## Aligning a Cylinder Gear

To align a cylinder gear, select the Operation | Align Gear… menu option or the Align toolbar icon…

…to open the Align Gear dialog box:

Align Gear dialog box for cylinder gear

Use the Align Gear dialog box to generate, measure, and/or execute a PC-DMIS program by selecting the appropriate check box(es):

To Do This | Select This Check Box
Generate | Measure
Generate a PC-DMIS program to align a gear |  |
Measure and execute an existing PC-DMIS program to align a gear |  |
G enerate, measure, and execute a PC-DMIS program to align a gear |  |

You can align three types of gears:

- External spur and helical gear

- Internal spur gear

- External gear with shaft

Generate: When you select this check box, PC-DMIS Gear will generate a new part program to align the gear according to the option you select for Align Type in the Align Type Area.

Measure: When you select this check box, PC-DMIS Gear will execute the part program that you select in the Part Program area.

Generate and Measure: When you select both check boxes, PC-DMIS will first generate a part program and then execute it to align the gear.

Part Program Area

Part Program: Type the name of the PC-DMIS program file, along with the full path. You can click the browse button and select the part program file. The name of the PC-DMIS program file will appear in the box.

Alignment Area

File name: The PC-DMIS Gear alignment program will save the gear alignment in this file. This alignment will be used by the PC-DMIS program that measures gear. This file will have .aln as the filename extension. You can click the browse button and select the external alignment file. The name of the file will appear in the box. For more information about alignment files, see the help topics on saving and recalling external alignments in the main PC-DMIS documentation.

Probe Area

Probe File: Type the name of the probe file that you want to use for aligning the gear, along with the full path. You can click the browse button and select the probe file name. The probe file name will appear in the box.

Note: You must select an existing probe file. Otherwise, when you click the Apply button, an error message will appear and indicate that the file you specified does not exist:

Probe has wrist: To specify that the probe configuration you are using contains a wrist, select this check box. In PC-DMIS, a probe configuration with a wrist uses the tip naming format "T1AXBY", where X and Y are the angles of the wrist (for example, T1A90B180). Without a wrist, PC-DMIS uses tip names as "TIPX", where X is the TIP #. PC-DMIS Gear needs to know whether the probe has a wrist so that it uses the correct tip naming format.

Initial Alignment Area

Import initial alignment: This option provides you with additional freedom to create custom gear alignments. You can create an alignment and save as external alignment. PC-DMIS Gear requires that the clocking of the X axis is done based on tooth position. Therefore, gear alignment will generate code only for clocking the rotational axis. The rest of the degrees of freedom will be constrained by the external alignment.

To align the gear using the external initial alignment method, select the Import initial alignment check box. The Initial Alignment area appears:

File name: Type the file name of the external initial alignment to be used, along with the full path. You can click the browse button and select the file name of an external initial alignment. The name of the external initial alignment file will appear in the box.

Align Type Area

Use this area to select an alignment type. This area is available if you are not using the initial alignment method to align the gear.

Align Type: Select an alignment type:

- External Spur and Helical Gear: This option generates a complete PC-DMIS part program to measure the alignment of the external spur and helical gear. The alignment consists of a plane to level, a circle for the origin, and two points for the clocking. The alignment program measures features in manual mode first, and then in DCC mode.

M anual mode hit pattern:

- To measure a manual plane, take hits on the top face of the gear.

- To measure a manual circle, take hits on the internal hole or external shaft.

- For an external spur and helical gear, take one hit on each side of the gear tooth for clocking.

- Internal Spur Gear: This option generates a complete PC-DMIS part program to measure the alignment of the internal spur gear. The alignment consists of a plane to level, a circle for the origin, and two points for the clocking. T he alignment program measures features in manual mode first, and then in DCC mode.

M anual mode hit pattern:

- To measure a manual plane, take hits on the top face of the gear.

- To measure a manual circle, take hits on the center internal hole.

- For an external spur and helical gear, take one hit on each side of the gear tooth gap for clocking.

- External Gear with Shaft: This option generates a complete PC-DMIS part program to measure the alignment of the e xternal spur and helical gear mounted on the shaft. The alignment consists of a cylinder to level, a point face of the gear for the Z origin, and two points for the clocking. T he alignment program measures features in manual mode first, and then in DCC mode.

M anual mode hit pattern:

- To measure a manual cylinder, take hits at the bottom of the cylinder and then at the top of the cylinder.

- To measure a manual hit, on face of gear to set Z origin.

- For an external spur and helical gear, take one hit on each side of the gear tooth for clocking.

See "Shaft Gear Area".

External/Internal Gear Area

The following options are available if you selected the External Spur and Helical Gear or Internal Spur Gear alignment type:

Plane: The alignment program will measure a DCC plane. The plane is measured by taking hits on a circular path having a radius equal to the Dist. value, and starting from the Start Ang. up to the End Ang. values.

Hits: Select the number of points that will be measured for the DCC plane.

Start Ang.: Type the start angle – the angular location of the first hit point of the DCC plane. The angles are defined as 0 being equal to the clocking axis of the manual alignment and increasing as you move counter-clockwise around the center of the origin. Negative numbers are not allowed.

End Ang.: Type the end angle – the angular location of the last hit point of the DCC plane. The angles are defined as 0 being equal to the clocking axis of the manual alignment and increasing as you move counter-clockwise around the center of the origin. Negative numbers are not allowed.

