XL80 Training Manual (Part 2)

Training manual
H-2000-1097-01-A
XL-80 laser system training course manual

(Part 2)
Part 2 contains:
• Straightness measurement and data capture;
• Squareness measurement and data capture.
© 2009 Renishaw plc. All rights reserved.
This document may not be copied or reproduced in whole or in part, or transferred to any other media
or language, by any means, without the prior written permission of Renishaw plc.
The information contained within this document is for training purposes only and should not be used
for any other purpose.
Renishaw reserve the right to make changes to these notes and to the product described herein
without obligation to notify any person of such changes.
Renishaw part no: H-2000-1097-01-A
Issued: March 2009

Contents
Contents
1.0 Before you begin
Disclaimer ..................................................................................................................... 1.2

Trademarks ................................................................................................................... 1.2
Changes to equipment .................................................................................................. 1.2
Laser safety ................................................................................................................... 1.3
Mechanical safety .......................................................................................................... 1.4
XL power supply unit ..................................................................................................... 1.4
Course overview ............................................................................................................ 1.5
Aims of the course ................................................................................................... 1.5
Objectives of the course ........................................................................................... 1.5
2.0 Introduction to straightness measurement
Straightness optics ....................................................................................................... 2.2
3.0 Straightness measurement and data capture
Pre-test checklist ......................................................................................................... 3.2

The optics ............................................................................................................... 3.2
The straightness accessory kit ................................................................................ 3.3
The machine setup .................................................................................................. 3.4
The optic movement ................................................................................................ 3.4
Positioning the laser ................................................................................................. 3.5
Laser alignment procedures ........................................................................................ 3.6
Laser setup prior to beam alignment ....................................................................... 3.6
Golden rules of alignment ....................................................................................... 3.7
Straightness alignment procedure along a horizontal axis ..................................... 3.9
Straightness alignment procedure along a vertical axis .......................................... 3.19
Manual removal of slope error ................................................................................ 3.29
Straightness software mode ......................................................................................... 3.33
Navigating the toolbar ............................................................................................. 3.34
Checking the sign of the machine movement ......................................................... 3.35
XL-80 laser system training course manual (Part 2)
Contents
Preparing the machine prior to data capture .......................................................... 3.36

Target / data capture setup ..................................................................................... 3.37
Data capture ........................................................................................................... 3.38
Broken beam recovery ............................................................................................ 3.39
Analysing results ..................................................................................................... 3.40
Removing residual slope error ................................................................................ 3.41
Factors affecting accuracy ........................................................................................... 3.43
4.0 Introduction to squareness measurement
Squareness optics ....................................................................................................... 4.2
5.0 Squareness measurement and data capture
Pre-test checklist .......................................................................................................... 5.2

The squareness measurement kit ........................................................................... 5.2
The optic movement ................................................................................................ 5.4
Positioning the laser ................................................................................................ 5.5
Laser alignment procedure ........................................................................................... 5.6
Laser setup prior to beam alignment ....................................................................... 5.6
Golden rules of alignment ....................................................................................... 5.8
Horizontal-to-horizontal squareness alignment procedure ...................................... 5.11
Vertical-to-horizontal squareness measurement alignment .................................... 5.23
Manual removal of slope error ................................................................................. 5.38
Checking sign convention ........................................................................................ 5.42
Calculating squareness ................................................................................................ 5.45
Configuring the optical square ................................................................................. 5.45
Producing the squareness data ............................................................................... 5.46
Factors affecting accuracy ............................................................................................ 5.47
Angular alignment of the optical square .................................................................. 5.47
Before you begin
1.1
Disclaimer
Before you begin
RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS

DOCUMENT IS CORRECT AT THE DATE OF PUBLICATION BUT MAKES NO WARRANTIES
OR REPRESENTATIONS REGARDING THE CONTENT. RENISHAW EXCLUDES LIABILITY,
HOWSOEVER ARISING, FOR ANY INACCURACIES IN THIS DOCUMENT.
1.2
Trademarks
RENISHAW® and the probe emblem used in the RENISHAW logo are registered trademarks of
Renishaw plc in the UK and other countries.
apply innovation™ is a trademark of Renishaw plc.
All other brand names and product names used in this document are trade names, service marks,
trademarks, or registered trademarks of their respective owners.
Changes to equipment
Renishaw reserves the right to change equipment specifications without notice.
Laser safety
Before you begin

In accordance with (IEC) EN60825-1, Renishaw XL lasers are
Class 2 lasers and safety goggles are not required (under normal
circumstances the eye will blink and look away before damage can
occur).
Do not stare directly into the beam. Do not direct the beam at other
people or into areas where people unconnected with the laser work
1.3
might be present. It is safe to view a diffuse-reflected beam during
system alignment.
FDA compliance (USA) – complies with 21CFR1040.10 and 1040.11

except for deviations pursuant to laser notice no. 50, dated July 26,
2001.
Rotating the shutter

to the position shown Do not pick up the XL laser by the
ensures no beam is shutter. This will cause the shutter
emitted. to detach from the laser and could
cause damage to the system and/or
injury to the operator.
There are no user-serviceable parts inside Renishaw XL laser system

products. Do not remove any part of the housing; to do so could expose the
user to high voltages and/or Class 3R laser radiation.
Ensure that you read and understand the XL laser measurement

system manual (supplied on CD) before using any Renishaw XL laser
system products.
Mechanical safety
Before you begin
When setting up and mounting Renishaw XL calibration products, beware of pinch

and/or crush hazards that may be created e.g. due to magnetic mounting bases or the
universal tripod.
Beware of trip hazards that may be created when using the Renishaw XL calibration
system. e.g. due to trailing cables.
1.4
Exercise caution if Renishaw XL calibration products are to be mounted to moving or
rotating machinery. Beware of cables becoming entangled.
Exercise extreme caution if Renishaw XL calibration products are to be mounted to

machinery that may accelerate rapidly or move at high speed, which could lead to items
colliding or being ejected.
If it is necessary to remove or disable any guards or safety features on the machine

under test, it is the responsibility of the operator to ensure that appropriate alternative
safety measures are adopted in line with the machine manufacturer’s operating
instructions or code of practice.
If you are using a part program or error correction parameters generated by the
Renishaw software, it is the responsibility of the user to validate these at low feedrate
and be prepared to operate an emergency stop button if necessary.
XL laser power supply unit

The XL laser system has been qualified for use with the power supply unit supplied
with the system. A specification for this power supply unit can be found in the
specification section of the electronic manual.
Take care not to allow the power supply unit to come into contact with fluids e.g.
coolant on the floor.
Quadrature output
Do not use the quadrature output
facility of the XL laser to provide
positional feedback control for
a machine. The system is not
designed to be used for feedback
control and injury could result
to the operator if used for this
purpose.
On / Off switch
Course overview
Before you begin

The following course notes are provided to assist you during the Renishaw XL-80 laser measurement
and data capture training course and, in conjunction with the specialist help and guidance offered by
your course tutor, will:
• familiarise you with the principles and components of straightness measurement and data
capture;
• familiarise you with the principles and components of squareness measurement and data 1.5
capture;
• teach you how to align optics;
• teach you how to use the compensation functions.
Aims of the course
The aims of the course are:

1. To provide you with the skills and confidence necessary to perform data capture on a chosen
machine.
2. To allow you to practice setting up optics and to capture data and provide feedback.
3. To provide initial support and coaching to allow you to adapt these new skills to the workplace.
Objective of the course
At the end of the course you will be able to set-up optics on a given machine tool and be capable of
capturing a range of test results that can be used for further analysis.
Notes
Before you begin
1.8
Introduction to straightness
measurement
2.1
Straightness optics
straightness measurement
The straightness measurement optics are used to measure straightness errors in a linear axis.
Straightness errors are displacements perpendicular to the axis of travel.
Introduction to
The outgoing beam from the laser passes through the straightness interferometer which splits it into
two beams which diverge at a small angle and are directed to the straightness reflector. The beams
are then reflected from the straightness reflector and return along a new path to the straightness
2.2
interferometer as shown below. At the straightness interferometer, the two beams are converged and a
single beam is returned to the entry port in the laser head.
Axis of
movement
Straightness reflector
Direction of measured
straightness error
Straightness
interferometer
The straightness is measured by detecting the optical path change from a relative lateral displacement
between the interferometer and the reflector. The straightness measurement can be in a horizontal or
vertical plane depending on the orientation of both the straightness interferometer and reflector. In the
non-measurement plane the optic acts as a linear reflector. In the measurement plane the optic acts as
Introduction to
a double mirror (see below).
Plan view 2.3

