This paper provides a detailed explanation of the installation, commissioning, probe calibration, and practical application examples of the Renishaw OMP60 workpiece measuring system software in a horizontal machining center equipped with a FANUC system. The system is designed to enhance precision and efficiency during machining processes.
**1. Renishaw OMP60 Machining Center Workpiece Measuring System**
The Renishaw OMP60, part of the OMI-2 optical transmission system, represents a new generation of optical measurement technology. Following the RMP60 wireless probe, the OMP60 has been introduced as an advanced optical probe suitable for medium and large machining centers, as well as turning and milling centers. It utilizes the latest modulation optical transmission method, offering strong resistance to light interference. The OMP60 is compatible with existing OMI-2 and OMI receivers, allowing users of older models like MP7, MP8, MP9, and MP10 to benefit from its enhanced features. With Renishaw’s proven trigger logic, the probe supports multiple on/off configurations without requiring disassembly. Powered by a standard AA battery, it can operate for over six months, reducing machine downtime and maintenance costs. Designed to withstand shocks and vibrations, it minimizes false triggering, ensuring reliable performance. Additionally, the OMP60 is backward-compatible, enabling it to replace previous systems developed by Renishaw for various applications.
**2. Software Installation and Parameter Setup**
(1) **Software Installation**: All files starting with "O97" and "O98" in the FANUC system should be renamed to avoid conflicts. The installation files 40120519, 40120520, 40120521, and 40120727 are copied into the FANUC system.
(2) **Parameter Setting**:
- **Probe Retraction Distance and Detection Feed Rate**: These parameters should be set based on the machine tool's condition. Open macro program O9836, where #506 defines the retraction distance (default: 0.5 mm), and #119 sets the detection feed rate (default: 5000 mm/min).
- **Tool Type Setting**: In macro program O9724, parameter #120 defines the tool type, which must match the FANUC system settings. For our factory’s horizontal machining center, #120 is set to 9.
**3. Probe Calibration**
(1) **Importance of Calibration**: Calibration helps detect the physical length error of the probe, its eccentricity on the X and Y axes, and the vector radius of the stylus ball, enabling accurate offset compensation during workpiece inspection.
(2) **Preparation for Calibration**:
- Clamp a cutting sample to the machining center table and mill its surface to ensure a roughness greater than 1.6 μm.
- Use a fine boring tool to create a stable hole (depth >35 mm, diameter >50 mm) and measure its inner diameter using an internal micrometer.
- Detect the Z-axis workpiece coordinate system using a gauge block.
- Install the probe on the spindle, measure its length with a caliper, and input the value into the FANUC tool table for tool length compensation.
(3) **Calibration Procedure**:
```
%O5211
M19 (Spindle orientation)
M35 (Probe open)
G0 G90 G54 X35. Y0 (Rapid move to upper end of the hole)
G43 H1 Z100 (Activate tool offset and move 100 mm above the sample)
G65 P9810 Z30. F3000 (Protective positioning 30 mm from the surface)
G65 P9801 Z0 T1 (Probe length calibration)
G65 P9810 X0 Y0 (Protective positioning to center)
G65 P9810 Z-5. (Protective positioning to -5 mm)
G65 P9802 D50.001 (X/Y stylus offset calibration)
G65 P9804 D50.001 (Ball diameter and vector calibration)
G65 P9810 Z100. F3000 (Protective retraction)
H00 (Cancel offset)
M36 (Probe close)
M30 (End of program)
%
```
(4) **Post-Calibration Data Check**: After calibration, check the macro variables in the FANUC system. #500 (XRAD) and #501 (YRAD) represent the X and Y calibration radii, while #502 (XOFF) and #503 (YOFF) show the X and Y stylus eccentricities. If values exceed expected ranges, recalibration is necessary. Ensure the stylus ball has less than 0.01 mm runout; if not, repeat the calibration process.
**4. Application Examples**
As shown in Figure 2, the workpiece measuring system is used to establish the G54 workpiece coordinate system with the hole as the center and the bottom surface as zero. When detecting the Z-axis zero point, if the measured value exceeds the original by more than 0.1 mm, an alarm is triggered, and the data is saved for quality tracking. The following procedure is used:
```
%O0010
T1 M06 (Change to probe)
G90 G0 G54 X100 Y0 (Rapid move to start position)
M19 (Spindle orientation)
M35 (Probe open)
G43 H1 Z100 (Activate tool offset and move 100 mm above the fixture)
G65 P9810 Z30 F3000 (Protective positioning)
G65 P9811 Z0 U0.1 W1 S1 (Measure Z-axis zero point)
G90 G0 G54 Z100 (Retract)
G90 G0 G54 X0 Y0 (Move to start)
G65 P9810 Z20 W1 F3000 (Protective positioning inside the hole)
G65 P9814 D60 S1 (Measure 60 mm diameter hole)
G65 P9810 Z100. (Reposition)
M36 (Probe close)
...
```
**5. Conclusion**
This paper outlines the installation, setup, calibration, and real-world application of the Renishaw OMP60 workpiece measuring system in a FANUC-controlled horizontal machining center. The system significantly improves machining accuracy and efficiency, reduces production costs, and lowers scrap rates, making it a valuable addition to modern manufacturing environments.
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