NIVELplane 2.020 30 40 50

M A D E T O M E A S U R E

User Manual

Leica Geosystems AGMönchmattweg 5CH-5035 Unterentfelden (Switzerland)Phone +41 62 737 67 67, Fax +41 62 723 07 34

II.2000 714 653 NIVELplane 2.0 3

Copyright © 2000 Leica Geosystems AG, Unterentfelden,Switzerland

All rights reserved. No part of this Hardware Guide may bereproduced in any way, or by any means, without permission inwriting from Leica.

Leica Geosystems AGMönchmattweg 5CH-5035 UnterentfeldenSwitzerland

Leica makes no express or implied warranty of any kind, includ-ing, but not limited to, the implied warranties of merchantabilityand fitness for a particular purpose, with regard to the programmaterial contained herein.

TrademarksProduct names mentioned herein are used for identificationpurposes only and may be trademarks and/or registeredtrademarks of their respective companies.

This Hardware Guide contains important safety directions aswell as instructions for setting up and operating the equip-ment. Read carefully through this Hardware Guide beforeswitching on the system.

Meaning of Symbols

The symbols used throughout this Hardware Guide have thefollowing meanings:

DANGER:Indicates an imminently hazardous situation which, if not avoid-ed, will result in serious injury or death.

WARNING:Indicates a potentially hazardous situation which, if not avoided,may result in injury or death.

CAUTION:Indicates a potentially hazardous situation which, if not avoided,may result in minor or moderate injury and/or appreciablematerial, financial and environmental damage. The symbol isalso used to alert against unsafe manipulations.

Important paragraphs which must be adhered to in practice asthey enable the product to be used in a technically correct andeffective manner.

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Table of Contents

1.0 The NIVELplane system 71.1 NIVELplane applications 81.2 System requirements 81.3 Installing NIVELplane onto your computer 9

1.3.1 Installing NIVELplane under Windows 98 and NT 101.3.2 Installing NIVELplane under Windows 95 13

1.4 Installing the remote control I-POINT 141.4 .1 Installation under Windows 95/98 141.4.2 Installation under Windows NT 151.4.3 Command keys of the I-Point device 171.4.4 Activating the remote control for use with NIVELplane 17

1.5 Sensor configurations RS232 / RS485 191.5.2 RS485 configuration 201.5.1 RS232 configuration 20

1.6 Sensor settings 211.6.1 Sensor address 211.6.2 Average function (arithmetic mean) 21

1.7 Sensor configuration with the program NIVELtool 221.7.1 Checking the sensor communication 241.7.2 Adjusting the offset parameters (zero point) 24

2. 0 Measurement procedures 292.1 Reference sensor for differential measurements 292.2 Sensor base plate for flatness measurements 342.3 Possible error sources 35

2.3.1 Dust and particles 362.3.2 Temperature influence in the measurement environment 362.3.3 Sensor warm-up time 372.3.4 Inversion of the sensor during a measurement 382.3.5 Temperature drift of the sensor (zero point stability) 39

2.4 Preparing the measurement object 402.4.1 Surfaces of static objects 402.4.2 Flatness and straightness deviation 432.4.3 Deflection of moving components 462.4.4 Levelness or absolute tilt measurements 47

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3.0 First steps with NIVELplane 493.1 File management 51

3.1.1 Creating a master startup file (parameter file) 523.2 Project settings and parameters 52

3.2.1 Project Administration 533.2.2 Project settings 553.2.3 Project units 59

3.3 View 603.3.1 Measurement grid 603.3.2 Sensor values 613.3.3 Sensor stability 623.3.4 Toolbar 633.3.5 Status Bar 64

3.4 Measurement 643.4.1 Flatness Mode 643.4.2 Angle Mode and Leveling 673.4.3 Sound 693.4.4 Autoscan 693.4.5 Clear measurement data 70

3.5 Data analysis 713.5.1 Common graphics functionality 713.5.2 Adjusted height deviations 743.5.3 Profiles 753.5.4 3D Heights 763.5.5 Surfaces 773.5.6 Report 783.5.7 Adding your company logo to the report template 803.5.8 Report paper size 80

4.0 Calculation method of NIVELplane 81

5.0 Monitoring with the program NIVELtrack 835.1 Starting a measurement project 835.2 NIVELtrack main menu 84

5.2.1 Sensor status 845.2.2 Recording status 855.2.3 Tracking file 86

6.0 Accessories and system components 89

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1.0 The NIVELplane system

This NIVELplane manual covers all relevant topics for flatnessand straightness measurement applications with theNIVELplane software using up to 2x NIVEL20 sensors.

Included in the NIVELplane package are the utility NIVELtool forsensor configuration and the application NIVELtrack for simpleobject monitoring.

Leica also offers other software packages for measurementswith up to 32x NIVEL20 sensors in a common network. Thesoftware package SOPOM is an alternative to NIVELtrack whenmonitoring deformation of objects or structures. SOPOMincludes the following:

● Behavior of machines and components when under load● Reaction of foundations to superimposed machinery● Providing assistance in the assembly of heavy machinery● Monitoring structures over time for statistical purposes

For further information about Leica products contact yourdomestic distributor or directly Leica Geosystems AG inSwitzerland.

Before using the program NIVELplane with the inclinationsensor, it is recommended that the NIVEL20 user manual withthe reference number 803592 is read carefully. This manualcontains important safety directions, operating instructions andtechnical specifications.

Although the NIVELplane program has been tested with severalkey customers, we acknowledge that users will find softwarefunctions and features that they would like to have improved. Ifthis is the case, we kindly ask you to bring your suggestions tothe attention of Leica Geosystems AG for further productimprovement.

Thank you for your cooperation!

Leica Geosystems AGMönchmattweg 5CH 5035 UnterentfeldenSwitzerlandwww.leica-geosystems.comFax: +41 62 737 68 34email: support.ims@leica-geosystems.com

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1.1 NIVELplane applicationsThe NIVEL20 is the only inclination-measuring sensor that iscapable of simultaneously recording both X and Y axesinclinations with high precision. The sensor reading systemoperates according to an opto-electronic principle with noinherent moving mechanical parts.

This compact and reliable design is insensitive to electro-magnetic fields and is free of electronic drifts.

These characteristics offer new solutions for precise results inmanufacturing and quality control.

NIVELplane 2.0 covers a variety of 2 dimensional measurementapplications in industry:

● Flatness of surfaces ● Straightness of lines and profiles ● Comparison of profiles or planes with each other to evaluate

their parallelism.● Squareness or angularity of components● Leveling of surfaces or components

All measurements may be performed with or without areference sensor.

1.2 System requirementsTo run the program NIVELplane 2.0 on your PC or laptop thefollowing is required:

● Operating system Windows 95/98 or NT version 4.0 withservice pack 5

● 1 serial port (COM) for sensor communication. A second serialport is required if the remote control unit I-POINT is used withthe NIVELplane application.

● Pentium class CPU, minimum 90 MHz● 64 Mb RAM for Windows 95/98 or 128 Mb RAM for Windows

NT● 20 Mb free hard disk space for program and project data● High color resolution for graphics display (32 000 colors)

or better

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1.3 Installing NIVELplane onto your computerNIVELplane will install 3 applications onto your computer:

NIVELplane for flatness and profile measurements with up to 2NIVEL20 sensors

NIVELtool utility for sensor settings and offset adjustment

NIVELtrack for real-time monitoring measurements with up to32 NIVEL20 sensors.

All 3 applications are installed in the program directory under“Program Files/Leica/NIVELplane” if not specified during theinstallation. It is recommended to use the suggested locationsand folder names.

Measurement data, sample projects, master start-up file andreport bitmaps are stored in the following directories:

Niveldata: The default location for all measurement projectscreated by the NIVELplane and NIVELtrack applications.

Examples: Two measurement examples are stored in thisdirectory for offline analysis with the NIVELplane application.

Logo: The default location for bitmaps being used with theanalysis reports within the NIVELplane application.

Master: The default location for the master start-up file used bythe NIVELplane application

Close all running applications before starting the installationroutine of NIVELplane.

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1.3.1 Installing NIVELplane under Windows 98 and NT

To perform a standard installation of NIVELplane:

● Insert the CD into your computer’s CD ROM drive● NIVELplane will automatically start the installation procedure

if the Windows AutoPlay is enabled. If Windows AutoPlay is not enabled, choose “Run” from the Windows Start menuand type “D:\Disk1\Setup.exe” in the open text box.

