ISO 9001:2008
Modern means of measuring equipment
 

Diagnostic system for metal cutting equipment Ballbar QC20-W

Production:
Renishaw plc (Graet Britain)
Thanks to the new Ballbar QC20-W system, the diagnosis at different lengths (telescopic ballbar diagnostics) has become even easier and at the same time even more effective.



The QC20-W system is the result of Renishaw´s many years of experience in testing machines using ballbar sensors. This system provides real benefits for users in terms of performance and ease of use compared to the already outdated QC10 system:
  • Using Bluetooth wireless technology can eliminate all problems associated with the presence of wires, as well as working in "closed doors" and reduces the likelihood of damage to the system.
  • Increased data reading speed allows advanced analysis of test results in small radius circles and at high feed rates.
  • New accessories allow testing in three planes with a single test setup; this became possible due to two tests of three on the so-called "incomplete arc".
  • Advanced software tools include "spatial (volumetric) estimation" (used in conjunction with a partial arc test), as well as many other new options and functions for performing tests and data analysis in an extended volume.

Using the standard QC20-W system kit

The standard QC20-W ballbar includes a sensor assembly 100 mm long and extensions of 50, 150 and 300 mm in length. Using different combinations of extensions, the radius of the test can be made equal to 100, 150, 250, 300, 400, 450, 550 or 600 mm.

The holders of the modified balls (the new central holder and the extension of the magnetic support having the recess) allow, using the QC20-W system, to perform additional tests on the "incomplete arc" of 220 ° in the planes passing through the axis of the central holder. This means that now it is possible to perform ballbar tests in three mutually perpendicular planes, without changing the position of the central holder, which speeds up the testing.

The results can also be analyzed using the spatial accuracy estimation function (see the section on software below); while you can be sure that all the data were obtained about the same point (when performing tests on the "incomplete arc" with a radius of more than 150 mm, it is necessary to provide a special fastening).

Using optional accessories

The functionality of the Ballbar QC20-W system can be extended by using various accessories.
  • Using additional extensions, you can perform tests on circles with a radius of up to 1350 mm.
  • A set of small-radius diagnostic accessories allows you to perform tests on a circle with a radius of 50 mm.
  • On two-coordinate machines, testing can be performed using a VTL adapter, and on many lathes - using the appropriate set of accessories for lathes.

All these additional tools, as well as the possibility of using different feed rates, make the QC20-W system an exceptionally versatile machine testing tool.

All these additional tools, as well as the possibility of using different feed rates, make the QC20-W system an exceptionally versatile machine testing tool.

System kit contents

The standard QC20-W system kit is supplied in a sturdy case; The kit includes the following components: Ballbar QC20-W wireless system, battery, spindle and table mounts (swivel), extensions for the 50, 150 and 300 mm system (for tests with different diameters), tools and CD- a disk with Ballbar software 20 and a user manual.

The kit also includes a calibrator for advanced analysis of results. (This calibrator allows you to obtain absolute values for scale errors, and is also a convenient means of verifying the correct operation of the ballbar sensor.)

In addition, the kit includes calibration certificates for the ballbar sensor and calibrator with fully traceable compliance standards, as well as labels for recording the time of the test on the machine.

Any individual component included in this kit can be ordered as a spare part.

Specifications of Ballbar QC20-W system


Software for the Ballbar QC20-W system (in Russian)

The Ballbar 20 software represents the development of the already proven Ballbar 5 package; this software can be used with both the ballbar, QC10 and QC20-W systems.

In addition to supporting the already existing traditional 360 ° tests with the extension of the available functions, this software also supports 220 ° partial arc testing using the QC20-W system (with the appropriate accessories) and a new option for evaluating spatial accuracy.

Ballbar 20: new features and tools

The Ballbar 20 was designed to be used in conjunction with the Ballbar QC20-W wireless system, but this package is also compatible with the existing Ballbar QC10 system. This means that the user can use the same program even if both systems, QC10 and QC20-W are in use. Even if you currently only have the QC10 system, why not upgrade the existing software to take advantage of the many additional features supported in the Ballbar 20 software?

The main advantages compared to the software Ballbar 5:

Wireless connection
The connection to the QC20-W system is performed using Bluetooth wireless technology. There is support for quick search and connection to other Ballbar QC20-W systems without having to configure the configuration of communication ports, etc.

220 ° incomplete arc test
The Ballbar QC20-W system, while being used with a central holder of a modified design and an extension of the magnetic support having a recess (standard in the case of the QC20-W system and ordered additionally in the case of a basic upgrade kit with transition to the QC20-W system) perform this new type of test.

Spatial accuracy estimation
This function allows you to select 3 files with test results performed in certain mutually perpendicular planes, and display the results in one window. The analysis of the results of such a test of a new type includes the total minimum and maximum values of the deviation from the circle ("sphericity"), as well as the results of the deviation estimate from the circle for each individual test (note: the spatial accuracy estimate is possible only if files, containing the test data collected by Ballbar software 20).

Newest standards
This software now includes diagnostics of results in accordance with ISO 230-4: 2005 standards and ASME B5.54-2008; at the same time, the possibility of analyzing the results in accordance with previous editions of these standards remains.

Exporting and importing machine folders and machine data files
This function ensures that service engineers are comfortable with the updating and sharing of data stored in the central directory / shared directory.

The cloning function of the machine
This function makes it easy to create several identical machines by selecting an existing machine and then cloning and editing it.

