Form Talysurf PGI 1240 PRODUCT

Precision form & surface finish measurement for aspheric optics

At Taylor Hobson we are proud of our reputation as the solutionprovider of choice within aspherics metrology. The Form Talysurf hasevolved over the past 20 years, delivering continuous improvement forour customers. The PGI 1240 Aspherics Measurement Systemrepresents a new level of performance for applications such as:

• Diamond-turned or Ultra-precision ground moldsfor plastic or glass optics

• Aspherics for laser applications• Digital cameras, projectors, etc• IR & Diffractive optics up to 200mm diameter

The Form Talysurf PGI 1240 from Taylor Hobson is a premium specification measurement system for the small to medium sizedaspheric optics market. It is designed for applications where optimum component quality and consistency cannot be compromized.

Ultra-high precision processes such as Single-Point Diamond Turningallow aspheric lenses to be manufactured with form tolerances downto small fractions of λ. To achieve such levels of precision, metrologymust be fully integrated with machining.

Form Talysurf PGI 1240 delivers this capability by directly exportingmeasurement results back to the machine tool, creating a corrective'feedback loop'. New custom styli expand the range of applicationswhich can be measured using the PGI 1240.

For more details of the Form Talysurf PGI 1240, please contactyour local Taylor Hobson sales agent, or go to our website.

The Form Talysurf PGI 1240 has been developed specifically for theoptics industry. Every aspect of manufacture is to the highest possiblelevel which results in unparalleled system performance.

• 200mm Traverse unit with 0.11µm \ 200mm straightness • 12.5mm Gauge range, 0.8nm vertical resolution• 50mm Gauge range possible with special styli • 1nm RMS noise floor provides market-leading optics surface

finish measurement capability• Extensive Range of Optional Accessories, including styli for

demanding applications

PGI 1240 - A new generation of excellence PGI 1240 has industry leading specifications

Taylor Hobson's recently launched Aspherics Analysis Softwareincorporates a number of new features expressly designed to meetthe needs of Aspherics Optics Manufacturers, including:

• Aspheric Form Analysis• User Selectable Radius Optimisation and λs Filter• Report Generation Capability • SAG Tables• Astigmatism Analysis• Derived Coefficients Module (optional)• Asphero-Diffractive Analysis (optional)

Aspherics Analysis Software

Designed to meet research & production needs

Specification PGI 1240

www.taylor-hobson.com

200mm / 0.1mm (7.9in / 0.004in)

0.1mm/s, 0.25mm/s, 0.5mm/s & 1mm/s (0.004in/s, 0.01in/s, 0.02in/s & 0.04in/s)

10mm/s max (0.39in/s max)

0.125µm over 200mm length (5µin over 7.9in length)

0.125µm [ 0.1mm to 15mm length ] ( 5µin [0.004in to 0.6in] )0.25µm [ 15mm to 30mm length ] ( 10µin [0.60in to 1.2in] )

1µm [ 30mm to 200mm length] ( 40µin [1.20in to 7.9in] )

110nm/200mm or [50 + 0.3X]nm (4.4µin/7.9in or [2 + 0.3X]µin)

12.5mm [ 60mm stylus arm] (0.49in [2.36in] ) 25mm [120mm stylus arm] (0.98in [4.72in] ) 38mm [180mm stylus arm] (1.53in [7.10in] )50mm [240mm stylus arm] (1.97in [9.45in] )

0.8nm @ 12.5mm range (0.03µin @ 0.5in) range

15,625,000 : 1

60mm arm, 2µm radius conisphere diamond stylus, 1mN force120mm arm, 0.5mm radius ball, 20mN force

(0.07 + 0.03 Z [mm] ) µm (3 + 30 Z [inches] ) µin - after calibration 4

0.025µm (1µin) 5 or 0.05µm (2µin) 6

0.08µm (3µin) 7

0.12µm (4.5µin) 7

Max 0.2µm @ 80mm (8µin @ 3.15in)Typically less than 0.1µm @ 80mm (4µin @ 3.15in)

1nm (0.04µin)

