CALYPSO

Option 13
Metrotomography

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.
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ing a utility model.
This manual is subject to modification. All rights pertaining to changes
in the CMM and its options reserved.
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responding proprietors.

Carl Zeiss CALYPSO: Operating Instructions

Business Group Revision status: 4.10
Industrial Metrology Ltd. Date of issue: 07/09
D-73446 Oberkochen Order No.: 61212-2830402
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“ on page This is a cross reference. If you view this book
-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.

61212-2830402 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 61212-2830402 Operating Instructions

Contents
Kapitel 1 Metrotomography
Basics of metrotomography . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Measuring a CT dataset with CALYPSO . . . . . . . . . . . . . . . . . . . . 1-3
Basic terms and parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Measurement with dynamic threshold . . . . . . . . . . . . . . . . . . . 1-4
Measurement with static threshold . . . . . . . . . . . . . . . . . . . . . 1-5
Gradient Threshold parameter . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Smooth Area parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Search Area parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Direction Match parameter (dynamic). . . . . . . . . . . . . . . . . . . . 1-6
Direction Match parameter (static) . . . . . . . . . . . . . . . . . . . . . . 1-7
Scaling Factor parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Visualization of the CT dataset . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Alignment of the CT dataset . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Preparing a CT dataset for measurement . . . . . . . . . . . . . 1-9

Preparations in CALYPSO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Importing CAD data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Importing a CT dataset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Reducing the size of the CT dataset . . . . . . . . . . . . . . . . . . . . 1-16
Settings for the CT data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Visualizing a CT dataset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Aligning the CT dataset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Nominal-actual comparison on a CT dataset . . . . . . . . . . . . . . . . 1-23

Manual measurements on the CT dataset . . . . . . . . . . . . 1-28

Measuring in intersection planes . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Creating an intersection plane . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Measuring on the intersection . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Measuring with templates . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

61212-2830402 Operating Instructions Contents 1

 Measurements on the CT dataset during the CNC run . . 1-34
Creating a measurement plan . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Features resulting from probing operations on the CT dataset 1-34
Generating profile elements on the CT dataset. . . . . . . . . . . . 1-35
Measuring and evaluating during the CNC run . . . . . . . . . . . . . . 1-35

Contents 2 61212-2830402 Operating Instructions

 Chapter

1 Metrotomography
.................................................................................................................................
The METROTOM allows you to use the computed tomography,
known from medical applications, for components and workpieces.
The CALYPSO Metrotomography option enables measuring and che-
cking of CT data acquired with the METROTOM.

This chapter contains:

Basics of metrotomography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Preparing a CT dataset for measurement . . . . . . . . . . . . . . . . . . . 1-9
Manual measurements on the CT dataset . . . . . . . . . . . . . . . . . 1-28
Measurements on the CT dataset during the CNC run . . . . . . . . 1-34

61212-2830402 CALYPSO Operating Instructions 1- 1

 Metrotomography

Basics of metrotomography
The Zeiss measuring machine METROTOM is used for radiographing
component parts from different angles and measuring the absorp-
tion. As with computed tomography, known from medical applicati-
ons, a three-dimensional model of the component part will be created
on the basis of the measuring results.
Pixels and voxels The space is divided into small cubes, i.e. voxels. A voxel (volume ele-
ment) is the three-dimensional equivalent to the pixel (picture ele-
ment).

Pixel Voxel

According to the measured values, a certain “gray value” is assigned

to each voxel – a measure for the permeability to x-rays. The different
gray values of the voxels are used to determine geometry and mate-
rial properties of the component.
Acquisition of On the METROTOM, the component part is positioned on a rotary
voxel data table, whereas the X-ray tube and the detector are firmly mounted.
The rotary table is used to turn the component part, thus enabling to
take pictures from all angular positions.
The resolution of the detector and the position of the rotary table
during the measurement determine the size of the individual voxel.
Depending on the voxel size, different resolutions and measuring
accuracies are possible.

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 Basics of metrotomography

Use of CALYPSO Specific programs are used for controlling the METROTOM measu-
ring machine and for reconstructing the voxels from the X-ray images.
CALYPSO will only be used afterwards, for evaluation of the voxel
data.
CALYPSO allows you to check the geometry of the voxel data. Almost
every CALYPSO evaluation option can be applied to voxel data.
Evaluation is not performed directly on the machine and simultane-
ously with the measurement. Measurement and evaluation are two
separate processes and can run on different computers.
Procedure in CALYPSO In CALYPSO, measurement of voxels is like measurement using a spe-
cial CMM: CALYPSO is connected to a “machine” that will return for
certain nominal points the associated actual points.
This procedure can be compared to a simulation in CALYPSO: Here
again, you will have to establish a connection to a “virtual” CMM,
running in this case in the simulation mode.

