Tag: Optical Measurement

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Comprehensive Analysis of Tool Setters: Principles, Usage, Common Faults, and Professional Repair Guide

I. Principles of Tool Setters

Tool setters, precision instruments based on optical measurement technology, are widely used in CNC machine tools to accurately measure and calibrate the geometric shapes and dimensions of cutting tools. They ensure machining accuracy and stability. The tool setter consists of a light source, optical system, and detector. The light source emits light that passes through the optical system and illuminates the tool. The reflected light from the tool’s surface passes through the optical system again and is received by the detector. The detector converts the received light signals into electrical signals, which are processed by a computer to determine the tool’s geometric shape and dimensions. The measurement accuracy of the tool setter depends on the precision of the optical system and the sensitivity of the detector, requiring high-precision optical components and highly sensitive detectors for manufacturing.

II. Usage Methods

The usage of tool setters varies slightly depending on their type (contact or non-contact), but the basic steps are similar:

  1. Installation: Secure the tool setter in an appropriate location on the CNC machine, such as the tool turret or worktable, ensuring a firm installation.
  2. Power and Communication Connection: If the tool setter requires power or communication with the CNC system, ensure correct connections.
  3. Cleaning: Clean the tool setter and tool to remove dust, oil, or metal chips.
  4. System Setup: Make necessary settings in the CNC system, including selecting the tool setter type and inputting tool setter position parameters.
  5. Calibration: Use a standard tool with known dimensions for initial calibration to ensure measurement accuracy.
  6. Initiate Tool Setting Program: Select or start the tool setting program in the CNC system, and execute corresponding operations based on the tool setter type (contact or non-contact).
    • Contact Type: Slowly move the tool until it contacts the probe and record the trigger point.
    • Non-contact Type (e.g., Laser Tool Setter): Position the tool under the beam, and the system automatically records the data.
  7. Data Processing: The tool setter sends the tool’s length and diameter data to the CNC system, which updates the tool compensation values accordingly.
  8. Save Settings and Test Cut: Ensure that the tool setting data is correctly saved in the CNC system, and perform a brief test cut or dry run to verify the accuracy of the tool settings.

III. Common Faults and Repair Methods

Common faults and their repair methods for tool setters include:

  1. Inaccurate or Unstable Measurements:
    • Cause: Worn components, contaminated optical system.
    • Repair: Replace worn components (such as measuring surfaces or mechanical contact points), clean the optical system and lenses.
  2. No Signal Output or Abnormal Signal:
    • Cause: Circuit board failure, damaged sensor, or wiring issues.
    • Repair: Inspect and replace the circuit board, sensor, or wiring.
  3. Large Deviation in Measurement Results:
    • Cause: Inaccurate calibration or incorrect parameter settings.
    • Repair: Recalibrate the tool setter, adjust CNC system parameters.
  4. Intermittent Faults or Decreased Accuracy:
    • Cause: Aging seals, accumulation of dust.
    • Repair: Thoroughly clean the tool setter, replace seals.

During repairs, use specialized tools for disassembly and assembly to avoid damaging precision components. Conduct repairs in a clean, dust-free environment. Stock common spare parts to reduce downtime and keep detailed records of repair processes and replaced components. After repairs, conduct comprehensive testing to ensure proper functionality. For complex faults, especially those involving precision electronic components, it is recommended to seek assistance from the manufacturer or professional repair services. Within the warranty period, repairs should be handled by authorized service providers.