0.1 - 80mm (0.004 - 3.15in) = 1 - 0.005% of nominal80 - 1000mm (3.15 - 39.4in) = 0.005 - 0.1% of nominal

1000 - 2000mm (39.4 - 78.7in) = 0.1% of nominal

0.5 arc minute uncertainty (+ / - 35º maximum range)

760 x 500 x 120mm (30 x 20 x 4.7in)

470 x 130 x 225mm (18.5 x 5.2 x 8.9in)

15Kg (33lbs)

Traverse length - X Max / Min

Measuring speeds 1

Traverse speeds

Data sampling interval in X (high)

Data sampling interval in X (standard)

Straightness error [Pt] (X = length) 2

Nominal measuring range (Z)

Resolution (Z) 3

Range to resolution ratio

Stylus arm length, tip size, force

Z axis nonlinearity (Z=gauge displacement)

Repeatability of Z axis indication(flat surface - diamond stylus)

Repeatability of Z axis indication(curved surface - diamond stylus)

Repeatability of Z axis indication(curved surface - ball stylus)

Form Error - Pt 8

(ball calibration radius)

System noise - RMS 9

Radius measurement uncertainty 10

Inclination measurement uncertainty

Dimensions L x D x H (granite base)

Dimensions L x D x H (traverse unit)

Weight (traverse unit)

1 For surface texture measurements, speeds of 0.5mm/s (0.02in/s) and less are recommended.

2 Measured over a glass flat nominally parallel to the traverse datum using a 60mm arm with a diamond stylus (speed = 1mm/s, LS Line analysis, primary filter λs = 2.5mm).

3 Using a 60mm arm with a diamond stylus.

4 Measurements up and down a 35º angled slope over 80% of the gauge range, using a 60mm arm with a diamond stylus.

5 Repeated measurements over a glass flat that is nominally parallel to the datum [10mm traverse length, primary filter λs = 0.025mm].

6 Repeated measurements over a glass flat that is nominally parallel to the traverse datum, [full traverse length, primary filter λs = 2.5mm].

7 Repeated measurements over an 80mm radius glass standard [primary filter λs = 0.25mm].

8 From a repeat measurement on the calibration artifact over 75% of the gauge range(LS Arc analysis, primary filter λs = 0.25mm).

9 Measured over a glass flat nominally parallel to the traverse datum using a 60mm arm with a diamond stylus (speed = 0.1mm/s, Gaussian roughness filter, 0.08mm cut-off, 30:1 bandwidth).

10 Assumes a calibration artifact of perfect radius.

NOTE: Taylor Hobson pursues a policy of continual improvement due to technical developments. We therefore reserve the right to deviate from catalog specifications.

System Performance 3

Vertical Performance

Horizontal Performance Environment

Storage temperature5ºC to 40ºC (41ºF to 104ºF)

Storage humidity10% to 80% Relative, non condensing

Operating temperature18ºC to 22ºC (64ºF to 72ºF)

Temperature gradient<2ºC (<3.6ºF) per hour

Operating humidity45% to 75% Relative, non condensing

Maximum RMS floor vibration2.5µm/s (100µin/s) at <50Hz5.0µm/s (200µin/s) at >50Hz

Electrical supply

Supply typeAlternating supply, singlephase with earth (3-wire system)

Instrument and computer voltage90V - 130V or 200V-260V(switch selectable)

Frequency47Hz to 63Hz

Supply voltage transients - widthEN 61000 - 4 - 4 : 1995

Power consumption500VA

SafetyEN 61010 - 1 : 2001

EMCEN 61000 - 6 - 4 : 2001EN 61000 - 6 - 1 : 2001Laser classificationClass 1 product to EN 60825-1 (2001)Continuous wavelength (CW) output<1mW Max power for the laser<50µW Max power for the product

The above technical data is for measurementstaken in a metrology laboratory controlledenvironment: 20ºC ± 1ºC (68ºF ± 1.8ºF), draftfree, and isolated from low frequency floorborne vibration.