NOTE Even if you do not possess an own METROTOM measuring machine,

hss this option allows you to evaluate in CALYPSO externally taken
images in the METROTOM format.

Measuring a CT dataset with CALYPSO

Except for a few functions (e.g. Step CMM with probing), you can use
all CALYPSO measurement strategies also for measurement according
to CT data. It is recommended to use high point densities:
– The individual points show a relatively strong distortion; large point
quantities therefore help improving the result. In most cases,
measuring large volumes of points hardly takes longer than
measuring few points.
– Probing a single point using the “Probing point” strategy will also
produce a distorted result, for which reason it is recommended to
use a higher point density even when measuring a single point.
With CALYPSO, you measure CT datasets collected on a CMM of the
METROTOM type. For this purpose, you create a measurement plan as
usual and have it executed.
Contrary to measurements on a normal CMM, you only control a “vir-
tual” CMM in this case. The measurement on the CMM is simulated
and the CT dataset represents the virtual workpiece, only existing in
the form of data.

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 Metrotomography

Presettings
To enable measurement according to CT data, some default settings
must be made in CALYPSO:
– Select the METROTOM as the machine type.
– Define the measurement method: Dynamic Threshold or Static
Threshold (STL).
– Enter further parameters in the CT Properties window that you
open via the Measurement Plan Resources.

General procedure
The further procedure is as follows:
– Defining the stylus
– Loading the CAD model, if existing
– Importing and visualizing the CT dataset
– Aligning the CT dataset
– Further execution of the measurement plan
– Measurement and evaluation

Basic terms and parameters

Measurement with dynamic threshold
According to the current state of development, the measurement
with Dynamic Threshold provides maximum accuracy when measu-
ring on the basis of CT data. The voxels calculated by the system are
used for the measurement.
Files with CT data The computed tomography system provides one or two files.

File name ending Meaning

*.uint16_scv uint16 = unsigned integer 16 bit; scv = signed CALYPSO Volume
*.zvi = AxioVision Image file

Select the file in the CT Properties dialog. The file will be loaded by
CALYPSO.
The following parameters are required for measuring on the basis of
the voxels:
– Gradient Threshold parameter
– Smooth Area parameter
– Search Area parameter

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 Basics of metrotomography

– Direction Match parameter (dynamic)

– Scaling Factor parameter

NOTE It is recommended to only change the default parameters in well-

founded cases.

Measurement with static threshold

It is also possible to use the Static Threshold method for measure-
ments with CALYPSO. In this case, no voxels are used for the measu-
rement, but the workpiece surface that is represented by triangles.
The file is usually provided in the STL format.

NOTE Different programs can be used for extraction of the surface from the
voxel data. The accuracy of the measurement with CALYPSO strongly
depends on the algorithm used for generation of the triangles.

The triangles are calculated using a static threshold value. All voxels
with gray values above the threshold are considered as material, those
whose gray values are below the limit are considered as environment.
When the measurement is performed, the nearest corner point is out-
put by CALYPSO as actual point.
Select the file with the surface data in the CT Properties dialog. The
file will be loaded by CALYPSO.
The following parameters are required for measuring on the basis of
the surface data:
– Direction Match parameter (static)
– Scaling Factor parameter

Gradient Threshold parameter

NOTE This parameter is only required for measurements with dynamic thres-
hold.

When measuring a CT point cloud, CALYPSO calculates the gradients

of the gray values along defined directions. Where a maximum gradi-
ent is detected, a transition point between material and air is sup-
posed.
Due to distortion, beam hardening and similar effects, the voxel con-
tains, however, falsifying gray value differences that cannot be alloca-
ted to any surface. In order to avoid misinterpretation, a fixed
gradient threshold is specified for the value of the gradient as of
which a transition point is to be supposed.

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Metrotomography

The threshold is specified as part of the absolute gray value maximum

between 0 and 1; the default value set is 0.25. If you have activated
the Automatic Parameter Definition, the gradient threshold will
automatically be determined. This is sufficient for most measuring
jobs.

Smooth Area parameter

NOTE This parameter is only required for measurements with dynamic thres-
hold.