Axis of movement Axis of movement
(Moving spindle) (Moving table)
Straightness Straightness
interferometer reflector
XL-80
OPTIC ACTING AS A LINEAR REFLECTOR IN THE NON-MEASUREMENT PLANE
Axis of movement
(Moving table)
Axis of movement Straightness

Side view (Moving spindle) measurement
plane
XL-80 Straightness
interferometer
Straightness
reflector
OPTIC ACTING AS TWO MIRRORS IN THE MEASUREMENT PLANE
Environmental compensation is not necessary when taking straightness measurements because the
two measurement beams are both equally affected by environmental change.
Notes
Introduction to
2.4
Straightness measurement and data
capture
3.1
Pre-test checklist
Straightness measurement
The optics
and data capture
The straightness measurement kit comprises:

• a straightness reflector;
3.2 • a straightness interferometer.
The straightness measurement kit is available in two versions: short-range for measurements from
0.1 m (4 in) up to 4 m (160 in) and long-range for measurements between 1 m (40 in) and 30 m
(1200 in).
Note: For short-range, these distances refer to the separation between the straightness interferometer
and the straightness reflector, i.e. the length of the axis that can be tested. For long-range, these
distances refer to the separation between the laser head and the straightness reflector. In both cases,
the range of straightness measurement is ± 2.5 mm (± 0.1 in).
The straightness interferometer and reflector are matched pairs. Therefore, you cannot interchange
elements with other straightness kits. Each straightness interferometer and reflector is marked with a
unique serial number.
Straightness
interferometer
Figure 1
The straightness accessory kit
The straightness accessory kit (Figure 2) allows for the measurement of vertical straightness in a
horizontal axis of a machine, straightness in a vertical axis and squareness.
and data capture

When straightness is measured only in a horizontal axis, only the straightness shutter from the
straightness accessory kit is required. Straightness shutters can be purchased separately - please
refer to your local Renishaw distributor for details.
3.3
The straightness accessory kit comprises of the following:
• large retro-reflector - used for certain applications, e.g. vertical axis straightness;
• straightness shutter - a special shutter assembly for the XL laser to accommodate

measurements where the return beam is in the same horizontal plane as the output beam;
• vertical turning mirror - used particularly for vertical axis straightness;
• straightness base - used to mount the straightness reflector and vertical turning mirror (or
laser steerer with fixed turning mirror) for vertical axis measurements. This base can also be
used for the mounting of linear and angular optics.
Fixed mirror Beam steerer
Alternative to vertical turning mirror
Straightness
base
Retro-reflector
Vertical turning
Straightness mirror
shutter
Figure 2
The machine setup

and data capture
3.4
Figure 3
The optic movement
Axis of
movement
Straightness
reflector
Direction of measured
straightness error
Straightness
interferometer
Figure 4
Notes
Positioning the laser
Figure 5
and data capture
3.5
Laser alignment procedures

Laser setup prior to beam alignment

and data capture
It is helpful to ensure that the laser is reasonably aligned, by eye, with the axis along which you wish
to capture data (Figure 6). Set all laser stage adjustments into the centre of the range, with the tripod's
vertical adjustment away from the end of its travel, before roughly aligning the laser by moving or
3.6 adjusting the tripod only (to ensure all available fine adjustment is preserved for later use).
Figure 6
When the laser has been aligned by eye, it should then be levelled with the help of the bubble level
supplied (Figure 7). This will fit into the circular recess on the top of the stage, on top of the tripod
stage adaptor or, alternatively, may be placed on top of the XL laser head itself.
Bubble level
Figure 7
Golden rules of alignment
When the moving optic is close to the laser end
and data capture

When the moving optic is close to the laser end, as shown in Figure 8, only horizontal 'translation'
adjustments should be made (up and down or side-to-side).
Straightness
measurement 3.7
Plan view plane
Clamp Straightness
block base
Axis of
movement
Straightness Clamp
interferometer block
Straightness
XL-80 reflector
Figure 8
The tripod stage facilitates both coarse and fine horizontal translation adjustment of the XL laser.
Coarse translation is by means of a quick translation lever on the side of the stage which gives a
coarse translation range of approximately 42 mm (1.7 in).
For fine horizontal adjustment (perpendicular with respect to the laser beam axis), rotate the
translation control knob on the XL laser mounting stage as shown in Figure 9. The stage has a fine
translation range of approximately 30 mm (1.2 in).
The XL laser and mounting stage can be freely rotated through 360° if the stage release lever is in its
mid position.
Fine rotational control of the XL laser is achieved by turning the yaw adjustment knob (Figure 10). This
gives an additional ± 1.5° adjustment.
Adjusting this knob

will translate the
laser horizontally
(side to side)
Adjusting this rotation

lever will translate the
laser vertically (up and
down)
Figure 9 Figure 10
When the moving optic is moved to the straightness reflector end

When the moving optic is moved to the straightness reflector end, as shown in Figure 11, 'rotational'
adjustments should be made (side swing or vertical swing). These adjustments can be made to the
and data capture
laser/tripod setup (Figure 12).
3.8
Plan view
Clamp Straightness
block base
Clamp
Straightness block
interferometer
Straightness
XL-80 reflector
Figure 11
A knob set in the XL-80's rear panel allows for fine adjustment of the angular pitch of the laser head
(Figure 12). This provides a fine range of ± 1.5°. Fine rotational control of the XL-80 is achieved by
turning the yaw adjustment knob. This gives an additional ± 1.5° adjustment.
XL-80
Adjusting this knob

will rotate the laser Yaw adjustment
vertically (pitch) knob
Figure 12
Straightness alignment procedure along a horizontal axis
The alignment procedure discussed in this section assumes that the optics are set up to measure
vertical straightness error along a horizontal axis as shown in Figure 13. The interferometer is the
and data capture

moving optic and the straightness reflector is the stationary optic. It will be necessary to fit the
straightness shutter to the laser.
3.9
Plan view
Axis of
movement
Straightness
interferometer
XL-80
Axis of
movement Straightness
Side view measurement
plane
XL-80 Straightness
interferometer
Straightness
reflector
Figure 13
Note: The alignment procedure for measuring horizontal straightness error along a horizontal axis is
very similar apart from the orientation of the optics and the straightness shutter.
1. Fix the straightness reflector to the machine in the desired position, fit a target to the centre of
the mirror and align the laser beam to the centre of the target by eye. Mount the straightness
reflector so that its longer edge is mounted vertically as shown in Figure 14. Make sure that it
and data capture
is mounted square to the laser beam (to within ± 2°). The straightness reflector should be at a
suitable distance from the moving straightness interferometer when the interferometer is at its
far end of the travel, i.e. nearest to the straightness reflector (at least 0.1 m (4 in) for short-range
straightness, and at least 1.0 m (40 in) for long-range straightness).
3.10
Straightness
reflector
Target
Figure 14
2. Rotate the straightness shutter so that the laser is outputting a reduced diameter beam as shown
in Figure 15. The smaller diameter beam makes it easier to see any misalignment.
Straightness
shutter
Reduced
beam Target
Figure 15
Note: Over long distances, alignment may be easier if the shutter is rotated to its full beam and
target position.
3. Position the straightness interferometer as close to the laser as possible and ensure it is
mounted square to the machine (to within ± 2°). Rotate the straightness interferometer’s face so
that the white target is on the right hand side as shown in Figure 16. Translate the interferometer,
and data capture

or the machine, until the beam hits the centre of the white spot on the target.
View from laser

3.11
Reduced beam on
white target
Figure 16
4. Drive the machine along the axis of travel away from the laser head until you see that the beam
starts to move off the target. Stop moving the machine when only half of the beam is still hitting
the white spot (Figure 17). Note how far off-centre the beam is.
Figure 17
5. Using the small knob at the rear of the left-hand side of the tripod stage, adjust the angular yaw
of the laser head so that the beam is swept back across the white target. Keep on moving the
beam until it is the same distance away from the centre on the opposite side as shown in
and data capture
Figure 18.
3.12
Figure 18
6. Now, using the larger knob midway along the left-hand side of the tripod stage, horizontally
translate the laser so that the beam is back on the horizontal centre line of the target
(Figure 19). Note the vertical position of the laser beam on the target.
Figure 19
7. Use the thumbwheel at the rear of the laser head to adjust its rotational pitch so that the beam
is swept vertically across the target. Adjust the thumbwheel until the beam is the same distance
from the centre of the target on the opposite side as shown in Figure 20.
Figure 20
8. Use the tripod's height adjustment wheel on the tripod's central spindle to wind the laser head up
or down until the beam is once again in the centre of the target (Figure 21). Note: At this point it
may be necessary to make another small horizontal rotational adjustment to get the laser beam
and data capture

back on the centre of the target.
3.13
Figure 21
9. Now resume driving the machine back along the axis of travel. Once again, stop the machine
when you can see that the laser beam has moved off the target. Repeat the laser alignment in
steps 4 to 11 until you have reached the end of the axis. When the end of the axis is reached,
move the machine back towards the laser to the beginning of the axis.
10. If the beam is no longer on the centre of the target, horizontally translate the laser so that the
beam is back on the vertical centre line of the target (Figure 22). Do not adjust the yaw knob.
Figure 22
11. Vertically translate the laser head to bring the beam back onto the centre of the target
(Figure 23). Note: At this point it may be necessary to make another small horizontal rotational
adjustment to get the laser beam back on the centre of the target.
Figure 23
12. Repeat horizontal and vertical beam adjustment until the beam remains in the centre of the
target over the entire length of axis travel.