Step 1

Click this button to start the installation process

Click this button if you want to install NIVELplane from adifferent folder or drive

Step 2 A suggested folder is displayed in the Program Directorydialogue box. The program NIVELplane will be stored in thespecified folder.

Click this button to continue the installation process

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Step 3 A suggested folder is displayed in the Program Locationdialogue box.

Click this button to continue the installation process

Step 4 A suggested folder is displayed in the Data Directory dialoguebox. The measurement data created with NIVELplane will bestored in the specified folder.

Click this button to select a different directory for the measure-ment data

Click this button to continue the installation process

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Step 5 The list of the installed components will be displayed after asuccessful installation. Close this dialog and continue with theinstallation process.

Step 6 In order to run NIVELplane the first time after the installation, itis necessary to restart your computer.Select the required re-start option. Remove the CD-ROM or thediskette from your drive before restarting.

Click this button to restart your computer and complete theinstallation process

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1.3.2 Installing NIVELplane under Windows 95

The following description applies only to Win 95 computerswithout installed Microsoft Office or Access applications.NIVELplane requires for the data handling the MicrosoftDCOM95 utility. Should your computer already have an Officeor Access application installed, refer to the installation asdescribed for Windows 98/NT in chapter 1.3.1.

To install DCOM95 and NIVELplane:● Insert the CD into your computer’s CD ROM drive● NIVELplane will automatically start the installation procedure

if the Windows AutoPlay is enabled. If Windows AutoPlay isnot enabled, choose “Run” from the Windows Start menu andtype “D:\Disk1\Setup.exe” in the open text box.

Click this button to start the installation process

Click this button if you want to install NIVELplane from adifferent folder or drive

The installation routine will search for an existing DCOM95 utilityon your computer. The necessary files will be installed auto-matically if this is not the case. The following dialogue will bedisplayed after the successful installation of the DCOM95 utility.Remove the CD-ROM or diskette from the computer drives.

Click this button to restart your computer and to finalize theNIVELplane installation

The installation of the NIVELplane program will continue afterthe reboot of your computer. Refer to the chapter 1.3.1 for theinstallation dialogues of NIVELplane.

The restart of the computer is essential at this point in order tocomplete the installation of the program NIVELplane and theutilities NIVELtool and NIVELtrack.

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1.4 Installing the remote control I-POINT The I-Point device is used within the NIVELplane application forremote recording of sensor inclinations. Before connecting theI-Point to your PC, the manufacturer’s user manual deliveredwith the unit should be read. Connect the receiver unit to theserial COM port 1 or 2 of your PC, prior to the installation of theI-Point software.

The following installation procedures describe the installationof the I-Point device. It is assumed that the user is familiar withthe operating system Windows 95/98 or NT. If this is not thecase, we suggest that you contact your system administratorfor assistance.

1.4 .1 Installation under Windows 95/98

For detailed information about the software installation refer tothe user’s guide provided with the I-Point.

Step 1 Select “Run” from the from the “Start” menu

Step 2 Enter the path as shown in the dialog and press “OK” to startthe installation process of the I-Point software.

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1.4.2 Installation under Windows NT

Prior to the installation of the I-Point software it is necessary tomodify the “boot.ini” file of your PC.

Step 1 Double click onto the icon “My computer” shown on the desktop.

Step 2 Double click onto the icon C: drive

Step 3 Click with the right mouse button onto the file “boot.ini” andselect “Properties”.

Step 4 Disable (uncheck) the “Read-only” flag in the dialogue andconfirm with “OK”.

Step 5 Double click onto the “boot.ini” file for editing with theNotepad utility.

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Step 6 Add to each line as shown the following command:/NoSerialMice

Step 7 Close the dialogue and save when prompted the new entrieswith “Yes”.

Step 8 Click again with the right mouse button onto the file “boot.ini”and select “Properties”.

Step 9 Enable (check) the “Read-only” flag in the dialogue and confirmwith “OK”.

Step 10 Restart the computer with the attached I-Point receiver.

Step 11 Insert the I-Point diskette into the floppy drive.

Step 12 Select “Run” from the from the “Start” menu

Step 13 Enter the path as shown in the dialog and press “OK” to startthe installation process of the I-Point software.

Due to an error in the I-Point installation routine for Windows NT, answer with NO when prompted for the restart of your PC. Restart the computer manually.

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1.4.3 Command keys of the I-Point device

Escape / close error message or dialogue

Enter / OK / accept error message or entry

Backward / F2 / one step backwards in the measure-ment grid

Record / F3 / measure current position in grid

Forward / F4 / one step forward in the measurementgrid

1.4.4 Activating the remote control for use with NIVELplane

A template file that contains the appropriate commands isrequired when working with the I-Point in combination with theNIVELplane application. This template file “NIVEL.tpt” is locatedin the directory “C:/Program Files/Leica/Nivelplane”. The following procedure shows how to get the I-Point to workwith the NIVELplane application.

Step 1 Select “I-Point” from the from the “Start” menu

–

+

Enter

Esc

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Step 2 Click onto “File” in the menu and select the function “Open”.Select the required template file “Nivel.tpt” from theNIVELplane/Remote directory. The template is now loaded andwill be activated every time you start the I-Point program.

Step 3 Press this button to activate the template file for usewith the remote control. This activation is required withevery start of the I-Point program.

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The following dialog should appear after the successfulactivation:

Press the “OK” button to close the message dialog. Minimizethe I-Point program to the taskbar and start the NIVELplaneapplication.

The I-Point remote control sends infrared signals to the receiverunit. Please note that the sender must be pointed towards thereceiver.

Refer to the Windows user manual or help pages if you wish toconfigure the I-Point programs as an autostart application. This means that the I-Point program will automatically start, assoon as you switch on your PC. Please note that the templatemust be activated manually with every program start, even ifconfigured as an autostart application.

1.5 Sensor configurations RS232 / RS485NIVELplane supports both RS232 and RS485 sensors. The sensor type is marked on the housing of the NIVEL20. Allsystems can be operated with the power supply 110/220V AC(571533) or the battery 4 Ah (571530) with charger 110/220V AC(571534)

The following examples show both the RS232 and the RS485networks. For more information about Leica accessories forNIVEL20 systems refer to chapter 1.6.

The data cables for RS232 and RS485 communication are notinterchangeable between the 2 network types.

Always turn your PC off when connecting and disconnectingthe sensors from your serial port. Changing connections on apowered system may damage the serial port or the sensor unit.

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1.5.1 RS232 configuration

The RS232 sensor can be directly connected to the serial COMport of your PC. NIVELplane supports only one RS232 sensor atthe same time. Data communication is limited to 20m distancebetween sensor and the application PC. For a detailed descrip-tion of the shown components, refer to chapter 6 of this manualor consult the NIVEL20 user manual for technical specifications.

801453

802906

802906802923802902

571533 or (571530 & 571534)

802907

801453

803365

801452802902 802904

571533 or (571530 & 571534)

803365

1.5.2 RS485 configuration

The RS485 sensors must be connected to the serial COM port ofyour PC via the RS232/485 converter. NIVELplane supports amaximum of two RS485 sensors simultaneously. The secondsensor in an RS485 network is used as a reference sensor.Please note that the measuring sensor must have a loweraddress number than the reference sensor.

For proper addressing and sensor marking refer to chapter 1.7.

Data cables for communication between sensor and PC areavailable in standard of 5 or 20m lengths. It is possible to usecable length up to 50m and these special cables are availableon request.

For a detailed description of the shown components, refer tochapter 6 of this manual or consult the NIVEL20 user manualfor technical specifications.

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1.6 Sensor settingsAll digital sensors are equipped with an internal CPU andmemory. This allows the setting of parameters for internalsensor functions. For information on how to set theseparameters refer to chapter 1.7

1.6.1 Sensor address

Each connected sensor must have an individual sensor addressfor communication within the RS232 or RS485 network. Eachsensor must be addressed individually, therefore connect onlyone sensor at a time when working with the configurationprogram NIVELtool.