As the gray values of the voxels are distorted, a distortion also exists
on the extracted gray value profile along the default line. Moreover,
other disturbances such as beam hardening may occur and cause a
distortion of the density transition.
In order to consider the distortion during the measurement, a smooth
area is defined. The smooth area defines the distance – measured in
voxels – used for smoothing the data.
The smooth area is set in millimeters to about 2 voxels by default.
Experience has shown that this value provides the best results. A lar-
ger smooth area may probably also consider a second, very near gra-
dient maximum, thus causing a displacement of the calculated
gradient maximum.
If you have activated the Automatic Parameter Definition, the gra-
dient threshold will automatically be determined. This is sufficient for
most measuring jobs.

Search Area parameter

NOTE This parameter is only required for measurements with dynamic thres-
hold.

The search area is specified in voxels and defines the distance from
the nominal point within which a gradient maximum is searched.
Search occurs both in positive and negative direction.
The search area, indicated in millimeters, is set to a length of 20
voxels by default. This is sufficient for most measuring jobs. For parts
with large deviation it may be useful to enlarge the search area.

Direction Match parameter (dynamic)

Once the intersection point of the default line (of the nominal vector
direction) with the “virtual” surface in the voxel space has been deter-
mined, the nearest voxel will be used to approximate the actual gradi-
ent direction from the values of the directly surrounding voxels.

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 Basics of metrotomography

The Direction Match parameter defines a limit for the deviation of

the default line from the actual gradient direction in the plane span-
ned by both of them. This parameter is specified in degrees (°). When
crossing the limit, the point found will not be output as measured
point.
By default, the parameter is set to 30°.

NOTE We recommend to set this parameter to eliminate faulty or undesired

points already before starting the evaluation.

Direction Match parameter (static)

Having determined the nearest triangle point to a defined nominal
point, the normal vector of the point will be determined from the tri-
angles concerned. The Direction Match parameter defines a limit for
the deviation of the default line (the nominal vector direction) from
the actual normal vector direction in the plane spanned by both of
them. This parameter is specified in degrees (°). When crossing the
limit, the point found will not be output as measured point. The para-
meter is not set by default.

Measuring Spanned plane

point

Default line

NOTE We recommend to set this parameter to eliminate faulty or undesired

points already before starting the evaluation.

Scaling Factor parameter

For some CT systems it is necessary to subsequently increase or reduce
the results by one factor. This is related to the rotary table position
relative to the tube and the detector together.
The position of the rotary table has an effect on the voxel size; a diffe-
ring position leads to a differing voxel size, thus causing a systematic
error.

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Metrotomography

This error can be eliminated by subsequently changing the voxel size.

With a scale factor > 1, the workpiece model will be enlarged, with a
factor - 1, it will be minimized.

! Important
A scaling factor ≠ 1 changes the measuring result. The METROTOM is
designed such that the scaling factor is always set to 1.

Visualization of the CT dataset

After import of the CT dataset, the data can be displayed in the CAD
window. Depending on the computer, the visualization can take a few
minutes.

NOTE When measuring with dynamic threshold, the visualized data dataset
only serves to check and align the data with respect to the CAD
model. Measurement is performed on the basis of the more precise
voxel matrix.

A voxel matrix does not exist for the measurement with static thres-
hold; the surface data is used for this measurement. The data is repre-
sented as small triangles by default.
– You may also switch to a display of single points.
– You can save the visualized data in FCT format.
– The visualization can be hidden by unticking CT Point Cloud in
the menu CAD → CAD Model Control.
The visualized point cloud can be treated in a similar way as the work-
piece on a CMM. By clicking the point cloud, you can create actual
points, as you do it by probing on a CMM. Manual alignment, too can
be done by clicking the visualized data.

Alignment of the CT dataset

Before starting a measurement on the CT point cloud, the data must
be manually aligned once.
Usually, the origin of the point cloud does not correspond to the ori-
gin of the nominal data. When measuring with dynamic threshold,
i.e. with the CT dataset read in as voxel matrix, the origin is usually
located at a corner of the matrix. The axis directions, too, normally do
not correspond to the nominal values.
To enable measuring according to the data, a manual prealignment
must be performed, as is the case for CMM measurements.