13. Position the interferometer so that it is about half way along the axis of travel. Move the
and data capture
interferometer out of the beam path or rotate it so that the beam passes through the hole.
Re-adjust the reflector, so that the beam is hitting the target as shown in Figure 24.
3.14
Straightness
reflector
Target
Figure 24
14. When this is done, rotate the face of the straightness interferometer so that the laser beam
passes centrally through the right-hand side of the 'input' aperture as shown in Figure 25.
Outward
beam
Figure 25
15. The beams should be approximately equidistant from its centre and approximately 6 mm to the
right of the central vertical axis of the straightness reflector. Remove the target then rotate the
straightness interferometer to ensure the two beams appear vertically aligned on the mirror. At
and data capture

this stage it is useful to use a piece of card to track the beams (see Figure 26).
3.15
Straightness
reflector
Laser beams
6 mm
Figure 26
16. Ensure that the reflected converging beams are focused on the return aperture of the
interferometer and then strike the target on the laser's shutter. If the two beams are returned
above or below the centre of the shutter's target, as shown in Figure 27, adjust the tilt control
knob on the straightness reflector.
Adjust tilt control

knob on straightness
reflector
Figure 27
17. If the two return beams do not overlap, as shown in Figure 28, finely rotate the interferometer
face.
and data capture
Finely rotate the

3.16 interferometer face to
bring the two return
beams on top of one
another
Figure 28
18. If the two beams are returned to the left or to the right of the shutter's target centre, as shown in
Figure 29, translate the straightness reflector or the laser horizontally.
Translate straightness
reflector
Figure 29
19. Ensure that the reflected converging beams are focused on the return aperture of the
interferometer and strike the target on the laser's shutter as shown in Figure 30.
Straightness shutter
Reduced beam Both return beams

on target
Figure 30
20. Rotate the inner element of the straightness shutter so that the full measurement beam is
emitted and the return beam enters the laser's detector aperture as shown in Figure 31.
and data capture

3.17
Straightness shutter in
measurement position
Figure 31
21. Check the signal strength meter in the straightness data capture software. If the 'SIGNAL LOW'
or 'BEAM OBSTRUCTED' error is shown, check that the outgoing or return beams are not being
clipped by the interferometer. If they are, translate the interferometer to make sure the beam
passes though the input aperture as shown in Figure 32.
Return Outward
beam beam
Figure 32
22. Move the straightness interferometer along the measurement axis again observing the signal
strength meter. You should now get good signal strength over the full length of axis travel. If the
'SIGNAL LOW' or 'BEAM OBSTRUCTED' error appears, you will need to return to step 1 and
and data capture
repeat the above alignment procedure.
Note: When the moving optic is brought so close to the static optic that the spots at the reflector
3.18 start to overlap, there will be a loss in signal strength. This is normal and does not warrant any
adjustment. To achieve the minimum separation between optics, small vertical translations of the laser,
interferometer and reflector may be required.
23. Remove any remaining misalignment between the machine's axis of travel and the straightness
reflector's optical axis using the manual slope removal (see 'Manual removal of slope error'
later in this section) if:
• a straightness measurement accuracy is required which is better than that stated in the
specification:
• measurements are being performed on a machine, i.e. CMM, which cannot be moved to a
precise position. Therefore if a slope error is present, the large positional error will result in a
significant contribution to the straightness reading.
24. Capture straightness data (see 'Straightness software mode' later in this section).
Notes
Straightness alignment procedure along a vertical axis
The alignment procedure discussed in this section assumes that the optics are set up to measure
straightness along a vertical axis as shown in Figure 33. The interferometer and large retro-reflector
and data capture

form the moving optic assembly and the straightness reflector and turning mirror are stationary. This
procedure can be adapted to other straightness configurations for measurement of vertical axes. The
illustrations show a view looking from the laser direction unless the laser itself appears.
3.19
Side view Large
retro-reflectors View from
laser
Axis of movement
Straightness
interferometer
Measurement axis
Straightness
reflector
XL-80 Straightness
base
Vertical turning mirror
Straightness interferometer fixed to large retro-reflector, moving large retro-reflector/
straightness interferometer and stationary straightness reflector
Side view
Axis of movement Large retro-reflector
Straightness interferometer
Measurement axis
Straightness
reflector
XL-80 Laser
steerer Straightness
base
Fixed turning
mirror
Straightness measurement using laser steerer with fixed turning mirror
Figure 33
1. Set up the XL-80 on the tripod. Attach the straightness reflector and vertical turning mirror to the
straightness base as shown in Figure 34.

and data capture
3.20
Straightness
base
Straightness
reflector Vertical
turning mirror
Figure 34
2. Clamp the straightness base on the machine table directly below the intended location for the
large retro-reflector. If available, slots in the machine bed can be used to clamp the straightness
base. Make sure that the straightness base is square to the measurement axis. You may want to
use the machine's spindle as a reference. The long axis of the reflector should be parallel with
the axis in which deviations are to be measured, and the aperture of the vertical turning mirror
should face the laser as shown in Figure 34.
3. Clamp the large retro-reflector to the spindle or vertically-moving element of the machine using
the M8 adaptor from the optics mounting kit. The M8 adaptor can be screwed into any one of four
holes in the top of the large retro-reflector. The other end of the adaptor can then be screwed into
standard magnetic bases, Renishaw clamp blocks, mounting pillars or CMM probe heads. See
Figure 35.
Pillar
M8 adaptor
Large reflector
Straightness
interferometer
Figure 35
4. Orientate the large retro-reflector so that the target aperture is above the vertical turning mirror,
and the interferometer apertures are above the straightness reflector as shown in Figure 36.
Make sure that the large retro-reflector is square with the machine axis in roll, pitch and yaw.
and data capture

Lock the retro-reflector in position using the knurled locking nut on the M8 adaptor and check
that the spindle and clamping arrangement does not rotate.
View from
Side view laser 3.21
Large retro-reflectors
Axis of movement
Measurement axis
Straightness
reflector
XL-80
Straightness
base
Figure 36
Reduced Target
beam
Figure 37
6. Fit a target to the vertical turning mirror aperture facing the laser so that the white spot is at the
top. Vertically and horizontally translate the laser so that the beam strikes the target, as shown in
Figure 38, then remove the target from the vertical turning mirror.
and data capture

3.22
Straightness reflector Target Laser beam striking

centre of target
Figure 38
7. Fit a target to the input aperture on the large retro-reflector so that the white target is on the
inside as shown in Figure 39.
View from laser
Figure 39
8. Lower the large retro-reflector assembly until it is as close as possible to the vertical turning
mirror but you can still see the target. A small hand-held mirror may help in viewing the target.
Translate the large retro-reflector so that the laser beam is reflected by the vertical turning mirror
and data capture

to strike the middle of the target as shown in Figure 40. If you can not translate the large retro-
reflector, translate the machine bed, laser and/or straightness base assembly.
View from laser 3.23
Figure 40
9. Now remove the target from the large retro-reflector and place it on the straightness mirror as in
Figure 41. Translate the large retro-reflector to position the laser beam onto the target.
Target
Figure 41
10. Gradually raise the retro-reflector to the far end of travel in short stages, making sure that
the beam hits the target on the straightness mirror by adjusting the two control knobs on the
adjustable turning mirror as shown in Figure 42. Make accurate alignment onto the target at the
and data capture
top of the travel.
3.24
Control knob 1
Control knob 2
Point of rotation about

which adjustments are
The incoming beam made
from XL-80
Figure 42
Note: If there is not enough adjustment available, the laser is not aligned with a horizontal machine
axis. Align the laser with a horizontal axis by first using the procedure described in 'Straightness
alignment procedure for a horizontal axis'. Alternatively, if you are an experienced user, you may
wish to obtain a better coarse alignment by centralising the position of both adjustment knobs and
then rotating and tilting the laser until the laser beam strikes the centre of the target. Continue the fine
alignment as previously described.
11. Lower the large retro-reflector to the near end of travel. If necessary, translate the large retro-
reflector to position the laser back onto the target on the straightness mirror.
12. Repeat steps 10 and 11 until there is accurate alignment of the laser beam on the target at the
top and bottom of travel.
13. Now attach the straightness interferometer to the large retro-reflector. It is wise at this stage to
protect the straightness reflector from any falling screws! Rotate the straightness interferometer
to the position as shown in Figure 43.
and data capture

