Seeking Assistance with Zeiss Calypso Software - Thickness Measurement Discrepancies

[[St...]]

Hello Community,

I am reaching out for guidance and insights regarding an issue we are encountering with the Zeiss Calypso software, specifically related to measuring the thickness of parts. We use the software to scan the outer diameter (OD) and inner diameter (ID) of a part, employing the Cartesian distance to determine the thickness. Our assumption is that the software calculates an average of both circle features and then computes the distance between these two averages.

However, we've encountered a discrepancy with our customer's manual measurements. They claim to measure high spots and low spots by manually measuring one point on the ID and one point on the OD using micrometer with ball end. When the same parts were tested on our machine, all measured as good, indicating a variance between our measurement method and theirs.

We are seeking insights into the following:
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Understanding the Measurement Process: How does the Zeiss Calypso software actually determine its points when measuring thickness? Is it indeed averaging the circle features, or is there another method at play?

Potential for Discrepancy: Given the difference in measurement methods (our averaged approach vs. the customer's single-point manual measurement), is it possible that this could lead to significant discrepancies? If so, under what conditions might these differences become pronounced?

Resolving Measurement Differences: What steps can we take to align our measurements more closely with the customer's manual method? Are there settings or procedures within the Calypso software that we can adjust to mimic their approach?

We aim to understand the nuances of the measurement process better and ensure that our quality checks align with our customer's expectations. Any advice, experiences, or insights into handling similar situations would be greatly appreciated. Your expertise is invaluable to us as we navigate this challenge.

Thank you in advance for your time and assistance.

[[To...]]

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If they're measuring the OD with the "ball end" of the micrometer, that means they're measuring the ID with the square end, which means it is not against surface and will measure bigger than it really is.

Hopefully, I am misreading your post.

You're right about the average diameters. If you are working with a model, you can create "Distance Checks" from the extract features window at the lower left corner of CAD window. Click where you want to a point, and it will put a Space Point where you touched the model and another Space Point on the opposite side, directly inline with the first point. It will also create a 3d Distance between the 2 points, pretty much like the ball mic measurement the customer is doing. Create as many of these as you need.

Screenshot 2024-01-08 102436.jpg

[[Da...]]

I agree with Tom to use space points for a point to point thickness check. My ball micrometer uses a pin for the anvil.

[[St...]]

Thank you for your help and insight. I'm going to apply this feature to measure some points around the part. Would there by a way to show high or low points with our current strategy? Ideally, we would take the average but also include any highs or lows that might throw it out.

[[Da...]]

You could use minimum and maximum results, but that will only show the lowest and the highest points.

[[Ri...]]

If you have Curve - you can use the Curve Distance Characteristic. You can report Average, Min, and Max results (it will even show you where the Min/Max results are. In addition, there is a nice little plot that it shows you as well. 🙂