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 Preparing a CT dataset for measurement

Preparing a CT dataset for measurement

Special aspects of the The structure of a measurement plan for a CT point cloud differs from
measurement plan that of a normal measurement plan in the following items:
– You do not need to care for navigation paths.
– You do not need to define clearance planes.
– You can use high point densities without noticeable effects on the
duration of the measuring run.
– You must use a higher number of measuring points. With a CT
measurement, even a single point must be averaged from several
measuring points as the individual probing point has relatively high
distortion.
Types of use CALYPSO offers different ways to measure the CT dataset:
– with CAD model
You can load a CAD model of the workpiece and create the
measurement plan from this model or you can use an already exis-
ting measurement plan.
– without CAD model
You can create the measurement plan without using a CAD model
by teach-in programming. For this purpose, you click the visualized
CT point cloud and CALYPSO probes the features accordingly. The
CNC run can then be started without special preparations.
Measurement of the CT To use CALYPSO for measuring a CT dataset, proceed as follows:
dataset
1 Preparations in CALYPSO
2 If necessary, Importing CAD data
3 Importing a CT dataset
4 Visualizing the CT dataset in the CAD window
5 Aligning the CT dataset
6 If necessary, Creating a measurement plan
7 Creating and measuring profile elements
8 Measuring and evaluating during the CNC run

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 Metrotomography

Preparations in CALYPSO
For virtual measurement, the icons in the list of prerequisites have the
following meaning:

Icon Name Function

CMM Home Position The CMM home position is not important for evaluation of
the CT data.
CALYPSO monitors the operating state of the system and
shows it in the stoplight window.
Stylus system Red: the measurement plan needs other styli
Green: styli are OK

CT Properties Red: no CT dataset loaded

Green: CT dataset has been loaded

Base / start align- Red: no base alignment defined

ment Green: base alignment has been defined

Clearance planes Red: clearance planes not defined

See “Clearance planes” in the Operational Instructions for
Basis module.
Green: clearance planes have been defined
Features Click this button to check and edit the settings for the result
representation logs (see „Editing measurement plan settings“ in the Operati-
onal Instructions for Basis module).

Measurement Plan Click this button to open the Measurement Plan Editor Fea-
Editor tures (see “Working with measurement plan editors” in the
Features Operational Instructions for Basis module).

Temperature Use this button to enter the workpiece temperature (see

Compensation “Temperature compensation” in the Operational Instructions
for Basis module).

Select the measuring machine and the probe in the system settings.
Then set up the connection. These settings must only be made once.
System settings To make the system settings:
1 Select Extras → Workroom → CMM.
2 Click the Measuring Systems tab.

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 Preparing a CT dataset for measurement

3 Assign a name to the new device, e.g. “CT”:

• Enter the name in the input field.
• Press OK to confirm.
• Click the Add button.
4 On the Machine notebook page, select the CMM type “METRO-
TOM”.
5 On the Probe notebook page, select “VAST” under Sensors.
Establishing connec- To establish the connection to the control:
tion
1 Click the Control tab.
to the control
2 Select the desired measurement method (data interface):
• Dynamic Threshold for data created with the METROTOM
• Static Threshold for STL data
3 Activate the Reconnect during system start function.
4 Click Connect.
5 Click Accept and then click OK to confirm.

Defining the stylus system

You actually do not need any styli when measuring CT data. It is,
however, necessary to create a stylus system formally. For virtual pro-
bing, you define a stylus with the radius zero.
To define the stylus:
1 In the measurement plan area of the list of prerequisites, click the
Stylus system button.
The Probing system qualification window opens.
2 Select the MasterProbe and click on Ref. sphere position.

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Metrotomography

3 Press OK to confirm.

4 Press OK to confirm.
5 Click Create New Stylus System.

6 Select CT for the stylus system and name, and 1 for the stylus
number.
7 Confirm repeatedly with OK.
The Stylus system button is now green, i.e. the stylus system has
been defined.

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 Preparing a CT dataset for measurement

Temperature compensation
When measuring CT data, you may enter only the workpiece tempe-
rature in the temperature compensation window. This is the tempera-
ture of the workpiece during the computed tomography scan.

The preparations have thus been completed.

Importing CAD data

If a CAD model exists for the workpiece, you should use this data. You
can either use an already existing measurement plan with the features
or extract the measurement plan elements from the CAD model.
To import the CAD data:
1 Open a measurement plan.
2 Select CAD → CAD File → Load.
The Open CAD File dialog box appears on the screen.
3 Select the CAD files of your choice and click Open.
The files will be loaded.

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 Metrotomography

You can now extract features and, if necessary, also characteristics

from the CAD model. You can find more details under “Deriving fea-
tures from CAD files” in the Operational Instructions for Basis
module.
In order to enable measurement with a loaded CAD model, you must
align the workpiece, i.e. the CT dataset.

Importing a CT dataset
With the imported dataset, CALYPSO receives the data needed for
simulated measurement in form of a virtual workpiece.