3.25
Figure 43
14. Return the retro-reflector to the mid travel point. Make sure that the beam passes into the retro-
reflector via the aperture and is reflected to the straightness interferometer, where it is split into
two diverging beams directed towards the straightness reflector as shown in Figure 44.
Alignment marks Tilt control knob
6 mm
Laser beams
Figure 44
15. Rotate the face of the straightness interferometer so that the two diverging beams strike the
'inner' half of the straightness reflector as shown in Figure 45. Ensure they are parallel to the
long axis of the mirror. It may be useful to use a card from this stage to track the beam paths.
and data capture
Side view
Large
3.26 retro-reflectors
Axis of movement
Straightness
interferometer
Measurement axis
Straightness
reflector
XL-80
Straightness
base
Figure 45
16. Adjust the tilt of the straightness reflector so that the two return beams pass into the return port
of the straightness interferometer.
Note: if the beams converge at a point on the axis through the centres of the apertures, but not on the
return port, further translation of the retro-reflector is required.
17. Finely rotate the straightness shutter's face so that the two return beams overlap on the targets
shutter as shown in Figure 46.
and data capture

3.27
Finely rotate the

interferometer face
to bring the two
return beams on
top of one another
Figure 46
18. Make sure that the return beam from the interferometer is reflected via the large retro-reflector
and the vertical turning mirror to the detector target on the laser straightness shutter as shown in
Figure 47. If the return beam is to either the left or right of the detector aperture, it may be
re-aligned by adjusting the tilt control of the reflector. If it is high or low, translate the large retro-
reflector or the straightness base, preferably using the machine's controller (or, in the last resort,
the laser).
To move the
beams vertically,
translate the large
retro-reflector or
straightness base
To move the beams

horizontally, adjust the
tilt control knob on the
reflector
Figure 47
19. Lower the retro-reflector to the near end of travel and make sure that the laser beam continues to
hit the target throughout the extent of travel. If deviation occurs, translate the large retro-reflector
or straightness base (preferably using the machine's controller) at the near end of travel and
rotate the control knobs on the vertical turning mirror at the far end of travel to ensure alignment.
20. Rotate the inner element of the straightness shutter so that the beam enters the detector
aperture as shown in Figure 48.

and data capture
3.28 Straightness
shutter
Laser detector
Measurement aperture
beam
Figure 48
21. Move the retro-reflector over the whole range of travel. If unacceptable signal loss is
experienced, repeat step 18 and if necessary repeat step 20 until adequate signal strength is
achieved over the whole range of travel.
22. Remove any remaining misalignment between the machine's axis of travel and the straightness
reflector's optical axis using the manual slope removal procedure (see 'Manual removal of
slope error' later in this section) only if:
• straightness measurement accuracy is required which is better than that stated in the
specification;
• measurements are being performed on a machine, which cannot be moved to a precise
position (e.g. if the positioning system is not connected). Therefore, if a slope error is present,
the large positional error will result in a significant contribution to the straightness reading.
23. Capture straightness data in accordance with 'Data capture' later in this section.
Manual removal of slope error
Slope error
and data capture

Slope error is a steady change in straightness reading as the straightness optic is moved along the
machine's axis of travel. This steady change is due to angular misalignment between the machine's
axis of travel and the straightness reflector's optical axis and is the result of imperfect alignment carried
out in order to setup the laser as in the previous procedures.
3.29
If straightness measurement accuracy is required which is better than that stated in the specification or
measurements are being performed on a machine (CMM or machine tool under manual control) which
cannot be moved to a precise position, the slope error should be removed.
The slope error should be reduced to better than 20 µm for short-range straightness or 100 µm for
long-range straightness. Any residual slope error can be removed during analysis using least squares
fit of the data.
When performing a squareness or parallelism measurement, any slope error on the first measurement
axis should be reduced to a lower value (100 µm) to ensure alignment can be achieved for the second
measurement axis.
Notes
Removal of slope error

To correct slope error, tilt the straightness reflector so that its optical axis becomes parallel to the
machine's axis of travel. The degree of tilt required is calculated in terms of a change in straightness
and data capture
reading. This procedure describes the rotation of the straightness reflector when the straightness
reflector and interferometer are at their greatest separation.
1. Datum the measurement reading with the straightness reflector and straightness interferometer
3.30 at their closest approach.
2. Measure and note the separation between the straightness interferometer and the straightness
reflector.
3. Move the machine so that the straightness reflector and interferometer are at their greatest
separation. Note the measurement reading as well as the distance travelled by the machine (see
Figures 49 and 50).
B A
Ro Datum
Figure 49
Ro
Datum
Figure 50
4. Adjust the tilt control of the straightness reflector so that the displayed reading changes to the
value calculated below:
and data capture

where:
3.31
Ro is the measurement reading obtained in step 3
A is the separation of the two optics at their closest approach recorded in step 2
B is the distance travelled by the machine and recorded in step 3

Notes:
You may wish to use estimates of values A and B, but this may result in having to repeat this
procedure several times.
If the distance travelled by the machine is small compared to the separation of the two optics at their
closest approach, the procedure requires a large change in reading, when the straightness reflector is
rotated, to achieve a small change in slope error.
5. During the adjustment of the reflector's tilt control, you may lose signal strength. This is caused
by the laser beam not being properly aligned with the axis of travel and the return beam clipping
on the straightness interferometer. If you do not lose signal strength, go straight to step 9.
6. Rotate the inner element of the straightness shutter so that the laser is outputting a reduced
diameter beam and the return beam is striking the target, as shown in Figure 51.
Note: If you are an experienced user, you may be able to regain signal strength by rotating and
translating the XL-80 without rotating the straightness shutter and hence causing a ‘beam break’.
Straightness
shutter
Reduced Returned
beam beams on
target
Figure 51
7. Rotate the laser head (horizontally for horizontal straightness and vertically for vertical
straightness) and translate the laser head (horizontally for horizontal straightness and vertically
for vertical straightness) to bring the beam back on to the centre of the shutter’s target. Check
and data capture
the outgoing and return beams pass though the aperture on the straightness interferometer
without clipping and the beams are symmetrical about the centre of the straightness reflector as
shown in Figure 52.
3.32
Tilt control knob Alignment marks
6 mm
1 : Input beams
2 : Output beams
Figure 52
8. Rotate the straightness shutter back to its measurement position and return to step 1.
9. Datum the display and move the optics to their furthest approach position and check the
new reading. If the reading is sufficiently small (typically better than 20 µm for short-range
straightness, 100 µm for long-range straightness), the axes are said to be aligned to within the
working tolerance.
10. If necessary repeat steps 1 to 9.
Straightness software mode
and data capture
3.33
Figure 53
As we proceed through this section, you will learn how to navigate the toolbar, how to setup the
software to capture data and how to use the various functions of data analysis.
Notes
Navigating the toolbar

and data capture
3.34
Figure 54
Notes
Checking the sign of the machine movement
Before capturing data, you must define a suitable sign convention. The example below shows a sign
convention covering both horizontal and vertical axes, but alternative conventions may be used if so
and data capture

desired (e.g. based on the machine's co-ordinate convention).
Check that the readings are of the correct sign as follows:

1. With the straightness interferometer positioned along the axis of test and stationary, gently push 3.35
the interferometer in the direction specified in the convention as being a positive deviation.
2. Check that the laser display reads an increasing positive value.
3. If this is not the case, change the sign by pressing the [Ctrl]+[-] keys or by clicking on the button
on the toolbar and check the sign convention again.
Whatever sign convention is used, it is important that it is recorded, particularly when separate
measurement results are to be compared (e.g. for squareness or parallelism measurement).
Horizontal axis -VE

Plan view
Bed Table
Direction of increasing target value

+VE Direction of positive
straightness error
Side view Direction of positive
straightness error
Direction of increasing
target value
+VE
Bed Table
-VE
Vertical axis
Direction of increasing Direction of increasing Direction
Side view target value target value of positive
straightness
error
Column Direction Column

of positive +VE
straightness
error -VE
-VE +VE
Figure 55
Preparing the machine prior to data capture

and data capture
3.36
Figure 56
Target / data capture setup
and data capture
3.37
Figure 56
Notes
Data capture
and data capture
3.38
Figure 57
Notes
Notes
Broken beam recovery
Figure 58
and data capture
3.39
Analysing results
and data capture
3.40
Figure 59
Notes
Removing the residual slope error
Residual slope error can be removed during analysis using least squares fit of the data. In analysis,
select least-squares fit, ‘close’ in the file properties box and then all data plot. This generates a graph
and data capture

plotted with the same data but the slope removed (see Figures 60 and 61).
3.41
Figure 60
and data capture
3.42
Figure 61
Notes
Factors affecting accuracy
Air turbulence:
and data capture

Mechanical vibration:
3.43
Slope error:
Optic error:
Optics not in correct position
Optics not fixed rigidly
Localised heat source
Thermal drift / reflector angle
Vibration in the reflector

Notes
and data capture
3.44
Introduction to squareness
measurement
4.1
Squareness optics
squareness measurement
The optical principles of squareness measurements are the same as those for straightness
measurements, but with the additional use of the optical square shown below. The optical square, used
Introduction to
only for squareness measurement, is a device for deflecting the beam through a precise 90° and is
used for at least one of the straightness measurements to allow the laser beam to be aligned along
each axis without touching the straightness reflector.
4.2 Squareness measurements are carried out by making straightness measurements along each of
the two nominally orthogonal axes of interest (as shown below), using the straightness reflector as
a common reference. The straightness reflector is neither moved (relative to the table), nor adjusted,
between the two straightness measurements. The two sets of straightness measurements can then be
compared and the out of squareness of the two axes calculated.
Optical square
Straightness
Plan view
reflector
Straightness Axis movement 1

interferometer (Moving spindle)
Optical square
XL-80
1ST AXIS MEASUREMENT
Optical square
Axis movement 2
(Moving spindle)
Plan view Straightness

reflector
Straightness
interferometer
XL-80
2ND AXIS MEASUREMENT

Setting up and aligning the laser system and capture straightness data for the first and second
measurement axes will allow you determine any out of squareness of the two axes as shown below.
Introduction to
Laser path through the optical square to straightness reflector
not aligned due to squareness error
4.3
Optical square
Plan view Straightness

reflector
Y axis captured second
X axis captured first
XL-80
Notes
Introduction to
4.4
Squareness measurement and data capture
5.1
Pre-test checklist
Squareness measurement
The squareness measurement kit

and data capture
The squareness measurement kit allows the measurement of axis squareness (perpendicularity).
It must be used in conjunction with the straightness measurement optics and also, when one axis
is vertical, the straightness accessory kit (refer to 'Section 3 - straightness measurement and
5.2 data capture' for details). If you have not already done so, it is advised that you perform and fully
understand straightness measurement before you proceed.
The squareness measurement kit (Figure 1) comprises:

• optical square (used to deflect the input beam through 90°);
• bracket (attached to the side of the optical square housing to accommodate the vertical
turning mirror from the straightness accessory kit);
• two clamp screws;
• two cap head screws.
Figure 1
Optical square
When using the optical square for squareness measurements along a vertical axis, the vertical turning
and data capture

mirror should be screwed to its side (as shown in Figure 2) using the bracket provided.
The vertical turning mirror can be fixed with its side aperture facing in the opposite direction to that of
the optical square, so that the two apertures face in the same direction, or so that it faces outward from
the optical square.
5.3
Figure 3
Figure 2
The optical square can also be used with the laser steerer and fixed turning mirror rather than the
vertical turning mirror (Figure 3).
Figure 3
The optic movement

and data capture
Optical square
5.4
Straightness
interferometer
Axis of movement
(moving spindle)
Straightness
reflector
Figure 4
Notes
Notes
Positioning the laser
Figure 5
and data capture
5.5
Laser alignment procedures

Laser setup prior to beam alignment

and data capture
It is helpful to ensure that the laser is reasonably aligned, by eye, with the axis along which you wish
to capture data (Figure 6). Set all laser stage adjustments into the centre of the range, with the tripod's
vertical adjustment away from the end of its travel, before roughly aligning the laser by moving or
5.6 adjusting the tripod only (to ensure all available fine adjustment is preserved for later use).
Figure 6
Figure 6
IMPORTANT:
It is important to establish, before capturing data down the first axis, that each optic can be placed in
suitable approximate positions to complete both the capture down the first axis and the second axis.
Establish that the optical square can be clamped with some available adjustment at the intersection
of the two axes. Also establish that the straightness reflector can be clamped when adjusted off the
end of the axis. In the case of the short range optics straightness reflector must be 100mm off the end
of the furthest travel of the straightness interferometer and in the case of long range this distance is
1m. Finally, establish that the moving straightness interferometer can be moved down the two axes
in alignment with the laser and optical square then optical square to straightness mirror with some
available adjustment.
and data capture

Bubble level 5.7
Figure 7
Notes
Golden rules of alignment

When the moving optic is close to the laser end

and data capture
When the moving optic is close to the laser end, as shown in Figure 8, only horizontal 'translation'
adjustments should be made (up and down or side-to-side).
5.8 Optical square

Axis of movement 2
(moving spindle)
Plan view
Straightness
interferometer
Straightness
reflector
XL-80
Figure 8
The tripod stage facilitates both coarse and fine horizontal translation adjustment of the XL laser.
Coarse translation is by means of a quick translation lever on the side of the stage which gives a
coarse translation range of approximately 42 mm (1.7 in).
For fine horizontal adjustment (perpendicular with respect to the laser beam axis), rotate the
translation control knob on the XL laser mounting stage as shown in Figure 9. The stage has a fine
translation range of approximately 30 mm (1.2 in).
The XL laser and mounting stage can be freely rotated through 360° if the stage release lever is in its
mid position.
Fine rotational control of the XL laser is achieved by turning the yaw adjustment knob (Figure 10). This
gives an additional ± 1.5° adjustment.
Adjusting this knob

will translate the
laser horizontally
(side to side)
Adjusting this rotation

lever will translate the
laser vertically (up and
down)
Figure 9 Figure 10
When the moving optic is moved to the straightness reflector end
When the moving optic is moved to the straightness reflector end, as shown in Figure 11, 'rotational'
and data capture

adjustments should be made (side swing or vertical swing). These adjustments can be made to the
laser/tripod setup (Figure 12).
Optical square
Axis of movement 2 5.9
(moving spindle)
Plan view
Straightness
interferometer
Straightness
reflector
XL-80
Figure 11
A knob set in the XL-80's rear panel allows for fine adjustment of the angular pitch of the laser head
(Figure 12). This provides a fine range of ± 1.5°. Fine rotational control of the XL-80 is achieved by
turning the yaw adjustment knob. This gives an additional ± 1.5° adjustment.
XL-80
Adjusting this knob

will rotate the laser Yaw adjustment
vertically (pitch) knob
Figure 12
Notes
and data capture
5.10
Horizontal-to-horizontal squareness alignment procedure
This section describes the alignment procedure for a horizontal-to-horizontal measurement with the
and data capture

laser in the same position when measuring both axes (see Figures 13 and 14).
Optical square
5.11
Plan view
Straightness
Straightness Axis of movement reflector
interferometer (moving spindle)
XL-80
Figure 10
First axis movement
Figure 13
Optical square
Axis of movement
(moving spindle)
Plan view
Straightness
interferometer
Straightness
reflector
XL-80
Second axis movement
Figure 14
Alignment along the first measurement axis

1. Position the optical square at the intersection of the two measurement axes, so that it is flat
and data capture
on the table with one aperture facing the laser and the other facing the far end of the second
measurement axis as shown in Figure 15.
Optical square
5.12
Plan view
XL-80
Figure 15
Note: The optical square must be mounted so that its largest surface is parallel to the plane through
the two straightness axes. This can be checked with the use of a d.t.i. clock.
2. Set up the laser on the tripod at the correct height above the table (approximately 48 mm (2 in)
for horizontal-to-horizontal squareness measurements). Adjust the height and the lateral position
of the laser so that the laser beam strikes the middle of the input window of the optical square
approximately 6 mm above the centre line as shown in Figure 16. A target can be used.
Alignment marks Reduced laser beam

6 mm
Figure 16
3. Position the straightness reflector beyond the end of travel of the second axis.
and data capture

5.13
Straightness
shutter
Reduced beam
Figure 17
5. Fasten the straightness interferometer to the machine spindle and position the straightness
interferometer as close to the laser as possible. Rotate the straightness interferometer’s face so
that the white target is at the top as shown in Figure 18. Translate the machine until the beam
hits the white spot on the target.
Reduced beam on
white target
Figure 18
6. Align the laser so that the laser beam strikes the centre of the target over the length of axis
travel (refer to 'Straightness alignment along a horizontal axis' contained in 'Section 3 -
straightness measurement and data capture').
7. When the laser beam is aligned, remove the interferometer from the beam path and adjust the
laser (using only translation movements) so the output beam strikes the middle of the input
window of the optical square approximately 6 mm above the centre line as shown in Figure 16
previously.
8. Adjust the straightness reflector so that the beam from the optical square strikes it centrally on its
optical face, approximately 6 mm (0.24 in) above the longitudinal centre line as shown in
Figure 19. A target can be used.
and data capture
Laser beam
5.14
6 mm
Mounting pillar
Straightness reflector Straightness
mounted to pillar using mounting base
clamping block
Figure 19
9. Re-position the straightness interferometer between the laser and the optical square as shown in
Figure 20.
Optical square
Plan view
Straightness
Straightness Axis of reflector
interferometer movement
XL-80
Figure 20
10. Translate the machine's spindle until the beam hits the interferometer's target as shown in
Figure 21. Check that the laser is still aligned by ensuring that the beam still strikes the centre
of the target over the length of axis travel. If it does not, re-align the laser as described from the
and data capture

start of this section.
Reduced beam on
white target
5.15
Figure 21
11. Rotate the face of the straightness interferometer so that the beam passes through the upper
side of the ‘input’ aperture as shown in Figure 22. The beam will now emerge as two horizontally
diverging beams which pass through the optical square to the straightness reflector as shown in
Figure 23.
Outward beam
Small aperture White target
Return beam
Figure 22
Optical square
Plan view
Straightness
Straightness Axis of reflector
interferometer movement
XL-80
Figure 23
12. Check that the two diverging beams from the interferometer strike the upper half of the reflector
equidistant from its centre and approximately 6 mm (0.24 in) above its central longitudinal axis
as shown in Figure 24. Use the markings on the straightness reflector housing immediately next
and data capture
to the 'window' as a reference.

5.16
6 mm
1 : Input beams
2 : Output beams
Figure 24
13. Ensure that the reflected converging beams pass though the optical square and are focused on
the aperture of the interferometer and then strike the target on the laser's shutter as shown in
Figure 25.
Straightness
shutter
Reduced beam Reduced beams on

target
Figure 25
14. If the two return beams do not overlap, as shown in Figure 26, finely rotate the face of the
interferometer until this is achieved.
and data capture

Finely rotate the
interferometer face
to bring the two
return beams on
top of one another 5.17
Figure 26
15. If the two beams are returned above or below the centre of the shutter's target, as shown in
Figure 27, vertically translate the straightness reflector.
Translate the
straightness reflector
Figure 27
16. If the two beams are returned to the right or to the left of the centre of the shutter's target, as
shown in Figure 28, adjust the tilt control knob on the straightness reflector.
Adjust the tilt

control knob on the
Figure 28
17. When the combined returning beams strike the centre of the shutter's target, rotate the inner
element of the straightness shutter so that the full measurement beam is emitted and the return
beam enters the laser's detector aperture as shown in Figure 29.
and data capture
5.18
Straightness
shutter
Laser detector
Measurement aperture
beam
Figure 29
18. Move the straightness interferometer along the measurement axis, again observing the signal
strength meter. You should now get constant signal strength over the full length of axis travel. If
the 'SIGNAL LOW' or 'BEAM OBSTRUCTED' error appears, you will need to repeat the laser
alignment so that the laser beam strikes the centre of the target over the length of axis travel.
Note: If necessary, remove any remaining misalignment between the machine's axis of travel and the
straightness reflector's optical axis in accordance with 'Manual removal of slope error' later in this
section.
Notes
19. Before taking any readings, confirm that the measurement sign convention is correct. With the
straightness interferometer positioned along the axis of test and remaining stationary, gently
push the interferometer in the specified direction of a positive error and confirm that the laser
and data capture

display reads progressively positive. If it doesn't, change the sign using the [Ctr]+[-] keys or the
button on the toolbar and repeat the check again. Refer to 'Checking sign convention' later in
this section.
20. Capture straightness data for the first measurement axis (Figure 30). See 'Section 3 -
straightness measurement and data capture' for instructions if required. 5.19
Figure 30
21. When straightness data has been captured it must be saved as a recognisable file i.e. save it as
the axis you are measuring e.g. 'y axis'.
Alignment along the second measurement axis

CAUTION: On no account should the straightness reflector be adjusted in any way. The alignment and
and data capture
tilt setting of this element form the reference from which all squareness calculations are made.
1. Rotate the body of the straightness interferometer through 90° and move the machine spindle to
5.20 bring the interferometer in line with the second measurement axis as shown in Figure 31. Make
sure that the interferometer is square to this axis.
Plan view
Optical square
Axis of movement
(moving spindle)
Straightness
interferometer
Straightness
reflector
XL-80
Figure 31
2. The system should be already aligned for the second measurement axis. Move the straightness
interferometer along the second measurement axis, observing the signal strength meter. If you
get enough signal strength over the full length of axis travel with no beam break, check the sign
convention and capture data.
3. If the 'SIGNAL LOW' or 'BEAM OBSTRUCTED' error appears, check the alignment as described
below.
Note: When the interferometer is brought very close to the reflector (100 mm short range and 1 m long
range) there will be a loss in signal strength. This is normal and no adjustment is required.
4. Check that the outgoing and return laser beams pass though the apertures on the straightness
interferometer without clipping as shown in Figure 32. If the beams are being clipped, translate
the interferometer vertically and horizontally by moving the machine spindle.
and data capture

Outward beam
5.21
Small aperture White target
Return beam
Figure 32
5. Rotate the inner element of the straightness shutter so that the laser is outputting a reduced
diameter beam and the return beam is striking the target, as shown in Figure 33.
Straightness
shutter
Reduced beam Reduced beams on

target
Figure 33
6. Check that the two return beams strike the centre of the shutter's target. Translate the laser to
correct and re-check the interferometer as in step 4 above.
7. Check that the two return beams overlap one another on the shutter target. If they do not, finely
rotate the face of the interferometer. Finely rotate the interferometer about its vertical axis.
8. Rotate the straightness shutter back to its measurement position and check the sign convention.
Refer to 'Checking sign convention' later in this section.
9. Capture data for the second measurement axis (Figure 34).

and data capture
5.22
Figure 34
10. When straightness data has been captured it must be saved as a recognisable file i.e. save it as
the axis you are measuring e.g. 'x axis'.
Notes
Vertical-to-horizontal squareness measurement alignment
This section describes the alignment procedure for a vertical-to-horizontal configuration on a moving
and data capture

spindle machine as shown in Figures 35 and 36. For other configurations, see the squareness
configurations in the XL-80 help.
5.23
Large retro-
Axis of movement
reflector
(Vertical)
Straightness
interferometer
Side view
XL-80
Vertical
Straightness turning Optical square
reflector mirror
First axis movement
Figure 35
Side view
Axis of movement
(Moving spindle)
Straightness XL-80
interferometer
Straightness
reflector
Second axis movement
Figure 36
Alignment along the first measurement axis