Please ensure that the measuring sensor has a lower addressnumber than the reference sensor. It is recommended toaddress the measuring sensor with the number 1 and the refer-ence sensor with the number 2. The measurement values arenot compensated for instability if the measuring sensor has ahigher number than the reference sensor!

1.6.2 Average function (arithmetic mean)

The NIVEL20 offers the possibility to output sensor values as anarithmetic mean. The average number is stored in the sensormemory and is used to average the internal inclination values.The NIVEL20 sensor has an internal sampling rate of 14 read-ings per second. Averaging diminishes the effect of vibrations(frequency) in an unstable measuring environment.

Default factory setting = 8xMinimum setting = 1xMaximum setting = 128x

The example below explains how the average function works ifapplied in a vibrating environment.

Example: If the sensor average number is set to 4, the sensorwill internally average 4 readings in both X and Y direction.Every averaged value is then written into the sensor memoryand sent to the PC if requested by the NIVELplane application.This average function is a continuous process.

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The numbers 1 through 4 shown plotted indicate the internalsensor readings, these 4 values are averaged (arithmetic mean)in the NIVEL20 and represent the final recording value A.

1 2 3 4

+X

-XA

Please note that a high average number increase the responsetime of the sensor. An average number of 128x results in asensor response time of max. 9 seconds. It is recommended toset the default of 8x standard flatness measurements. Otherpossibilities to monitor the sensor instability are the settings ofthe threshold and tolerance parameters as described in chapter 3.2.3.

1.7 Sensor configuration with the program NIVELtool The NIVELtool utility includes functions for the configurationand calibration of digital NIVEL20 sensors for use with Leicasoftware packages or 3rd party products.

Each sensor must be configured individually. NIVELtool doesnot support multiple sensor communication. Connect only onesensor at the time when working with the NIVELtool utility.

Configure your system according to chapter 1.5 and connect theNIVEL20 to a serial port of your PC.

Ensure that the sensor is connected to the power supply or afully charged 4 Ah battery. The green LED of the 12V DC powersupply indicates that the 12V output is in operation.

When working with the 4 Ah battery, check the capacity statusby pressing the red test button on the battery housing.Recharge the battery if the displayed capacity is lower than 25%before continuing with the NIVELtool utility.

Start the NIVELtool application from“Start/Programs/NIVELplane 2.0/NIVELtool”The NIVELtool utility will automatically search on all serial portsfor a connected NIVEL20.

Full functionality of the configuration tool is only available aftera successful sensor initialization.

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The following information is displayed after the initialization:

Should the program not find the connected sensor, select theactive COM port manually and press the button.

Sensor: Displays the sensor type, serial number and firmware version ofthe connected NIVEL20.

Name: Allows you to store a sensor name in the sensor memory. Theentry of a name is optional. The number of characters for thesensor name is limited to 8.

Port: Currently used COM port for sensor communication

Average: The sensor values of both directions and temperature are aver-aged internally (arithmetic mean) by the selected number.Select the required average factor from the list and save theparameter by pressing the [Write] button. Refer to chapter 1.6.2for a detailed description of the average function.

Address: For communication purposes it is necessary that each sensorhas its own individual address. Select the address N1 for themeasuring sensor and the address N2 for the reference sensor.It is suggested to label your sensors with the correspondingsensor number for proper identification. Select the requiredaddress number from the list and save the parameter by press-ing the [Write] button. Refer to to chapter 1.6.1 for more infor-mation about sensor addressing.

Current sensor settings or parameters are displayed.

Newly entered parameters and settings are stored in the sensormemory.

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1.7.1 Checking the sensor communication

It is suggested to coarse level the NIVEL20 or to set the sensoronto a leveled surface, so that the bubble is within the circularmarking.

Press this button to start the measuring routine. The sensorinclinations X, Y and the internal temperature are now dis-played continuously. If any of the inclination axes are out of theworking range the value ± 2.000 mrad will be displayed.

Press this button to stop the measuring routine.

1.7.2 Adjusting the offset parameters (zero point)

This function allows the electronic adjustment of the offset erroror zero point in both the X and Y directions and in the tempera-ture. Where only changes of inclination are of consequence,such as flatness measurements or monitoring applications, theoffset error is of minor importance or can be neglected allto-gether. For high precision leveling work with the NIVEL20, it isrecommended to adjust the offset error from time to time. The time period depends on how much the equipment is usedand how carefully the sensors are stored. In comparison toconventional mechanical (pendulum type) inclination sensors,the NIVEL20 seldom requires zero point adjustments prior tomeasurements.

The following must be considered before performing the offsetadjustment:● An absolutely stable and rigidly mounted plane plate or

surface is required to adjust the offset. ● The flatness of this surface should be 0.001 mrad within a

diameter of about 200 mm.● A steel straight edge or a triangle is required to measure the

sensor positions 1 and 2● The stability of the plane plate or surface (no deformation due

to the weight of the sensor)● Cleanliness of the surfaces (dust particles between sensor

and plane plate)● Thermal distortion of the sensor or plane plate (air draft,

sunlight, heat sources)

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The original factory calibration is overwritten with this adjust-ment process. A faulty calibration may cause the displayedinclination values of your sensor to incorrectly correspond withthe line of gravity!

The sensor requires a warm-up time between 60 and 80 minutes. During the warm-up time, the measured values candiffer from their calibrated values due to the varying thermalbehaviour of components as the internal temperature of thesensor rises. Refer to chapter 2.2.3 for detailed informationabout the warm-up characteristics of the NIVEL20 sensor.

The currently valid offset parameters dx, dy and dT aredisplayed.

Press this button to enter the offset correction routine.

Step 1 Measurement of position 1

Position the sensor along the straight edge ortriangle. Wait for about 5–10 seconds until thesensor has settled.

Press this button to record the offset values of position 1.

1

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Step 2 Measurement of position 2

The current inclination values X and Y of position 1 aredisplayed

Move the sensor by 180˚ without lifting thesensor base off the surface to position 2 andalign the sensor base along the straight edge.

Wait for about 5-10 seconds until the sensor has settled

Press this button to record the offset values of position 2.

2

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Step 3 Saving the new offset parameters

The current inclination values x2 and y2 of position 2 and thenewly calculated offset parameters of dx and dy are displayed.

By pressing this button the new offset parameters are saved inthe sensor memory.

Repeat the measurement steps 1 through 3 until the offsetvalues in X and Y direction are less than 0.002 mrad.

If precision-leveling work is done with an attached sensor base,it is recommended to perform the adjustment with the attachedsensor base. Whenever a sensor base configuration is changednew offset parameters should be determined.

Step 4 Saving the new temperature offset

The difference between the displayed sensor temperature andthe actual room temperature may be directly entered as thetemperature offset dT. The difference is calculated with the helpof a precision thermometer and the displayed temperature ofthe NIVEL20.

Enter the new temperature offset directly into the entry window.

Press this button to save the temperature offset in the sensormemory.

Press this button to exit the offset adjustment routine.

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2. 0 Measurement procedures

The surface or the object to be measured should be leveled tobe within the working range of the sensors. The NIVEL20 is in working range when the spirit bubble is within the circularmarking. It is recommended to level the object to ± 0.5 mm/m or better.

2.1 Reference sensor for differential measurementsReference sensors are used for applications where high preci-sion is required or where the object surface may be unstable.The reference sensor monitors the measuring object during themeasurement process and the NIVELplane program will thencompensate these changes in inclination. When measurementsare made simultaneously by the reference and the measure-ment sensors, any instability/changes in inclination are com-mon to both sensors. Depending on the type of measurementmethod, the sensor is positioned on the object surface whenmeasuring flatness or set onto the object base when measuringthe deflection of a moving machine component. The following examples show typical situations where a refer-ence sensor is required for good results.

Please ensure that the reference sensor is oriented in the sameX and Y direction as the measurement sensor.

The reference sensor must not be moved or touched during theentire measurement process.

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Flatness measurement without a reference sensor

The entire object is unstable and tilts during the measurementprocess at grid position 3. This tilt change is recorded in positions 4 and 5 as a heightdeviation.

Result without reference sensor

The tilt change during the mea-surement is displayedincorrectly as a height deviation in the grid positions 4 and 5. The total error is in this case 0.05 mm.