NOTE Even if you do not possess an own METROTOM measuring machine,

hss this option allows you to import and evaluate externally taken images
in the METROTOM format.

As long as no data has been imported, the CT Properties button in

the list of prerequisites is red.

!
Memory requirements Important!
CT data that has been generated with high accuracy can only be
imported on a computer having a large memory capacity (minimum 2
Gbytes).

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 Preparing a CT dataset for measurement

Procedure To import the CT dataset:

1 Click the red CT Properties button in the list of prerequisites.
The CT Properties window opens.

2 Click Open file and select the appropriate file type.

You can select between two file types:

Measurement with: File types

dynamic threshold *.uint16_scv, *.zvi
static threshold *.stl, *.fct

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 Metrotomography

3 If the file is very big: Click Section and enter path and name for
later saving to reduce the size of the dataset without losing impor-
tant information. Please read additional information below.

NOTE If you reduce the size of the CT dataset using the Section function,
hss this will significantly reduce RAM load during loading and visualiza-
tion of the CT dataset and accelerate the system.

If the dataset is too large for the memory capacity of your compu-
ter, the Section function will automatically become active.
After execution of the section function, CALYPSO automatically
returns to this dialog.
4 Select the directory and file and click Open.
The import of the data can take a few minutes to complete. After
completion, the message “CT dataset has been read” appears.
When measuring with dynamic threshold, the CT dataset will be
stored as a three-dimensional field in a voxel matrix.
If a previously loaded dataset had to be deleted, the message will
appear with delay.
5 Set the parameters for the CT data.

Reducing the size of the CT dataset

To perform the Section function, the Clip Volume program opens:

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 Preparing a CT dataset for measurement

It displays for any Z value the gray values of the voxels in the X/Y
plane.
To reduce the size of the dataset:
1 Use the scrollbar to pass through the layers in Z direction from bot-
tom to top. Remember the Z coordinates for beginning and end of
the body shown.
2 Add at least 20 layers of air in each direction and enter these
values at the top left under Z Start and Z End. The first section is
defined with Set.
3 Slowly pass through the layers of the body using the scrollbar and
remember the maximum and minimum X and Y values of the dis-
played body.
4 Add 20 voxels of air to each of these extreme values. Then select
any layer and use the mouse to draw a rectangle with these
dimensions around the body.
5 Check all entries and confirm by clicking OK.
A cuboid containing the entire body displayed is cut from the voxel
matrix. This cuboid is saved as a new CT dataset. The Clip Volume
program is closed and CALYPSO returns to the CT Properties win-
dow.

Settings for the CT data

The values set apply to the complete workpiece, i.e. to all features of
the workpiece. The settings are not automatically stored in the
measurement plan.

Setting option Meaning

Automatic Has effect on the parameters Gradient Threshold and Smooth
parameter setting Area (default: activated).
Gradient Threshold The value can lie between 0 and 1. The value is automatically set by
default.
Smooth Area In order to consider the distortion during the measurement, a
smooth area is defined. The smooth area defines the distance –
measured in voxels – used for smoothing the data.

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Metrotomography

Setting option Meaning

Search Area The search area defines the area of the point cloud in which surface
data is searched.
The size of the search area is proposed as a function of the workpi-
ece size. Usually, you do not need to change it.
As during the real measurement, CALYPSO expects the surface in
direction of the nominal normal. If this criterion is not met, no actual
point will be transmitted to CALYPSO. In the worst case, an entire
feature will be missing in the measurement plan.
If a feature cannot be calculated during the determination of the
base alignment, the run is interrupted.
Direction Match The direction match parameter checks the matching of actual and
nominal vector. The input field is used to define the admissible angle
between the actual and the nominal vector.
If this function is not activated, all points will be taken into account.
Scaling Factor The scaling factor considers systematic errors of the CT system. Sca-
ling may be necessary for data that has not been determined using
the METROTOM.
With this function, all actual values will be multiplied by the scaling
factor, e.g. by the value 1.0002.
Important!
This action cannot be seen on the printout. The results are your sole
responsibility.

Visualizing a CT dataset
Similarly to the visualization of the CAD model in the CAD window,
you can have the CT dataset displayed in the CAD window. Contrary
to a CAD model, it is, however, not possible to extract features from
the CT dataset.
To create a measurement plan, you therefore need the visualized CT
dataset in the CAD window. You will then perform probing opera-
tions on the visualized dataset.
– When measuring with static threshold, the imported dataset can
immediately be visualized.