1. Ensure that the tripod stage's horizontal adjustment is translated to the left-hand side when
and data capture
looking at the XL-80 from behind (approximately 20 mm from its end). This allows the laser to be
translated over to the right to strike the straightness reflector when measuring the second axis.
Mount the vertical turning mirror to the optical square, using the mounted bracket provided, as
shown in Figure 37.
5.24
Vertical turning
mirror bracket
Optical square
Figure 37
Notes
2. Locate the vertical turning mirror and optical square on the machine table at the intersection
of the two measurement axes as shown in Figure 38. The optical square should be positioned
at the laser end of the horizontal axis and the straightness reflector at the far end. Ensure the
and data capture

straightness reflector is positioned where it can be clamped with some adjustment for the later
stages of the alignment. The side aperture of the vertical turning mirror faces the laser and the
side aperture of the optical square should face the intended position of the straightness reflector.
Note that this means that the straightness reflector will be offset from the line of the laser beam
The top apertures of both the vertical turning mirror and the optical square should face upwards.
5.25
Important: The squareness optic needs to be positioned parallel to the plane of the two axes to
an accuracy as shown in 'Factors effecting accuracy' later in this section. This is necessary in
order to ensure the accuracy of the data captured.
Side view
Vertical turning XL-80

mirror bracket
Optical square
Figure 38
Notes
3. Fit a target to the vertical turning mirror aperture facing the laser so that the white spot is on the
right hand side. Target the beam with the laser as shown in Figure 39.
and data capture
5.26
Laser beam on target
Vertical turning
mirror bracket
Figure 39
4. Remove the target from the vertical turning mirror without moving the optical square. Fit the
target to the input aperture on the large retro-reflector so that the white target is on the inside as
shown in Figure 40.
View from laser
Figure 40
5. Clamp the large retro-reflector to the spindle or vertically moving element of the machine using
the M8 adapter from the optics mounting kit. The M8 adapter can be screwed into any one of four
threaded holes in the top of the large retro-reflector. The other end of the adapter can then be
and data capture

screwed into standard magnetic bases, Renishaw clamp blocks, mounting pillars or CMM probe
heads. Orientate the large retro-reflector so that the target aperture is above the vertical turning
mirror, and the interferometer aperture is above the optical square as shown in Figure 41. Make
sure that the large retro-reflector is square with the machine axis in roll, pitch and yaw. Lock the
retro-reflector in position using the knurled locking nut on the M8 adapter and check that the
5.27
spindle and clamping arrangement does not rotate.
Large retro-reflector
Axis of movement
(Vertical)

XL-80
Optical square
Figure 41
6. Lower the large retro-reflector assembly until it is as close as possible to the squareness optic
but so that you can still see the target. A small hand-held mirror may help in viewing the target.
Translate the large retro-reflector so that the laser beam is reflected by the vertical turning mirror
to strike the middle of the target.
7. Now remove the target from the large retro-reflector and place it on the straightness mirror as
shown in Figure 42. Translate the large retro-reflector to position the laser beam onto the target.
and data capture
5.28
Figure 42
8. Gradually raise the retro-reflector to the far end of travel in short stages, making sure that
the beam hits the target on the squareness optic by adjusting the two control knobs on the
adjustable turning mirror as shown in Figure 43. Make accurate alignment onto the target at the
top of the travel.
Control knob 1
Control knob 2
Point of rotation about

which adjustments are
The incoming beam made
from XL-80
Figure 43
9. Lower the large retro-reflector to the near end of travel. If necessary, translate the large retro-
reflector to position the beam back onto the target on the squareness mirror.
10. Repeat steps 9 and 10 until there is accurate alignment of the laser beam on the target at the top
and data capture

and bottom of travel.
11. Move the retro-reflector to its mid point of travel and remove the target from the squareness
optic. A beam will be emerging from the optic towards the straightness reflector. Reposition the
straightness reflector to put the beam on the target as shown in Figure 44. Note: It is useful to
use a white card to track the beams around all optics from this stage on. 5.29
Figure 44
Notes
12. Now attach the straightness interferometer to the large retro-reflector (Figure 45). It is wise
at this stage to protect the squareness optic from any falling screws! Rotate the straightness
interferometer to the position as shown in Figure 44.
and data capture
5.30
Figure 45
13. Rotate the face of the straightness interferometer so that the two diverging beams strike
the 'inner' half of the optical square's aperture as shown in Figure 46. The beams should be
approximately equidistant from its centre. Use the markings on the optical square's housing
immediately next to the 'window' as a reference. If the beams do not strike the aperture in
the correct position, translate the large retro-reflector to achieve the correct alignment. Large
translations or the laser beam being clipped usually indicate that the large retro-reflector or the
optical square is not square with the machine’s axis.
Figure 46
14. Take the target off the straightness reflector. The beams should be approximately equidistant
from its centre and approximately 6 mm to the left of the central longitudinal axis of the
straightness reflector. Use the markings on the straightness reflector housing immediately next to
and data capture

the 'window' as a reference. See Figure 47.
5.31
Laser beams
6 mm
Figure 47
15. Adjust the tilt knob and, if needed, slightly translate the squareness reflector so that the
two converging return beams pass back via the optical square to the return aperture of the
interferometer as shown in Figure 48.
Input aperture
Straightness
interferometer
To straightness reflector
Return beam
(from straightness reflector)
Return beam White target

Beam input
to laser from laser
Figure 48
16. Ensure the return beam from the straightness reflector is reflected through the straightness
interferometer, large retro-reflector and turning mirror back to the target on the laser shutter as
shown in Figure 49.
and data capture
Large retro-
5.32 reflector Axis of
movement
Straightness (Vertical)
interferometer
Return beam
XL-80
Vertical
Straightness turning
reflector mirror Optical square9
Figure 49
17. If the two return beams do not overlap, as shown in Figure 50, finely rotate the interferometer
face.
Finely rotate the

interferometer face to
bring the two beams on
top of one another
Figure 50
18. If the two beams are returned above or below the centre of the shutter's target, as shown in
Figure 51, adjust the tilt control knob on the straightness reflector.
and data capture

5.33
Adjust tilt control knob on
Figure 51
19. If the two beams are returned to the right or to the left of the centre of the shutter's target, as
shown in Figure 52, translate the straightness reflector horizontally.
Translate straightness
reflector
Figure 52
20. Rotate the inner element of the straightness shutter so that the beam enters the detector
aperture as shown in Figure 53.
Straightness shutter in
measurement position
Figure 53
21. In order to ensure that there will be acceptable signal strength when the second axis is checked,
complete the final alignment of the laser beam to the axis of travel of the machine by manual
removal of slope (see 'Manual removal of slope error' later in this section). Check that the
straightness readings are of the correct sign convention (see 'Checking sign convention' later
in this section).
22. Capture data for the first measurement axis.
Alignment along the second measurement axis

and data capture
CAUTION: On no account should the straightness reflector be adjusted in any way. The alignment and
tilt setting of this element form the reference from which the squareness calculations are made.
5.34
1. Remove the optical square and vertical turning mirror from the machine bed. Remove and
disassemble the large retro-reflector and straightness interferometer.
in Figure 54. The smaller diameter beam may make it easier to see any misalignment.
Straightness shutter
Reduced beam
Target
Figure 54
3. The laser will be offset from the straightness reflector by half of the combined widths of the
vertical turning mirror and the optical square. Important: Do not use a target on the straightness
reflector in this instance as to do so will definitely change the angle of the mirror and affect the
squareness value obtained from the analysis Horizontally translate the laser head so that the
laser beam strikes the middle of the input window approximately 6 mm to the right of the centre
line as shown in Figure 55. If you run out of horizontal travel, you will need to move the tripod.
Straightness
reflector
Laser beam
6 mm
Figure 55
4. Attach the straightness interferometer to the moving spindle, using the optics mounting kit and/
or a suitable clamping arrangement. Position the straightness interferometer as close to the laser
as possible. Rotate the straightness interferometer’s face so that the white target is on the right
and data capture

hand side as shown in Figure 56. Translate the machine until the beam hits the white spot on the
target.
Reduced beam
on white target 5.35
Figure 56
5. The beam will normally strike the target over the length of travel because of the alignment to the
first axis. If not, adjust the laser alignment. Refer to ‘Straightness alignment procedure along a
horizontal axis’ contained in 'Section 3 - straightness measurement and data capture'.
6. Rotate the straightness interferometer to allow the beam through. The emerging two
beams should strike the straightness mirror and be seen returning through the straightness
interferometer as shown in Figure 57. Slight adjustment by translation may be required of both
the laser straightness interferometer.
Straightness
reflector
Return Outward
beam beam
Laser
beams
6 mm
Figure 57
7. Check that two return beams strike the centre of the shutter's target. If the beams are horizontally
or vertically misaligned, translate the laser head and recheck the position of the beams on the
straightness interferometer and straightness reflector so that no clipping is observed and the
and data capture
beams hit the optics in the correct place as in Figure 58.
5.36
Horizontally or
vertically translate
the laser
Figure 58
8. Check that the two return beams overlap one another on the shutter target. If they do not, finely
rotate the face of the interferometer then finely rotate of the interferometer about its vertical axis
(Figure 59).
Finely rotate the

interferometer
face to bring the
two return beams
on top of one
another
Figure 59
9. Rotate the straightness shutter back to its measurement position (Figure 60).
Straightness
shutter in
measurement
position
Figure 60
10. Move the straightness interferometer along the measurement axis, again observing the signal
strength meter. You should now get good signal strength over the full length of axis travel. If the
'SIGNAL LOW' or 'BEAM OBSTRUCTED' warning appears, repeat from step 5.
and data capture