Dist.: This is the distance from the edge of the circle that is measured in the manual alignment. Type the distance beyond the edge of the circle to measure for the plane.

- For an external circle: Radius of Plane Measurement = Radius of Manual Circle – Distance

- For an internal circle: Radius of Plane Measurement = Radius of Manual Circle + Distance

Move: To move the probe up to the clearance plane between each hit on the plane, select the ClearPlane check box. Define the required Clearance Height in the Execution Control area.

Circle: The alignment program will measure a DCC circle. This circle is defined by the following values. The center of circle is the origin of the manual alignment and diameter is equal to the diameter of manual circle.

Hits: Select the number of hit points desired to measure the DCC circle.

Start Ang.: Type the start angle – the angular location of the first hit point of the DCC circle. The angles are defined as 0 being equal to the clocking axis of the manual alignment and increasing as you move counter-clockwise around the center of the origin. (Negative numbers are not allowed.)

End Ang.: Type the end angle – angular location of the last hit point of the DCC circle. The angles are defined as 0 being equal to the clocking axis of the manual alignment and increasing as you move counter-clockwise around the center of the origin (Negative numbers are not allowed.)

Dist.: The depth below the DCC plane at which the circle will be measured.

Type: This option is available only for the Internal Spur Gear alignment type. If the circle is external, select EXT.. If the circle is internal, select INT..

Move: To move the probe up to the clearance plane between each hit on the plane, select the ClearPlane check box. Define the required Clearance Height in the Execution Control area.

Shaft Gear Area

The following options are available if you selected the External Gear with Shaft alignment type:

Cylinder: The alignment program will measure a DCC cylinder. This cylinder is defined by the following values as well as the first point of each of the two rows of the manual cylinder. The Z location of the first point and the fourth point of the manual cylinder from the manual alignment origin will define the depth and length of the DCC cylinder.

Number of Points: Select the number of hit points desired to measure for each row of the DCC cylinder.

Start Angle: Type the start angle – the angular location of the first hit point of the DCC cylinder. The angles are defined as 0 being equal to the clocking axis of the manual alignment and increasing as you move counter-clockwise around the center of the origin. Negative numbers are not allowed.

End Angle: Type the end angle – the angular location of the last hit point of the DCC cylinder. The angles are defined as 0 being equal to the clocking axis of the manual alignment and increasing as you move counter-clockwise around the center of the origin. Negative numbers are not allowed.

Type: If the cylinder is external, select EXT.. If the cylinder is internal, select INT..

Use multiple tips when measuring outer cylinder: When you select this option, the alignment program will use multiple tips of an indexing probe to measure the outer cylinder of the gear.

"A" Angle: This box becomes available when you select the Use multiple tips when measuring outer cylinder check box. Type the “A” angle that will be used for the measurements. The “A” angle of the probe remains constant. If you use a star probe and you do not want any probe head rotation, type 0 (zero) in this box.

Use alternate tip when measuring Z point: When you select this option, the alignment program will use multiple tips of an indexing probe to measure the Z Point on the gear.

"A" Angle: This box becomes available when you select the Use alternate tip when measuring Z point is check box. Type the “A” angle that will be used for the measurements. The “A” angle of the probe remains constant. If you use a star probe and you do not want any probe head rotation, type 0 (zero) in this box.

Execution Control Area

This area contains the values that control the motion of the machine while executing the DCC alignment.

Prehit Distance: Type the distance from the theoretical point at which the motion speed changes from Move Speed to the slower Touch Speed. Distance is specified in current part units (inches or millimeters).

Retract Distance: Type the distance the probe retracts from the surface after taking a hit. The distance is specified in current part units (inches or millimeters).

Check Distance: Type the distance the probe will retract in the XY direction. The distance is given in current part units (inches or millimeters).

Clearance Distance: Type the distance the probe will retract in the XY direction.

Clearance Height: Type the distance the probe will retract in the Z direction. The distance is given in current part units (inches or millimeters).

Touch Speed: Type the speed at which the CMM takes hits. The value entered is the percentage of the machine’s defined top speed.

Move Speed: Type the point to point positioning speed of the CMM. The value entered is the percentage of the machine’s defined top speed.

Fly On: The Fly mode provides a way to move the probe around the part in a smooth, non-stopping motion. Check this box to select fly. This option depends on the capability of the controller to execute circular moves.

Fly Radius: Type the radial distance of the arc path along which the probe will travel between move points.

Clocking Points Area

Use multiple tips: When you select this check box, the alignment program will use multiple tips of an indexing probe to measure the clocking points.

"A" Angle: This box becomes available when you select the Use multiple tips check box. Type the “A” angle that will be used for the measurements. The “A” angle of the probe remains constant. If you use a star probe and you do not want any probe head rotation, type 0 (zero) in this box.

Rotation: This list specifies where to take clocking point X+, X-, Y+, or Y- (in other words, at the three o'clock, nine o'clock, twelve o'clock, or six o'clock position). The probe will be selected based on rotation selection.

Use different prehit and retract distance: Sometimes it may be necessary to use smaller prehit and retract distance for clocking points. Check this box to define different the Prehit and Retract Distance for clocking points.

Prehit Distance: Type the prehit distance for clocking points.

Retract Distance: Type the retract distance for clocking points.

The following buttons are available in this dialog box:

| This button launches PC-DMIS and generates an alignment program, measures a selected alignment program, or generates and measures an alignment program according to your selection.
| This button applies any changes you have made and leaves the dialog box open.
| This button cancels your changes and closes the dialog box.