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 Preparing a CT dataset for measurement

– For a measurement with dynamic threshold, a specific file must be

created internally for the visualization. CALYPSO, however, measu-
res the stored voxel data.
By using the Visualize CT dataset function, the workpiece is
made visible and displayed beside a CAD model. The result of the
visualization is an approximated representation by triangles.

NOTE If the CT model is shown in the “Points” display mode, you cannot
probe using the mouse.

To visualize the CT dataset:

1 In the CT Properties window, click the Visualization tab.

Any measurement Both for voxel data and for surface data:
2 Select the color for representation in the CAD window.
3 Define the representation type.
• Points: as point cloud with setting of the point density
• Smoothed: as body with surfaces
Only measurement Only for the conversion of voxel data to surface data:
with dynamic threshold
4 Enter the number of materials of the workpiece.
5 For display by triangles, specify the number of triangles.

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Metrotomography

6 Specify the threshold value.

7 Enter the factor for the point reduction.
With this function, only every nth voxel will be used for calculation
of the surface.
8 Click Visualize CT dataset.

NOTE For conversion of the voxel data to surface data, CALYPSO requires a
certain time, depending on the size of the dataset and the storage
capacity.

Once CALYPSO has completed visualization, you can see the work-
piece in the CAD window.

If the workpiece is not visible, zoom the view until the workpiece is
in the visible zone.

NOTE The representation in the CAD window has a coarser resolution than
the one permitted by the data. During the measurement, CALYPSO
uses the more exact voxel data.

The settings Color, Points and Smoothed have no effect on the con-
version of the voxel data, but only on the representation of the con-
verted data. You can therefore still change the settings after
visualization.

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 Preparing a CT dataset for measurement

Aligning the CT dataset

Voxel matrix Depending on the alignment of the original workpiece on the rotary
table during CT scanning, the CT dataset is located more or less dia-
gonally in the base alignment of CALYPSO. The CAD model generally
has different angles with respect to the coordinate axes than the CT
dataset.
The workpiece therefore has to be aligned to the CAD model, just as
it is necessary for “real probing”.
The objective of the alignment is to align the two displays with each
other. Only then you can start the execution of a measurement plan
in the CNC mode.

Performing the alignment

To perform the alignment of the CT point cloud:
1 In the measurement plan area of the list of prerequisites, click the
Base / Start Alignment button.
The button is green if a base alignment has already been defined.

2 In the Load Create Or Change Base Alignment dialog box,

select an option, e.g.Create new Base Alignment.
You can enhance precision by iteratively computing the alignment
of the part alignment.
3 Click Loop and enter the loop parameters.
You can find more details under “Example: Customizing a base
alignment iteratively with abortion condition” in the Operational
Instructions for Basis module.

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Metrotomography

4 Press OK to confirm.
The base alignment window opens.

5 Set the parameters for a base alignment.

You can find more details under “Creating a new base/start align-
ment” in the Operational Instructions for Basis module.
6 Click the Execute Manual Run Now button.
Then the Manual Alignment window is displayed.
7 Select one of the two options.
The two options are explained in the following.

Define manual alignment by clicking

To define the manual alignment by clicking:
1 Activate, if necessary, the display of the CT point cloud via CAD →
CAD Model Control → CT Point Cloud.
Then CALYPSO starts “probing” the point cloud.
2 Select from the CAD buttons the Define points mode.
3 From the STL model, select a feature, click several points using the
mouse and confirm with OK.
The probing points are marked in green.

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 Preparing a CT dataset for measurement

4 Proceed in the same way for the other features.

Once the alignment has been completed, the two models will coin-
cide.

! Important!
Even if the manually set probing points on the STL model are selected
most carefully, you cannot achieve best possible accuracy.
• Therefore, you must repeat the alignment in the CNC mode.
We recommend to set the loop counter for the automatic align-
ment and to set 3 loops.

Define manual alignment by moving

To define the manual alignment by moving:
1 Select the Define manual alignment by moving option.
The Define Manual Alignment dialog box is opened.
2 Enter here the values for Offset and Rotation, with respect to the
currently valid alignment.
3 Click Set Base Alignment to zero to set the base alignment to
zero.
You can find more details under “Setting a base alignment to
zero” in the Operational Instructions for Basis module.
4 Click Center to use the center of the voxel cube as the origin (only
for measurement with dynamic threshold).
5 Click Best Fit for automatic fitting of the CT data into the CAD
data.