X

Y1 2 3 4 5

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Flatness measurement with a reference sensor

The reference sensor monitors the object surface for any incli-nation changes in the X and Y direction that occur during themeasurement. These inclination changes are applied to themeasured values of the measurement sensor to compensate forthese instabilities.

Result with reference sensor

The true height deviations or flatness of the surface isdisplayed.The reference sensor measurements enable compensation ofthe object tilt during measurement and the true flatness of thesurface is then 0.002mm.

X

Y1 2 3 4 5

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Profile or straightness measurement without a referencesensor

A common problem when measuring a moving machine table,is the load change of the table when it is moved between thetwo end positions. The entire machine structure may tilt as rigidbody as the table moves from one end to the other. This objecttilt influences the measurement result, as these absolutemachine movements are considered by the measuring sensoras tilt changes. The absolute tilt change does not represent therelative inclination changes between machine body and table.

Result without reference sensor

The absolute machine body tilt during the measurementprocess is measured as a table deviation in profile straightness.This results in an incorrect total error of 0.054 mm over theworking range of the machine table.

X

Y

12

34

56

78

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Profile or straightness measurement with a reference sensor

The reference sensor enables measurement values of themeasuring sensor to be compensated for any machine tilt thatoccurs during the measurement process. This has the effectthat the true or relative tilt between machine body and machinetable is measured. Note that the above cases assume a rigidtable or machine body. Table flexure or deflection are not com-pensated by the reference sensor and require different meas-urement procedures to be determined. Refer to chapter 2.4.3 for more information about this topic.

Result with reference sensor

The true profile straightness of 0.008 mm is displayed, becausethe reference sensor compensated for the machine tilt duringthe table measurement.

X

Y

12

34

56

78

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2.2 Sensor base plate for flatness measurementsDepending on the object size and surface quality, various sensorbase plates can be used for measurements. Leica offers thecommonly used standard base with the dimensions 150x150mm.The entire base is hardened to ensure high stability anddurability. The 3 circular measuring surfaces are lapped to guar-antee the perfect contact between sensor and object surface. Itis recommended to re-lap the measuring surfaces of the baseplate from time to time.

Larger base plates with the dimensions 200, 250 or 300 mm caneither be manufactured locally or supplied by Leica. For applica-tions where higher grid density than 150mm is required, it ispossible to measure the surface directly with the 80 mm sensorbase of the NIVEL20 sensor. This means that the number ofcalculated height deviations is higher and offers the user moreinformation about the height deviations of a measured surface.

The following must be considered when manufacturing yourown base plate:● Choose 3 circular shaped measuring surfaces (see drawing

below)● All contact surfaces of base and sensor mount must be lapped

or grinded and edges chamfered● Alignment of sensor directions X and Y to the base should be

within 0.1mm/m (orthogonality)● Rigid design made of steel or granite● Parallelism between measuring base and sensor base should

be within 0.01mm

The torque of the assembly screws should be equal for all 3 positions when mounting the NIVEL20 onto a base plate.Unequal torque may cause tensions in the assembly anddeform the measuring base.

Large and sturdy designed base plates may deform the objectdue to their high weight. This deformation will result inmeasuring errors. It is recommended that the influence of thiserror source be investigated before taking valid measurements.

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Dimensions of the Leica base plate with mounting screws:

The diameter of 15 mm is the standard for the Leica base platewith the dimensions 150 x 150 mm. Larger diameter measuringsurfaces are recommended for larger base plates. Customizeddimensions should be commensurate with object surface useand requirements.

2.3 Possible error sourcesVarious factors may influence the accuracy of measurements.Accurate results require the careful preparation of themeasuring surface and the corresponding measuringequipment.

The most common error sources are:● Insufficient warm-up time of the measuring equipment. ● Temperature difference between the surface and the NIVEL20

sensors.● Thermal influences such as air draft, sunlight or touching the

sensor base by hand. ● Dust particles or oil between the sensor base and object

surface. ● Damaged or warped sensor base.● Short waved bumps in the surface structure, which can not be

sampled correctly or covered accurately by the measuringbase dimension.

● Vibrations or object tilt during the measurement processwhen no reference sensor is used.

● Unstable object supports or floor when no reference sensor isused.

● Object distortion or deformation during the measurementprocess.

150

150

80,0 +/- 0,05

80,0 +/- 0,05

A A15

View A-A

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2.3.1 Dust and particles

The main influence during a measurement, especially in amanufacturing environment, is dust or dirt between the sensorbase and the object surface. A dust particle of 0.001 mm underthe 80 mm sensor base affects the measurement with an errorof 0.012 mm/m.

Carefully clean the object surface and the sensor base withalcohol, naphtha or other degreasing cleaning detergent beforetaking measurements.

Do not use water-based detergents for the cleaning of thesensor base as these may cause corrosion.

2.3.2 Temperature influence in the measurement environment

Temperature differences between the NIVEL20 sensor and themeasurement object have a great influence on the accuracy ofthe results. Direct sunlight or cold air draft influences themeasurement accuracy as well. Thermal differences influencethe measurement because of thermal expansion of the sensor and its base plate. This means that the sensor base isconstantly changing until the temperature potential isequalized. Refer also to chapter 2.3.5 for information about thezero point stability of the NIVEL20.

The temperature flow between sensor, measuring object andenvironment as an example:

Always check the object and air temperature before taking a measurement. In case of a temperature difference, leave the sensor on the object and wait until the temperaturepotential is equivalent.

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2.3.3 Sensor warm-up time

There is a self-generated warm-up period after switching on the NIVEL20 sensor. The resultant rise in temperature dependson the electronic configuration of the sensor. The warm-upcharacteristics are different between RS232 and RS485 sensorsdue to different power consumption.

Over a particular time period, the temperature changes causean instability of the measurement values X and Y. The diagramsbelow show the variation of measurement values with time,after switching on the NIVEL20 with a constant room tempera-ture of 20 ˚C.

The RS232 sensor requires a warm-up time of approximately 80 and the RS485 sensor 60 minutes. If a reference sensor isused, the reference sensor will compensate a large amount ofthe warm-up offset. The sensor values X and Y remain stableafter his warm-up period.

RS232 sensor

5

0

–5

–10

–15

–20

–25

0 10 20 30 40 50 60 70 80 90 100 110 120 130

Time in minutes

µra

d

X valueY value

RS485 sensor

15

10

5

0

–5

0 10 20 30 40 50 60 70 80 90 100 110 120 130

Time in minutes

µra

d

X valueY value

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2.3.4 Inversion of the sensor during a measurement

The NIVEL20 requires a settling time of approximately 70 minutes if a sensor is turned upside-down (base plate ontop) during operation and then returned again to the normalworking position.

The following diagram shows the last portion of a sensor thatwas in operation for 12 hours at 20 ˚C, then inverted for 5 minutes and returned back into normal working position.

Do not invert the sensor during operation. It is suggested tostore the sensor in a horizontal position.

Sensor settling after inversion

5

0

–5

–10

–15

–20

–25

–30

–35

0 10 20 30 40 50 60 70 80 90 100 110

Time in minutes

µra

d

X valueY value

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2.3.5 Temperature drift of the sensor (zero point stability)

Temperature changes during the measurement will influencethe zero point of the inclination sensor being used. Thefollowing diagram shows the average inclination changes incombination with different environment temperatures. Thestandard tolerance for the zero point stability is max. 5µrad/C˚.

During a high precision measurement, avoid temperaturechanges such as air draft or direct sunlight. Any temperaturechange will affect the accuracy of the measurement.

Zero point stability

100

80

60

40

20

0

–20

–40

–60

–80

–100

–20 –10 0 10 20 30 40 50 60

Temperature Celsius

µra

d

ToleranceX valueY value

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2.4 Preparing the measurement objectNIVELplane can be used either for the measurement of “static”surfaces such as granite tables, machine beds, machine profilesor for “dynamic” measurements of moving machine compo-nents to determine the profile and flatness of the slideways. Fora “static” measurement the sensor is moved forward by handand for a “dynamic” measurement the machine moves thesensor forward for measurement at each position. Dynamicmeasurements are recorded step by step when the machine isstationary and no recordings are made during the machinemovement.

The following measurement examples for flatness and surfaceprofile are based on a surface. The same procedure can be usedfor profile straightness or line measurements.