Repeat tests / series of tests (only in advanced mode)
This function allows you to sequentially perform a user-defined number of tests with automatic saving of files with data (and corresponding increase in the notation included in the filename).

Data path to user data file
This feature allows you to solve the difficulties associated with accessing the administrator to data stored in the Program files folders (security solution for Windows Vista).

Existing software features for the Renishaw ballbar system

Comprehensive testing and detailed reporting
Ballbar 20 software allows you to set up and run ballbar tests using "one-time" data or based on a user-defined test pattern. The data obtained as a result of the tests can be displayed in the form of reports with analysis results in accordance with the requirements of various international standards, for example, ISO230-4, ANSI B5.54, etc., and also in accordance with the comprehensive Renishaw diagnostic standard. In addition to the window with a graphical representation of the trajectory in the Ballbar 20 package, each diagnosed error is classified according to its influence on the total accuracy of the machine. The results of this classification are displayed in an understandable, clear form along with the tolerance value for positioning accuracy.

History of machine characteristics changes
Using a user-defined test pattern, it is now possible to clearly define which of the machine´s operational characteristics, measured with the ballbar system (for example, deviations from the radius and from the circle according to ISO 230-4, tolerance for positioning accuracy, deviation from perpendicularity, backlash ect.), have changed over time. In other words, a report on the history of the machine is, in a way, his "medical map"!

Graphs make it easy to identify patterns and, accordingly, in advance to schedule the timing of specific maintenance, and discontinuities in the graphs help to diagnose a malfunction when a machine breaks down.

It is also possible to set limits for the issuance of warnings and fault messages for any of the machine characteristics measured with the Ballbar QC20-W system. Once set, these limit values are displayed on the machine history charts and can also be used to instantly check the results of any ballbar test as it is executed.

Comprehensive online help
The online help includes an alphabetical index and a search option. A convenient reference system in reports with analysis results allows you to quickly find the required section of the online help with a description of possible causes of errors of any type of machine and recommendations for their elimination.

The Ballbar QC20-W system and online help are usually sufficient to provide the user with all the information necessary to understand specific problems directly at the workplace. This eliminates the need for unnecessary calls to the maintenance personnel. If you still need to apply for technical assistance, then the user already has at hand all the information to accurately identify the problem and, accordingly, reduce downtime.

Control program generator
This function allows you to quickly perform automatic generation of control programs for checking CNC machines using the ballbar system. It is enough to set test parameters, and then choose the type of CNC machine (various ready-made versions are supplied with the software, but it is also possible to add new versions and edit them in accordance with specific tasks). Then, at the touch of a button, a program is generated which can be edited, if necessary, and then transferred to the CNC. The generated programs can be stored in the memory accessible to the software, in order to use them in the future.

The ballbar simulation program
This program allows you to evaluate the effectiveness of the expected maintenance and adjustment of the machine.

The program allows you to view the test results on the screen, and then change the various geometric characteristics, play and dynamic parameters of the machine to test different scenarios on the charts and assess their impact on the deviation from the circle (roundness) and positioning accuracy. This procedure is performed using a separate simulation program, so the original verification data remains securely protected.

Multilanguage support
The Ballbar 20 package provides reports in several languages, regardless of the language of the working interface (available languages: English, German, French, Italian, Spanish, Czech, Chinese, Japanese, Korean and Russian). It is recommended to check the latest updates related to support for new languages.

Extensive file administration capabilities.
Folders are set taking into account the location of machines, such as machines, etc., which makes it easy to determine the location of test results.

User-selectable modes of operation
The Ballbar 20 system is easy to use, but the three different operating modes provided in it make the work even more convenient, allowing you to limit the set of available functions to specific tasks, as well as the operator´s skill level and access level.
  • Express test mode - For one-time inspection of machines.
  • Operator mode - For regular comparative analysis of changes in the technical characteristics of machines. Pre-defined test templates allow you to speed up the verification process and ensure that its conditions remain unchanged.
  • Advanced mode - Full access to the functions for selecting and modifying test conditions and organizing the data of a particular machine.
Minimum computer configuration requirements (Ballbar 20 software)
Specifications Ballbar QC20-W
Resolution of the sensor, mkm 0,1
Accuracy of the Ballbar sensor, mkm (20 °C) ±0,5
Accuracy of measurements in the system, mkm (20 °C) ±1,25
Sensor movement, mm -1,25 … +1,75
Sensor measuring range, mm ±1,0
Maximum reading frequency, values per second 1000
Process temperature, °C 0 … 40
Dimensions of the suitcase for storing and carrying the system L × W × H, mm 395×300×105
Mass of the suitcase, kg 3,75 (with the kit)
Data transmission range under typical conditions (Bluetooth® class 2 device), m 10


Computer Desktop or laptop (PC type)
Processor Pentium 500 MHz
Amount of RAM, MB 256
Operating system Windows® XP SP2 or SP3, Vista™ (32 bit or 64 bit), Windows 7
Drives CD-ROM drive for software installation
Monitor Minimum resolution 800 х 600, SVGA
HDD To install the program requires 100 MB of free disk space
Interface Computer with Bluetooth support (Microsoft enumerator)
or compatible Bluetooth-USB adapter, and one
USB port for connecting mouse.
Peripherals Microsoft keyboard and mouse or compatible pointing device

Additional information

See also: