calypso-advanced-training (2)

Prévia do material em texto

Carl Zeiss 3D Metrology Services GmbH
We make it visible.
4.8
Training manual
Advanced
TrainingSoftware Revision: 4.8
Calypso®
© Carl Zeiss 
3D Metrology Services
� Calypso Advanced Training
This manual is copyrighted. No part of this documentation may be copied, reproduced, translated 
or processed, multiplied or transfered by means of electronic devices without the expressive appro-
val by Carl Zeiss 3D Metrology Services GmbH. Non-compliance will be prosecuted.
All documents in this manual are compiled in concordance with the respective copyrights. If there 
are parts of this manual that indicate foreign copyrights, please inform Zeiss accordingly at info@
zeiss3d.de. 
All rights reserved, especially in cases where a patent is granted or a utility model is registered.
This manual is subject to modifications.
Carl Zeiss 3D Metrology Services GmbH will not be held liable for this manual, including the implied 
warranty for commercial quality and suitability for a certain purpose.
Carl Zeiss 3D Metrology Services GmbH will not be held liable in any case for errors, accidental 
damages or subsequent damages arising from the provision, function or use of this manual.
All product names are registered trademarks or trademarks of the respective proprietors.
© Carl Zeiss 3D Metrology Services GmbH.
Heinrich-Rieger-Str. 1
73430 Aalen
Software revision: Calypso 4.8
14th Edition, January 2009
�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Customer Training
Calypso Advanced Training
Calypso Rev. 4.8
Subject no. 000000-1135-608
Prerequisites:
- Calypso Basic Lesson 
This class:
- Covers additional Calypso functions
- lasts 5 days 
- is recommended in one of our training centers
- starts at 8 am and ends at 4 pm,
- Self-made exercises without a coach possible after 4 pm
- provides class-relevant documentation
Review
Questions from the basic class
Questions from the practical use
•
•
Offline programming with
CAD functions 	 	 
- Calypso Basic Lesson
Simulation on the CMM or the offline PC
Optimized programming with resources
Strategy settings
Styli 
Programming with CAD model
CAD import and resources
•
•
•
•
•
•
•
Coordinate systems 	 	 
Alignment with offset plane
3 Aalen, Germany
RPS best fit method
Creating a base alignment as per DIN ISO 5459
Start system
RPS best fit method
•
•
•
•
•
•
•
Measurement methods, Part 1 	 	 
Gauß, Minimum, Tangential elements•
Filter and outliers
Form test
Different scanning procedures
Editing methods
Calculations, operations and evaluations 	 	 
Recalls 
Special calculations
Introduction to form and position
•
•
•
•
•
•
•
•
Understanding Understanding
© Carl Zeiss 
3D Metrology Services
� Calypso Advanced Training
Expanded programming functions 	 	 
Patterns
Linear pattern
Circular pitch
True position on circular pitch
Pattern measurement as per DIN 3960
Result element 
Formulas
Result element 
Relatively positioned probings
•
•
•
•
•
•
•
•
•
Automation interface 	 	 
Pallet measurement, serial measurement
Printout setup 	 	 
Graphic illustration - plotting
Settings with form plot
Printouts 
Modifying the printout header
User-defined printout
•
•
•
•
•
•
Stylus systems and accuracy 	 	 
Automatic qualification
Special styli
Styli monitoring
Holder position functions
Analyzing measurement inaccuracies
•
•
•
•
•
Measuring methods, part 2 	 	 
Scanning with unknown contour
Scanning with 2 styli
Point masking in open scanning paths
Self-centering probing
Safety Cube
Park position
Missing bore
•
•
•
•
•
•
•
Exercises 	 	  Review
How the trainer evaluates the class
How the participants evaluate the class
•
•
Special training or workshops are offered to teach more Ca-
lypso program options.
For example:
Training option curve, 3 days
Training option PCM, 3 days 
Training planner / simulation
Workshop Auto-Run
Workshop Form and Location
Understanding Understanding
�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Content
Offline Programming with CAD Functions ............................. 8
1.1 Calypso Configuration ............................................................................................ 9
1.1.1 Simulation on the CMM PC ..............................................................................................9
1.1.2 Simulation on the offline PC...........................................................................................10
1.2 Optimized programming with resources .......................................................... 11
1.2.1 Filter and outlier resources ............................................................................................12
1.2.2 Strategy resources .........................................................................................................12
1.2.3 Preassigning the stylus system for measurement plan ....................................................13
1.2.4 Copying the format: Changing the coordinate system with the "paintbrush" .................14
1.2.5 Coordinate system preassignment .................................................................................15
1.3 Programming with CAD model .......................................................................... 16
1.3.1 Working on the model ..................................................................................................17
1.3.2 CAD import and resources ............................................................................................23
1.3.3 Additional functions ......................................................................................................27
2: Coordinate system .......................................................... 28
2.1. Alignment with offset plane ............................................................................. 30
2.2 3D best fit method on the exercise cube .......................................................... 33
2.3 RPS best fit method on the exercise cube ........................................................ 35
2.4 Creating the base alignment as per DIN ISO 5459 ............................................ 36
2.5 Start System .................................................................................................... 38
2.6 Maintaining the feature position ...................................................................... 40
2.7 RPS best fit method .......................................................................................... 41
3: Measuring methods, Part 1 ............................................. 42
3.1 Gauß, Minimum, Tangential elements ............................................................. 43
3.2 Filter and outlier basics .................................................................................... 44
3.3 Form test on the roundness example ............................................................... 50
3.4 Automatic calculation of the scanning parameters ........................................... 51
3.5 Self-made changes to the scanning and evaluation parameters ....................... 53
3.6 Editor ............................................................................................................... 55
© Carl Zeiss 
3D Metrology Services
� Calypso Advanced Training
4: Calculations, operations and evaluations ........................ 56
4.1 Recall ................................................................................................................... 57
4.1.1 Point recall from polyline ...............................................................................................57
4.1.2 Point recall from the circles ............................................................................................60
4.1.3 Point recall from cylinders ..............................................................................................61
4.1.4 Point recall from curve ...................................................................................................64Scanning with unknown contour
Both elements can be extracted with a single point or with scan-
ning probe heads with the mode "unknown contour".
For details, read the section "Scanning unknown contour".
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Cone, circle on cone
When extracting a circle on a cone surface from the CAD mo-
del, the feature "circle of cone" is set automatically.
With manual probing, the circle on cone can first be opened 
(from measuring - special features) in order to probe points di-
rectly or it can be adjusted afterwards.
In both cases, the cone angle is required for the probing 
direction.
In the first case, this comes directly from the CAD model, 
with manual probing, it must be entered.
If the respective cone is already present as a feature, you 
can access the actual value directly via "formula".
Special features "Circle on cone":
"Circle on cone" corrects the probing points in normal direc-
tion of the set cone angle.
During the measurement, Calypso switches on a scanning 
routine which allows stable driving on the inclined cone 
surface.
Changing the nominal geometry of the cone and the circle to 
cone
When the cut height in the circle is changed to cone (nominal 
values in X, Y, Z), the cone diameter is not recalculated and 
adapted.
So, if the cone is moved along the Z axis in this example, the Z 
nominal value is changed - the diameter will not change!
Only with the use of the respective button can the diameter be 
corrected by a movement.
Here, you can change:
Feature reference point or 
relative height.
Only the respective spatial direction is released.
Then, all components are recalculated.
•
•
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Radius, sphere and angle point
With the features radius, sphere and angle point, you can select 
the respective radius correction with single point measurements 
in different situations in order to correctly define the contact 
point.
Regarding the radius point:
A radius point is not automatically detected by CALYPSO. 
Insert the feature "Radius point" from the measurement menu 
- special features into the measurement plan, define the cen-
ter point and then conduct the probing.
Sphere point:
With the sphere point, the measured value is corrected into the 
direction of the connecting line between the probing sphere 
center point and the indicated center point.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.2.2 Limiting freedom degrees
Task: 
A frequently occurring measuring problem is the measurement of 
a small circle section. 
Here, the center point of the circle to be measured is often deter-
mined. I.e., the coordinates are defined with X value and Y value.
The probing points are calculated for a circle, whose diameter is 
a characteristic.
Or the radius is predetermined and the center point coordinates 
must be determined.
Both methods are shown here.
The exercise can be conducted on any workpiece; this example 
shows the carrier.
Probe 4 probings on the circle to be measured.
Enter the nominal values properly.
Define the characteristics X, Y, D as well as the radius measure-
ment.
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
Let the sequence run while creating a com-
pact printout.
In the following, you will change the evalu-
ation and create one compact printout each 
to compare to. It is recommended saving 
these printouts.
Compact printout of the "normal" Gauß 
circle.
Constrain the evaluation.
Evaluation - evaluation constraints.
The function "evaluation constraints" allows defining vectors for 
X, Y, Z with the circle or the radius.
X, Y value constrained
Conduct the different evaluations and observe the compact 
printout.
Radius constrained
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.2.3 Changing the tolerance mode
1. Principle:
Depending on the mode, deviations are output in different ways.
The two possibilities are the number vector or amount mode.
Number vector mode: 
 The formula for the deviation in Calypso is:
Deviation = actual value - nominal value
Standard mode = number vector mode
Number vector mode: 
 E.g. in chassis manufacturing and other applications, deviations 
are shown in a different way:
Deviation = (actual value - nominal value) x 
actual 
actual 
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
2. Retrieval:
Extras - workroom - measurement - nominal
There are two possibilities of switching:
1. For the entire system: In the system settings of the 
workroom.
2. For the loaded measurement plan: Resources - cha-
racteristics settings editor - tolerance mode
Only applies to the most recently loaded measure-
ment plan
Notes:
1. The deviations are shown in the printout.
2. If the amount mode is set for the current measurement plan 
(or system), a "" will be displayed in the printout header of 
work and compact printout after the column header "Dev.". 
The printout header of the custom printout cannot (does not 
need to) be changed.
3. You can also access the deviation via the PCM formula.
z
 getActual(„DIN Rundlauf1“).deviation
4. The prefix of the recall value is the same as the setting in the 
measurement plan or the control panel.
5. In the table file, an additional printout header field is used. 
The name of the field is "deviation mode". The value of the 
field is "number vector" or "amount", translated into the 
respective current set language.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
3. Example
Both of these default printouts show the difference between 
number vector mode and amount mode.
The mode can be displayed in the printout 
header. For this, the respective variable must 
be inserted.
Example of a printout header:
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
4.2.4 Tangents
The function "Tangent" is a construction.
In principle, the function offers two calculations:
given are 2 circles, calculation of the tangents or 
given are 2 lines, calculation of the tangential circles.
Here, you can use more than circles and lines.
The alternatives and additional possibilities can be found in the 
Operating Instructions.
•
•
Task: 
1. Measure two circles, e.g. on the exercise cube and link them 
via the tangent function (see illustration).
2. Measure two lines and determine the tangential circles while 
specifying the diameter.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.3 Introduction to form and position
4.3.1 Flatness, cylinder form
Flatness
Measuring feature:
 Plane with scanning paths
Tolerance zone
 2 parallel planes with distance t
Test length: 
 Size of the surface
Calculation: 
 The plane is evaluated as a minimum feature
 Procedure: All measured points are transfered to an assigned 
plane as per the minimum feature. 
 The distance between the highest and lowest point, with 
reference to this plane, is the form deviation.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Cylinder form
Characteristic:
 Outside cylinder
Strategy settings 
Radial cutting method: Circle sections, here e.g. 4 circles with 
the same distance or
surface line method: 4 surface lines or
screw line method: Helix path.
Tolerance zone
 2 coaxial cylinder, distance t
Calculation: 
 Evaluation of all measuring points as a minimum cylinder.
 Calculated deviation = minimum - maximum
•
•
•
Cylindridcity includes the following deviations:
Roundness of every cross section, 
straightness of the axis, 
straightness of the surface line, 
parallelism of the surface line.
Each of these individual deviations cannot be greater than the 
cylinder form.
Components of the cylinder form deviation:
Parallelism compared to surface lines,
Roundness
straightness.
Cylinder form deviations without roundness deviations
ball-shaped => drum form; 
double-concave => saddle form;
crooked;
cone-shaped.
Only with a crookedcylinder, the axis is also crooked.
Here, the captured axis is not the same as the assigned axis.
For the cylinder form, this does not matter, as only the outer 
contour is tested.
This is different for other evaluations, such as parallelism.
•
•
•
•
•
•
•
•
•
•
•
Cylinder form4 Flatness, cylinder form4
Cylinder form241th 
 Minimum cylinder Point recall outside
------------------------------------------------------------
 X -0.01880 0.00000 S 0.01331
 Y 0.00397 0.00000 Min (477) -0.02851
 Z 3.00000 3.00000 Max (500) 0.02851
 D 31.97045 32.00000 Form 0.05703
 