IV. Brands and Models of Tool Setters Repaired by Longi Electromechanical

  1. Renishaw
    • OTS Series: OTS
    • NC4 Series: NC4
    • RMP60 Series: RMP60
    • HPMA Series: HPMA
    • TS27R: Tool Setter
  2. Blum-Novotest
    • Z-Nano Series: Z-Nano
    • Z-Pico Series: Z-Pico
    • LC50 Series: LC50-DIGILOG
    • TC Series: TC52, TC76
  3. Marposs
    • Mida Series: Mida Laser Tool Setter (LTS), Mida NTK, Mida VTS
    • TS Series: TS10, TS20
  4. Heidenhain
    • TT Series: TT 160, TT 460
    • TL Series: TL Micro
  5. Zoller
    • smile Series: smile / pilot 2.0
    • venturion Series: venturion 450, venturion 600
    • pom Series: pomBasic, pomSeries
  6. Hexagon (m&h)
    • 4100 Series: m&h 41.00
    • 61.00 Series: m&h 61.00-PP
    • 78.00 Series: m&h 78.00-LTS
  7. HAIMER
    • Microset Series: VIO linear tool presetter, UNO smart, UNO premium
  8. BIG KAISER
    • BK Mikro Series: BK Mikro9, BK Mikro8
    • EWA Series: EWA Automatic Boring Tool
  9. Nikken
    • Elbo Controlli Series: E46L, E68, E82
  10. Speroni
    • MAGIS Series: MAGIS
    • STP Series: STP ESSENTIA, STP FUTURA
  11. EZset
    • EZ Series: EZset IC2, EZset IC3D
    • IC Series: IC1, IC2
  12. Omega
    • Digi-Pro Series: Digi-Pro
    • TT-1 Series: TT-1
  13. Elbo Controlli
    • E46L: Portable Tool Setter
    • E68: High-Precision Tool Setter
    • E82: Multi-Function Tool Setter

Longi Electromechanical Company specializes in the repair and maintenance of tool setters and controllers, with nearly 30 years of experience. We offer prompt repairs for various instruments and also engage in the recycling and sales of tool setters and controllers. Feel free to contact us for more information.

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 Understanding and Using a Colorimeter: Principles, Instructions, Faults, and Brands

Colorimeter: An Optical Measurement Instrument Simulating Human Eye’s Response to Red, Green, and Blue Light

I. Working Principle of Colorimeter

Optical System:

  • The colorimeter typically consists of a light source, a sample, and a detector (or sensor).
  • The light source emits light (which can be white light or specific wavelengths, such as the D65 light source simulating natural lighting conditions), and the light passes through or reflects off the sample before being received by the detector.

Color Detection:

  • The detector usually has three channels corresponding to red, green, and blue.
  • Each detector is calibrated to respond to specific wavelengths associated with its respective color channel.
  • The detected light intensities are used to calculate the object’s tristimulus values (X, Y, Z), representing the object’s color in a standardized color space (e.g., CIE XYZ color space).

Color Space:

  • The colorimeter can convert between different color spaces (e.g., RGB, Lab, LCH, etc.).
  • The Lab color space is one of the commonly used spaces, consisting of lightness (L), the a-axis (red-green axis), and the b-axis (yellow-blue axis).

Color Difference Calculation:

  • The colorimeter assesses color consistency by measuring the difference between the sample and a standard sample.
  • It first measures the color information of the standard sample as a reference, then measures the color information of the test sample, and compares the two.
  • The color difference value is calculated using mathematical algorithms (such as ΔE*ab) to evaluate the degree of color difference in the sample.

II. Usage Instructions for Colorimeter

  1. Warm-up:
    • Turn on the colorimeter and allow it to warm up for a specified time (e.g., 30 minutes) to ensure stable performance.
  2. Calibration:
    • Calibrate the instrument according to the manual before measurements to ensure accuracy.
    • Calibration typically includes zero calibration and white calibration steps.
  3. Select Color Parameters:
    • Choose the appropriate color parameters (e.g., CIE Lab*, CIE LCh) based on measurement needs.
  4. Place the Sample:
    • Position the test sample on the measurement platform, ensuring it is flat, without reflection or impurities.
    • For opaque samples, place them on a black background for measurement.
  5. Set Measurement Mode:
    • Choose the suitable measurement mode (e.g., standard mode, quick mode) based on actual requirements and set parameters such as light source and observation angle.
  6. Start Measurement:
    • Follow the manual’s instructions to set the measurement mode and press the start button. The instrument will measure automatically.
  7. Record Data:
    • After measurement, the instrument will display the results. Record relevant data (e.g., L, a, b* values) as needed for further analysis.
  8. Clean the Instrument:
    • Clean the instrument’s surface and internal parts promptly after use to maintain cleanliness.
  9. Shutdown and Storage:
    • Turn off the instrument after all measurements. Store it in a dry, cool place, avoiding direct sunlight and humid environments.

