the height of the receiver is extended using shimming tubes,then the value of the shims is edited using the measurementcontext menu item 'Extend by tube'.

7b. To acccess 'Extend by tube', press . The context menu appears.

7c. Use the navigation keys to highlight the context menu item'Extend by tube'. Use / to highlight 'On'. Press to reveal the'tube summation' screen (see overleaf).

Measurement options

This configuration is based on thelong range (LEVALIGN laser) ver-sion.

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7d. Use / to highlight 'Add'. Press to enter the value of thedistance sleeve (tube) to be used in the specific measurement.

Measurement options

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Measurement options

8a. Measurement can also be carried out using wireless datatransmission. Before proceeding with this measurement option,please refer to the guide to using the Bluetooth RF module (00594 1184).

8b. The context menu item 'Bluetooth/XY view' is used for setting upwireless communication and centering the laser beam duringmeasurement respectively.

8c. After highlighting 'Bluetooth' using the navigation keys, press to confirm selection. The Bluetooth RF-module selection screenappears.

The Bluetooth option is accessedfrom the measurement screen.Pressing reveals the contextmenu. Use the navigation keys tohighlight 'Bluetooth'.

8d. Use / to highlight 'Scan' and then press . With this step,the neighbourhood is scanned for Bluetooth devices. After thescanning process is completed, any RF modules detected will belisted with a green tick on the side (see figure overleaf).

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Measurement options

8e. Use / to select the appropriate RF module (e.g.'PRÜFTECHNIK RF-module 00000018'). Press to confirmselection and proceed with measurement.

The system memory retains theserial number of all Bluetooth RFmodules used with the system. Theexample opposite shows that themodule 23050026 was not detectedduring the scanning process, buthad previously been used with thesystem (probably during the testprocess).

9a. The submenu item 'XY view' is used to assist in centering thelaser beam. Use / to highlight the submenu item 'XY view'.

9b. Press to confirm selection. The XY view screen appears (seeoverleaf).

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Measurement options

9c. After centering the laser beam, press to continue withmeasurement.

9d. To access the XY view context menu press .

'Bluetooth'/'Cable' – used to select the measurement datatransmission mode.

'Trace on'/'Trace off' – used to follow the beam path in thedetectors; useful for beam adjustment.

'Set to zero'/'Absolute' – currently adjusted beam position is setto ‘0’ to serve as a reference; ‘Absolute’ isused to return to the original status.

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Measurement options

To enter the V-Offset value, use thenavigation keys to highlight 'Autooffset'. Press to activate thefunction. A check mark appears onthe box next to 'Auto offset'. Nowuse the navigation keys to highlight'V-Offset value'. Press . Theediting box appears. Use the dataentry keys to enter the predefinedoffset value. Confirm selection bypressing either or .

10a. The measurement context menu item 'More' has the submenuitems 'Options', 'Full view', 'Zoom out' and 'Zoom in'.

10b. The 'Options' menu item can be used to set auto routing andaveraging, define measurements to be taken per position, andselect auto offset. Vertical offset can be entered only when'Auto offset' is checked.

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2.9 Evaluating results

After taking position measurements, press to display results.

Interpreting results

Measurement values at cursor position

While in the results screen, theview can be zoomed in and outusing and respectively.

measurement in the vertical plane (V)

measurement in the horizontal plane (H)

The straightness condition is shown here as measured, i.e. thedetector readings are plotted directly as they appear in the measure-ment position list. The cursor line marks the current position whoseexact vertical and horizontal values appear both on the middle frameand the status line of the display.

2.9.1 Interpreting resultsa) The default setting in results display shows all measurement

positions relative to the laser beam. The reference here is the laserbeam.

b) If however you are focussing on relative straightness of themeasured workpiece, use the reference option 'Bestfit'. The beststraight line through the measured positions will be calculated.

c) Another option used to interpret results is to designate twomeasurement points as fixed. Points designated fixed are automat-ically anchored to V=0 and H=0.

Top tolerance value

Bottom tolerance valueTop measured value

To fix a measurement point, use / to highlight position to befixed and then press . Pressing with the cursor highlighting afixed measurement position unfixes this particular position.

Only a maximum of two measurement points can be fixed on anyone defined workpiece.

Note

Position cursor

Position cursor

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The results context menu items help in interpreting measurementresults. To access the results context menu, press . The contextmenu appears.

2.9.2 Context menu items

The context menu items and thecorresponding submenu items arehighlighted using the navigationkeys .Press to access any selectedmenu item.

1. The context menu item 'Reference' has two submenu items –'Laser' and 'Best fit'.With Laser as reference, the display shows the displacement of themeasured points with respect to the laser beam.If 'Best fit' is selected, the computer automatically recalculates thedisplacements.

The diagram opposite shows thebest fit vertical view with twopoints (1 and 8) fixed.

Positions 1 & 8 are fixed

Specified tolerance

Maximum top value

Results

Measurement position 7 is hidden

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2. The context menu item 'Value mode' has three submenu items –'Original', 'All positive and 'All negative'.

The value mode takes the reference line into consideration.Original values – uncorrected values respective to the reference

lineAll positive – the reference line has the lowest valueAll negative – the reference line has the highest value

The value mode is employed in the repositioning and reworking ofworkpieces. It may occur that a workpiece can only be welded. Inthis case, the "All negative" mode would generate ideal solution. Note

Results

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Selecting 'Table' displays measured positions and the measure-ment details of the positions in a tabular format.

Measurement positions in tabularformat

3. The context menu item 'Save' is used to save the measurementfiles.

4. The context menu item 'View' has four submenu items – 'V/H', 'V','H' and 'Table'. The Vertical (V), horizontal (H) and 'V/H' submenuitems appear depending on view currently selected.

Results

The pencil icon indicates that themeasurement has been manuallyentered.

The plus icon indicates that themeasurement position is not visible.

The traingle icon indicates that themeasurement position is fixed.

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5. The context menu item 'Details'/'No details' toggle depending onview currently selected, showing or hiding the measurementdetails of the selected measurement position.

6. The context menu item 'Zoom' is used to zoom the screen in andout. The submenu item 'View' displays all the measurementpositions.

The measurement contour is also zoomed in and out using and respectively. Make sure the navigation keys are pressed long

enough.You can also zoom in and out using and respectively.

Note

Results

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7. The context menu item 'More' has the submenu items 'Statistics','Tolerances' and 'Options'.

The submenu item 'Statistics' displays the statistical data related tothe entire measurement. It is accessed by highlighting 'Statistics'and then pressing .

Use / to highlight 'More...'.The submenu items can be high-lighted using / .

Results

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The submenu item 'Tolerances' is used to set the tolerance value.

Checking the 'Auto range boxactivates the auto range value

When the 'Auto range' box is checked, the tolerance is setautomatically at the highest measured value.

User defined tolerance value can only be set when the 'Auto range'box is unchecked.

Results

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The submenu item 'Options' is used to set the reference valuemode, the default reference and the mode in which the positionsare connected.

Results

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2.10 The live move mode

After measurement has been carried out and results analysed, it maybe necessary to make corrections by moving sections of the work-piece slightly. A major goal during the correction process is tominimize movement and still reach the required objective. Thesystem's live move mode makes it possible to monitor these correc-tions, hence minimizing the chances of overshooting the requiredcorrection.

b) Press . The context menu appears. Use / to highlight thecontext menu item 'Move'.

a) Once measurement has been completed and the relative straight-ness determined, use / to highlight measurement position to bemoved.

Live move

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c) Confirm selection by pressing . The 'Move set-up' displayappears.

d) After ensuring that both the measurement position and the 'bestfit' position fall within the detector surface, press . Use /to highlight the context menu item 'Start'.

Measurement position to be moved

The 'best fit' position where themeasurement position is to be moved

Before starting live move, it isimportant to ensure that thedetector is positioned in such a waythat the laser beam does not driftaway from the detector surface.

e) Confirm selection by pressing . The ' Live Move' displayappears.

Live move

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f) Adjust the selected measurement position such that it intersectsthe 'best fit' position.

g) After this adjustment, press . Use / to highlight thecontext menu item 'Stop'.

h) Confirm completing measurement by pressing .

i) To view the results after the adjustment, press .