Cylinder form_241 DIN cylinder form 
---------------------------------------------------------------
Cylinder form_241 0.05000 0.05703 0.00703
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.3.2 DIN position of two bores
In this example, the distance between two bores is to be 
determined.
Test features are the 2 bores on the front side of the cube.
This initially classic distance calculation via the "distance" func-
tions is intended to lead to the use of a DIN position.
The first drawing shows a classic distance value with tole-
rances.
The second drawing shows a DIN position with only one 
reference.
The third drawing also shows a true position, but with com-
plete reference to the outside surfaces.
Task:
Observe the drawing information and discuss the advantages 
and disadvantages of the different dimensioning.
Pay special attention to:
the creation of the reference system,
the calculation of the test features (Gauß, minimum, ...),
the form of the features,
the measuring strategy,
a possible best fit method.
•
•
•
•
•
•
•
•
Here you can see the input window for the third drawing.
Note regarding references:
Calypso initially offers the base alignment as a reference.
If this is the same as the required references, the base align-
ment must have been calculated with the tangential features 
of the planes!
If Gauß features are used here,
there will be different results for the position!
Basically, the question remains for other evaluations:
whether the base alignment has been captured with the cor-
rect features in the proper mode.
Note:
The use of form and position tolerances and 
their deviation calculations are the subjects of 
a different training session.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
5: Expanded programming functions
5.1 Pattern ................................................................................................................. 79
5.1.1 Linear Pattern ................................................................................................................80
5.1.2 Polar pattern offset ......................................................................................................83
5.2 True position on circular pitch .......................................................................... 88
5.2.1 Coordinate system from bore pattern best fit method ..................................................91
5.3 Pattern measurement as per DIN 3960 ............................................................ 93
5.3.1 Circular pitch .................................................................................................................93
5.3.2 Linear pattern ................................................................................................................97
5.4 Formula ............................................................................................................ 98
5.4.1 Result Element .............................................................................................................98
5.4.2 Probing a sheet metal ................................................................................................100
5.4.3 Probing positions relative to a feature ........................................................................101
5.4.4 Alignment with offset plane via formula .....................................................................102
5.5: Automation interface ..................................................................................... 105
5.5.1 Pallet measurement: ..................................................................................................105
5.5.2 Serial measurement: ..................................................................................................105
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
5.1 Pattern
With patterns, there are distinctions between:
patterns in the measuring feature
characteristic "circular pitch"
Patterns in the measuring feature:
Patterns are first understood as regularly arranged features 
of the same geometry. These should be combined and mea-
sured.
In Calypso, a measuring features receives a pattern and multi-
plies either linear or rotary.
In addition, patterns can also be irregular.
Then, a "position list" will specify the positions.
Characteristics from features with pattern automatically recei-
ve a loop.
•
•
Characteristic "circular pitch":
A similar term is the feature "circular pitch".
This either requires
a measuring feature with pattern or
several measuring features without pattern.
The circular p also evaluates individual and sum pattern errors.
The characterstic does not form a loop.
•
•
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
5.1.1 Linear Pattern
A workpiece with linear pattern is programmed offline.
The bores are to be measured with the measuring feature circle.
This circle will only appear once in the measurement plan and will 
be multiplied via the loop function.
Here, there are two practical possibilities:
1. Pattern function in the measurement feature (this exercise)
2. Pattern via formula function (section "circular pitch").
This exercise is programmed offline!
1D linear pattern
Open a new measurement plan and pull three planes and a circle 
into the list of measuring features.
Enter the nominal mass of the workpiece 
into the three planes.
Define a base alignment from the three planes and apply the 
safety cube.
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Enter the coordinates of the circle:
X= -37.5
Y = 12.5
Y = 0
Y = 12.5
Define a pattern in the circle.
First, select a 1D linear pattern; here, a new pattern will be crea-
ted.
Calculating the nominal geometry:
As you are not working with formulas here, do not change 
this setting.
These bores are displayed in the graphic.
Enter these values:
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Create the characteristics from the circle.
x, y, z: 
Keep in mind, that Calypso recognizes an automatic loop creation 
here.
Start the CNC program in the "simulation" mode.
In the custom printout, you will recognize the projected nominal 
values of every single circle.
2D Linear pattern
With a 2D pattern, you can measure an offset in 2 coordinate 
direction.
Copy the most recently created circle and define a new 2D pat-
tern.
Enter the characteristics and start the CNC run.
Reuse the simulation.
Switch on the simulation mode.
 Planner - simulation stylus system
Start the run.
Set up via "Exclude indexes" that the following bores are not to 
be measured:5, 7, 9, 11
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
5.1.2 Polar pattern offset
Task: 
Measuring 6 bores as a polar pattern offset.
By specifying a polar pattern offset, the 
measurement run for a circle is expanded to 
all 6 circles of the pattern.
Sequence:
Loading the CAD model
The undulation must be loaded as usual. The alignment should be 
created with sensible features.
Features for the alignment:
Example:
Primary: Cylinder 32 mm diameter
Secondary plane on diameter 60
Origins on cylinder axis, on top of the planeof a pitch step. 
The arc length is calculated from the distance of the first nominal 
geometry to the center point of the pitch center.
pk: Total pattern angle
Angles or arc length between the first feature of the pattern 
measurement and the second feature of the respective pitch step.
The arc length is calculated with the distance of the first nominal 
geometry to the center point of the pitch.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Calculated deviations:
fp: Individual pitch error
Difference between actual and preset 
distance between two adjacent features.
The result is an angle or a arc length.The 
arc length is calculated with the distance 
of the first nominal geometry to the 
center point of the pitch.
The nth result of this evaluation cha-
racteristic is the pitch error between the 
last (the nth) and the first feature.
Fre: Roundness
Radial deviation of a feature to the partial 
circle radius of the pattern.
The partial circle is calculated as per 
Gauß, the center point is calculated from 
the actual features of the pattern.
The radius is the distance between the 
calculated partial circle center point and 
the first actual feature of the pattern.
fp: Cumulative pitch error
Sum of the pattern individual deviations. Difference between 
actual and nominal distances of a feature from the first fea-
ture of the pattern measurement.
The result is an angle or a arc length. The arc length is calcu-
lated with the distance of the first nominal geometry to the 
center point of the pattern.
The nth results of this evaluation characteristic is always 0° 
(the angle from the first feature to itself).
fu: Pattern jump
Difference between the actual and the previous pattern indivi-
dual deviation.
The result is an angle or a arc length.
The arc length is calculated with the distance of the first no-
minal geometry to the center point of the pattern.
The first result is always 0.
Fr: Concentricity
Radial deviation of a feature to the par-
tial circle radius of the pitch. The center 
point of the partial circle represents the 
center of the pitch. The radius is the 
distance between the center of the first 
actual feature of the pattern.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Sequence:
Individual feature with pattern
Create an alignment and measure the circles as a polar pat-
tern offset. 
The bores are named circle1(6).
Take a circular pitch as a characteristic.
Select "individual measuring feature with pattern"
Enter Circle1 as a test feature.
The evaluation methods are determined by selection and 
deselection.
•
•
•
•
•
•
Different test features
Create an alignment and measure different circles. 
Take a circular pitch as a characteristic.
Select "different test features"
Enter the test features into the subsequent input window.
•
•
•
•
This page appears to show the features:
Here, the features are entered and can be moved in the given 
sequence.
As no feature with pattern is used, the center of the pattern 
as well as the angle and projection must be entered here.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Print output
In the "normal" compact and custom prin-
tout, the minimum and maximum values are 
indicated.
All values only appear if "Expanded pattern 
output" is selected!
Example of a compact prin-
tout:
Here, only the extremes are 
shown; the table offers a detai-
led listing of the values.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
5.3.2 Linear pattern
Analog to the circular pitch, a linear pattern can be evaluated.
Here, the same system applies as for the previously described 
circular pitch.
p: 
Distance between the two features of a pattern step. 
Total pattern distance pk
Distance between the first feature of the pattern measure-
ment and the second feature of the respective pattern step. 
Pattern individual deviation fp
Difference between actual and preset distance between two 
adjacent features.
Divsion total deviation Fp
Sum of the pattern individual deviations.
Difference between the actual and nominal distance
of a feature from the first feature of the 
pattern measurement.
Pattern jump
Difference between the actual and the previous pattern indivi-
dual deviation.
The first value is "0".
Task:
Create a linear pattern on the workpiece and evaluate the pat-
tern.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
5.4 Formula
5.4.1 Result Element
Task: 
A section width is determined from the difference in diameters of 
two circles.
Sequence: 
The measurement to be found is the difference between the two 
radii.
Create two circle arcs (measure them or extract them from 
the CAD).
For the formula: take a "Result element" from 
"Size - move - result element"
For formula-based calculations, press the right mouse button 
and enter the formula:
getActual("Circle1").radius - getActual("Circle2").radius
•
•
•
Note:
In Calypso, many calculations can be performed via "construc-
tion".
Of course, you can use other methods to handle the shown 
problems.
Therefore, the following example should be seen as an intro-
duction into the subject of "Use of formulas".
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Rename the characteristic accordingly.
Enter the nominal value.
In the CNC run, this characteristic is treated and evaluated like a 
normal characteristic.
•
•
© Carl Zeiss 
3D Metrology Services
100 Calypso Advanced Training
5.4.2 Probing a sheet metal
Sheet metal measurements are often critical due to the easy de-
formation of the materials. So, if you want to measure a bore in a 
piece of sheet metal, the exact probing height is important.
This height varies up to several tenths of millimeters.
(Shown higher in this illustration.)
Note:
In sheet metal measuring, "Relative measuring" with the Calypso 
option "Free form" is often used.
Here, this problem is handled with a formula.
Task: 
First, the surrounding sheet metal (1) must be probed to roughly 
get on the actual measuring height (2).
The actual height of the probing can be determined and used via 
the "formula".
Sequence: 
1. Probe the bore as a circle
2. Probe an individual point on the surrounding surface of the 
bore.
3. Open the Z value (nominal value) in the circle with a formula.
4. Enter the actual value of the point into this formula and sub-
tract half of the sheet metal thickness.
 Example: with a sheet metal thickness of 1 mm:
 getActual("Point1“).z - 0.5
Caution: NEVER use the comma as a decimal point in formulas, 
only a period!
5. Check the function by changing the point probing with a coin.
101Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
5.4.3 Probing positions relative to a feature
Task: 
Measure the bore and refer other probings to the center point
Measure bore 3 as the center point of the bore pattern.
The probings in bores 4 - 7 must be defined relative to bore 3.
For example, if bore 1 was offset by 0.5 mm, the probings in the 
other bores should also be offset by 0.5 mm.
•
•
Sequence:
1. Measuring the center bore will yield circle 3.
 
2. Insert another circle from the toolbox into the list: 
 
3. Open circle 4 and apply formulas to the nominal values as 
shown:
 
4. Assign a circle section with 4 probings to the circle in the 
strategy.
5. Copy the circle and change the formula three times as per the 
nominal values of the other bores.
6. Create the features diameter and start the sequence.
© Carl Zeiss 
3D Metrology Services
10� Calypso Advanced Training
5.4.4 Alignment with offset plane via formula
Note:
Only perform this exercise after you have worked through the 
formula functions in this training session.
Task:
This exercise has an offset plane that is created differently from 
the exercise previously shown - via the formula functions.
This leads to more of a variety, as a arbitrary number of measu-
ring points can be available for theoffset plane.
A workpiece is resting on three points that are at different 
heights.You must use these three points to determine a plane 
which will be declared the primary reference in the base align-
ment.
This is the classic calculation of an offset plane.
However, an offset plane from the toolbox always consists of 
exactly three probings, whose height can be corrected.
This new WKS should be run at least twice to create the correc-
tion of the offset probings in the correct coordinate system.
Open the second point (P5), recall P3, correction by 8 mm.
Add 2 more points (P4, P5) from the toolbox into the list.
Open the first of these points (P4), 
Recall one feature: P6
Edit the Z value with the formula:
"getAcutal["Point2"].z+10"
Sequence: 
Load the CAD model of the exercise cube
Click on 3 points in the CAD window:
 1. Point (P1) on the cover surface
 2. Point (P2) in the front slot
 3. Point (P2) in the rear slot
10�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Place a loop over the base alignment.
Start the run and interpret the result.
Take one plane from the toolbox and define it via recall of P1, 4, 
5.This plane 1 is situated analog to the cover surface.
Form the first symmetry point from 2 probings (P6, 7): front right 
- front left.
Form the second symmetry point from 2 probings (P6, 9): rear 
right - rear left.
Create a 3D line from these 2 symmetry points.
Set point 10 on the front surface to Y=0.
Create a base alignment:
Plane 1 for primary
3D line for secondary
3D line for origin in X
Point 10 for origin in Y
Plane 1 for origin in Z
© Carl Zeiss 
3D Metrology Services
10� Calypso Advanced Training
10�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
5.5: Automation interface
In this section, we will give you brief introduction to this subject. 
You should participate in special training if you desire to do so.
5.5.1 Pallet measurement: 
Several identical parts are to be measured consecutively - 
clamped on a pallet.
This requires an accurate clamping device, as the same mea-
surement plan is offset by the X, Y values of the clamping 
locations.
5.5.2 Serial measurement: 
Several different parts are to be measured consecutively and 
automatically.
Different measurement plans are run subsequently.
Autorun works with a special user interface, which has the actual 
Calypso run in the background.
This interface is intended for users that are basically only suppo-
sed to start programs.
In autorun mode, the user rights must be adjusted specifically for 
each user and they do not affect the user rights in Calypso. 
The function "Autorun" generally permits two different run versi-
ons:
© Carl Zeiss 
3D Metrology Services
10� Calypso Advanced Training
Example for a serial measurement:
Example for a pallet measurement:
More specific information about this subject can be found in the 
Operating Instructions or a special training session.
10�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Place your own images into the autorun inter-
face.
Example for a designed interface:
Here, there is a special image for every CNC run.
In addition, a background image can be defined.
These functions can only be activated by clicking the right mouse 
button on the background or the run.
The images must be in *.bmp, *.jpg or *:gif format.
See the Operating Instructions for more detailed descriptions.
© Carl Zeiss 
3D Metrology Services
10� Calypso Advanced Training
6: Result display - printout design
6.1 Graphic display - plotting ................................................................................... 109
6.1.1 Flatness and graphic display .........................................................................................109
6.1.2 Settings of form plot ....................................................................................................114
6.1.3 Plot output only if tolerance range is exceded ..............................................................115
6.2 Printout .............................................................................................................. 116
6.2.1 Modifying the printout header .....................................................................................117
6.2.2 Changing the printout header for plots ........................................................................119
6.2.3 Changing compact printout header .............................................................................119
6.2.4 Total result ..................................................................................................................120
6.2.5 One-line custom printout .............................................................................................121
6.2.6 User-defined printout...................................................................................................125
6.2.7 Attaching a comment to the characteristic ..................................................................128
6.2.8 Inserting a text element ...............................................................................................129
6.2.9 Groups in the custom printout .....................................................................................130
6.2.10 Saving printouts .........................................................................................................131
6.2.11 Changing the INI file for printout header data ............................................................133
6.2.12 Inserting a variable into the printout ..........................................................................136
10�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.1 Graphic display - plotting
6.1.1 Flatness and graphic display
Exercise sequence
In this exercise, you must measure a surface of the exercise cube 
as a plane and evaluate this with the different functions of the 
Flatness:
1. Flatness and preset path
2. Flatness as processing
3. Flatness as CAD plot
4. Output via the function "Graphic feature“
© Carl Zeiss 
3D Metrology Services
110 Calypso Advanced Training
First, measure the front side of the exercise cube with a polyline.
Take a flatness into the measurement plan.
Evaluate as usual.
1. Flatness and standard plot
This display is offered as a standard by Calypso.
The plot can be adapted in its display via "Edit".
Here, you can change the display of the points.
111Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
2. Flatness as processing
The "processing" is the more rare display and not 
usually used for the evaluation of a polyline.
Here, the flatness of linear segments is displayed.
3. Flatness as a CAD plot
In order to get the view pictured here as a plot, pro-
ceed as follows:
Load the CAD model
open the plane
click on the ACIS window with the right mouse 
button, 
select "display actual points"
close the plane
open the Flatness
CAD - view - save view
Enter name, here: Ebenheit1 (flatness1)
click on "Graphic"
select "CAD view" in the top menu
select characteristics "Flatness 1",
click on the "Plot"
•
•
•
•
•
•
•
•
•
•
•
© Carl Zeiss 
3D Metrology Services
11� Calypso Advanced Training
4. Output via the function "Graphic element“
For already existing graphic evaluations, such as roundness, flat-
ness, an alternative display can be retrieved with the additional 
function "Graphic element".
Note:
This functionality can only be used if the "Zeiss reporting module" 
is loaded.
Sequence:
Take a graphics element from the auxiliary means (Resources 
- utilities).
In this menu, you can select one or more plots, which are output 
with templates that can also be selected.
This menu also allows you to change the templates.
Example of a roundness plot.
Adjustment options and information mode.
11�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Example for a multiple plot
© Carl Zeiss 
3D Metrology Services
11� Calypso AdvancedTraining
6.1.2 Settings of form plot
With two-dimensional form plots, the outliers in the 
respective plot can be made visible and marked speci-
fically.
In the properties window of the form plot, the follow-
ing page can be retrieved.
Limit deviations to
Entering the limits for the deviations in the form plot. 
You can enter a arbitrary (positive) number. This will determine 
that outlier points, which are above the entered numeric value 
(e.g.: whose value is more than twice as much as the max. per-
missible tolerance) are transformed to the range limits (alas, here: 
to twice the max. permissible tolerance). 
Display range limits for outliers
By activating this box, the areas containing one or more outliers 
are marked by lines in the form plot. The lines begin at the X co-
ordinate (all non-round plots) or the angle (all roundness plots) of 
the first outlier point and they end at the last outlier belonging to 
the same range. If the "range" consists of one single outlier, only 
this line is drawn directly to this outlier.
Form plot: Surface lines with cylinder scanning
With the form plot "Cylinder form", a surface linear 
plot can be displayed.
11�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.1.3 Plot output only if tolerance range is exceded
Minimum standard deviation for form plot:
This determines the input of the values for the minimum stan-
dard deviation, as of which a form plot is to be displayed in 
the automatic run (CNC run). The input is form plot related. 
The dimension of the standard deviation is always a length.
Min. tolerance deviation in % for the 
form plot:
This determines the input of the values 
for the minimum tolerance deviation, as 
of which a form plot is to be displayed in 
the automatic run (CNC run). The input is 
in percent values.
Formula input instead of fixed value:
The menu is activated by pressing the right mouse button.
The selection of the menu item "Formula" opens the formula 
editor window, where the formula (or the parameters) are 
defined. When clicking different characteristics in the list, the 
background color of the input field turns white accordingly 
(input value) or yellow (formula).
With the bore pattern plot, a plot is output as soon as a value 
exceeds the limit values.
During a CNC run, the form plots can only be displayed if at least 
one of the following two conditions is fulfilled: 
1. The standard deviation of the feature to be displayed exceeds 
a preset value.
2. The percent of tolerance usage of the feature to be displayed 
exceeds a preset value.
The respective values are entered into the measurement plan 
editor "Characteristics" (Resources Menu). In additional to pure 
numeric values, you can also enter formulas (PCM).
© Carl Zeiss 
3D Metrology Services
11� Calypso Advanced Training
6.2 Printout
Define printout:
Retrieval:
Resources - define printout.
This page controls the printout for all prin-
touts. The functionality is very versatile and 
often self-explanatory. 
The compact printout as well as the custom 
printout can be changed regarding their 
extent and sequence.
The settings made here apply to the respec-
tively open measurement plan.
11�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.1 Modifying the printout header
Task:
The standard printout header should be 
changed.
Modified printout header.
Find the path for the printout header formats:
C:\Zeiss\Calypso\opt\om\protform\default
Copy the folder "Default" and rename it to "Training"
Note:
The folder "Default" is reassigned for every new measurement 
plan for the design of the printout. If its contents are changed or 
destroyed, the printouts may no longer function properly.
For this reason you work in a copy, here "Training". A retroactive 
renaming of "Training" into "Default" or to "Backup_Default" is 
not a problem.
This is only one of the possible variants - creating a backup first 
and then working in "Default" is also possible.
Assign the printout header "Training" to 
the measurement plan.
Resources - define printout
Output format "Training"
© Carl Zeiss 
3D Metrology Services
11� Calypso Advanced Training
Opening the graphic program to change 
printouts:
Resources - design custom printout - printout
Open the file "vphead.gra"
Inserting "Case number" and "Comment".
These fields must be selected from the list on 
the left.
Change the title.
Delete the Zeiss logo.
CNC run with the modified printout header:
This printout header has been prepared with 
some fields, which can automatically be com-
pleted by the system or the user when starting 
the program.
The workpiece name can be the name of the 
measurement plan.
Time and CMM are not used as commonly and 
can be removed if applicable.
Insert a new graphic, e.g. an image of the 
workpiece or a company logo.
Save the file as "Training".
The file is overwritten.
11�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.2 Changing the printout header for plots
Task:
The header of the graphic plots should be changed.
Resources - design custom printout - printout
Open file: 
Conduct the changes analog to the printout header.
Important:
Changes affect ALL plots!!
6.2.3 Changing compact printout header
Retrieval:
Resources - design custom printout - printout
Notes:
Just like with the custom printout, different formats can be 
defined.
The file is called "cphead.gra".
A special printout header is selected via the data structure to-
gether with the custom printout. (This file is located in the 
same directory as the files for the pres.printout formats). 
Differences from the Pres.printout, as compact printout is 
ASCII:
Positioning the fields within the columns / lines grid
Fixed font size
No graphic
A different format can be used for each measurement plan.
•
•
•
•
•
•
•
•
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
6.2.4 Total result
In the custom printout, the total result can be shown first.
Hence, you can tell right away, whether one or more characteri-
stics are out of tolerance and whether the whole part should be 
evaluated as "good" or "bad".
Printout
Switching on the total result:
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.5 One-line custom printout
 