Uncertainties and maximum permissible errors(MPE’s) are at 95% confidence in accordancewith recommendations in the ISO Guide to theexpression of uncertainty in measurement(GUM:1993). All errors are expressed as MPE’s.

Copyright©2005 • Taylor Hobson Precision • Form Talysurf PGI 1240_Product_05/05

SOFTWARE

Operation and control

• Full instrument control • Ease of use through extensive use of icons• Built-in tolerance checking giving simple pass/fail indication• User programmability – allowing repetitive tasks to be automated• Simplified User Interface capability to allow programs to be

executed from a simple push-button interface.

Powerful analysis

• Primary (unfiltered) parameters• Roughness parameters• Waviness parameters• R & W parameters• Rk parameters• Bearing Ratio and Amplitude Distribution• Pitch and Intercept• Interactive results displays

Form removal options

• Datum• LS Line• MZ Line• LS Arc• LS Arc absolute• LS ellipse / hyperbola

Filtering

• 2CR or Gaussian • Support for the latest ISO standards • Support for VDA 2006 (no Ls filter for Primary, Roughness

and Rk)

Presentation of results

• Comprehensive single page layouts• Custom layout capability• Built-in tolerance checking gives simple pass/fail indication• Export to SPC

Optional analyses

• Dual Profile (for comparing two measured profiles)• Dominant Wavelength (VDA 2007) identifies most significant

wavelengths in a surface. Useful for sealing applications

Languages

Brazilian Portuguese, Chinese, Czech, English, French, German,Italian, Japanese, Polish and Spanish.

Ultra Surface Finish Software

Designed and written specifically for use on Windows XP, Ultra software provides a powerful and easy-to-use environment for controllingthe measuring instrument and producing high-quality results that can be tailored to meet the needs of the user. With integral tolerancechecking and output for SPC, Ultra can be readily integrated in to the production process.

Powerful software for the analysis of surface finish and form

High-quality results presentations are incorporated as standard, enabling the user toproduce professional outputs with the minimum of effort. Extensive form analysis optionsallow most surfaces to be measured for form and surface finish in a single measurement.

R&W analysis (ISO 12085) showing roughness motif and waviness motif profiles.

Interactive material ratio and amplitude distribution curves.

www.taylor-hobson.comCopyright©2005 • Taylor Hobson Precision • Ultra Surface Finish Software_4/05

Specifications are subject to change without notice. Availability of some features is dependent on instrument type or optical licence.

Powerful software for the analysis of surface finish and form

Dominant Wavelength Analysis (VDA 2007)Provides important information for sealing applications. Primaryprofile is shown together with dominant wavelength profiles andresults. (Optional)

Custom layouts

Ultra software is supplied with a comprehensive set of pre-definedresult layouts, enabling the user to produce high-quality printoutswith the minimum of effort. The software also gives the user greatflexibility in creating “custom” layouts, enabling them to tailor thelayouts to meet their individual needs. Once a custom layout hasbeen created it can be selected as the default layout for additionalmeasurements of that type.

User programmability

A major benefit of Ultra is user programmability. This enables users towrite their own measurement sequences for repetitive measurementtasks. In production environments this can be invaluable for automatingmeasurement procedures, reducing cycle time and minimizing operatorvariability. Programming modes include learn mode, program editing,single step and user breakpoints.

Dimensional measurementInteractive results views allow simple dimensions to bemeasured by means of cursors.

Profile zoom and extraction functionElements of a profile can be selected and analysedfor form and surface finish in a single operation.

Ultra Surface Instrument ControlSOFTWARE

Designed and written specifically for use on Windows XP, Ultra software provides a powerful, easy-to-use interface for controlling TaylorHobson roundness and surface finish measuring instruments. User programmability enables users to quickly achieve a high degree ofautomation thereby saving time and removing operator variability from the measurement process. Ultra software provides you with:

User friendly software for controlling surface finish instruments

Full instrument control

• Continuous moves / speed selection• Move to absolute position• Move by relative amount• Auto-contact• Gauge resolution selection• Work in user or instrument co-ordinates

Single screen set-up for configuring automated functions• Automated set-up methods have comprehensive dialogs allowing

all options to be specified in one place.