2.4.1 Surfaces of static objects

Surfaces to be measured must be prepared in order to establishthe grid lines and the measurement area. The following exampleis based on a surface with the dimensions 1300 x 650 mm andusing a 150 x 150 mm Leica base plate.

Step 1 Definition of the measurement grid or density

X length of object divided by X length of base plate = 1300/150 = 8 steps + 100 mm border zone

Y length of object divided by Y length of base plate = 650/150 = 4 steps + 50 mm border zone

Measurement grids or density = 8 x 4 = 32

The border zone of 100 mm in X and 50 mm in Y is dividedequally to both ends in X and Y direction. Border zones are notmeasured. A possible solution to avoid or minimize border zonesis to use a sensor base plate with appropriate dimensions.

50

25

25

50

X

Y

1 2 3 4 5 6 7 8

2

3

4

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Step 2 Grid markings for the measurement

Alignment aids are required to position the sensor onto the cor-rect grid and to align the sensor in the X and Y direction duringthe measurement process. Marking the grid lines on the objectfor correct sensor positioning is recommended. The best way ofdoing this, is to attach sticky tape along the Y-axis and mark thesensor base length of 150mm on the tape strips. For the X-axisa steel or metal ruler can then be placed between the corre-sponding markings of the Y-axis. The ruler is also marked withthe sensor base length of 150mm.

Step 3 Placing the NIVEL20 sensors onto the surface

Clean the object surface, sensor base plate and the referencesensor base with alcohol or any other degreasing cleaningdetergent. Refer to chapter 2.3 for possible error sources.

The measurement always starts at the coordinate X/Y origin inthe lower left hand corner and continues from left to right. Thereference sensor is always positioned in the first Y-profile in theright hand corner.

X

Y

15015

0

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The following diagram shows the sensor placement of themeasuring and the reference sensor at the first recordingposition. The measuring sensor is moved forward as the meas-urements progress. The reference sensor remains untouchedduring the entire measurement process.

Slide the sensor base on the object surface a few times with acircular motion before setting it into position. This movementwill help to remove eventual dust particles between the sensorbase plate and the object surface.

Step 4 The measurement process

Generally all measurement modes are similar. The sensormovement process depends on the chosen measurementmethod. The sensor always moves from the origin in the lowerleft corner to the endpoint in a zigzag motion as shown below.

When moving the sensor to the next position, only touch theplastic housing of the sensor and not the sensor base. Thelargest error sources during the measurement are dust particlesbetween sensor and object surface. Always slide the NIVEL20into position and avoid lifting it off the surface.

The reference sensor remains untouched throughout the entiremeasurement process.

X

Y

X

Y

Measuring

Reference

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2.4.2 Flatness and straightness deviation

The following example is based on a machine surface with aworking range of 1000 x 600 mm. The NIVEL20 can be mountedwithout a base plate directly onto the machine surface. Instead of using the base plate length, a user definable machinemovement of 100 mm in X and Y is used for this example.

Step 1 Definition of the measurement grid or density

X working range of the machine divided by the step movement= 1000/200 = 5 steps

Y working range of the machine divided by the step movement= 600/200 = 3 steps

Measurement grids or density = 5 x 3 = 15

The machine movement step or base plate dimensions in X andY direction has been set to the minimum of 5 mm as a softwarelimitation.

X

Y

1

2

3

4

5

2

3

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Step 2 Placing the NIVEL20 sensors onto the machine

For the mounting of the NIVEL20 sensors onto the machinesurfaces it is recommended to use a plane plate as a sensorbase. This base plate is then mounted onto the machine surfacewith sliding blocks.

Refer to chapter 2.2 for the drill hole dimensions of the sensorbase.

The tilt of the entire machine body, due to the changing load during the surface movement, can be measured andcompensated with the use of a reference sensor. Rigid machineand components are assumed. The following example showsinclination measurement of the machine surface.

X

Y

Measuring

Reference

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Step 3 The measurement process

The measuring process is identical to the surface measurementprocedure, except that the sensor movements are made by the moving machine table. The inclination measurements at thevarious positions of the moving machine table provide theprofile straightness and flatness of the table slideways.

Please consider when using computer-controlled machines, that positioning of the table with a high acceleration willincrease the sensor settling time. It is recommended to use alow acceleration speed to position the sensor.

X

Y

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2.4.3 Deflection of moving components

This is the case when the table or machine body are not assumedto be rigid components but may flex or deflect at various posi-tions and under loads. Three procedures are described below.

1. Surface measurement

Step 1 Static measurement at central locationThe sliding table is positioned in the center of the machine anda static flatness measurement is made as described in chapter2.4.1. This can be taken as the reference flatness surface shapeto compare other deflected surfaces against at their variouspositions or with various loads.

Step 2 Static measurement at end locations or under loadThe sliding table is moved to an extreme position and/orloaded. The static measurement for flatness is repeated as isstep 1 above and the shape deviations give the deflections overthe surface. Step 2 may be repeated for any other location andload combinations as required.

2. Static position measurement

Step 1 An alternative simplified technique is to position the measure-ment sensor near the edge of the sliding table and to take areading with the table in its central position or other referencelocation.

Step 2 Move the table to an extreme position or place a load on thetable and re-measure once it has settled. The change ininclination compensated for rigid body tilt is the deflection ofthe table. This method lends itself more to the use of either the angle mode (3.4.2) for display or the NIVELplane (5.0) formonitoring.

3. Dynamic measurements during slow motion

This is a case of monitoring deflection while the movingcomponent is being moved slowly or loaded incrementally.

Step 1 Place or fix the measurement sensor onto the moving compo-nent and take a static measurement with the component at a central or reference location. A reference sensor should be placed on the machine to enable rigid body tilt to becompensated.

Step 2 Set the component in slow motion and use either the anglemode (3.4.2) for display of deflections or the NIVELplaneprogram (5.0) for continuous monitoring recording.

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2.4.4 Levelness or absolute tilt measurements

So far procedures have been described for flatness which onlyrequires the measurement of relative tilt changes. Mostsurfaces measured will be very close to horizontal though asensor can be mounted on a base plate at an inclination tomeasure surfaces with slopes greater than ± 1.500 mrad.

When levelness (absolute tilt) of a line or surface is required the zero offset of the combined base plate and sensor must becalibrated for each task. Refer to chapter 1.7.2 for moreinformation about the offset adjustment.

Sensor

Surface

Mount with adjustment screws and base plate

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3.0 First steps with NIVELplane

It is assumed that the measuring object is prepared and allsensors are connected to the serial port of your application PC.For the configuration of your system refer to the chapters 1.5.1and 1.5.2

The following chapters describe the NIVELplane programfeatures and its functionality.

The standard measurement process is divided into 3 steps:

Step 1 Administrational information and settings for the measurementprocess

Step 2 The measurement process itself with the NIVEL20 sensors

Step 3 Analysis and reporting of the calculated results

File name Measurement

Project administration

Project settings

Flatness

Analysis

Reporting

Angularity

Project units

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Start the NIVELplane program from“Start/Programs/NIVELplane 2.0/NIVELplane”

The Autoscan function will automatically search for connectedsensors with every start of the NIVELplane program. All con-nected sensors will then be displayed with the correspondingserial port number, sensor address, sensor type and serialnumber of the NIVEL20.

Should the Autoscan function not recognize the connectedsensors:

● Check the power supply and all cable connections accordingto chapter 1.5.1 and 1.5.2.

● Close the dialogue and restart the Autoscan function asdescribed in chapter 3.5.3

● Check the sensor addressing with the NIVELtool function asdescribed in chapter 1.7.

Press this button to accept the current sensor configuration orto clear the dialogue.

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3.1 File managementThe dialogue “New project” will be automatically displayedwith every start of the NIVELplane application. It is assumedthat the operator will measure a new surface and thereforecreate a new project (file).

Enter a file name and press this button to activate the project.

If it is not intended to create a new project, close the dialogueand open an existing project with “Open Project”. All “Project”functions are selectable under “File” in the main menu.

The functions “New” and “Open” Project are also selectablefrom the NIVELplane toolbar.

New Project

Open Project

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● The “New Project” function allows defining a new file namefor a measurement project.

● The “Open Project” function allows opening a previouslymeasured project for further analysis or reporting.

● The “Close Project” function allows closing or aborting acurrent measurement project.

Projects created with NIVELplane 1.0 are not compatible withthe version NIVELplane 2.0. Measurements of version 1.0 maybe opened, analyzed and reported. Measurements within an oldproject file are not possible due to database incompatability.

3.1.1 Creating a master startup file (parameter file)

The parameters such as administration, project and unit set-tings are read from a master startup file when creating a newproject. Such a master file is useful and time saving whenworking on projects with identical settings and parameters. To create such a master startup file:

● Close the current project with “Close Project”● Open the project “Master.mdb” which is stored at

C:\Niveldata\Master● Define all default entries and selections in the dialogues

“Project Administration, Project Settings and Project Units”.● Close the Master startup file with the “Close Project” function.

The new settings and default entries will be effective with thenext project.

The startup master file settings do not apply when opening anexisting project. In this case the project specific settings will berestored for this particular project.

3.2 Project settings and parametersAll parameters, settings and comments are entered or selectedin the dialogues “Project Administration, Project Settings andProject Units”. All “Project” functions are selectable under “File”in the main menu. Default settings may be defined in a masterstartup file as described in chapter 3.1.1.

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3.2.1 Project Administration

The entered information’s in the groups “Job Information andComment” are optional. These entries will be printed on theanalysis reports if available.

The administration dialogue is also selectable from theNIVELplane toolbar.

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Dimensions: Object surface dimensions are required for the gridcalculation.

Enter the measurable X and Y object dimensions and thesensor base size into the entry fields. Refer to chapter 2.4.1 fordetailed information on how to specify the measuring area orobject size. The standard Leica base plate is 150 x 150 mm. Theminimum base plate size is limited to 5mm when measuringdeflections of a machine component. In this case the machineor table movement defines the sensor movement. For asy-metrical base plates the X and Y dimensions may be different.

Mesurement mode: Four different measurement modes areavailable for the most common surface measurement tasks.

Fine GridThis method is suggested for maximum accuracy and data density.The grid size is equal to the sensor base plate dimension.

Coarse GridThis method is suggested for a quick measurement or to verifya surface condition during a production process. The grid sizein Y direction is double the sensor base plate and in X directionequal to the sensor base plate. The measurement time and datadensity is half compared to the “Fine grid” method.

1D and 2D LineThis method is suggested for profile measurements of machinerails or surfaces. The 1D line method applies to rails where onlythe X direction or profile is of interest. Only the X inclination isrecorded in this 1D line measurement mode. For the 2D lineboth the X and Y inclination are measured providing a profileribbon. This can apply to rails where both the longitudinal andtransverse directions of the rails and carriage are of interest.

II.2000 714 653 NIVELplane 2.0 55

3.2.2 Project settings

All measurement relevant settings are made within the “Project Setting” dialogue.

The Project Settings dialogue is also selectable from theNIVELplane toolbar.

Calculation Method

Three different calculation methods for the results of the heightdeviations are available. Choose the appropriate calculationmethod for your flatness measurement. The most commoncalculation method is the relative type. The calculation methodmay be changed during analysis and the measurements willthen be recalculated and displayed accordingly.

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Absolute: The absolute method is mainly used to inspect machine rails orguidance surfaces where, as well as straightness or flatness,they also need to be level with respect to gravity. The followingexample shows the position and the deviations of an“absolute” surface in space.

The adjusted height deviations are calculated between the truehorizon and the calculated surface positions in space. In otherwords the measured tilts are referenced to gravity and theassessment is levelness of the surface. Levelness is the anglethat the best fit line or flatness plane makes with the horizontal.This assumes that the used NIVEL20- base plate combinationhas been correctly calibrated for zero offset. Refer to chapter 2.4.4for more information about the sensor base plate.

Relative: The relative method is the most commonly used method foranalyzing the flatness of a surface. The following example showsthe same surface as shown in the absolute example in a relativeposition. Note that, though the surface shapes are identical,they look different because one is tilted by the angle of the bestfit plane to gravity and the large difference in vertical scale.

The adjusted height deviations are calculated between a refer-ence plane and the calculated surface positions. These heightdeviations are relative to the calculated surface or simply thedeviations to the best fit line or plane through the height differ-ence points. Refer to chapter 4.0 for more information about thecalculation method of NIVELplane.

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Compare with: The compare function enables the comparison of the totaldeviations between two measured surfaces. The routine usesthe selected surface as a reference plane. The calculated resultsshown in the analysis, represent the adjusted height deviationsand the rotation angles (Rx, Ry) between the reference surface(selected surface from a previous project) and the currentsurface (current project). The displayed rotation angles Rx andRy in the dialogue below are the actual rotation values of theselected reference plane.

Enter the project name of a previously measured surface intothe entry field or select the project with the browser.

Press this button to start the browser.

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Measurement settings

The tolerance settings for the measurement recording andstability check are directly linked to the “measurement grid”and the “sensor stability” window. Refer to chapters 3.4.1 and3.4.3 for more information about these windows. The sensorsor the object might move slightly or tilt (vibrations) during arecording. The measurement settings for tolerance, stability andrepetitions disable measurement recording until all are metsimultaneously. The minimum number of repetitions must begreater than 1 to activate the measurement and sensor stabilityroutine.

Measurement An error message will be displayed during the recording if the Tolerance: measured deviation exceeds the entered tolerance value. The

repetition count restarts from 1 each time the tolerance isexceeded and the mean measurement is not recorded until theset number of repetitions is reached.

Stability The “sensor stability” window indicates with green and red Tolerance: status colors if the sensors are within (green) or outside (red)

the entered stability tolerance. The stability check routine is acontinuous process and has mainly a visual character for the user. Recording is disabled until the required number ofrepetitions each within the entered stability tolerance isreached.

Reference Indicates wether the connected reference sensor should be sensor: used or not for the flatness measurement. Measurement values

from the measurement sensor are only compensated andcorrected if the reference sensor is included in the measurementprocess. Mark the checkbox if the reference sensor should beincluded in the measurement process.

Note that the “Average function” referred to in chapter 1.6.2gives an averaged value internal to the NIVEL20 memory andeach averaged value is one repetition in NIVELplane.

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3.2.3 Project units

The currently active units are displayed in the status bar locatedon the bottom of the program window.

Length: The units for the object and base plate definition in the “Project Administration” dialogue.mm = millimeterm = meterIn = inchft = foot

Inclination: The inclination values displayed in the sensor values windowdisplay the current sensor inclinations in the X and Y direction. mrad = milliradmm/m = millimeter per metermIn/ft = milli-Inch per foot mgon = milligon (400,0000 Gon)sec = Seconds (360,0000 decimal degree)

Height: The calculated height deviations displayed in the analysisfunctions.mm = micrometermm = millimetermIn = milli-Inch In = inch

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3.3 View All dialogues and windows for the measurement process maybe hidden or displayed by selecting the corresponding window.A check mark appears next to the menu item when a window isselected for display. The individual dialogues and windows areselectable under “View” in the main menu.

The windows of “Grid, Sensor Values and Sensor Stability” arealso displayed when selected from the NIVELplane toolbar.

3.3.1 Measurement grid

The measurement grid displays the object grids as specified inthe “Project Administration” dialogue. The green sensor in the lower left corner indicates the measuring sensor and theblue sensor in the lower right hand corner the reference sensor.The reference sensor is additionally marked with “REF”. This window must be displayed in order to record any sensorvalues. For detailed informations about the grid functionalityrefer to chapter 2.4. and 3.5.1.

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3.3.2 Sensor values

The “Sensor Values” window displays the current inclinationvalues of the measuring and the reference sensor. This windowis only an informative display and is optional when measuring asurface. The window will automatically be displayed whenworking in the “Angle” mode. (see 3.4.2)

The background colors of the sensor values indicate theNIVEL20’s working range:

Sensor values between ± 1.500 mrad are displayed in green

Sensor values between ± 1.500 and ± 1.900 mrad are displayedin yellow

A red background color indicates that the sensor is out of itsworking range.

Measuring sensor coordinates Sensor status

Sensor status: The status color shows the data communication status betweenthe sensor and the application PC.

NIVELplane is reading the sensor values for the stability checkfunction (green).

NIVELplane is currently reading and storing the sensor valuesin the database (red).