Task: 
The standard custom printout consists of a section with a symbol 
and several lines.
For extensive measurement plans, this creates printouts with 
multiple pages. Here, reducing every characteristic to one line 
makes sense.
Note:
The change of the printout is facilitated by 
knowledge in common graphic programs as 
well as understanding the assignment of the 
printout header and the characteristics list.
Sequence:
Opening the Calypso drawing program:
Prepare
 Design custom printout
 Characteristic
Click on symbol "Load" (=open folder)
Note: 
All printout formats (header, characteristic, 
feature...) are located in one directory under 
the path 
 C:\Zeiss\Calypso\opt\om\protform\default
When this drawing program is loaded, the 
file "
 C:\Zeiss\Calypso\opt\om\protform\default
is always loaded first.
If this file is changed in the "default" folder, 
the supplied version is destroyed.
For this reason, you must save it under a 
different name!
Copy the "default" folder. It will automatically be named "Copy 
of default".
This is your backup copy!
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Open the printout editor.
Edit the characteristics display as follows:
Delete the icon, move the entries, add 
vertical lines.
By moving the position of nominal and actual values, etc., the 
Printout header must be edited:
Load the drawing program for the printout header:
Resources
 Design custom printout
 Printout header
When you open the drawing program, the file 
„...Zeiss\Calypso\opt\om\protform\default\vphead.gra“ will 
always be loaded.
Here, you must also immediately save in the "single line" folder.
Edit according to the desired appearanceof 
the characteristic. 
The headline and the numeric values must 
be on top of each other.
Note: 
Control the appearance via a new printout 
on the printer! If the headlines should not 
match during the first attempt, continue 
until the desired results are reached.
Also edit the Printout header for subsequent pages:
Resources
 Design custom printout
 Header lines
When you open the drawing program, the file „...Zeiss\Calypso\
opt\om\protform\default\vphead.gra“ will always be loaded.
This is the printout header for the subsequent pages starting with 
page 2.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Assign this new printout header to a measurement plan:
Prepare
 Resources - define printout - output format: default com-
pressed
You will receive the shown printout as a 
result.
The printout header is changed in a similar 
manner. Here, you must load the file 
vphead.gra and edit it.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Overview of the printout header variables
The printout header data (reference)
SYS 
CMM no. dmesn
Time time
from nrpgs
Date date
Measurement plan name planid
Software revision: 
Department: vda_departm
Software dmeswi
Phone: vda_departm
No. vda_number
Control type Controller
Sheet actpgnr
CMM type dmeid
Tester operid
Run measRun
EDIT 
Clamping means no. clmpsn
Remark: vda_departm
Clamping means clmpid
Name partid
Previous operation prevop
Ser. no. Workpiece partsn
Comment measurement 
plan partcomment
Subject no.: vda_departm
Fixture no. fixtsn
Name: Name: 
Version: Version: 
Fixture fixtid
Rev. Workpiece partsn
Test report no. vda_auditno
Drawing no. drawingno
START 
Comment at start startcomment
Remark: vda_departm
Name: 
Test ID lotid
Lot ID partnbLong
Subject no. vda_subjno
Name: Name: 
Process plan mfgdev
Order order
Part number, incremental partnbinc
Version: Version: 
Test report no.: Version: 
Tool tooldf
Signature: Version: 
OTHER 
Modified by changeoper
Software rev creation creationswi
Change date changedate
Compiled by produceoper
Creation date creationdate
CMM type creation creationdme
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.6 User-defined printout
Sequence:
Create a measurement plan with characte-
ristics.
Opening the Calypso drawing program:
Prepare
 Resources - design custom printout - 
 user-defined printout
Task: 
The standard custom printout is to be re-
placed by a printout showing a graphic of 
the workpiece. The characteristics should 
be listed on the side and reference the 
respective features in the illustration.
Note:
The change of the printout requires know-
ledge in common graphic programs as well 
as understanding of the assignment of the 
printout header and the characteristics list.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Note: 
The printout header formats of the column 
"User defined" are located in the measure-
ment plan folder (inspection).
Insert the "captured" image from the 
screen.
Observe the list of available characteristics.
You insert the characteristics into the form and align them to the 
side.
Format the page so that it fits into the print area of your printer.
File - format
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Use arrows to point from the characteristic to the graphic.
Now, the printout header itself is missing yet.
You can generate a new header; here, to simplify matters, the 
header of a standard printout has been added.
Now the task must be modified for the opened measurement 
plan:
Prepare
Resources - define printout
Here, the list output is deactivated and the user-defined printout 
is activated.
If this step is not performed, the printer will output both prin-
touts.
Start the run and check the result.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
6.2.7 Attaching a comment to the characteristic 
Task: 
Attaching a comment to the characteristic
Create a measurement plan with usable characteristics and view 
the presentation as well as the compact printout.
Shown here, without a comment, 
the characteristic "Diameter" should get a comment.
Select the diameter and click the right mouse button to rename 
the characteristic.
The display of the printouts after a second 
run:
Make sure that the length of the characteristic becomes longer in 
the custom printout if the comment covers several lines.
Enter a comment text; this should contain at 
least two lines for this example.
Formula in the comment field
In the comment, the deviation of the respective characteristic 
should be output.
Click into the comment field on the right and select "Sigma" as 
shown in the attributes.
The output will now yield the deviation in the comment.
This can be improved significantly with a few PCM commands:
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.8 Inserting a text element
Select the text element from the toolbox and insert it into a sensi-
ble location in the measurement plan.
Important: The appearance of the text is subject to the common 
rules of the characteristic-oriented run. The appearance of the 
printout can influence the text element because of selective CNC 
runs or switching programs.
Start the CNC run with all characteristics. 
The printouts will have the following ap-
pearance:
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
6.2.9 Groups in the custom printout
In the custom printout, the group names will be highlighted.
A unique format can be defined for characteristic groups (file 
name "‚grpcf.gra").
(Open pulldown menu > Resources > characteristics settings 
editor - group in custom printout) 
Example with a larger font for group names:
Note:
Here, the display of groups in the printout must be set to "ON".
 Measurement plan editor - characteristics
 Groups in the custom printout: ON
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.10 Saving printouts
The saving process will be explained using the example of the 
compact printout:
Resource
The compact printout is saved as a text file.
Name of the text file:"cprotokoll.txt" in the measurement plan 
directory: ...calypso\opt\om\workarea\inspections\
Printouts can be saved in any desired way via the following func-
tion:
Selecting the name assignment.
Indication of the path and the name con-
vention:
The file name and the path can be com-
bined from the fields of the printout header,
syntax as per PCM convention.
If the file name does not contain a path, the 
standard path is used, otherwise, the path 
from the defined name.
Possible output files
1. Default printout
2. Compact Printout
3. 3 table files (hdr,chr,fet)
4. pdf files (graphic, text)
5. DMIS 
6. QDAS 
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
"C:\TEMP\"+getRecordHead("planid")+getRecordHead("date")+"_Teil_"+getRecordHead("
partnbinc")+"praes.pdf"
"C:\TEMP\"+getRecordHead("planid")+getRecordHead("date")+"_Teil_"+getRecordHead("
partnbinc")+"praes.pdf"
Output of ASCII files with the extension *.txt:
The compact printout and the default printout can be output 
using this method.
Output in PDF format with the extension *.pdf:
PDF file graphic: puts out the custom printout
PDF file text: puts out the compact printout
Exercise: 
Define the output of the compact printout and the custom prin-
tout as a *.pdf file to the "Temp" directory.
Keep in mind, that different names will be assigned.
The name should be composed as follows:
 Measurement plan name + date + part number
PDF file graphic: 
 
PDF file text: 
Note:
The option PDF must be set to "ON' in the menu "Resources 
- results on file".
PDF must be activated in the CNC start window to output PDFs!
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2.11 Changing the INI file for printout header 
data
If a file "userfields.ini"is present, Calypso will take from this file 
which data will be queried in the dialog box "input parameters" 
and which values can be captured for the individual printout 
header parameters.
The settings in this file overwrite the settings of the possibly pre-
sent file userfields.txt.
The file "zzz_userfields.ini" was included in the initial install (this 
file contains an example for user-defined printout header fields). 
You activate the delivered file "zzz_userfields.ini“ by renaming it 
to "userfields.ini".
The further description of the *.ini file can be taken from the 
operating instructions.
In this section , there will be an example for a change:
Create a arbitrary formatted printout header with the following 
new fields:
Month
Day of the week
Edited by
Editing machine
These fields should be completed as pulldown menues during the 
start of the program.
The next two pages show a "userfields.ini" file with explanations.
•
•
•
•
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
REM this is an example for the "userfields.ini" file.
[Field names] ; 
REM userfield names must always begin with "u_".!!
REM e.g. u_hallo_1, u_protocol, u_test
REM *****************************************************
REM **nach REM und ; Texte und Meldungen **
REM ** werden vom Programm nicht benötigt **
REM *****************************************************
u_field_1
u_field_2
u_field_3
u_field_4
u_field_5
; Definierung des ersten userfields mit dem Namen „u_field_1“
[u_field_1]
name=Monat ; Bezeichnung / Name des inputfield/list
editMode=true ; Wird dieses Feld mit „true“ bestätigt,erscheint es bei den 
 ; Edit Parametern. 
runMode=true ; Wird dieses Feld mit „false“ bestätigt,erscheint es nicht
 ; bei den Start Parametern
selectiveList=true ; Diese Liste ist entweder ein Pull down menue oder eine
 ; combo box.
selectiveListValues=u_field1_valueList ; Die selektier Parameter für diese Liste findet man in den
 ; profilen mit dem namen „u_field1_valueList“
editable=true ; Ist dieses Feld mit „false“ benannt ist keine Eingabe in der 
 ; entstehenden combo box möglich. mit „true“ entsteht die 
 ; editierbare combo box.
defaultValue=1 ; Der Wert der im erzeugten Feld zunächst erscheint ist der
 ; Weet mit dem optionsname „1“
REM Hier wird die Eingabeliste für das Userfeld ( Pulldown menue ) mit dem Namen „Part“ definiert.
[u_field1_valueList]
REM Nach dem = sind beliebige Namen möglich.
1=Januar ; Ebenfalls ein Standartwert zu erkennen option defaultValue
 ; Definiert durch u_field_1
2=Februar
3=März
4=April
5=Mai
6=Juni
7=Juli
8=August
9=September
10=Oktober
11=November
12=Dezember
; if this field is confirmed with "true", it will appear with the 
; edit parameters. 
; if this field is confirmed with "true", it will not appear with the 
; start parameters
; This list is either a pulldown menu or a 
: box
; The selected parameters for this list can be found in the
; profiles with the name "u_field1_valueList"
; If this field is labeled "false", there is no input possible in the 
; created combo box. With "true", the 
; editable combo box will be created.
; The value that appears in the created field first, is the
; value with the option name "1"
; You will also detect a standard value option default value
; Defined by u_field_1
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
REM Definition of the second user field with the name "u_field_2"
[u_field_3]
name=Bearbeiter
editMode=false ; Wird dieses Feld mit „false“ bestätigt,erscheint es nict bei 
 ; Edit Parametern. 
runMode=true ; Wird dieses Feld mit „true“ bestätigt,erscheint es bei den
 ; Start Parametern
selectiveList=false ; Keine Liste ( Pull down menue) 
editable=false ; keine ( combo box )
defaultValue=Meier ; Dieser Wert erscheint so lange im Eingabefeld bist er 
 ; geaendert wird.
[u_field_2]
name=Wochentag
editMode=true
runMode=true
selectiveList=true
selectiveListValues=u_field2_valueList
editable=false
defaultValue=3
[u_field2_valueList]
1=Montag
2=Dienstag
3=Mittwoch
4=Donnerstag
5=Freitag
6=Samstag
7=Sonntag
[u_field_3]
name=Bearbeiter
editMode=false ; Wird dieses Feld mit „false“ bestätigt,erscheint es nict bei 
 ; Edit Parametern. 
runMode=true ; Wird dieses Feld mit „true“ bestätigt,erscheint es bei den
 ; Start Parametern
selectiveList=false ; Keine Liste ( Pull down menue) 
editable=false ; keine ( combo box )
defaultValue=Meier ; Dieser Wert erscheint so lange im Eingabefeld bist er 
 
[u_field_4]
name=Bearbeitungsmaschine
editMode=true
runMode=true
selectiveList=true
selectiveListValues=u_field4_valueList
editable=true
defaultValue=D12
[u_field4_valueList]
1=D12
2=D13
3=D14
4=D15
[u_field_5]
name=Currency
editMode=true
runMode=true
selectiveList=true
selectiveListValues=u_field5_valueList
editable=true
defaultValue=Euro
; if this field is confirmed with "false", it will not appear with the 
; edit parameters. 
; if this field is confirmed with "true", it will appear with the 
; start parameters
; No list (pulldown menu) 
; none (combo box)
;This value will appear in the input field until it is changed.
; if this field is confirmed with "false", it will not appear with the 
; edit parameters. 
; if this field is confirmed with "true", it will appear with the 
; start parameters
; No list (pulldown menu) 
; none (combo box)
; This value will appear in the input field until it is
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
6.2.12 Inserting a variable into the printout
This task can only be performed with the PCM option.
The exercise consists of selecting the "part number incremen-
tal" from the variables of the printout header, which are known 
from previous exercises and to insert them as a comment into a 
characteristic.
Keep in mind that this example is only intended to give you an 
idea of the complex operation possibilities of variables by means 
of formulas.
Think of your own applications to deepen the subjects.
Sequence:
Take another diameter from the previous example, open it and 
delete the comment. 
Click into the comment field on the right and select "Formula".
Enter into the formula field:
The function "getRecordHead()" reads a variable from the list of 
the printout header variables, here the variable "partnbinc". This 
is the part number incremental.
The printout now puts out the part number in the comment.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
CAD file -> Convert CAD entities
With this function, CAD files can be converted into *.sab files in 
the background.
The selected files are converted in the background and saved 
once more under their name with the extension *.sab in the same 
directory. The printout of the conversion is saved under the file 
name with the extension *.log in the same directory.
A background conversion can diminish the performance of the 
applications running in the foreground.
You can select multiple files.
CAD file -> CAD model comparison
Compares models, e.g. after drawing modifications.
This function is to be considered an auxiliary function only, as 
CAD programs can better perform this comparison on their own.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
7: Stylus systems and accuracy
7.1 Automatically qualify stylus system afterwards ................................................. 139
7.2 Special styli ........................................................................................................ 142
7.3 Stylus monitoring ............................................................................................... 146
7.4 Rack preassignment .......................................................................................... 148
7.5 Qualify the stylus change rack into the CNC....................................................... 149
7.6 Avoid measurement inaccuracies .......................................................................150
7.6.1 Temperature compensation .........................................................................................150
7.6.2 Behavior in case of collisions ........................................................................................152
7.6.3 Clamping Workpieces for Measurement ......................................................................153
7.6.4 Stylus Systems .............................................................................................................155
7.6.5 Inaccuracy with a CMM ...............................................................................................158
7.6.6 Inaccuracy Analysis ......................................................................................................159
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
7.1 Automatically qualify stylus system afterwards
Task: 
Stylus systems must be qualified beforehand.
Creating a qualification measurement plan
The star stylus must be requalified. 
This can take place in two different ways.
Method 2: 
Via a measurement plan with characteristics for each individual 
stylus system.
Functions as a regular measurement plan. Here, the stylus sy-
stems to be qualified can be selected.
Method 1: 
With the button:
Here, only the stylus system located in the probe head is qualified 
automaticallly.
Note:
Many stylus functions depend on the probe head and 
are not shown here.
Further information can be found in the document "Sen-
sors".
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
Method 1:
The reference sphere must be qualified.
Only the stylus system located in the probe head is qualified.
The mode of the original qualification is used.
Navigation around the sphere are calculated automatically.
•
•
•
•
The printout shows these values:
Method 2 Retroactive qualification while maintaining the 
bending parameters (tensor)
Resource: 
The star stylus (and possible additional stylus systems) should be 
present and qualified.
Principle: 
First, the master probe automatically qualifys the reference 
sphere at the most recently used position.
Then, the stylus systems are qualified in the order of the plan.
Single styli can be selected.
Stylus changes are performed automatically (except when the 
stylus is not assigned to any holder).
•
•
•
•
Open a new measurement plan; and from the toolbox or the 
resources menu - utilities, insert as many entries "Stylus system 
qualification" as there are stylus systems - including master pro-
be. 
Rename the characteristics. 
This does not assign the respective stylus! (see below).
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
Open each characteristic, here for the master probe: 
 
 
 
 
 
 
 
 
 
(1) Assigning the stylus system
(2) Setting up the mode for this requalification
(3) Selection of the stylus for (4)
(4) Adding or removing individual styli for the "requalification“
Set up the adjustments for the master probe 
as shown.
Open the star stylus.
Only select individual styli.
Set the mode for each stylus to "Geometry 
- Requalification“.
Start the sequence
 CNC start window: "Use position points only"
The CMM only runs the "6 point" mode for this "requalification".
The tensor remains intact from the original qualification, the geo-
metry values (sphere center points and diameters) are redetermi-
ned.
Caution: 
The mode "Use position points only" remains during the subse-
quent CNC start, even if another program is started!
You must switch back to "use clearance planes", otherwise there 
may be severe collisions!
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
7.2 Special styli
Disc stylus
Task: 
Qualifying the disc stylus and subsequent correction on the ring 
gage.
A disc stylus is not a complete sphere but a section of a sphere.
The danger with working with the stylus are probings with the 
edge of the disc and not with the sphere section surface.
The problem with qualifying is hitting the probings exactly at 
"equator height".
For this reason, the diameter is corrected afterwards on one ring 
gage.
Procedure: 
1: Qualify the disc stylus on the reference sphere
2: Requalify on the reference sphere or on the ring 
gage
3: Manual correction of the stylus data
Re: Step 1:
Qualify the reference sphere with master probe
Insert the disc stylus and qualify in the "manual" mode with 
the "disc" geometry. 
 
The first probing must now take place in the direction of the 
shaft of the installed disc; from this, Calypso will detect the 
shaft direction for this stylus pin.
This probing will not be included in the calculation.
1.
2.
3.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
The following probings must be made on the circumference.
As this method is not sufficient for a very accurate qualification 
(bending parameter, point recording only on the circumference), 
you should requalify on the ring gage.
Re: Step 2:
Clamp the ring gage and align it.
Measure the circle in the ring gage.
Compare the circle diameter with the nominal diameter of the 
ring.
The diameter of the disc can only be corrected manually.
1.
2.
3.
4.
Re: Step 3:
Output of the diameter in the default printout.
The deviation from the actual diameter must now be cor-
rected.
Open the stylus data and edit the radius.
Measure the ring gage again and check the diameter.
Perform another correction if necessary.
1.
2.
3.
4.
5.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Qualifying a slanted stylus
Qualifying a slanted stylus as per "eye measure"
Determining the shaft inclination with the cylinder feature
Requalifying with the correct vector data
•
•
•
Assemble a slanted stylus.
Use this stylus as a new stylus.
"Improvised" qualification
Qualify the slanted stylus on the reference sphere.
Mode: 6 points for the "improvised" qualification.
Only with the "true" qualification with the then known angles 
will you need to work in the "tensor" mode.
"Probing in shaft direction" means: best possible probing as per 
eye measure from the shaft direction.
The query for the angles of the shaft is displayed 
These are not known yet.
Simply confirm with OK.
The stylus is qualified and measurements are possible.
Close the stylus menu.
Use the shaft of the stylus to probe eight points in two planes on 
the reference sphere.(see image)
A cylinder is recognized.
The inclination of the cylinder axis, output via the projected 
angles A1 and A2 is determined by the inclination of the stylus 
shaft.
The two angles A1 and A2 must be entered when the query 
appears with the subsequent "true" qualification (in the tensor 
mode).
This process ensures that Calypso uses a "semi sphere" to qualify 
under the correct angle, which is a resource for correct probings.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Qualifying a cylinder stylus
Sequence:
Qualifying the cylinder stylus in manual mode
Requalification on the reference sphere
Manual correction of the stylus data
•
•
•
Assemble a cylinder stylus.
Measure the stylus in the "cylinder" mode, on the equator of the 
reference sphere, with three points each in two planes.
After you complete the qualification, you should switch to the 
features side.
Measure a circle on the equator of the reference sphere.
Compare the diameter of the circle with the diameter of the 
reference sphere.
The deviation from the actual diameter must now be corrected. 
Open the stylus data and edit the radius. (See disc stylus sequen-
ce)
Iterate this process if necessary.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Monitoring the CNC qualification
Here, there are two possibilities:
1. Using global limit values. 
These are set via the workroom.
 They apply to every stylus that is qualified in the CNC run.
2. Setting stylus-related limit values.
 
Here,the stylus-related setting overlays the global one.
In both versions, the shown criteria are monitored.
In the workroom, you can globally preassign the limit values and 
the stylus test:
Extras - workroom - CMM - stylus systems
This function must be divided into two areas:
Monitoring the CNC qualification
 Here, you will check for correct geometry, temperature and 
deviation (Sigma) during the qualification.
Monitoring the styli during CNC start
Here, you will check which styli are required for the CNC 
run, whether the stylus has been qualified, whether a stylus 
change position has been assigned to it or whether a manual 
stylus change is planned. The mode of the original qualifica-
tion is used.
Depending on the validity status, the run can be terminated or 
started or a warning message can be displayed.
If one of these limits is exceeded, the stylus must be set to the 
"unqualified" status.
Note: 
Further information can be found in the operating in-
structions or the online help.
7.3 Stylus monitoring
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Switching on the function:
Resources - stylus system - stylus check at CNC start
You can set up the respective function in this self-explanatory 
menu.
Task:
Set up the limit value in a measurement plan and test different 
termination criteria.
Checking the styli during CNC start
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
2. Switch on function
Resources - measurement plan - rack assignment
Here, a rack location assignment can be saved for each measure-
ment plan.
During CNC start, the correct assignment is checked.
Note: 
Further information can be found in the operating in-
structions or the online help.
7.4 Rack preassignment 
Application
1. Creating and managing rack assignments
The assignments are managed in the menu "Automatic stylus 
change" via "Administration".
If the function is activated, there will be check when the mea-
suring run is started whether the saved assignment matches the 
assignment in the stylus change rack.
If the assignment does not match, there will be a message as to 
which of the used stylus systems should be mounted in which 
rack positon.
The displayed assignment includes the holder location name, the 
holder location name and the stylus system name.
Caution: 
The parameters entered under "approach parameters" are 
not saved. This means that those parameters that were active 
prior to loading are executed. This can lead to collisions.
Task:
Allocate an assignment to a measurement plan and examine 
several application cases.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
This function allows the automatic qualification of the stylus 
holders in the CNC.
This function is only required if the stylus change rack changes 
positions frequently, e.g. if it is mounted on a pallet, which is 
clamped onto different positions within the measurement volu-
me.
Further information pertaining to this unusual case can be 
found in the operating instructions or the online help.
7.5 Qualify the stylus change rack into the CNC
Retrieval:
Resources - utilities - qualification of stylus system holders
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
7.6 Avoid measurement inaccuracies
7.6.1 Temperature compensation
The temperature compensation must be switched on first.
They distinguish between two cases:
1. The CMM does not have a temperature sensor.
When the temperature compensation is opened, the values 
for the workpiece and the ratio are at 20.000 °C .
Measure the temperature of the workpiece
Enter the temperature and the workpiece expansion coeffi-
cient.
Corrections are performed automatically during the run.
2. Temperature sensors are connected.
When the temperature compensation is opened, the current 
values for the workpiece and/or the ratio are displayed.
Select the connected sensors. If there are two sensors, the 
temperature will be averaged out.
Enter the workpiece expansion coefficient.
Corrections are performed automatically during the run.
•
•
•
•
Calypso calculates the geometry of a workpiece for the material 
properties at 20°C. 
20°C is the reference temperature for length measurements as 
per DIN EN ISO 1. 
If the temperature deviates from 20°C, the measured geometry 
data must be corrected.
For this, the temperature of the CMM and the workpiece must be 
known.
The respective expansion coefficient must always be entered 
manually.
Retrieval of the temperature compensation
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Temperature effect with styli
Expansion of the used materials:
• Aluminum: Length change = 2.3 µm/degree
• Titan: Length change = 0.6 µm/degree
• Carbon fiber / ceramic: Length change = 0.1 µm/degree
Example: Comparison of materials with a temperature difference
of "only" 5°
(Measurement began at 20°, 
end of measurement 25°, stylus length L= 200mm)
Aluminum extensions : Length change = 23 µm !!!
Titanium extensions : Length change = 6 µm !!!
Carbon fiber/ceramic extensions : Length change = 1 µm !!! 
Remedy:
If you are expecting temperature fluctuations on the measuring 
device, use the components listed in the following, if possible
in the listed sequence:
• 1. Carbon fiber
2. 
3.
4.
5.
•
•
•
Monitoring functions
Calypso issues a warning during CNC start and in the printout if 
the limit values are exceeded.
You must pay special attention to the temperature when qua-
lifying styli.
First, the temperature is saved along with the stylus data and can 
be taken into consideration here..
Furthermore, even temperature differences in the stylus caused 
by the heat of your hands must be avoided shortly before the 
qualification.
Display the temperature in the printout header.
The temperature can be displayed with the SYS parameter "tem-
peratureworkpiece".
Alternative, PCM can be used.
The temperature can be compared at the beginning and the end 
of a measurement by means of the PCM and a message can be 
generated.
More information regarding this subject is included in the PCM 
Note: 
Temperature compensation cannot be used during stylus 
qualification.With temperature differences between the stylus 
qualification and the measurements on the workpiece, you 
must requalify the styli if necessary! 
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
7.6.2 Behavior in case of collisions
With the characteristic "CMM Check", you can monitor your 
coordinate measuring device quickly, safely and as per standard 
(DIN EN ISO 10360 and VDI/VDE 2617). 
The qualified characteristic "CMM Check" allows a quick and 
standardized monitoring of the CMM. The control and evaluation 
software allows an expressive evaluation by monitoring factors.
Recommended monitoring cycle:
or:
After a collision
The following components of the CMM are monitored by "CMM Check":
The probe head system (precision sphere, adjustment ring, reinforcement normal):
the variance of the probe head system, measured in relatively small meauring areas
the probing behavior of the probe head system, overlayered by the features of the CMM (oscil-
lation, hystereses, dynamic deformations)
the scanning features of the probe head system.
The CMM Geometry
the variance in the entire measuring volume of the CMM, caused by the straightness variance of 
the guides and their perpendicularity to one another 
the length measuring variance (end dimension 40 mm / end dimension 400 mm)
the CMM as form measuring device including its filtering functions
The rotary table (2 precision spheres as options)
the four axle movement for the CMM with rotary table
the sum of variances from the CMM geometry and component variance of the rotary table.
•
•
•
•
•
•
•
•
Literature Reference:
 „Genau messen mit Koordinatenmessgeräten, 
H.-G. Pressel, expert-verlag
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
7.6.3 Clamping Workpieces for Measurement
A4.1.5 Point recall from a file ....................................................................................................65
4.2 Special calculations .............................................................................................. 66
4.2.1 Measuring features ........................................................................................................66
4.2.2 Limiting freedom degrees ..............................................................................................69
4.2.3 Changing the tolerance mode ........................................................................................71
4.2.4 Tangents .......................................................................................................................74
4.3 Introduction to form and position .....................................................................................75
4.3.1 Flatness, cylinder form ...................................................................................................75
4.3.2 DIN position of two bores ..............................................................................................77
5: Expanded programming functions .................................. 78
5.1 Pattern ................................................................................................................. 79
5.1.1 Linear Pattern ................................................................................................................80
5.1.2 Polar pattern offset ......................................................................................................83
5.2 True position on circular pitch .......................................................................... 88
5.2.1 Coordinate system from bore pattern best fit method ..................................................91
5.3 Pattern measurement as per DIN 3960 ............................................................ 93
5.3.1 Circular pitch .................................................................................................................93
5.3.2 Linear pattern ................................................................................................................97
5.4 Formula ............................................................................................................ 98
5.4.1 Result Element .............................................................................................................98
5.4.2 Probing a sheet metal ................................................................................................100
5.4.3 Probing positions relative to a feature ........................................................................101
5.4.4 Alignment with offset plane via formula .....................................................................102
5.5: Automation interface ..................................................................................... 105
5.5.1 Pallet measurement: ..................................................................................................105
5.5.2 Serial measurement: ..................................................................................................105
6: Result display - printout design ..................................... 108
6.1 Graphic display - plotting ................................................................................... 109
6.1.1 Flatness and graphic display .........................................................................................109
6.1.2 Settings of form plot ....................................................................................................114
6.1.3 Plot output only if tolerance range is exceded ..............................................................115
�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
6.2 Printout .............................................................................................................. 116
6.2.1 Modifying the printout header .....................................................................................117
6.2.2 Changing the printout header for plots ........................................................................119
6.2.3 Changing compact printout header .............................................................................119
6.2.4 Total result ..................................................................................................................120
6.2.5 One-line custom printout .............................................................................................121
6.2.6 User-defined printout...................................................................................................125
6.2.7 Attaching a comment to the characteristic ..................................................................128
6.2.8 Inserting a text element ...............................................................................................129
6.2.9 Groups in the custom printout .....................................................................................130
6.2.10 Saving printouts .........................................................................................................131
6.2.11 Changing the INI file for printout header data ............................................................133
6.2.12 Inserting a variable into the printout ..........................................................................136
7: Stylus systems and accuracy ......................................... 138
7.1 Automatically qualify stylus system afterwards ................................................. 139
7.2 Special styli ........................................................................................................ 142
7.3 Stylus monitoring ............................................................................................... 146
7.4 Rack preassignment .......................................................................................... 148
7.5 Qualify the stylus change rack into the CNC....................................................... 149
7.6 Avoid measurement inaccuracies ....................................................................... 150
7.6.1 Temperature compensation .........................................................................................150
7.6.2 Behavior in case of collisions ........................................................................................152
7.6.3 Clamping Workpieces for Measurement ......................................................................153
7.6.4 Stylus Systems .............................................................................................................155
7.6.5 Inaccuracy with a CMM ...............................................................................................158
7.6.6 Inaccuracy Analysis ......................................................................................................159
8: Measuring methods, part 2 ........................................... 161
8.1 Scanning with unknown contour .................................................................... 162
8.2 Scanning with 2 styli ...................................................................................... 163
8.3 Point masking in open scanning paths ........................................................... 165
8.4 Self-centering probing .................................................................................... 166
8.5 Safety cube ..................................................................................................... 168
8.6 Park position .................................................................................................. 171
8.7 Missing bore ................................................................................................... 172
© Carl Zeiss 
3D Metrology Services
� Calypso Advanced Training
Offline Programmingmanufactured workpiece must be positioned on the coordinate machine for measuring. Usually, 
a clamping machine is used to achieve this. The clamping machine is adapted precisely to the work-
piece and fulfills the following functions: 
Defining the Workpiece: Positioning features such as stops, linings, index pins, prisms, are 
used to place the workpiece into a certain position on the CMM. 
Clamping the workpiece: Clamping features such as quick clampers, clamping claws, spring 
tensioners, hold the workpiece in the desired position during the measuring process. 
The determination and tensioning of the workpiece must ensure that the workpiece will not warp 
and that it does not move during the measuring procedure. A clamping of this type is called "stati-
cally defined". With "statically underdefined" clamping, the workpiece is still able to move (e. g. the 
rotating part of a prism without length stop). With "statically overdefined" clamping, the workpiece 
will be deformed/warped (e. g. clamping of a surface on four placement points). 
With statically defined clamping, the clamping features should be located as directly as possible 
across from the defining features. This will prevent deformations of the workpiece during the clam-
ping process. 
Another important advantage of the statically defined clamping is also that the workpiece and the 
clamping machine can change with different temperatures, without bending forces influencing the 
measurement process. With statically overdefined clampings, where the workpiece is "pulled" into 
a forced position, bending forces will be generated with temperature changes, which deform the 
workpiece inside its clamping. 
The 3-2-1 clamping is a typical, statically defined clamping for prismatic workpieces (lathing 
pieces, housing. . . ). Three placements position the workpiece in the space (Z axis). Two stops 
prevent the rotation in the placement plane (Y axis) and one stop determines the position along the 
Y axis (origin). 
Chuck clamping is often used for rotating parts. Here, the prism defines the space axis (Z axis); the 
radial stop prevents the rotation around the Z axis and the length stop defines the position along 
the Z axis (origin). 
Defining features are made of hardened materials. They must allow a continuous repeatedly accu-
rate position of the workpiece and must never close. Damages to the workpiece are avoided by a 
high surface quality. 
Examples for Defining Features: 
Stops, placements
Pins
Prisms
Centering cones
three spheres (Bessel points for long parts, example: Portal check)
•
•
•
•
•
•
•
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Clamping features must provide the necessary tensile force 
during the measurement. They must not deform or damage the 
workpiece. They must not become loose during the measurement 
or during transport of the workpiece
Examples for Clamping Features: 
Claws, tensioning connections
Quick clampers (knee lever tensioners)
Screws, also with torque limits
Puddy, adhesive
Spring tensioner
Swivelling clamper
Magnets
Vacuum
Example for a Clamping Machine
•
•
•
•
•
•
•
•
Handling tips for Clamping Machines
Clean the surfaces where the workpiece is to be placed (defined) prior to clamping it. Also, you 
should keep the defining features of the machine clean. 
After placing the workpiece into the machine, check whether the workpiece is shaking in the 
clamping. Dirt, shavings, burs on the workpiece and worn out defining features on the ma-
chine can jeopardize the safe tensioning. 
Make sure that the clamping features are in their intended positions during the measurement. 
That way, collisions and damages on the stylus system can be prevented during measure-
ment. 
The workpiece should always be clamped in the optimized measuring range of the CMM, i. e. 
not along the edge. This requires a deep knowledge of your CMM. 
With highly accurate measurements, you should avoid using magnets for clamping. The measu-
ring result is falsified by the magnetic affect on the workpiece and the stylus system. 
Use defined spring forces for clamping and defined torques for screwed connections (torque 
wrench).
•
•
•
•
•
•
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
7.6.4 Stylus Systems
Generally, you should make sure that a visual check is performed before stylus definition 
or measurement in order to check the cleanliness and integrity of the stylus features, styli and
extensions. 
Extensions/connections/intermediate pieces: 
Watch for cleanliness and damages to the insertion surfaces and possibly loose adhesive con-
nections. 
Tighten the screwed connections correctly and thoroughly (use only the intended tool, other 
Extras may cause damages)
Secure the permanent connections with extensions and intermediate pieces with adhesive. 
Setup with as few individual parts as possible (extensions and intermediate pieces) per stylus. 
Prefer a special feature with directional changes and angled pieces !
Assembly configurations: 
Sufficient wait time after the assembly and before the qualification to discharge the heat from 
the hands. >> Otherwise: qualification and accuracy errors!!
Configurations/stylus lengths: 
You must read the machine description!!!
Measuring probe head: Max. weight 600 g
Switching probe head: Max. weight 200 g !!
Specialty: Symmetric placement of the mass !!
Note: Always use the stylus only as long as necessary and as stabile (rigid) as possible!
Probing sphere diameter as small as possible (reason: influence of the accuracy via the surface 
of the test object => mechanical filtering effect)
Use the stylus bending correction feature only with highly accurate measurements and/or long 
styli
We recommend a check on an ring gauge (D) and a form plot (v2)
Calibrating disc styli
Based on the very small contact segment between the stylus and the sphere normal, we recom-
mend a check on an ring gauge (D) and a form plot (v2) 
•
•
•
•
•
•
•
•
•
•
•
•
•
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Checking the Stylus Data and Configurations
Probing sphere diameter
• We recommend a check on an ring gauge (D) and a form plot (v2) 
In case of deviations, perform a manual correction of the sphere radius. 
Probing sphere distances / diameters / quality of the stylus features used
• Sphere measuring on sphere normal with the first stylus tip of a configuration. Determined 
 center coordinates in XYZ are declared origins. 
• All other probing spheres are measured in reference to this origin and compared. 
• If the sphere normal is always in the same location, this means repetitive measuring. 
• If the sphere normal is physically offset, this is used to capture systematic errors on the CMM. 
• The creation of an automated run in the style of a measuring program "Stylus Qualification 
Check" to check the stylus data is recommended when multiple and/or complex configurations 
are used. 
Description of the Measuring Program "Stylus Qualification Check": 
• The measuring program is used to check the stylus data determined in the course of a qualifi-
cation, manually or via a CNC program, or to check the long-term stability of the used styli in 
serial measurement, up until a new qualification of the styli. 
• The result of a measuring program run is the representation of the variances in the coordinates 
X, Y, Z, of all styli used and configurations of a stylus configuration group to the reference 
"ZERO" (origin), determined by means of the master probe or the first stylus of a configuration 
(master probe). 
• In addition, the sphere normal diameter is put out as a measure for the stylus diameter determi-
ned during the qualification. 
• The sigma value is an indicator for the degree of contamination, wear, damage or loosening of 
styli and stylus features, within a configuration. 
• The output is a measurement printout. 
• Changes in the stylus data can be detected by comparingthe results of the individual measure-
ment runs (printouts). 
• The results can be saved and evaluated via qs STAT (option) if a corresponding qs STAT interface 
is available. 
• By issuing the respective limit values with the permissible deviations of the individual parame-
ters, the user's decision making process is facilitated. 
The size of the deviations and/or sigmas to the reference "Zero" depends on the following parame-
ters: 
• Quality of calibration
• Length and stability of the used styli and extensions
• Degree of the temperature deviations and time temperature fluctuations on the CMM
• Degree of contamination, wear, damage of the stylus spheres
Existence of of loosened or damaged stylus and/or extension features. 
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Causes of extensive qualification sigma values
• After a hard collision with a stylus, in every case, a complete recalibration/requalification of 
the configuration is required. 
• Stability of the stylus components is not sufficient (e. g. incorrect shaft materials, faulty 
 adhesive connections, screw on surfaces contaminated, damaged)
• Stylus components not screwed together tightly enough. 
• Three point bearing on the probing head or the changer plate contaminated. 
• Stylus feature was mechanically damaged by improper treatment or hard collision. 
• Stylus layouts that are too long or too heavy are used (perm. limit values are exceeded). 
• Impedance by a magnetic field due to steel components used
Stylus change machine / reproducibility: 
• Switching system = 1.0 µm on 200 mm
• Measuring system = 0.25 µm on 200 mm
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
Influential Factors
Temperature fluctuations / sun radiation / draught air 
Example: Only 1 degree of temperature difference in the granite traverse creates a mea-
suring error of 12 (twelve) µm/m, if you measure at a distance of 600 mm from the X 
measure, 
i. e. on the table surface of CMM. 
Scanning / individual points: 
 Basically, the following applies: The more measuring points that are picked up, the safer 
and more expressive the result! 
 Here, take into consideration the correct use of shaft and outlier filters. 
Material – test workpiece: 
The temperature of the test workpiece has a decisive influence on the measuring result. 
The test workpieces must generally be "acclimated" prior to measuring, i. e. they must be stabi-
lized to the ambient temperature of the CMM. 
Bascially, a capturing and calculation of the workpiece temperature must take place by means 
of the temperature stylus or the temperature sensors on the CMM in order to achieve a 
correct measurement result. 
Projections
• Avoid short measuring lengths with simultaneous large evaluation length. I. e. projections with 
a multiple of the measuring length. 
 Example Measuring Requirement: Coaxiality of two symmetric cylinders with a measuring length 
of 20 mm with an axial distance of 100 mm. 
•
•
•
•
•
•
•
•
7.6.5 Inaccuracy with a CMM
Environmental Conditions
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
7.6.6 Inaccuracy Analysis
The contributions to the measuring inaccuracies for a CMM consist mainly of the 
following
 the known systematic deviations (21 deviation components including pro-
bing variances), which can basically be corrected
 the arbitrary influences, recognizable in the arbitrary probing variances, 
which are caused by interpolation errors, dynamic influences and hysteresis 
effects. 
 the unknown systematic deviations, e. g. by uncorrected temperature influ-
ences, qualification inaccuracies of the used CMMs, short periodic portions 
of the deviation components, simplification of the mathematical models to 
overlay the different inaccuracy contributions. 
The detected inaccuracy contributions for a coordinate measuring process 
are shown in Fig. 1. 
Determining the Inaccuracy Influences
Significant inaccuracy contributions of a coordinate measuring process result from 
the probing procedure, the machine geometry and the stability of the CMM due to 
temperature effects. 
To determine the probing inaccuracy (P), a qualified sphere and a qualified gauge 
ring (CMM check) are measured. 
To determine a length measuring inaccuracy (E) (geometry), a bore pattern (portal 
check) is measured in several locations on the CMM. 
•
•
•
Measuring the deviation components of a CMM with a bore 
pattern
Literature Reference:
 "Genau messen mit Koordinatenmessgeräten", 
H.-G. Pressel, expert-verlag
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
8: Measuring methods, part 2
8.1 Scanning with unknown contour .................................................................... 162
8.2 Scanning with 2 styli ...................................................................................... 163
8.3 Point masking in open scanning paths ........................................................... 165
8.4 Self-centering probing .................................................................................... 166
8.5 Safety cube ..................................................................................................... 168
8.6 Park position .................................................................................................. 171
8.7 Missing bore ................................................................................................... 172
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
8.1 Scanning with unknown contour
Features (besides points, 2D line and plane) have the "unknown 
contour" strategy.
Here, there will be a starting point and an endpoint, just like with 
curve measurement.
The machine tries to measure the shortest path between the 
starting point and the endpoint.
A typical example for this scanning method is the slot.
Exercise: 
Clamp a workpiece with an slot and align the 
workpiece.
Take a new slot from the toolbox and open the strategy.
Click on the unknown contour, open it and probe the starting 
point and the endpoint.
These points can be identical.
Set the speed and the step distance to sensible values.
Indicate a space axis, here, the normal direction of the slot.
The end criterion sphere means that the end the contour was 
recognized as soon as the stylus "arrives" in a "sphere" with a 5 
mm radius.
To run this unknown contour, in the strategy, click on "Execute 
now" with the right mouse button
Now, the slot will be scanned.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
8.2 Scanning with 2 styli
If it is not possible to scan a circular path on a workpiece with 
just one stylus (e.g. full circle on cam shaft), this function will 
allow you to measure partial circle paths with different styli at the 
"same" height and to combine them into one circular path.
This will create a correct roundness plot.
Exercise: 
Align the exercise cube so it "sits on its head".
Measure two circle section with different styli on the cylinder at 
three heights.
Apply correct styli and angle names.
There will be 6 circle sections.
Group two circle sections with the marked group.
Start the run and optimize the drive behaviour so that the end of 
a path is located on the same side as the start of the next path.
Create a roundness plot for every path.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
The following conditions must be observed:
1. Applicable to: Cylinder, cone, circle and circle on cone.
2. Strategies besides "circle section" will not be considered.
3. In order dissolve a group, all its elements must be marked. 
Actuating the button "Group circle sections" dissolves the 
grouping.
4. The summary of the selected circle paths takes place directly 
after the measurement and is switched in front of the actual 
evaluations.
5. The path angle of the circlepaths to be combined is arbitrary.
6. The number of the circle paths to be combined is arbitrary.
7. The respective rotation direction of the circle paths to be 
combined is arbitrary. The rotation direction of the combined 
circle path is the same as the rotation direction of the first 
circle path.
8. The sequence of the circle paths to be combined is arbitrary.
9. The circle paths to be combined can be overlapped or feature 
gaps. Overlaps are removed.
A selection of the possibilities is shown in the illustration.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
8.3 Point masking in open scanning paths
This function masks points at the start and the end of the scan-
ning path.
The number of points is controlled via the time factor seconds, as 
mainly the oscillations of the measuring system are to be elimina-
ted.
In the measuring feature editor, the activation of the function 
for the entire measurement plan and for individual measuring 
features can be set up.
The point masking works for the following scanning paths 
(not with individual point measurements):
Circle cross cut of circles, cylinders, cones, spheres, if the total 
angle area is smaller than or equal to 360°
Circle cross cut of circles, cylinders, cones, spheres, if the total 
angle area is smaller than or equal to 360°
Helix of circles, cylinders, cones
VAST helix of cylinders
Grid (lines and meanders) of planes
Polylines of planes
Circle on plane of planes, if the total scanned angle area is 
smaller than or equal to 360°.
Line of 2D line
Unknown contour of circles, cylinders, cones, spheres, el-
lipses, slots, rectangles, 2D and 3D curves
Curve segments of 2D and 3D curves
Notes about the settings:
Standard: Start 0.25 sec; end 0 sec
Short: Start 0.1 sec; end 0 sec
Long: Start 0.4 sec; end 0,25 sec
•
•
•
•
•
•
•
•
•
•
•
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
8.4 Self-centering probing
Self-centering recording of an unknown contour, i.e. a slot. The 
functionality can be used on points, lines, circle paths (with and 
without rotary table), curves (with and without rotary table). 
The entries for the measuring force and for the self-centering 
probing must be made directly for one feature.
An entry from a superior feature (suggestion) is not permitted.
The self-centering probing can only be adjusted for strategies.
This can take place in several ways.
With 
"Resources - self-centering probing" for the recently selected 
feature or directly in the feature via "strategy".
The dialog box opens; with circle paths, the field "Force direc-
tion" is displayed in the window as well.
For this, the respective direction must be selected.
Notes:
• In the measuring feature list, features are marked with self-
centering probing/scanning by receiving an orange border.
• Setting possibilities in the element editor (ON, OFF, Edit). The 
strategy can be edited with "edit".
• With strategies with vectorial probings, the vectorial probing 
must be adapted with circular pitch.
• Probing points can only be measured with individual points.
Lines and circle paths, on the other hand, can be scanned 
only and without tangential probing (homing) (VAST Naviga-
tor). 
• With circle paths with rotary table (also for curves), the circle 
path must be situated rotationally symmetrical to the rotary 
table axis.
• In general, self-centering measurements can only take place 
within certain limits.Hence, right angles cannot be recorded 
self-centering. Curves should feature a rotation direction, 
similar to a circle path.
VAST XXT and self-centering:
A self-centering probing is not allowed here, as momentum 
created by friction forces leads to inaccurate measurements.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Exercise: 
On the exercise cube, the slot is to be scanned on top in a 60° 
area. This can take place via self-centering.
Prepare a plan where the circle section exists as a strategy.
Now set the adjustments for the self-cen-
tering probing in the strategy window as 
follows:
The measuring force
The measuring force can only be assigned to features.Use all 
measuring strategies belonging to the feature when this force is 
measured.
In order to assign a measuring force to one or more features, it is 
selected and the menu Resources -> measuring force is activated. 
The above dialog window is displayed, where you can enter the 
desired force.
Another example for self-centering:
On a toothed wheel, the gaps between the teeth are to be 
probed via self-centering and circular pitch.
Note: The force direction orients itself by the feature coordi-
nate system. E.g., with points, the force is only switched in 
Fz and against the vector direction.
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
8.5 Safety cube
General information
The safety cube can be aligned as per a arbitrary coordinate 
system (also machine system MS).
With workpieces, where the base alignment is very slanted, the 
safety cube will be slanted as well. If the majority of the features 
is not aligned with the base alignment or the MS, this may lead 
to problems with the drive paths.
Safety cubes with selectable coordinate system 
The safety cube can be selected according to a arbitrary coordi-
nate system from this measurement plan.
Safety cubes with different coordinate systems
Safety cube aligned with base alignment
The drive paths of the stylus run along the safety cube; here, at 
an angle to the machine axes.
Safety cube aligned on the device system
The drive paths of the styli run along the machine axes.
Note:
If the base alignment changes, the safety cube is "not taken 
along"!
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Exterior safety cube
During the measurement run, the follow-
ing should be avoided:
a collision with other workpieces,
a collision with the stylus change rack,
driving into the end position.
•
•
•
•
For this, an exterior safety cube can be helpful. The size can be 
the measuring volume of the machine. If it is selected smaller, 
other workpieces are outside this cube.
The definition takes place via:
 Plan - navigation - outer clearance
Switching on the drive test:
 Here, there are more possibilities:
Plan - navigation - correction needed
The drive behavior of the machine changes as follows:
• Style change rack
Automatic consideration including the stylus system in the rack.
The stylus that protrudes furthest into the measuring range of each rack determines a plane on 
which the drive path is checked.
The foremost stylus tips of the rack are shown as points.
• Measuring range limits (end positions):
Consideration of the values from the configuration in the workroom.
Drive behavior:
With every generated drive path between the measuring features, there is a test for collision/end 
position with all defined obstacles.
If a collision/end position is detected, the next one will be "tried" and so forth.
With long narrow stylus systems, you will drive by the workpiece along its side, with flat wide styli 
only on top.
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
Block edges
Individual edges of the safety cube can be blocked.
The circled edges refer to the machine table. This can change 
depending on the axis position!
Retrieval:
Plan - navigation - block edges
Exercise: 
Place the safety cube far to the side on the machine and define 
an exterior safety cube.
Test the run while considering:
• End positions
• Exterior safety cube
• Stylus change locations
• Blocked edges
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
8.6 Park position
General information
A park position is a defined position of the stylus at the end of 
the CNC run.
Retrieving a park position
Plan - navigation - CNC end park position 
An icon can be retrieved via the function 
"List drive paths" in the same menu.
A path to this position can be programmed into thepark positi-
on.
Furthermore, a relative positioning to the master probe and stylus 
change is possible.
The following illustrations show a park position after the cylinder 
measurement in front 100 mm above the workpiece.
Note:
What often makes sense is the use of a safety position with 
the correct safety plane directly before the drive command to 
a position.
Note:
Park position will not work with measurement plans that 
only contain characteristics of the type "Qualifying the stylus 
system".
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
8.7 Missing bore
General information
To prevent a CNC run from terminating if a bore is missing from 
the workpiece, the function "Missing bore" can ensure continuo-
us operation.
Retrieval:
Only with circles: via "Projection" in the features window
Further features: Measuring feature editor
•
•
Task:
Measure two bores as a circle on a cube. The first bore is to be 
missing during the test run.
For the first circle, the function "missing bore" is activated.
The clearance distance is 10 mm; this may be enough to drive 
safely above the workpiece to the second bore.
In the CNC run, place a coin over the first bore to test the func-
tion.
Function:
The bores are driven from a certain height at search 
speed.
If there is no bore, the system drives to the next 
feature at this height.
This height is the clearance distance:
The clearance distance is the distance from the 
circle in the initial start direction.
If the bore is not found, Calypso will drive to the next feature 
at this height (here, circle 2).
This means that the search distance must be greater than the 
submersion depth of the material.
Note:
If the safety distance is too short to drive free of the workpi-
ece, there is a risk of collision.
If the function is preset in the measuring feature editor, Calyp-
so will check the distance and may issue a collision warning.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
C
al
yp
so
 T
ra
in
in
g 
M
at
er
ia
ls
 P
rin
te
d 
in
 G
er
m
an
y
Su
bj
ec
t 
to
 m
od
ifi
ca
tio
ns
 o
f 
th
e 
la
yo
ut
 a
nd
 s
co
pe
 o
f 
de
liv
er
y 
as
 w
el
l a
s 
te
ch
ni
ca
l d
ev
el
op
m
en
ts
©
 C
ar
l Z
ei
ss
 3
D
 M
et
ro
lo
gy
 S
er
vi
ce
s 
G
m
bH
.
©
 C
on
ce
pt
, t
ex
t 
an
d 
de
si
gn
: ©
 C
ar
l Z
ei
ss
 3
D
 M
et
ro
lo
gy
 S
er
vi
ce
s
P_Cal_Aufbauschulung_4_8_e_SZ_001
10/2008
© Carl Zeiss 3D Metrology Services GmbH.
Heinrich-Rieger-Str. 1
73430 Aalen, Germany
Phone: +49 (73 61) 5 59-1800
Fax: +49 (73 61) 5 59-1899
e-mail: hopp@zeiss3d.de
http://www.zeiss3d.de
	Offline Programming with CAD
	1.1 Calypso Configuration
	1.1.1 Simulation on the CMM PC
	1.1.2 Simulation on the offline PC
	1.2	Optimized programming with resources
	1.2.1 Filter and outlier resources 
	1.2.2 Strategy resources
	1.2.3 Preassigning the stylus system for measurement plan
	1.2.4 Copying the format: Changing the coordinate system with the "paintbrush"
	1.2.5 Coordinate system preassignment
	1.3 Programming with CAD model 
	1.3.1 Working on the model 
	1.3.2 CAD import and resources 
	1.3.3 Additional functions
	2: Coordinate system
	2.1. Alignment with offset plane
	2.2	3D best fit method on the exercise cube
	2.3	RPS best fit method on the exercise cube
	2.4 Creating the base alignment as per DIN ISO 5459
	2.5
	2.6	Maintaining the feature position
	2.7	RPS best fit method
	3: Measuring methods, Part 1
	3.1	Gauß, Minimum, Tangential elements 
	3.2	Filter and outlier basics
	3.3	Form test on the roundness example
	3.4	Automatic calculation of the scanning parameters
	3.5	Self-made changes to the scanning and evaluation parameters
	3.6 Editor
	4: Calculations, operations and evaluations
	4.1 Recall
	4.1.1 Point recall from polyline
	4.1.2 Point recall from the circles
	4.1.3 Point recall from cylinders
	4.1.4 Point recall from curve
	4.1.5 Point recall from a file
	4.2 Special calculations
	4.2.1 Measuring features
	4.2.2 Limiting freedom degrees
	4.2.3 Changing the tolerance mode
	4.2.4 
	4.3 Introduction to form and position
	4.3.1 Flatness, cylinder form
	4.3.2 DIN position of two bores
	5: Expanded programming functions
	5.1 Pattern
	5.1.1 Linear Pattern
	5.1.2 	Polar pattern offset
	5.2	True position on circular pitch
	5.2.1	Coordinate system from bore pattern best fit method
	5.3	Pattern measurement as per DIN 3960
	5.3.1 Circular pitch
	5.3.2 Linear pattern
	5.4
	5.4.1
	5.4.2 Probing a sheet metal
	5.4.3		Probing positions relative to a feature
	5.4.4	 Alignment with offset plane via formula
	5.5: Automation interface
	5.5.1 	Pallet measurement: 
	5.5.2 	Serial measurement: 
	6: Result display - printout design
	6.1 Graphic display - plotting
	6.1.1 Flatness and graphic display
	6.1.2 Settings of form plot
	6.1.3 Plot output only if tolerance range is exceded
	6.2 Printout
	6.2.1 Modifying the printout header
	6.2.2 Changing the printout header for plots
	6.2.3 Changing compact printout header
	6.2.4 Total result
	6.2.5 One-line custom printout
	6.2.6 User-defined printout
	6.2.7 Attaching a comment to the characteristic 
	6.2.8 Inserting a text element
	6.2.9 Groups in the custom printout
	6.2.10 Saving printouts
	6.2.11 Changing the INI file for printout header data
	6.2.12 Inserting a variable into the printout
	7: Stylus systems and accuracy
	7.1 Automatically qualify stylus system afterwards
	7.2 Special styli
	7.3 Stylus monitoring
	7.4 Rack preassignment 
	7.5 Qualify the stylus change rack into the CNC
	7.6 Avoid measurement inaccuracies
	7.6.1 Temperature compensation
	7.6.2 Behavior in case of collisions
	7.6.3 Clamping Workpieces for Measurement
	7.6.4 Stylus Systems
	7.6.5 Inaccuracy with a CMM
	7.6.6 Inaccuracy Analysis
	8: Measuring methods, part 2
	8.1	Scanning with unknown contour
	8.2	Scanning with 2 styli
	8.3	Point masking in open scanning paths
	8.4	Self-centering probing
	8.5	Safety cube
	8.6 Park position
	8.7 Missing borewith CAD Functions
1.1 Calypso Configuration ............................................................................................ 9
1.1.1 Simulation on the CMM PC ..............................................................................................9
1.1.2 Simulation on the offline PC...........................................................................................10
1.2 Optimized programming with resources .......................................................... 11
1.2.1 Filter and outlier resources ............................................................................................12
1.2.2 Strategy resources .........................................................................................................12
1.2.3 Preassigning the stylus system for measurement plan ....................................................13
1.2.4 Copying the format: Changing the coordinate system with the "paintbrush" .................14
1.2.5 Coordinate system preassignment .................................................................................15
1.3 Programming with CAD model .......................................................................... 16
1.3.1 Working on the model ..................................................................................................17
1.3.2 CAD import and resources ............................................................................................23
1.3.3 Additional functions ......................................................................................................27
�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
1.1 Calypso Configuration
This section shows how to easily program with standard Calypso 
without the planning and simulation options.
Goal of this section:
Switching in simulation mode
- Calypso Basic Lesson
Safe manual input of features and strategies
Changing the nominal geometries
Preparing styli in simulation mode
Programming on the CAD model
Simulated CNC runs
•
•
•
•
•
•
•
1.1.1 Simulation on the CMM PC
Every Calypso PC can be programmed offline.
Two possibilities:
with an existing connection to the CMM,
by clicking "simulation mode",
bears the risk of collisions at CNC start,
Existing stylus data is used.
Connection with simulation
is used to be able to also start sequences.
Here, the stylus data must first be crea-
ted.
Switching on simulation mode:
1. Disconnect existing connection: Close 
the stoplight window
2. Extras - workroom - control: Simulati-
on: create connection.
Caution: 
Check all simulation settings to match 
the machine settings.
Make sure that you are working in 
simulation mode!
If you are not in simulation mode you will 
change the stylus data and there is a risk 
of collision!
•
•
© Carl Zeiss 
3D Metrology Services
10 Calypso Advanced Training
1.1.2 Simulation on the offline PC
The programming station is a stand-alone Calypso PC, where 
remote machine measurement plans are created. The installation 
of Calypso on the PC was performed as a "simulation".
The workroom houses the measuring device used later, although 
no control is connected to it.
But the stoplight window is present, because measurement plans 
can be started.
Caution: 
Check all settings of the simulation so that they conform to 
the online device settings.
11Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
1.2 Optimized programming with resources
This section describes the possible settings for quick program-
ming with default values and system settings.
1. Filter and outlier resources
2. Strategy settings
3. Preassigning the stylus system for measurement plan
4. Preassignment of coordinate system
5. Copying the format: Changing the coordinate system 
with the "paintbrush"
Resource Change with
Measurement
Probing path Extras - workroom - measurement
Clearance Extras - workroom - measurement
Clearance plane Can be edited by means of editor or feature
Rounding locations Extras - workroom - measurement - nominal value
Preassignment of coordinate 
system
Extras - workroom - measurement - nominal value
Tolerance mode Extras - workroom - measurement - nominal value
Filter / outlier Prepare - resources
Strategy settings Prepare - resources
Styli Preparing - styli
Coordinate System Prepare - preassignment for new features
Printout
Print output Resources - define printout
Print output - files Resources - results to file
File name for output file Resources - names for output file
Feature evaluation Resources - presentation of features
Feature - naming Extras - workroom - work environment- IndicationNames
CNC
CNC CNC - preassign CNC start values
The table represents possibilities for resources , not changes for individual features/characteristics/
runs
© Carl Zeiss 
3D Metrology Services
1� Calypso Advanced Training
1.2.1 Filter and outlier resources 
1.2.2 Strategy resources
 