• Inclusion of measurement settings on the same dialog leavesyou in control of the process.

Software “joystick” for “nudge” moves

Ease of use through extensive use of icons

Set-up aids for common operations

• Gauge set-up• Auto-cresting

Axis status icons show current position andallow access to axis configuration information

Simple “point and press icons” for the controlof all major positioning and measuring axes

Pop-up menus provide quick and easyaccess to essential functions

Automated calibration routines

User programmability

• Easily automate repetitive tasks• Learn mode• Editing facilities• User breakpoints for debugging

Move Relative Left

Move to Absolute Position

Move Relative Right

Auto-crest in X axis

www.taylor-hobson.comCopyright©2005 • Taylor Hobson Precision • Ultra Surface Finish Software Control_05/05

Specifications are subject to change without notice. Availability of some features is dependent on instrument type.

User friendly software for controlling surface finish measuring instruments

Languages: Brazilian Portuguese, Chinese, Czech, English, French, German, Italian, Japanese, Polish and Spanish.

Program selection and activation

• Programs can be accessed through a“Simplified User Interface”.

• Programs can be linked to simple buttonsor to list boxes.

• Buttons can be identified by means of text or a bitmap such as a picture.

• Program “chooser” allows programs to be selected from a list

Measurement program creation

• User programs can be written quickly and easily using the learn mode facility

• Simple or detailed listings can be shown.• User breakpoints can be used to help in the

debugging of complex measurement programs

Measurement data file creation and archiving

• Data is presented through a familiar “tree view”• Different measurement types are identified and easily recognized

by means of distinctive icons• Analysis results are stored under the measurement from which

they are derived• Naming, organization and storage of measurement data is greatly

simplified with the auto numbering feature• Entire folders containing programs, measurements and results

can be exported for transfer between Ultra-based systems or for archiving purposes

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SOFTWAREUltra Surface Finish Parameters

Powerful software for the analysis of surface finish and form

Form errorDeviation from nominal form is calculatedwith reference to a best fit straight line, bestfit circular arc or best fit conic section.

Form deviation may also be be calculatedwith reference to a minimum zone straightline (the minimum separation between twoparallel lines containing the data set).

RadiusUsing a least squares best fit, the radiusof concave or convex circular arcs can beautomatically calculated from selected data.The option to exclude any unwanted surfacefeatures such as edges is also available.

Alternatively, the absolute radius can beset to analyze the actual deviation from adesign master. Other calculated parametersinclude the center coordinate.

Angle (slope)Surface tilt can be determined and removedprior to parameter analysis by means of astraight line or minimum zone algorithm.Other calculated values include interceptand pitch.

DimensionThe linear relationships of surface featurescan be assessed and compared by meansof calculated X and Z coordinate positions.

• Datum slope• Delta slope• Pitch (between arc centers)• Intercept X / Intercept Z• Slope

Interactive curvesMaterial Ratio (mr)Amplitude Distribution (ADK)

Dual Profile (optional)This analysis function enables comparisonof one measured profile to another or evento a master profile which has been savedas a template. A “difference” profile canbe displayed at the touch of a button andused for further analysis.

Primary parametersPa, Pc, Pda, Pdc*, Pdq, PHSC*, Pku, Pln,PLo, Plq, Pmr(c)*, Pmr*, Pp, PPc*, Pq, PS,Psk, PSm, Pt, Pv, PVo*, Pz, Pz(JIS)

Roughness parametersR3y, R3z, Ra, Rc, Rda, Rdc*, Rdq, RHSC*,Rku, Rln, RLo, Rlq, Rmr(c)*, Rmr*, Rp, Rpc*,Rp1max, Rq, RS, Rsk, RSm, Rt, Rv, RVo*,Rv1max, Rz, Rz(DIN), Rz(JIS), Rz1max

Waviness parametersWa, Wc, Wda, Wdc*, Wdq, WHSC*, Wku,Wln, WLo, Wlq, Wmr(c)*, Wmr*, Wp, WPc*,Wq, WS, Wsk, WSm, Wt, Wv, WVo*, Wz

Rk Parameters and Rk curveA1, A2, Mr1, Mr2, Rk, Rpk, Rvk

R + W ParametersAR, AW, Pt, R, Rke, Rpke, Rvke, Rx, Sar,Saw, Sr, Sw, W, Wte, Wx

Dominant Wavelength VDA 2004 (optional)WD1Sm, WD1c, WD1t, WD2Sm, WD2c, WD2t

FiltersGauss, ISO 2CR, Rk

Cut-offs (Lc)0.08, 0.25, 0.8, 2.5, 8mm and 25mm

Bandwidth10:1, 30:1, 100:1, 300:1 and 1000:1 or asdefined by data spacing (VDA 2006)

Pass / Fail tolerancesAll parameters can be assigned nominal,minimum and maximum values.

* QualifiersAll parameters marked with an asteriskrequire user assigned single or multiple qualifiers. For example, material ratio (mr)may be assessed at one or more slicelevels within a single measurement.

Note: Where applicable, the above parametersconform to and are named as per the standardsISO 4287-1997, ISO 13565-1-2 and ISO 12085.

Form removal and analysis functions Surface finish parameters Filters and additional features

Dual Profile analysis allows two sets of measurement data to be displayed at once with one set being used as thedatum against which the other set is tested; a master profile or template may also be used for the comparison

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www.taylor-hobson.comCopyright©2005 • Taylor Hobson Precision • Ultra Surface Finish Parameters_8/05

Specifications are subject to change without notice. Availability of some features is dependent on instrument type.

Dimension, form and texture - a practical explanationThe three elements of a surface - dimension, form error and texture - are inseparable in the function of a component. Measuring oneelement without regard to the others may lead to decisions based on misleading or incorrect information. Form Talysurf instrumentsprovide the capability to simultaneously measure dimension, form error and texture with a single trace on flat, curved or inclined surfaces.

Measure all three at once

Measurements from Form Talysurf systemscan be used to assess dimension, formerror and surface texture. This ensures thateach element is evaluated as it should be,in relation to the other surface elementsand how they work together.

Measuring technique

A contacting stylus is traversed across thecomponent. Slight undulations in the surfaceand the overall shape are traced by the stylusand digitized using modern electronics toprovide a representation of the surface.

What is dimension?

Dimensions (radius, distance and angle) areused to define the functional shape of asurface. The shape of features as well asthe linear relationships between them canbe assessed using powerful analysis tools:

• Least squares arc (radius)• Least squares ellipse• Least squares hyperbola• LS or MZ line (angle)• True X and Z co-ordinates

Dimension (nominal shape)

Form error (deviation from nominal shape)

Waviness (undesireable machine tool effect)

Roughness (produced by the machining process)

The elements of a surface areinseparable in the function of acomponent (not drawn to scale)

What is form error?

Form error is deviation from the intendednominal shape of the surface, ignoring anyvariations due to roughness and waviness.

All objects will have measurable deviationsaway from the intended shape that can becaused by various factors:

• Clamping during machining that is too firm or not firm enough

• Inaccuracies of the slides or guide mechanisms in the machine tool

• Inadequate or improper stress relief of the component

• Sagging of the component under its own weight

• Thermal effects produced during machining

Form error, deviation from intended shape,will affect feature size, assembly of onecomponent with another and functionalperformance.

What is waviness?

Waviness, an unintended and undesiredmachine tool effect, is nearly always presentin manufactured surfaces.

To the extent that it is a defect produced byan imperfect machine tool, waviness canbe minimized by attention to the following:

• Vibration caused by lack of stiffness or other instabilities

• Deflection of the tool path caused by asymmetric forces

What is roughness?

As a purpose driven element of componentdesign, roughness is controlled by the actionof the cutting tool or the machining process.Roughness analysis is divided into threemain parameter groups:

• Amplitude parameters - vertical distancebetween peaks and valleys

• Spacing parameters - horizontal distancebetween peaks and valleys

• Hybrid parameters - dealing with bearingsurfaces, lubrication and wear