Nominal-actual comparison on a CT dataset

If the measurement plan also contains a CAD model, you can perform
the nominal-actual comparison. Deviations between the CT dataset
and the CAD model are displayed in color.

NOTE For the nominal-actual comparison, the dataset must be aligned in

the same way as for a usual measurement. Any errors due to a faulty
alignment will be included in the nominal-actual comparison.

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 Metrotomography

Once the visualization has been carried out, an additional index card
Nom/Act Comparison is displayed in the CT Properties window.

Prerequisite The CT dataset has been aligned.

To carry out the nominal-actual comparison:
1 Enter the tolerance.
2 Activate Exact to calculate the deviations between the CT dataset
and the exact surface of the CAD model. This calculation is more
complex.
- or -
• Deactivate Exact to calculate the deviations between the actual
points and the facets of the CAD model.
The attainable precision depends on the image quality you have
defined (CAD → Settings → Display – Image Quality).
3 Activate Dynamic Threshold to perform the nominal-actual com-
parison according to the dynamic threshold method. This calcula-
tion is more complex.
- or -
• Deactivate Dynamic Threshold to perform the nominal-actual
comparison according to the static threshold method.

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 Preparing a CT dataset for measurement

4 Click Calculate.
The CT dataset deviations are calculated and shown with default
values.
5 If needed, change the settings for visualization of the deviations:
– Magnification
– Color Shades and Color Gradient
– Color Extension

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Metrotomography

– Representation of points
Your changes are immediately displayed in the CAD window.

The displayed object can be moved, rotated in three dimensions

and zoomed by means of the mouse buttons. Thus you can exactly
check every interesting detail.

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 Preparing a CT dataset for measurement

6 Click Save to save the current nominal-actual comparison. In this

case, select the SES (Calypso Session) file type.
You can also view this file later on any computer by means of the
Calypso Viewer.
7 If you do not need the nominal-actual comparison any more: Click
Delete CT-dataset in CAD window to empty the CAD window.

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Metrotomography

Manual measurements on the CT dataset

CALYPSO allows you to run some special measurements on an impor-
ted CT dataset.
– It is possible to visualize in color the deviations between the nomi-
nal and the actual values, thus immediately obtaining an overview
of the workpiece quality.
– You can intersect the CT dataset at any desired position, measure
manually in the intersection plane and create profile elements.
– Measuring results can be determined easily with the aid of templa-
tes.

Measuring in intersection planes

The Profile Elements additional feature allows you to intersect the
CT dataset and perform measurements in the intersection plane.

Creating an intersection plane

To intersect the CT dataset, the Profile Elements additional feature is
required.
1 Add the additional feature Profile Elements to the measurement
plan with Measure → Additional Features → Profile elements.
The additional feature is displayed in the list of features.

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 Manual measurements on the CT dataset

2 Open the definition template.

The definition template offers three index cards. The Section index
card allows you to define the intersection plane.

3 Define the reference coordinate system, the coordinate plane and

the distance between the intersection plane and the coordinate
plane.
4 Determine the search distance and the point density in the inter-
section curve and click Calculate Section Curve.
CALYPSO calculates the intersection planes and represents them in
the CAD window.
The check boxes located in the lower part of the index card are
used to modify the representation in the CAD window.

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Metrotomography

5 Activate Section View to represent the intersection.

NOTE The section view can no longer be rotated but it can be moved and
zoomed.

Measuring on the intersection

It is possible to measure directly on the section curve of the CT data-
set. To do so, create 2D features or characteristics.

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 Manual measurements on the CT dataset

To measure on the intersection:

1 Activate the Creation index card.

2 Select the desired feature under Measurement.

Below you will see what has to be probed now.
3 Use the mouse to perform the probing operations on the section
curve in the CAD window.
4 The feature is added to the measurement plan and filled immedia-
tely with the measured values.

Measuring with templates

Measurements with templates allow fast manual measurements on
the section curve.

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Metrotomography

To measure with templates:

1 Activate the Creation index card.

2 Click one of the template icons and then the section.

Template Function
Point template (crosshairs)
Point Determines the position in X, Y, Z.
Circle template with inner and outer tolerance ring
Circle Determines the center point as well as D, R, the form and the upper and lower
deviation.
Circle template without tolerance rings
Circle Determines the center point, D1, D2, R1 and R2.
Rectangular template
Rectangle Determines X, Y, Z, L1, L2 and the angle.
Angle Template
Angle Determines the vertex, A1 and A2 from two lines.
Line template with tolerance zones
Line Determines X, Y, Z, A1, the form and the upper and lower deviation.