These resources can be used to quickly extract already finis-
hed features with settings from the CAD model.
The following possibilities exist:
Defining and saving filter and outlier settings
Defining and saving strategy settings
Saving both types of settings together
A data file is created for each of the mentioned cases.
This can be found at
 . . . \Zeiss\Calypso\home\om\config\
rules\ . . . 
Calypso will always access this path auto-
matically.
•
•
•
Task:
Define the filter and outlier resources as 
shown.
Save these under the name 
"AufbauSchulung_Filter" (AdvancedTrai-
ning_Filter)
Define the strategy resources and save 
these under the name 
"AufbauSchulung_Strategie" (Advanced-
•
•
The following applies to the filters/outliers: 
The setting of the current measurement 
plan is changed.
The following applies to the strategy: 
The default setting for new features is 
changed for every measurement plan.
With an update from former Calypso ver-
sions, this equals existing functions.
1�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Open a new measurement plan, load the 
model 
 "Scanmax.sat" 
and program the following task.
Goal:
Program the sequence CNC with as few 
mouse clicks as possible.
•
Click on "General" and save both under 
the name "AufbauSchulung_Alle" 
(AdvancedTraining_All)
•
1.2.3 Preassigning the stylus system for measure-
ment plan
Use this very convenient function with 
your programming:
If geometries are extracted from the CAD 
model, you need not worry about styli.
They can be assigned automatically later 
by: 
Resources -> Stylus System -> Preassign 
the stylus system for measurement plan 
autom.
© Carl Zeiss 
3D Metrology Services
1� Calypso Advanced Training
1.2.4 Copying the format: Changing the coordinate system with the 
"paintbrush"
Task:
Create a 2nd coordinate system in the center bore.
Assign a new coordinate system to the circles (1-6) without ope-
ning the features.
Assign the new coordinate system to the first of the circles.
The "paintbrush" changes the properties 
of objects, the assignment of a coordinate 
system is one of the properties.
Select the
"Paintbrush - transfer format" 
.
Only select "coordinate system“.
Now select the five other circles, which are also to be transferred 
to the coordinate system (circles 5 - 7).
Close by clicking OK.
1�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
1.2.5 Coordinate system preassignment
This function can be used to determine which coordinate 
system the subsequent measuring features are to be calcula-
ted in.
Retrieval:
 Resources - preassignment for new features
Select the desired coordinate system.
Do NOT close this window.
The assignment is only made for the features that are mea-
sured or determined while the window is open.
Preassignment for the projection plane
The function can also be used for projection planes.
© Carl Zeiss 
3D Metrology Services
1� Calypso Advanced Training
1.3 Programming with CAD model 
Depending on the respective CAD program,the CAD files are 
written in a specific format.
There is a difference between
manufacturer-specific data sets such as ProE
system-neutral data sets such as STEP.
Furthermore, there must be a differentiation between 
2D and 3D data:
2D data is based on vector-oriented drawing programs and it 
produces two-dimensional data. 
This data can be used for programming in Calypso.
3D data sets deliver geometry data for a volume model. 
Wire models, surface models and volume moduls are the basis 
for programming with Calypso. 
The decisive factor is often the quality of the delivered data. 
Incomplete or faulty constructions of surfaces in the model 
complicate the programming of the measuring run.
Therefore, controlling the model is always the first step when 
working with CAD files.
•
•
•
•
1�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
1.3.1 Working on the model 
Note: 
A larger version of this drawing can be found in the Appendix.
© Carl Zeiss 
3D Metrology Services
1� Calypso Advanced Training
Loading and controlling the model
The exercise workpiece is loaded as an Acis model and rendered 
to check for completeness.
The position of the basic system stems from the design phase.
If the position does not meet the requirements for measurement, 
the model must be moved.E
Manually transforming the model
Adapting the origin and the axis directions
Here, the Calypso offers two possibilities:
Manually transforming the model
Directly creating the base alignment
In this example, the model is first manually transformed and the 
coordinate system is created afterwards.
•
•
Moving the model by 180 mm
Rotating the model by -90° 
Base alignment in desired position
1�Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Selecting features and defining solid geometry
Defining a solid geometry means: individually extracting 
known spatial geometric features from the model. 
Here, the dimensions and the name of the feature (for some 
formats, as indicated by the designer) are made available for 
Calypso.
Furthermore, the creation of circles, straight lines and points is 
possible. These, however, are not spatial features and must the-
refore be selected separately.
Modifying the model
Clicking the cone:
Here, you can see that only one half has be stored.
This means, that a model revision would make sense.
After the reworking, here "merge faces with same geometry", 
the cone and all other features can be extracted correctly.
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
Measuring on the CAD model
Features for the base alignment:
The base alignment is to be created from three planes.
These planes are extracted as solids.
After that, the planes are equipped with strategy (probing points) 
and entered into the base alignment.
The safety cube is defined with the function "safety cube of 
CAD model".
The edge distance of 10 mm is sufficient.
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Strategy Defaults:
This procedure defines the measuring strategy of the transfer or 
creation of measuring features when extracting from the CAD 
model.
Example: Plane with multi polyline
Strategy defaults can be set for every feature 
on this list.
Here, for example, the multi polyline is set 
for a plane and the top plane is re-extracted.
Based on these settings, this plane features 
a scanning path along every border.
This plane can now be used for characteristics that require the 
form of this surface, e.g. the perpendicularity to the side surface.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Additional menus and settings
"View' menu
This menu can be used to make settings and save some data.
Note:
Details regarding these functions can be taken from the ope-
rating instructions. 
"Display" menu (CAD model control)
This function can be used to alter the display in the ACIS window.
Modifying CAD features
This menu point covers a multitude of functions, only some of 
which are presented here.
Deleting features and rendering them invisible
Creating features from the wire model
Positioning the model
Cutting the model
•
•
•
•
Example: Creating elements from the wire model
Principle:
Switch on the wire model
Click on a contour
Click the respective button
Clicking a circle creates a circle, clicking two circles creates a 
cylinder
Offset to move the generated feature
Curves with preset point numbers
Spatial points at preset position.
•
•
•
•
•
•
•
Note:
These functions and many more are the subject of the 
training seminar "Planner and Simulation"
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
1.3.2 CAD import and resources 
Data transfer of CAD programs to Calypso
Calypso works with the ACIS format of the Spatial company, 
which uses data with the extension *.sat or *.sab.
In order to preserve this format, different methods can be ap-
plied:
Calypso imports the respective original data format via an 
import filter. (=direct import)
Calypso imports a conversion format such as STEP. 
For this, the CAD system exports into this format from its 
original format (e.g. STEP).
The CAD program exports the ACIS format for Calypso direct-
ly.
Neutral data formats:
VDAFS: Developed by the "Verband deutscher Automobilbau-
er" (Association of German Automobile Manufacturers), a very 
important format in the past.
IGES:works with 2D and 3D data, when imported into Calypso, 
there can be problems due to the inaccuracies in the original.
STEP: Modern, internationally used format, which converts 
volume models with nearly zero losses and which can contain 
additional information such as mass.
This format is the preferred choice.
1.
2.
3.
Important:
CAD programs often allow different export settings.Here, one 
must experiment with the correct export setting to achieve opti-
mized results in Calypso.
CAD model file formats
Currently, Calypso supports the following file types:
ACIS files *.sat or *.sab
CATIA files *.exp, .model
CATIA V files *.CATPart
Drawing interchange format *.dxf
STEP files *.stp
IGES files *.igs
VDAFS files *.vda
Unigraphics *.ug
ProE *.prt
Parasolid *.x_t
Inventor *.ipt
Solidworks *.sldprt, .sldasm
IDEAS *.idi
What is important during the import is that the file extension is 
correct, as Calypso recognizes the file type via its extension.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Importing a model
The CAD model can be located on any file path.
You can access the respective directory via .
You can always import *.sat files with "file type".
Additionally, one or more import filters can be relea-
sed.
The respective files are only shown if you switch to 
the respective file type.
In this example, the always included ACIS model of 
the exercise cube is loaded.
Problems while loading?
Problems during the loading process are multi-facetted and can 
be difficult to eliminate.
Type of data set correct? A file extension does not necessari-
ly have to be correct, there could have been retroactive 
changes. Be careful with unknown file formats.
Does the data set version match the Calypso converter?
Check the interface. Is the correct interface unlocked in Calyp-
so?
Is the data set really a volume model, not just a drawing 
saved as a model?
If the model is visible, but features additional auxiliary lines, 
these can be deleted.
If the CAD model does not appear on the screen, the window 
Scheme ACIS Interface Driver extension in the taskbar 
might contain additional information. 
Also, a log file with the model name will be created. This 
file contains additional information and possibly a list of 
errors.
•
•
•
•
•
•
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
This resources process consists of several steps:
Simplification
Stitching
Build geometry
Correct boundary curves
•
•
•
•
Examples for faulty loaded models:
Automatic healing
The model can be adapted in four steps bymeans of the modification -> combine CAD features
The following two cubes are two spatially separated objects.
Thus, there is no visible connection between the two.
Nothing has changed visually after this command was entered 
(the bodies are not "stuck together"). Their position in the space 
remains the same. However, Calypso treats them as one body.
A typical use is the addition of a clamping device to the model to 
be measured.
If the measured object and the device are considered one unit, 
they are tested as one compared to the stylus, also with collision 
measurements.
Another case, where this command is very useful is if the CAD 
object is present as a surface model. Depending on the graphic 
card, this command can lead to the model being much quicker to 
handle (rotate, move…)
1.3.3 Additional functions
CAD -> modification -> delete free lines and points
This function is intended to clean a CAD model of points and 
lines, which were only intended to be a help for the designer and 
which do not have any meaning for the Calypso user.
Careful, if the designer wanted to mark by free points, where the 
metrology technician was to probe the model; if these free points 
were relevant for measuring needs. In this case, you will lose this 
information.
CAD -> modification -> merge faces with same geometry
Independent of the topology, surfaces with the same geometry 
are merged.
An example for this is a cylinder consisting of two semi-bowls 
which is merged into a complete cylinder by this function.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
2: Coordinate system
2.1. Alignment with offset plane ............................................................................. 30
2.2 3D best fit method on the exercise cube .......................................................... 33
2.3 RPS best fit method on the exercise cube ........................................................ 35
2.4 Creating the base alignment as per DIN ISO 5459 ............................................ 36
2.5 Start System .................................................................................................... 38
2.6 Maintaining the feature position ...................................................................... 40
2.7 RPS best fit method .......................................................................................... 41
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Procedure Number of points Application
3D best fit method Arbitrary number of 
points or geometry 
elements
Gauß best fit method of all actual points to the 
nominal points
Selection of points according to the function of the 
workpiece. Prefered use with free forms with regu-
lated geometric elements for positioning.
RPS 3 -6 3-2-1
A coordinate is determined three times (must be 
on one plane), the second one two times, the third 
one once.
Usual procedure of chassis metrology, the points 
are indicated in the respective drawing.
P6 3 1. Point is origin.
1st and 2nd point is spatial direction
1st and 3rd point is additional direction
Application example: Special procedure for the 
automobile industry, tubular bodies
Perforated template
best fit method
Arbitrary 
bores
Optimized best fit method of bore patterns
Procedure with 
offset plane
3
for plane
Raw cast parts
All processes should be conducted with loops as an iteration.
If you select the option Best fit method to the CAD model, the actual points are initially 
aligned with the nominal points (as per Gauß); after that, the perpendicular foot points of 
the aligned actual points from the CAD model are calculated. Finally, the actual points are 
aligned with the perpendicular foot points (as per Gauß). 
•
•
Overview of the best fit method methods:
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
2.1. Alignment with offset plane
This exercise uses a theoretical plane 50 mm above the workpi-
ece as a primary reference of the alignment.
This plane cannot be probed directly, but should be captured 
with 3 points on the cube, whose height must be corrected.
This offset plane is a feature in Calypso and must be probed with 
exactly 3 points.
Take an Offset plane (measuring - special features) into the 
measurement plan and open it.
Probe three points for the plane on the exercise cube.
Point 1 at the rear of the cover surface
Point 2 in the circular slot
Point 3 in the front slot
Do NOT complete the feature with OK.
•
•
•
These points must be corrected immediately, so that a plane 
is created 50 mm above the cube.For this, click on "Evaluation 
- modify points“.
The correction values are (as per drawing):
1: -50
2: -58 mm ( -60 if using offline training)
3: -60
Correction direction:
(+) in the direction of the vector
(-) against the direction of the vector
The prefix originates in the desired offset height and shows what 
measurement value is used to correct the individual point.
Close offset plane.
•
•
•
Select further sensible features for the alignment and probe 
them.
Here, a circle in the top bore 30 and a 2D line on the front sur-
face.
Enter the features into the base alignment.
Special:
 Enter an offset in Z by -50 mm so that the base alignment 
comes to rest on the workpiece.
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Define the safety cube
Edit the clearance and the probing path.
Take into consideration that every point on the offset plane will 
be probed with a standard probing path (5 mm), just like in a 
normal plane. However, this is not possible with the points in the 
slot.
Note: Later during the exercise, the cube will be tilted slightly.
Please take this into consideration with the probing points 
and probing paths of all features.
Start the run once to ensure a flawless process.
Insert the loop 
Only the loop allows an approach calculation.
Why this is necessary will be described on the following pages.
Here, you can practice entering a break condition:
 baseSystem().valueArun!), if the condition 
is met.
This will be explained in further detail later.
Slightly tilt the workpiece on the measuring table and 
restart the run.
(Not possible during offline training).
The base alignment will be run five times. Here, the cal-
culation will approach more and more, an iteration will 
be conducted.
 