Note: When the moving optic is brought so close to the static optic that the spots at the reflector start
to overlap, there will be a loss in signal strength. This is normal and does not warrant any adjustment.
To achieve the minimum separation between optics, small vertical translations of the laser and 5.37
interferometer may be required.
11. Check that the straightness readings are of the correct sign convention. Refer to 'Checking the
sign convention' later in this section.
12. Capture data for the second measurement axis.
Notes
Manual removal of slope error

Slope error
and data capture
Slope error is a steady change in straightness reading as the straightness optic is moved along the
machine's axis of travel. This steady change is due to angular misalignment between the machine's
axis of travel and the straightness reflector's optical axis and is the result of imperfect alignment carried
out in order to setup the laser as in the previous procedures.
5.38
When performing a squareness measurement, any slope error on the first measurement axis
should be reduced to a lower value (100 µm) to ensure alignment can be achieved for the second
measurement axis.
Removal of slope error
To correct slope error, tilt the straightness reflector so that its optical axis becomes parallel to the
machine's axis of travel. The degree of tilt required is calculated in terms of a change in straightness
reading. This procedure describes the rotation of the straightness reflector when the straightness
reflector and interferometer are at their greatest separation.
1. Datum the measurement reading with the straightness reflector and straightness interferometer
at their closest approach.
2. Measure and note the separation between the straightness interferometer and the centre of the
optical square. Add this to the distance from the centre of the optical square to the straightness
reflector.
3. Move the machine so that the straightness reflector and interferometer are at their greatest
separation. Note the measurement reading as well as the distance travelled by the machine.
4. Adjust the tilt control of the straightness reflector so that the displayed reading changes to the
value calculated below. See Figures 61 and 62.
where:
Ro is the measurement reading obtained in step 3
A is the separation of the two optics at their closest approach recorded in step 2
B is the distance travelled by the machine and recorded in step 3

Notes:
You may wish to use estimates of values A and B, but this may result in having to repeat this procedure
several times.
If the distance travelled by the machine is small compared to the separation of the two optics at their
closest approach, the procedure requires a large change in reading, when the straightness reflector is
rotated, to achieve a small change in slope error.
and data capture
A2
5.39
A1
Datum
B
A = A1 + A2
Ro
Figure 61
Ro
Datum
A2
A1
Figure 62
5. During the adjustment of the reflector's tilt control, you may start to lose signal strength. This is
caused by the laser beam not being properly aligned with the axis of travel and the return beam
clipping on the straightness interferometer. If you do lose signal strength, use the laser rotation
and data capture
adjustment (horizontally for horizontal straightness and vertically for vertical straightness) to
see more strength on the strength meter. It may well be possible to continue with the slope error
correction, possibly with further beam strength corrections. If signal strength is ok, proceed to
step 9.
5.40 6. Rotate the inner element of the straightness shutter so that the laser is outputting a reduced
diameter beam and the return beam is striking the target as shown in Figure 63.
Straightness
shutter
Returned beams
Reduced beam on target
Figure 63
7. Rotate the laser head (horizontally for horizontal straightness and vertically for vertical
straightness) to bring the beam back onto the centre of the shutter’s target. Check the outgoing
and return beams pass though the aperture on the straightness interferometer without clipping
and the beams are symmetrical about the centre of the straightness reflector as shown in Figure
64.
6 mm
1 : Input beam
2 : Output beam
Figure 64
8. Rotate the straightness shutter back to its measurement position and return to step 1.
9. Datum the display and move the optics to their furthest approach position and check the new
reading. If the reading is sufficiently small (typically better than 100 µm), the axes are said to be
aligned to within the working tolerance.
10. If necessary repeat steps 1 to 9.
Notes
and data capture
5.41
Checking sign convention

1. Before data capture takes place, you must specify a suitable sign convention. The sign
and data capture
convention defined within the software is as shown in Figures 65 and 66 below.
Direction of positive
displacement of the
straightness interferometer
5.42
Direction of positively
increasing target positions
Figure 65 (Sheet 1)
Figure 65 (Sheet 2)
and data capture
5.43
2. Using the convention shown above, the calculated squareness error will be positive if the angle
between the two axes is greater than 90° as shown in Figure 66.
and data capture
Y axis (optic)
5.44
Y axis (machine)
Positive sign
squareness error
The 90° angle

defined by the
optical square
X axis
(optic and machine)
Optical square
Figure 66
Calculating squareness
Configuring the optical square
and data capture

1. In the analysis software, the figure from the white label inside the squareness optic needs to be
entered into the software as shown in Figure 67 below.
5.45
Figure 67
Producing the squareness data

1. The two files to use for calculating squareness must be opened from within the analysis section
of the software. Open one of the files then select squareness analysis and open the second
and data capture
file by selecting ‘change’ from the second window. The squareness value appears in the green
figures at the foot of the graphs that are then drawn (see Figure 68).
5.46
Figure 68
Factors affecting accuracy
The same factors which affect the accuracy of straightness measurements will also affect the accuracy
and data capture

of squareness measurements. Please refer to 'Section 3 - straightness measurement and data
capture' for factors affecting accuracy.
The angular alignment of the optical square is also important.
5.47
Angular alignment of optical square
The optical square must be mounted so that its largest surface is parallel to the plane through the two
straightness axes as shown in Figure 69.
Noncritical alignments
Axis of Axis of
motion motion
Figure 65
Noncritical alignments
Figure 69
Angular misalignment to this plane will lead to a squareness measurement error as follows:
Misalignment over small pads (40 mm) Misalignment over large pads (140 mm) Measurement
µm µm error
(µm/m)
12 40 0.09
23 81 0.3
68 203 2
118 407 8
349 1222 78
698 2443 305
Angular alignment of the square within the measurement plane is less critical. Misalignments of up to
± 2.5° are acceptable.
Notes
and data capture
5.48

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Renishaw plc T +44 (0)1453 524524
New Mills, Wotton-under-Edge, F +44 (0)1453 524901
Gloucestershire, GL12 8JR E uk@renishaw.com
United Kingdom
www.renishaw.com
For worldwide contact details,

please visit our main website at
www.renishaw.com/contact
*H-2000-1097-01*

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Training manual

XL-80 laser system training course manual

Renishaw part no: H-2000-1097-01-A

Issued: March 2009

1.0 Before you begin

Disclaimer ..................................................................................................................... 1.2

2.0 Introduction to straightness measurement

Straightness optics ....................................................................................................... 2.2

3.0 Straightness measurement and data capture

Pre-test checklist ......................................................................................................... 3.2

Preparing the machine prior to data capture .......................................................... 3.36

4.0 Introduction to squareness measurement

Squareness optics ....................................................................................................... 4.2

5.0 Squareness measurement and data capture

Pre-test checklist .......................................................................................................... 5.2

RENISHAW HAS MADE CONSIDERABLE EFFORTS TO ENSURE THE CONTENT OF THIS

apply innovation™ is a trademark of Renishaw plc.

Before you begin

FDA compliance (USA) – complies with 21CFR1040.10 and 1040.11

Rotating the shutter

There are no user-serviceable parts inside Renishaw XL laser system

Ensure that you read and understand the XL laser measurement

When setting up and mounting Renishaw XL calibration products, beware of pinch

Exercise extreme caution if Renishaw XL calibration products are to be mounted to

If it is necessary to remove or disable any guards or safety features on the machine

XL laser power supply unit

Before you begin

Aims of the course

The aims of the course are:

Objective of the course

Plan view 2.3

OPTIC ACTING AS A LINEAR REFLECTOR IN THE NON-MEASUREMENT PLANE

Axis of movement Straightness

OPTIC ACTING AS TWO MIRRORS IN THE MEASUREMENT PLANE

The straightness measurement kit comprises:

3.2 • a straightness interferometer.

and data capture

• straightness shutter - a special shutter assembly for the XL laser to accommodate

• vertical turning mirror - used particularly for vertical axis straightness;

Fixed mirror Beam steerer

Alternative to vertical turning mirror

The machine setup

The optic movement

Laser alignment procedures

Laser setup prior to beam alignment

and data capture

Adjusting this knob

Adjusting this rotation

When the moving optic is moved to the straightness reflector end

laser/tripod setup (Figure 12).

Adjusting this knob

and data capture

and data capture

View from laser

and data capture

target over the entire length of axis travel.

and data capture

Adjust tilt control

Finely rotate the

Reduced beam Both return beams

and data capture

repeat the above alignment procedure.

and data capture

Axis of movement Large retro-reflector

5.0 Squareness measurement and data capture