III. Common Faults and Repair Methods

1. Light Source Issues:

  • Fault Manifestation: Damaged light source, failure to illuminate, or insufficient brightness.
  • Possible Causes: Damaged light source, poor line connection, insufficient battery power, or damaged battery.
  • Repair Methods:
    • Check and replace the light source (e.g., pulsed xenon lamp or tungsten bulb).
    • Check line connections for proper contact.
    • Replace or recharge the battery.

2. Battery Issues:

  • Fault Manifestation: Insufficient battery power, failure to charge, or damaged battery causing instrument malfunction.
  • Possible Causes: Aging battery, incorrect battery installation, poor battery contact.
  • Repair Methods:
    • Install the battery correctly.
    • Check battery power and recharge or replace as needed.

3. Display Issues:

  • Fault Manifestation: LCD screen failure or abnormal display.
  • Possible Causes: No battery installed, insufficient battery power, incorrect battery installation, line fault.
  • Repair Methods:
    • Install the battery or connect the AC adapter correctly.
    • Check and repair line faults.

4. Key Malfunctions:

  • Fault Manifestation: Measurement buttons or body keys not functioning.
  • Possible Causes: Damaged keys, charging in progress, or connection to a PC application.
  • Repair Methods:
    • Ensure to press the measurement button when the READY indicator is on after charging.
    • Disconnect from the PC application.
    • Replace damaged keys or have them repaired by professionals.

5. Connection Issues:

  • Fault Manifestation: Failure to connect to PC applications or printers.
  • Possible Causes: Incorrect connection method, multiple instruments connected in the PC.
  • Repair Methods:
    • Connect to the PC correctly, ensuring only one instrument is connected.
    • Select the correct connection option from the settings screen (e.g., “USB Connection” → “PC” or “Printer”).

6. Indicator and Buzzer Issues:

  • Fault Manifestation: LED indicator not lighting up, buzzer not sounding.
  • Possible Causes: Settings issue (e.g., set to “off”).
  • Repair Methods:
    • Connect to the PC application and check/modify relevant settings.

7. Calibration Issues:

  • Fault Manifestation: Colorimeter unable to complete calibration or inaccurate calibration results.
  • Possible Causes: Worn, contaminated, or discolored calibration white board, or incorrect execution of the calibration process.
  • Repair Methods:
    • Clean or replace the calibration white board.
    • Follow the manual to execute the calibration process correctly.

8. System Faults:

  • Fault Manifestation: General system errors, instrument malfunction.
  • Possible Causes: Aging bulb, aging circuit board, software issues.
  • Repair Methods:
    • Replace the bulb or circuit board.
    • Upgrade or restore software to the latest version.
    • For complex issues, contact Longi Ectromechanical Company or a professional repair team for inspection and repair.

IV. Brands and Models of Colorimeters Repaired by Longi Ectromechanical Company

  1. Datacolor:
    • Datacolor 600
    • Check 3
    • SpyderX Elite
    • ColorReader Pro
    • SpectraVision Spectro 700
    • SpectraVision Spectro 1000
  2. Konica Minolta:
    • CM-700d
    • CM-600d
    • CM-5
    • CM-3600A
    • CM-3610A
    • CM-25d
    • CM-26dG
  3. X-Rite:
    • Ci64
    • Ci7600
    • Ci7800
    • eXact Standard
    • eXact Advanced
    • RM200QC
  4. HunterLab:
    • UltraScan PRO
    • ColorFlex EZ
    • LabScan XE
    • MiniScan EZ 4500L
    • Vista
  5. BYK-Gardner:
    • spectro2guide
    • spectro-guide
    • micro-gloss
    • color-guide
  6. 3NH (ThreeNH):
    • YS6060
    • NH310
    • TS7600
    • NS800
    • NH300
  7. PCE Instruments:
    • PCE-CSM 8
    • PCE-CSM 10
    • PCE-CSM 20
    • PCE-TCD 100
  8. Hach:
    • DR1900
    • DR6000

Longi Ectromechanical Company has nearly 30 years of experience in repairing colorimeters, enabling swift repairs for various instruments. Additionally, we recycle and sell used colorimeters. For more information, please feel free to contact us.