View the default printout:
What is interesting here, is the "delta value", a calcula-
tion of the moving, rotating and tilting values.
The "delta value" indicates by how much the coordinate 
system has changed since the last alignment.
You can hence call this value a best fit method value.
In a later exercise, this value is queried via a break condi-
tion.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Thoughts about correcting the probing points
With this alignment, the "incorrect" correction during the first run 
will yield an offset plane with an error in the device coordinates.
If the alignment is repeated and the plane direction of the first 
run is accessed, the result will improve considerably. In a third run 
- with the correction direction of the second alignment - the error 
will approach zero.
This principle of approaching is similar with other alignments.
The entered loop is worked off, here, an improvement is determi-
ned via the base alignment of the previous run.
In a later section, the alignment with offset plane will be rerun.
Here, the probing points will be calculated on a theoretical plane 
via formula functions.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
2.2 3D best fit method on the exercise cube
This procedure can be used for the calculated alignment of work-
pieces, for which no unique reference features were defined. 
With the 3D best fit method, a arbitrary number of points can be 
adapted as best as possible to their nominal geometry.
In our example, we would like to adapt four intersections of 
cylinders with planes using the above mentioned procedure, until 
the sum of all error squares between nominal and actual points 
becomes minimal (best fit method as per Gauß).
Probe the required features on the exercise cube.
Plane_top
Plane_top
Plane_top
Cylinder_30_front
Cylinder_15_front
Cylinder_30_top
Cylinder_12_top
•
•
•
•
•
•
•
Open the toolbox and place the operation "Intersection" into 
the measurement plan four times.
Intersection:
Intersection 1: Plane_front - cylinder_30_front
Intersection 2: Plane_front - cylinder_15_front
Intersection 3: Plane_top - cylinder_30_top`
Intersection 4: Plane_right - cylinder_12_right_center 
These four intersections are used as best fit method points.
•
•
•
•
Select the
 Resources - measurement plan - base alignment
At the prompt "New base alignment“, select the 
"3D best fit method".
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
1 , -50 , 0 , -34
2 , -75 , 0 , -47 
3 , -40.2 , 0 , 32 
4 , 30 , 0 , -34
Select the intersections by selecting "Select features“.
The nominal values of the intersections refer to the coordina-
te origin in the front top left.
Here, every arbitrary origin can be used, the nominal values 
must be adapted accordingly.
Best fit method to the CAD model:
The best fit method takes place in three steps: 
Gauß best fit method of the actual points to the assigned 
nominal points 
Calculation of the perpendicular leg points of the thus adap-
ted actual points on the CAD model.
Gauß best fit method of the actual points to the assigned 
perpendicular leg points.
•
•
•
Start the program.
The run will conduct 3 loop cycles and calculate a base align-
ment every time.
Every run takes the previous base alignment and "improves" 
it. This change of the previous run can be seen as the "delta 
value" in the default printout.
If the delta value is only slightly changed, the base alignment 
is well adapted.
Note:
The delta value does not necessarily need to approach zero. 
This is only the case in the base alignment.
If a 3D best fit method is used as a second or later coordinate 
system, the delta value changes toward a arbitrary numeric 
value.
Entering a break condition
 baseSystem().valueAExercise: 
Creating the base alignment in the center of the bore
Plane with 4 points
Circle with scanning strategy
Straight line with 2 points
Notes:
Create the start system as a complete coordinate system, not 
only by means of 3 points for the zero position.
The start system can only be created if the base alignment 
exists already.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
The start system can be prepared via
Resources - base alignment - start alignment
Measuring the features and creating the start system
Click "OK":
The offset values of the base alignment to the start system are 
displayed.
Create arbitrary characteristics to permit a sensible CNC start.
Test the start system with the possible options "manual align-
ment", etc.
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
2.6 Maintaining the feature position
When selecting a coordinate system in the feature, the 
position of the feature to the new coordinate system can be 
kept.
When the coordinate system is changed, the numeric values 
of the nominal values do not change.
The position of the feature practically "wanders" into the 
new coordinate system.
Application
When programming workpieces with identical assemblies 
(e.g. V motor), we like to program one side, then set a new 
coordinate system in order to copy the features here. 
This only makes sense if they change positions.
In this case, this option is used.
Application with "Paintbrush function"
When using the "Paintbrush function", this option can be 
selected.
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
2.7 RPS best fit method
Example:
A geometry best fit method is to be conducted on two slanted 
surfaces.
Every side is measured as a plane.
Retrieving the geometry best fit method:
Resources - utilities - geometry best fit
Selecting the two surfaces.
If necessary, limit the freedom degrees; here they are all open.
With geometry best fit method, several features, especially pla-
nes, can be adapted to their respective nominal geometries.
The best fit method calculates as per Gauß.
Freedom degrees with the best fit method calculation can be 
arbitraryly limited.
The result is a coordinate system that can be used for subse-
quent evaluations.
The printout is the same as with the 3D best fit method.
Calypso calculates a best fit method of all points to the nominal 
geometry of the two planes.
This results in a new coordinate system.
Here, you can position a theoretical plane, which is located in the 
center between the two planes.
Application example: 
Aligning dovetail guide.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
3: Measuring methods, Part 1
3.1 Gauß, Minimum, Tangential elements ............................................................. 43
3.2 Filter and outlier basics .................................................................................... 44
3.3 Form test on the roundness example ............................................................... 50
3.4 Automatic calculation of the scanning parameters ........................................... 51
3.5 Self-made changes to the scanning and evaluation parameters ....................... 53
3.6 Editor ............................................................................................................... 55
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
3. Measurement methods, Part 1
3.1 Gauß, Minimum, Tangential elements 
Calypso initially calculates features as per the Gauß process: Mi-
nimizing the error squares or method of the smallest error square 
sum.
Surface portions go into the material and away from it from the 
ideally calculated Gauß circle. 
As soon as a geometric feature is to be merged with another 
feature, the evaluation as per Gauß should be considered.
In this example, a bolt must fit into a bore.
If both features are evaluated as per Gauß, no statement can be 
made regarding the best fit method.
Here, the bolt must be evaluated as a external feature and 
the bore must be evaluated as a internal feature.
As outliers affect the surface considerably, you must filter and 
activate the outlier elimination.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
3.2 Filter and outlier basics
What does "filter" mean?
Every surface of a body varies from its ideal geometry.
This is called shape variance.
Shape variance can be subdivided into 
Dimensional variance
Form variance
Position variance 
Surface variance
Filtering separates the form variance of different orders 
from each other, but is also used to balance arbitrary mea-
suring variances.
Goal: 
The geometry deviations relevant to the functions must be 
captured and presented as a measurement result.
For most of the measuring results, surface roughness does not 
play a role, but are included in the measurement result.
These temporary structures are eliminated by filtering.
Here, you need a low-pass filter.
•
•
•
•
How does a surface look?
From a technical viewpoint, a surface is the overlapping of many 
undulations with different undulation lengths (with different 
amplitude peaks and phase responses).
This illustration shows undulations of different undulation lengths 
that were "added together" and make up the surface structure.
Here, the amplitude peak is drawn the same to simplify the view.
With a plane from the bowed form to the invisible roughness.
With a cylinder, from the oval form to the roughness.
What does "filter" mean?
only take into consideration short or long undulations during an 
evaluation.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Functionality of the Gauß filter
On all measured points, their average value with the surrounding 
points is calculated.
The surrounding points are weighted, therefore they will only 
contribute a smaller portion. The weighting is not linear but cal-
culated with the Gauß bell curve.
The width of the bell determines with the extent of the captured 
points.
The wider the bell, the "stronger" the filtering.
With the straight measurement, they refer to the limit undulati-
on length (lc), which is defined in millimeters. Here, the length of 
the undulation is important.
If a roundness measurement is considered during the filte-
ring, they refer to a limit undulation number, which is defined as 
undulations per revolution.
Conversion:
Limit undulation length lc = D x 3.14 / limit undulation number
Limit undulation length = D x 3.14 / limit undulation number
Recommended setting:
Straightness measurement: Limit undulation lengths 8.0, 2.5, 
0.8, 0.25 mm
Roundness measurement: Limit undulation numbers 15, 50, 
150, 500 W/U
Minimum number of points for filtering:
Number of undulations per revolution x 7 points = minimum 
number of points
Points per undulation: 7. 
Calculation: Length*points per undulation / limit undulation 
length
Example:
length= 113
Limit undulation length 0.25 0.8 2.5 8.0 mm
> Min. number of points = 3164 988 316 99
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Filter types
2RC (ISO 4291, no longer commonly used) 
(R = resistance; C = capacitor)
The 2RC filter is a mathematical replication of a real RC filter.
The transfer during the limit undulation length is 75%. The 
amplitude of the limit undulation length is also dampened by 
a fourth.
Gauß (ISO 11562)
The standard filter and commonly used in metrology.
The transfer during the limit undulation length is 50%.
The amplitude of the limit undulation length is thus dam-
pened by a half.
Spline
Newer filter with better functionality on open contours.
Quicker calculation and more stable performance with outliers 
than Gauß.
This filter is not normed.
Limit undulation length
If you enter the undulation length to the amplitude into diagram, 
this will create the limit of which the "cut" is made once a certain 
undulation length is reached.
This is called the limit undulationlength.
With roundness, the undulations/revolution (U/r) to the ampli-
tude are recorded.
With planes, the undulation length l to the amplitude is consi-
dered.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Types of filters:
Low-pass filter
Low frequencies (minor W/U) pass through the filter, high 
ones are filtered out.
Surface roughness is filtered out.
Low-pass filter
High frequencies (high W/U) pass through the filter, low ones 
are filtered out.
Form deviations are filtered out.
Examining roughness.
Band-pass filter
A certain frequency band passes the filter.
Certain form portions and rough areas are filtered.
Examining ripples.
The limit undulation lengths are described in more detail in the 
applicable standard.
Note:
This subject is covered in detail in the
form and position deviation training.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
Workpiece 
diameter 
[ mm ]
Form only
Standard form measure-
ment
e.g. wear / coupling
Form and ripples, form 
including grid marks
z
Ripples only
periodic profile portions
e.g. size of grid marks
Limit 
undulation 
number 
[ U/r ]
Measuring 
points per 
circum-
ference
Limit 
undulation 
number 
[ U/r ]
Measuring 
points per 
circum-
ference
Limit 
undulation 
number 
[ U/r ]
Measuring 
points per 
circum-
ference
8 15 105 50 350 15 – 150 1050
8 25
80 50 > 350 150 1050 50 - 500 > 3500
> 80 to 250 150 1050 500 3500
Limit undulation length Measuring points per 
mm
Step width
lc[ mm ] [ mm ]
.,25 28 0,0357
0,80 > 8.75 0,1143
2,5 > 2.8 0,357
8 > 0.875 1,143
25 0,28 3,570
Filter settings are not normed.
Tests have yielded experience results, which have lead to the 
following recommendations, among others in AUKOM:
Roundness measurement: Filtering and measuring points
Straightness measurement: Filtering and measuring points
Recommendations
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Outliers
A measuring point is considered an outlier, if its distance to the 
calculated Gauß feature exceeds a fixed threshold value*.
*Threshold value = factor * standard deviation
Outliers within workpiece: Cavity in the material
Outliers outside workpiece: Bulge in the material
Switching on filters and outliers
1. Global
Switching on via:
Resources - save/load defaults
Valid for all subsequently measured elements.
2. Feature-related
Valid for the feature, is taken into consideration with every 
evaluation of the feature.
3. Evaluation-related
During the selection of the feature in the characteristic. Only 
applies to this evaluation.
Recommended setting:
The setting depends on the specific workpiece and its machining.
An outlier elimination of 3*S can be used in many cases without 
problems.
Make sure that no more than 5% of the measuring points are 
deleted as outliers.
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
3.3 Form test on the roundness example
In this section, you will learn:
how to define scanning paths,
how to have the optimal parameters of Calypso set automatically,
how the scanning speed affects the result,
what effect filtering has,
how to handle outliers,
how to use tangential and minimum features,
how to use strategy presets.
•
•
•
•
•
•
•
Resourcess for the exercise
1. Measure a circle in the cylinder at the front side.
2. Place the strategy "Circle section" into this feature.
Bores in another workpiece can also be used for this exercise.
3. Run this feature once more.
Do not change to the settings in the circle section yet!
4. Open the default printout to constantly monitor the results
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Click on strategy step distance.
Click on calculation.
Now, there will be a query regarding the use of the feature.
As there has not yet been an allocation of the circle to an evalua-
tion, e.g. diameter, Calypso requires this information to calculate 
the speed and the number of points.
Click on Calculate and then choose between location, size and 
form. Observe the changes in speed and the step width.
Click basic settings. You will reach the 
familiar page in system settings.
Changes on this page will result in modifica-
tions of the basic parameters.
Please keep in mind that changes to the 
operation of the measuring device can nega-
tively impact the scanning process.
3.4 Automatic calculation of the scanning parameters
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
In the next section, three characteristics will be linked to this 
circle.Use this circle
for a position: Z value
for a measurement: diameter
for a form: Roundness.
In the Roundness, a graphic evaluation is possible. 
•
•
•
Select the circle in the list of features and open "Use..." with the 
right (center) mouse key.
You will see where the feature is used.
The button "Use" in the strategy offers 
additional information about tolerances and 
evaluation procedures.
Changes to the characteristic and the fea-
tures are possible.
Note:
This subject is covered in detail in the
form and position deviation training.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
3.5 Self-made changes to the scanning and eva-
luation parameters
In the following steps you will manually change the scanning 
settings step by step and you can create a printout each time for 
comparison.
1. Calculation: 
 Speed 12
Roundness
0,0239
2. Speed increase
 Speed 80
Roundness
0,0220
3. Speed reduction
 Speed 2
Roundness
0,0174
4. Use of a filter
 Speed 12
 Filter 150 W/U
Roundness
Filtering not possible! 0,0239
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
6. Use of a filter and an outlier feature
 Speed 12
 Filter 50 W/U
 Outlier 2xS 
Roundness
0,0035
7. Use of a filter and an outlier feature
 Speed 12
 Filter 50 W/U
 Outlier 2xS + neighbor
Roundness
0,0027
8. Minimum circumscribed element
 Speed 12
 Filter 50 W/U
 Internal feature
Roundness
0,0099
5. Use of a filter
 Speed 12
 Filter 50 W/U
Roundness
0,0093
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
3.6 Editor
In addition to the presets for e.g. filters and outliers that were 
already presented in a different section, these assignments can 
easily be changed using the Editor:
Opening the Editor:
Resources - characteristics - settings editor
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
4: Calculations, operations and evaluations
4.1 Recall ................................................................................................................... 57
4.1.1 Point recall from polyline ...............................................................................................57
4.1.2 Point recall from the circles ............................................................................................60
4.1.3 Point recall from cylinders ..............................................................................................61
4.1.4 Point recall from curve ...................................................................................................64
4.1.5 Point recall from a file ....................................................................................................65
4.2 Special calculations .............................................................................................. 66
4.2.1 Measuring features ........................................................................................................66
4.2.2 Limiting freedom degrees ..............................................................................................69
4.2.3 Changing the tolerance mode ........................................................................................71
4.2.4 Tangents .......................................................................................................................74
4.3 Introduction to form and position .....................................................................................754.3.1 Flatness, cylinder form ...................................................................................................75
4.3.2 DIN position of two bores ..............................................................................................77
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.1 Recall
4.1.1 Point recall from polyline
The term "recall" bears the possibility to perform further calculati-
ons from earlier features using already measured values.
Task: 
Measure a plane with one or more polylines and recall the mea-
sured points into the feature "Line" to perform an evaluation of 
True straightness.
This exercise is done on the CAD model.
Create the base alignment and safety cube as usual.
Take a plane from the toolbox and place it onto the right side of 
the cube with three lines.
Take the feature
"3D line" into the measurement plan twice.
Open a line and define the nominal value definition with "point 
recall".
Select the plane, watch for the buttons that will now appear in 
the top bar:
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
First click on the left button; the actual points will be displayed as 
Xs in the feature.The right button allows a new selection.
The actual points (!!) are shown as red Xs.
Select the left scanning path using the "lasso".
Further possibilities regarding the point selection are shown 
These points are taken over and calculated as a 3D line.
When using the buttons like the example, a "box" is manually 
created in the CAD window. Calypso calls this a "box". This box is 
defined via the corner points, similar to the safety cube.
In addition, there is the "path" (currently not selected).
 