Measuring The sensor grid location is indicated by Xi and Yj where X and sensor Y correspond respectively to the grid rows and columns

coordinates: where i and j correspond respectively to positions along the X and Y axes. In this case, the measuring sensor is currently atits origin position X0 and Y0.

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3.3.3 Sensor stability

The “sensor stability” window indicates whether the sensors arewithin the specified tolerance as entered in the “Project Settings”dialogue. The green or red status window clearly indicates thestability condition of sensors and the object. Refer to chapter3.3.2. on how to change the measurement settings.

The green status indicates that the sensors are stable and with-in the specified tolerance. The recording of sensor values isenabled.

The red status indicates that the sensors or the object are notstable, and that the current deviations exceed the specified tol-erance value. The recording of sensor values is disabled. Whenthe environmental conditions are not suitable for high precisionmeasurement (vibrations, object instability, etc), it may be nec-essary to increase the sensor stability tolerance value.

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3.3.4 Toolbar

The toolbar is typically displayed horizontally below the main menu items. These buttons represent the most commoncommands used within NIVELplane.

The individual icons and their function:

Icon Shortcut Function

Alt – F, N Create or open a new project

Alt – F, O Open an existing project

Alt – F, A Display the Project Administration dialogue

Alt – F, T Display the Project Settings dialogue

Alt – V, G Display the measurement Grid, sensor values andstability check windows

F7 Zoom-in the measurement grid

F8 Zoom-out the measurement grid

F2 Measurement sensor one grid position backward

F3 Record current position of the measurement sensor

F4 Measurement sensor one grid position forward

Alt – A, D Display the numerical Table of the calculated height deviations

Alt – A, P Display the Profile graphics of the calculated height deviations

Alt – A, H Display the Column graphics of the calculatedheight deviations

Alt – A, S Display the Surface graphics of the calculatedheight deviations

Alt – A, R Display the Report generator

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3.3.5 Status Bar

The status bar is displayed at the bottom of the NIVELplaneapplication window and shows the applied calculation methodand the currently active units.

3.4 MeasurementThe measurement of a surface or the leveling of a componentin angle mode may be started after the definition of the param-eters and in the dialogues Project Administration, Settings andUnits. Select the corresponding menu items as described in thechapter 3.3 to display all relevant windows for a measurement.It is assumed that the object to be measured is prepared, thesensors are warmed-up ready for recording.

The windows of “Grid, Sensor Values” and “Sensor Stability”are displayed when selected from the NIVELplane toolbar.

3.4.1 Flatness Mode

The following windows will be active when beginning with aflatness measurement. The measuring sensor is at its startingposition X0/Y0 and the reference sensor at its monitoringposition Xn-1/Y0.

II.2000 714 653 NIVELplane 2.0 65

For a surface measurement it is necessary to have at least themeasurement grid displayed. The “Sensor Value” and the“Sensor Stability” windows are optional. It is recommended tohave at least the “Sensor Stability” window displayed, as thiswindow indicates the stability or readiness of the connectedsensors.

Three different options are available to record the sensor valuesof the measurement sensor at the current grid position:

Select the function “Record” from the Measurement menu orpress the function key F3 on your keyboard.

A click onto this icon in the toolbar will record the currentvalues of the measurement sensor.

A double-click with the mouse pointer in the currentmeasurement grid position will record the sensor values aswell.

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The measuring sensor will move graphically to the next gridcoordinate after recording. Move your NIVEL20 accordingly onthe object surface and record the next position. Continue thisprocess sequentially until all grid positions are measured.Recorded grid coordinates are displayed in yellow and unmea-sured positions in black font color. The analysis icons will be activated once the measurement is complete and ready foranalysis. Refer to chapter 3.6 for details on data analysis.

A mismatched “sensor to object grid“ to its graphical equiva-lent can be corrected by repeating the correctly matched meas-urement and overwriting it. A single grid position or an entiresequence may be repeated and recording overwritten. Selectthe functions “Backward” or “Forward” from the measurementmenu for re-measuring a position and moving the sensorgraphically in the grid. A mouse click into the grid will move thedisplayed sensor to the selected coordinate.

Click this icon to move backward

Click this icon to move forward

The position of the sensor on the object surface must coincidewith the grid coordinate shown graphically and numerically inthe grid window. A mismatch will introduce erroneous data andwill not represent the true flatness as calculated and display inthe analysis function.

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3.4.2 Angle Mode and Leveling

The angle mode allows components to be levelled to a refer-ence surface or to a specific slope angle. The “Angle” mode isaccessible from the measurement menu. Once the angle modeis selected the entire measurement window will change to thismode. Therefore the “Grid” window will be switched off and the“Sensor Value” Window will display the current sensor values.Sensor values can not be stored when working in the “Angle”mode, as they are only for display information purposes.

Select the function from the main menu or press the functionkey F5 on your keyboard to switch to the “Angle” mode.

The values of the measuring sensor displayed in the column“Meas” are the current inclinations from the true horizon definedby the zero (0.000) inclination of that sensor. When the sensorand base combination has been calibrated for the zero offset, thishorizon is referred to gravity and absolute tilt is displayed. Thevalues displayed in the “Angle” windows are the current devia-tions of the measuring sensor since the mode started.

Example: Two surfaces need to be adjusted to a certain slope angle orleveled to gravity. The first step is the adjustment of the firstsurface to the required angle. For this purpose the “Meas”window is used to set the slope angle of both the X and Y direc-tion. Once the values of the first surface are within the requiredtolerance, the second surface needs to be adjusted accordingly.Before moving the sensor to the second surface, it is recom-mended to “Reset” the “Angle” display. Refer to the next stepon how to reset the angle display.

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Select the function from the main menu or press the functionkey F6 on your keyboard to “Reset” the “Angle” display

The “Angle” display is zeroed (0.000) after the “Reset” isperformed.

Example: Once the “Angle” display is reset, the measuring sensor may nowbe moved to the second surface for adjusting its slope angle. Thesecond surface is now adjusted accordingly until the displayedvalues shown in the “Angle” window are within the requiredtolerance. The same adjustment could also be done by readingthe values from the “Meas” window. Especially when setting acommon slope angle for 2 or more components, it is easier to workwith the “Angle” window as the displayed values represent thedifferences between the reference (reset) and the current surface.

Select the function from the main menu or press the functionkey F5 on your keyboard to switch back to the “Surface” modefor flatness measurements.

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3.4.3 Sound

A sound event may be activated for acoustic feedback withevery recording of a measurement. This sound event is linkedwith the event “Default Beep” in the current sound settings of the Windows operating system. Refer to the Windows usermanual for detailed information about sound settings.

Select the function “Sound” from the measurement menu. Acheckmark is displayed next to the menu item if it is activated.

3.4.4 Autoscan

The “Autoscan” function allows searching and initializing ofconnected NIVEL20 sensors on any serial COM port. This couldbe the case after a power interrupt between the NIVEL20 sen-sors and the power sources or the accidental disconnection ofthe communication cables.

Select the “Autoscan” utility from the measurement menu tostart the automatic sensor search

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The following window with the sensor status in detail will bedisplayed after the sensor scan.

Press this button to clear the dialogue and to activate theconnected sensors for the communication with the NIVELplaneapplication.

3.4.5 Clear measurement data

If wrong or bad data has been recorded during a measurement,it is possible to delete all existing records in the current data-base. This will also graphically reset the measuring sensor to itsstarting position X0/Y0 in the “Grid” window.

Select the “Clear Data” function from the measurement menu

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3.5 Data analysisThe data analysis functions allow the visualization, analysis andreporting of the calculated deviations or flatness of a measuredsurface. The measurement of the specified surface must bemeasured completely in order to access the analysis functionsfrom the main menu.

Select the required analysis function or the report generatorfrom the analysis menu or from the toolbar.

3.5.1 Common graphics functionality

The graphics functions “Profiles, 3D Heights” and “ Surfaces”have common functionality and identical control elements.

Toolbar

Reporting

Rotation

Tolerance4

3

2

1

3

4

2

1

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Toolbar:

Icon Function

Zoom in of displayed graphics

Zoom out of displayed graphics

Toggle function between 3 or 18 tolerance classes for colorshaded error display

Stretch the displayed graphics in height direction

Skew the displayed graphics in height direction

Toggle switch between bold (B) or normal (N) fonts

Increase font size

Decrease font size

Rotation The displayed graphics may be rotated with the horizontal and sliders: vertical rotation sliders. Rotation is also possible by clicking into

the graphics window with a pressed left mouse button.