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 Manual measurements on the CT dataset

A blue template is displayed on the section.

3 Move and zoom the elements of the template until the template
touches or encloses the points to be measured.
4 Select Create in the context menu to create the feature.
Select Delete in the context menu to delete the template again.

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Metrotomography

Measurements on the CT dataset during the

CNC run
It is also possible to measure on the CT dataset during the CNC run.
The special aspects are described in the following.

Creating a measurement plan

The Metrotomography option provides you the same options for defi-
ning features as CALYPSO:
– You create a new feature and define it via its nominal values.
– Once a CAD model has been loaded, you can define features by
clicking the CAD model in the CAD window.
The Metrotomography option provides additional functions:
– If a CT dataset has been loaded and visualized, you can generate
features by probing points on the CT dataset and then define the
characteristics.
– If a CT dataset has been loaded and visualized, you can generate
features in intersection planes of the CT dataset.

Features resulting from probing operations on the

CT dataset
To enable the generation of probing points on the CT data set, the CT
Point Cloud representation type must be selected.

If the CT dataset is hidden, the probing points will be generated on

the basis of an existing CAD model.

NOTE Solid geometries and other geometric elements cannot be generated

from the CT dataset.

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 Measurements on the CT dataset during the CNC run

Generating profile elements on the CT dataset

The additional feature Profile Elements can be used to generate, on
the basis of the CT dataset, features and characteristics in intersection
planes. The features are added to the measurement plan and measu-
red in the CNC run.
Add the Profile Elements additional feature to the measurement
plan.
First define the intersection plane in which the areas to be measured
are located on the Section index card.
Select the desired feature or characteristic on the Create index card
and define it by probing with the mouse in the CAD window.
Once the feature has been added to the measurement plan, it can be
edited, grouped and renamed.

Measuring and evaluating during the CNC

run
The measurement plan can be run on a loaded and visualized CT
dataset just like on a workpiece.

Special aspects of the CNC run

No navigation paths in By default, CALYPSO calculates the navigation paths required for
the CNC run measuring the various features. However, no navigation paths are
necessary when using CALYPSO with the Metrotomography option.
You can therefore suppress the automatic calculation of navigation
paths during the CNC run.
This can be done in the Start Measurement window when starting
the CNC run.
1 Select Plan → CNC-Start.
The Start Measurement dialog box appears on the screen.
2 Under Navigate-Feature To Feature, select the Use Position
Points Only entry.
Alternatively, you can also select the desired features or characteristics
and select Execute Now! in the context menu or press F9. The
measurement plan starts running using the default settings suitable
for the measurement on the CT dataset.
Template features If the measurement plan contains template features or template cha-
racteristics, CALYPSO will interrupt the CNC run to allow you to posi-
tion the template in an optimal way. The CNC run will then continue.

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Index
A M
Alignment Measuring
CT dataset 1-8 according to CT data 1-9
special aspects of CT data 1-35
B METROTOM 1-2
Metrotomography
Basics
aligning CT data 1-21
Metrotomography 1-2
basics 1-2
loading CT data 1-14
C parameters 1-4
Computed tomography preparations 1-10
for coordinate measurements 1-2 probing CT record 1-34
CT data settings 1-17
basics 1-2 visualization 1-8
measuring and evaluating 1-35 visualizing CT data 1-18
CT dataset
aligning 1-8, 1-21 P
creating probing points 1-34
Preparations
direction match (dynamic) 1-6
for metromotography 1-10
direction match (static) 1-7
dynamic threshold 1-4
gradient threshold 1-5 R
importing 1-14 RAW file 1-4
measuring with Calypso 1-3 REC file 1-4
measuring, run 1-9 REK file 1-4
parameters 1-4
scaling factor 1-7 S
search Area 1-6
Scaling Factor
section 1-16
metrotomography 1-7
settings 1-17
Search Area
smooth Area 1-6
metrotomography 1-6
static threshold 1-5
Settings
visualizing 1-8, 1-18
CT data 1-17
Smooth Area
D metrotomography 1-6
Direction match (dynamic) Static threshold 1-5
metrotomography 1-6 Symbols Preface-2
Direction match (static)
metrotomography 1-7 T
Dynamic threshold 1-4
Text conventions Preface-1
Threshold
G dynamic 1-4
Gradient threshold static 1-5
metrotomography 1-5
V
VGI file 1-4
Voxel 1-2

61212-2830402 Operating Instructions Index 1

Index 2 61212-2830402 Operating Instructions