 
This describes the entire scanning path.
In the sequence of the buttons, you have the following means of 
recalls:
Point
Point range
Box
Circle Path
Angle area
Cylinder
Observe the reference to the coordinate system with "box"!
1.
2.
3.
4.
5.
6.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
Create a second 3D line with a different scanning path.
Evaluate one straightness from the 3D lines.
Plot the result.
Interpret the plot!
© Carl Zeiss 
3D Metrology Services
�0 Calypso Advanced Training
4.1.2 Point recall from the circles
Task: 
Measure three circles in a bore and recall the measured points 
into the measurement feature "cylinder".
Take a cylinder from the toolbox.
Select "nominal value definition - point recall".
Select three circles and use the known buttons in the header bar 
to display the actual points and select them.
Here, the box is shown for each of the two captured circles.
Naturally, "path" can be selected for both circles, as all points in 
the circle section are to be used for the recall.
You can now put a box around the circles and select the actual 
points using the "lasso".
This will calculate the desired cylinder and is available as a calcu-
lated feature.
The selection of individual points is also possible by clicking on 
the CAD graphic.
�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.1.3 Point recall from cylinders
Task: 
The surface lines of a cylinder should be checked for straightness.
Define a strategy that makes sense for the CMM to check the 
form of the cylinder; here, this would be 2 circle sections and 4 
surface lines.
For a straightness evalulation, 2D line or 3D line could be used.
The 2D line is calculated on the surface of the workpiece, the 3D 
line is calculated from the stylus sphere center points.
Take a 2D line and select "Recall feature points".
Select the measured cylinder.
Think about how usable these results are for your measuring 
task.
You can select the individual strategies of the cylinder.
The main interest here is a surface line.
Path (3) is the first of the surface lines.
This path is selected.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
You will get the desired 2D line and can insert it into the True 
straightness.
The graphic evaluation of the form plot gives you a visual impres-
sion of the cylinder surface.
Caution: 
The evaluated scanning path was driven in the direction of the 
nominal value cylinder (!).
Therefore, the evaluation cannot be used here, look at the gra-
phic as well.
The following thought is the base:
In the nominal value cylinder, the angles A1, A2 are rounded to 
"0".
The surface lines are therefore sanned in the axle direction of the 
nominal geometry and not in the direction of the "true" cylinder.
Here, a "pre-alignment" is necessary to measure in the aligned 
coordinate system.
A typical evaluation could be the parallelism of two opposite 
lines.
A statement about, for example, a possibly cone-shaped figure is 
therefore possible.
Begin a new exercise by measuring a cylinder, here this cylinder 
consists of 2 circles with point recall.
Create a new coordinate system with the spatial direction of the 
first cylinder.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
In this coordinate system, you will measure 
the actual cylinder.
As before, recall two opposite surface lines as a 2D line.
These lines can be examined for parallelism, as they were cap-
tured along the actual direction.
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
4.1.4 Point recall from curve
Note: 
This evaluation can only be performed if the option "curve" is 
available.
 
As this subject is dealt with in the training "Curve measurement", 
more detailed information is not required at this point.
The recall from curve points was mentioned here to be thorough 
and because of its interesting uses.
The example in curve training is the following:
Task: Points are extracted from a curve and calculated into a 
geometric element.
Here, the curve is measured on the top side of the cube. After 
that, approx. 10 points in the curve are calculated into a circle.
��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
4.1.5 Point recall from a file
The files must be saved as text files, with the file extension ".txt".
Example of a data file:
Here:
x, y, z: coordinates of the point
Limit undulation number [ W / U ] Directional vector
r: Probe sphere radius
Separating character: Tab
The header is not necessary.
When "r" is entered, the correction is in vector direction by 
the radius.
The data files can also be created via PCM or exported from 
curves.
If features are selected in the list in addition to the "Point recall 
from a file", there will be a measurement prior to the recall. This 
can be helpul if the files for the point recall are not created until 
they are in the selected features.
If the features cannot be measured or if there are errors during 
the measurement, the point recall cannot be performed.
•
•
•
•
•
•
x y z u v w r
0.0000 -41.1667 19.9998 0.0000 -0.8233 0.5676 2.5
26.4592 -31.5372 20.0002 0.5292 -0.6307 0.5676 2.5
40.5402 -7.1540 20.0001 0.8108 -0.1431 0.5676 2.5
35.6550 20.5770 20.0000 0.7131 0.4115 0.5676 2.5
14.0901 38.6802 20.0001 0.2818 0.7736 0.5676 2.5
-14.0681 38.6882 20.0001 -0.2814 0.7738 0.5676 2.5
-35.6437 20.5968 19.9998 -0.7129 0.4119 0.5676 2.5
-40.5442 -7.1310 20.0001 -0.8109 -0.1426 0.5676 2.5
-26.4771 -31.5221 20.0001 -0.5295 -0.6304 0.5676 2.5
-0.0230 -41.1667 19.9998 -0.0005 -0.8233 0.5676 2.5
© Carl Zeiss 
3D Metrology Services
�� Calypso Advanced Training
4.2 Special calculations
4.2.1 Measuring features
Slot
Note: 
For this exercise, we will use another workpiece. Here, there is a 
slot as well as a rectangle.
Define a base alignment on the exercise workpiece.
Define a safety cube.
Measure the slot with one of the shown probing strategies.
The automatic feature recognition can capture the feature.
Create the characteristics length, width and feature angle to 
check the dimensions and the angle position of the feature.
Rectangle
Measure a rectangle, minimum number of points: 5, better than 
2 points on each side, distributed evenly.park positi-
on.
Furthermore, a relative positioning to the master probe and stylus 
change is possible.
The following illustrations show a park position after the cylinder 
measurement in front 100 mm above the workpiece.
Note:
What often makes sense is the use of a safety position with 
the correct safety plane directly before the drive command to 
a position.
Note:
Park position will not work with measurement plans that 
only contain characteristics of the type "Qualifying the stylus 
system".
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
8.7 Missing bore
General information
To prevent a CNC run from terminating if a bore is missing from 
the workpiece, the function "Missing bore" can ensure continuo-
us operation.
Retrieval:
Only with circles: via "Projection" in the features window
Further features: Measuring feature editor
•
•
Task:
Measure two bores as a circle on a cube. The first bore is to be 
missing during the test run.
For the first circle, the function "missing bore" is activated.
The clearance distance is 10 mm; this may be enough to drive 
safely above the workpiece to the second bore.
In the CNC run, place a coin over the first bore to test the func-
tion.
Function:
The bores are driven from a certain height at search 
speed.
If there is no bore, the system drives to the next 
feature at this height.
This height is the clearance distance:
The clearance distance is the distance from the 
circle in the initial start direction.
If the bore is not found, Calypso will drive to the next feature 
at this height (here, circle 2).
This means that the search distance must be greater than the 
submersion depth of the material.
Note:
If the safety distance is too short to drive free of the workpi-
ece, there is a risk of collision.
If the function is preset in the measuring feature editor, Calyp-
so will check the distance and may issue a collision warning.
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�� Calypso Advanced Training
1��Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
© Carl Zeiss 
3D Metrology Services
1�0 Calypso Advanced Training
1�1Calypso Advanced Training
© Carl Zeiss 
3D Metrology Services
C
al
yp
so
 T
ra
in
in
g 
M
at
er
ia
ls
 P
rin
te
d 
in
 G
er
m
an
y
Su
bj
ec
t 
to
 m
od
ifi
ca
tio
ns
 o
f 
th
e 
la
yo
ut
 a
nd
 s
co
pe
 o
f 
de
liv
er
y 
as
 w
el
l a
s 
te
ch
ni
ca
l d
ev
el
op
m
en
ts
©
 C
ar
l Z
ei
ss
 3
D
 M
et
ro
lo
gy
 S
er
vi
ce
s 
G
m
bH
.
©
 C
on
ce
pt
, t
ex
t 
an
d 
de
si
gn
: ©
 C
ar
l Z
ei
ss
 3
D
 M
et
ro
lo
gy
 S
er
vi
ce
s
P_Cal_Aufbauschulung_4_8_e_SZ_001
10/2008
© Carl Zeiss 3D Metrology Services GmbH.
Heinrich-Rieger-Str. 1
73430 Aalen, Germany
Phone: +49 (73 61) 5 59-1800
Fax: +49 (73 61) 5 59-1899
e-mail: hopp@zeiss3d.de
http://www.zeiss3d.de
	Offline Programming with CAD
	1.1 Calypso Configuration
	1.1.1 Simulation on the CMM PC
	1.1.2 Simulation on the offline PC
	1.2	Optimized programming with resources
	1.2.1 Filter and outlier resources 
	1.2.2 Strategy resources
	1.2.3 Preassigning the stylus system for measurement plan
	1.2.4 Copying the format: Changing the coordinate system with the "paintbrush"
	1.2.5 Coordinate system preassignment
	1.3 Programming with CAD model 
	1.3.1 Working on the model 
	1.3.2 CAD import and resources 
	1.3.3 Additional functions
	2: Coordinate system
	2.1. Alignment with offset plane
	2.2	3D best fit method on the exercise cube
	2.3	RPS best fit method on the exercise cube
	2.4 Creating the base alignment as per DIN ISO 5459
	2.5
	2.6	Maintaining the feature position
	2.7	RPS best fit method
	3: Measuring methods, Part 1
	3.1	Gauß, Minimum, Tangential elements 
	3.2	Filter and outlier basics
	3.3	Form test on the roundness example
	3.4	Automatic calculation of the scanning parameters
	3.5	Self-made changes to the scanning and evaluation parameters
	3.6 Editor
	4: Calculations, operations and evaluations
	4.1 Recall
	4.1.1 Point recall from polyline
	4.1.2 Point recall from the circles
	4.1.3 Point recall from cylinders
	4.1.4 Point recall from curve
	4.1.5 Point recall from a file
	4.2 Special calculations
	4.2.1 Measuring features
	4.2.2 Limiting freedom degrees
	4.2.3 Changing the tolerance mode
	4.2.4 
	4.3 Introduction to form and position
	4.3.1 Flatness, cylinder form
	4.3.2 DIN position of two bores
	5: Expanded programming functions
	5.1 Pattern
	5.1.1 Linear Pattern
	5.1.2 	Polar pattern offset
	5.2	True position on circular pitch
	5.2.1	Coordinate system from bore pattern best fit method
	5.3	Pattern measurement as per DIN 3960
	5.3.1 Circular pitch
	5.3.2 Linear pattern
	5.4
	5.4.1
	5.4.2 Probing a sheet metal
	5.4.3		Probing positions relative to a feature
	5.4.4	 Alignment with offset plane via formula
	5.5: Automation interface
	5.5.1 	Pallet measurement: 
	5.5.2 	Serial measurement: 
	6: Result display - printout design
	6.1 Graphic display - plotting
	6.1.1 Flatness and graphic display
	6.1.2 Settings of form plot
	6.1.3 Plot output only if tolerance range is exceded
	6.2 Printout
	6.2.1 Modifying the printout header
	6.2.2 Changing the printout header for plots
	6.2.3 Changing compact printout header
	6.2.4 Total result
	6.2.5 One-line custom printout
	6.2.6 User-defined printout
	6.2.7 Attaching a comment to the characteristic 
	6.2.8 Inserting a text element
	6.2.9 Groups in the custom printout
	6.2.10 Saving printouts
	6.2.11 Changing the INI file for printout header data
	6.2.12 Inserting a variable into the printout
	7: Stylus systems and accuracy
	7.1 Automatically qualify stylus system afterwards
	7.2 Special styli
	7.3 Stylus monitoring
	7.4 Rack preassignment 
	7.5 Qualify the stylus change rack into the CNC
	7.6 Avoid measurement inaccuracies
	7.6.1 Temperature compensation
	7.6.2 Behavior in case of collisions
	7.6.3 Clamping Workpieces for Measurement
	7.6.4 Stylus Systems
	7.6.5 Inaccuracy with a CMM
	7.6.6 Inaccuracy Analysis
	8: Measuring methods, part 2
	8.1	Scanning with unknown contour
	8.2	Scanning with 2 styli
	8.3	Point masking in open scanning paths
	8.4	Self-centering probing
	8.5	Safety cube
	8.6 Park position
	8.7 Missing bore