Live move

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j) You may proceed to save the measuremnt file using the resultsdisplay context menu or the global menu.

Saving results

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Blank page

Blank page

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A

Absolute 2-39Adapter

ALI 6.952 2-15Additional ROTALIGN Ultra

straightness packages 1-8ALI 13.701 CD

Alignment Reporter CD 1-6ALI 2.905

Lens cleaning cloth 1-6ALI 3.198

Sliding bracket for straightness 1-6ALI 3.199

adapter 2-4ALI 3.581-5

receiver cable, 5 m 1-5ALI 3.588

tape measure 1-5ALI 3.600

ROTALIGN receiver 1-4ALI 3.610

ROTALIGN laser 1-4ALI 4.007

ROTALIGN Ultrastraightness 2D compact package 1-8

ALI 4.020-LROTALIGN Ultra

straightness 2D long range package 1-7ALI 4.200

ROTALIGN Ultra computer 1-4ALI 4.451 SET 1-6ALI 4.501

magnetic foot adapter 1-5ALI 4.502-2

ROTALIGN Ultra USB cable 1-5ALI 4.503 1-5ALI 4.735 2-7ALI 4.745

Ultra straightness firmwareregistration certificate 1-6

ALI 4.811straightness case 1-4

ALI 6.952magnetic foot accessories 1-5

ALI 6.953distance sleeves 1-5

ALI 9.847.G 2-20All negative 2-43All positive 2-43

Auto offset 2-16, 2-33activated 2-34

Auto range 2-47Auto-routing 2-25, 2-30

symbol 2-30Averaging 2-32

B

Best fit 2-42Bestfit 2-41

C

Check all 2-29Context menu items 2-42

D

Deleting points 2-18Distance sleeve

(offset shim) 2-15

E

Edit point 2-12Editing

individual positions 2-12Editing offset values 2-15Equidistant 2-11Extend by tube 2-35

I

Interpreting results 2-41

L

Laserlong range 1-8

Laser adjustment'far' position 2-22procedure 2-20

Laser adjustnment'near' position 2-20

LEVALIGN laserALI 6.910 1-8

LEVALIGN Ultra straightness firmwareregistration certificate

ALI 4.745 2-7Licence manager 2-6Line position

defining state 2-17Live move 2-49

Index

Index

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M

Manual entry 2-27Measurement table 2-28Measurements per position 2-32Mounting

laser and receiver 2-2, 2-4

N

New linecreating 2-8

New measurement pointsadding 2-10

Number of pointsmaximum 2-8

O

Offset value 2-16Options

more 2-40

P

Position cursor 2-41Primary move 2-30

R

Receiverconnecting 2-5

Reference 2-42RF Bluetooth module 2-37

ALI 4.621 2-5, 2-23ROTALIGN Ultra

straightness 2D packageALI 4.020 1-4

S

Safety symbols 1-9Scan 2-37Set to zero 2-39Sign convention 2-25Straightness applications

typical 2-1Straightness firmware

licence 2-6SYS 3.651

battery charger 1-5

T

Tolerances 2-46Trace off 2-39Trace on 2-39Trough 2-35Tube summation 2-35

V

vertical offset value 2-34

X

XY view 2-38

Z

Zoomed in 2-9

Index

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PRÜFTECHNIK Alignment SystemsD-85737 Ismaning, GermanyTel.:+49 89 99 61 60Fax:+49 89 99 61 61 00Email: [email protected]

From the inventors oflaser shaft alignment

Printed in Germany ALI 9.848.07.06.0GROTALIGN® is a registered trademark of PRÜFTECHNIKDieter Busch AG. PRÜFTECHNIK products are the subjectof patents granted and pending throughout the world.Contents subject to change without further notice,particularly in the interest of further technical develop-ment. Reproduction, in any form whatsoever, only uponexpress written consent of PRÜFTECHNIK AG.© Copyright 2006 by PRÜFTECHNIK AG

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ROTALIGN-Ultra Straightness ALI 209-848!08!06 1.13 G

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Transcript of ROTALIGN-Ultra Straightness ALI 209-848!08!06 1.13 G