Keep the mouse button pressed and rotate the graphics untilthe required view is achieved. Release the mouse button whenfinished with the rotation. The rotation mode does not apply forthe profile window.

Reporting: The current graphics view may be added to the report genera-tor. A new report is added to the report generator with everykey press. This allows a 3D surface to be reported several timeswith different views if this was required.

Click this button to add the current graphics view to the reportgenerator.

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Rotation

The values Rx (rotation X) and Ry (rotation Y) represent theapplied or calculated rotation parameters of the measured sur-face to the horizon defined by the zero inclination of the meas-uring sensor. When calculating the results with the “Absolute”method, the rotation values indicate the true inclination of themeasured surface in space because the zero offset equals zero.When working with the “Relative” method, the rotation valuesare the applied parameters for the rotation of the calculated sur-face onto the reference plane defined by the zero inclination ofthe measuring sensor. The rotation values are displayed in thesame inclination units as indicated in the status bar.

Tolerance

The color-shaded surface is based on the entered tolerancevalue and on the selected number of tolerance classes (3 or 18colors) chosen for display.

Example: The entered tolerance value is 2mm as shown below. Whenselecting the 3-tolerance class mode, all height deviations <=2 µm are displayed in green, > 4 µm (2x tolerance) in yellow andlarger than 6mm (3x tolerance) in red color. When switching to the 18-tolerance class mode, each color segment of green,yellow and red is divided additionally into 6 color shades. Eachtolerance class (2 µm) in green, yellow and red is divided into 6 classes from light to dark shading. Each tolerance class orcolor shading represents in this case 0.33 µm.

Enter the required tolerance value for the color shading into theopen entry box

Press this button to apply the entered height tolerance to thecurrently displayed graphic.

Press this toggle switch to change between the 3 or 18 tolerance-shading mode

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3.5.2 Adjusted height deviations

The adjusted height deviation for each measured grid positionis displayed in the current height deviation unit. The currentunit and the applied calculation method are indicated in thestatus bar. The largest adjusted height deviation is displayedwith red background color and is the value of flatness for thissurface by definition (see chapter 4.0 calculation method ofNIVELplane).

Press this icon to select the height deviation table from thetoolbar

The table may be directly added to the report generator ifrequired. Another option is to copy the values and export theminto another application, such as Notepad, Excel or any otherprogram. To copy the entire grid, click with the mouse into theupper left corner until the grid is displayed as selected with ablue background color. Copied data can be inserted into anotherapplication with the “Edit/Paste” function.

Press this button to copy the selected height deviations in thegrid for export

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3.5.3 Profiles

All measured profiles can be individually displayed for straight-ness. The current unit and the applied calculation method areindicated in the status bar. Straightness is defined as the largestheight deviation in a measured profile.

Press this icon to select the profile graphics from the toolbar.

Scrolling through the individual profiles is possible by using thearrow keys [⇑ ] [⇓ ] on your keyboard or the profile selectiontool on the bottom of the dialogue.

Select the required profile direction X or Y and thecorresponding profile number.

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3.5.4 3D Heights

The calculated height deviations are displayed as columns. Thecurrent unit and the applied calculation method are displayed inthe status bar

Press this icon to select the 3D height graphics from the toolbar.

Press this toggle button to change between single column andmultiple column view

In the single column view is only the position with the largestheight deviation displayed.

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3.5.5 Surfaces

The adjusted height deviations are displayed as a shadedsurface. The current unit and the applied calculation method aredisplayed in the status bar

Press this icon to select the surface graphics from the toolbar.

Press this toggle button to change between the 2D and 3Dviewing mode

The calculated surface is displayed as a planimetric view in the2D viewing mode.

Press this toggle button to add the wire mesh grid to thedisplayed surface.

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3.5.6 Report

The report generator buffers all report entries that have beensaved in the analysis windows with the [Add to Report] key.Once the analysis is complete, the saved report may then bereviewed and printed. A color printer is recommended forreporting. The contents in the report generator will automaticallybe deleted when data is re-measured or project parameters arechanged. All previous “Add to Report” keys will have to berepeated to regenerate the report.

Press this icon to select the report generator from the toolbar.

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The report generator toolbar:

Icon Function

Print all reports shown in the report generator

Display the reports in actual size

Display the report as a full page

Zoom in (or left mouse click onto the report page)

Zoom out (or right mouse click onto report)

Display the first page

Display previous report page

Display next report page

Display last report page

Report generator command page

Use the [Delete] key on your keyboard to delete a report page.

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3.5.7 Adding your company logo to the report template

The report template includes as default the Leica Companylogo. The bitmap for the company logo is located at“C:\Niveldata\Logo”. To add your own company logo:

● Create a company logo and save the file as “Logo” with thefile format BMP, JPG or WMF (Example: Logo.bmp).The maxi-mum size for the logo is 59mm (width) by 40mm (height)

● Copy the new logo file to “C:\Niveldata\Logo” and replace ordelete the existing files.

● The bitmap or picture will be aligned in the lower left cornerof the logo placeholder in the report template.

● The new company logo will be active with the next createdreport.

3.5.8 Report paper size

The paper size for the reports may be selected according to the used paper format. The report generator must be open inorder to select the paper size A4 (210 x 297 mm) or Letter (216 x 280 mm). A checkmark next to the menu item indicatesthe currently active paper format.

Select the required paper format from the analysis menu.

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4.0 Calculation method of NIVELplane

NIVELplane determines the height deviations according toGeometrical Tolerancing of Form of the ISO 1101 standard.Straightness can be defined as the largest height deviation in ameasured profile (see 3.5.3) and Flatness as the largest heightdeviation in a measured surface (see 3.5.4). The sensor baseplate used during the measurement process defines the gridsize. The surface and base plate dimensions define the numberof grid positions used for the calculation.

Step 1 Conversion of measured inclinations to height differences

At each grid location the inclination sensor NIVEL20 providestwo values, one in the X and one in the Y-direction. The meas-ured inclinations are converted to height differences (dhX anddhY) by using the known X and Y dimensions of the sensorbase plate being used. Thus the position where each base platemeasuring surface was in contact with the surface gets a heightdifference that is referenced to the lower left-hand position(X0/Y0) of the surface being measured. A grid location XiYjshould end up with a height difference at each of its four cor-ners. This explains why the lower right-hand bottom corner ofthe surface with grid location (Xn-1/Y0) is measured but doesnot receive a height difference in that grid corner.

Looking onto the measured grid positions A1, B1 and B2 of asurface.

The signs are determined according to the following definition:dhX = B2 – B1dhY = B1 – A1

B1 B2

A1

XY

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Step 2 Determining the height deviations

A best fit line or plane is calculated through the height differ-ences established in step 1 using a least squares adjustmentsolution. All the height differences are inserted into the Leastsquares adjustment as unknowns because there are redundantobservations. The perpendicular offset of each adjusted heightdifference from the line or plane in a linear profile or 2D surfacerespectively determines each height deviation.

Each individual inclination measurement in X and Y can berelated to the best fit line or plane and to the horizontal planedefined by the zero inclination of the measurement sensor.

Step 3 Surface translation

All the adjusted height differences are then translated in thenegative direction by assigning the height zero (0.000) to thepoint with the lowest adjusted height difference value (largestnegative residual).

base length

surface

to be measured

α

α

α

α’αi

α’αiαi – 1

αi + 1

horizontal

vertical

mean tilt (of surface)

α = mean tilt of the surfaceαi = i th. tilt measuredα’ = αi – α = tilt referred to the surface being measured

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5.0 Monitoring with the program NIVELtrack

5.1 Starting a measurement projectThe information about changes in tilt of machine platforms,machine components or building structures can be measuredand monitored with the program NIVELtrack. This programallows the use of up to 32x RS485 NIVEL20 sensors or 1x RS232sensor on each serial COM port. The RS485 communicationnetwork is recommended when monitoring with NIVEL20sensors. Special data cables, bus terminators and wall adaptersfor vertical surfaces are available on request.

Start the program NIVELtrack from“Start/Programs/NIVELplane 2.0/NIVELtrack”

The Autoscan function will automatically search for connectedsensors with the start of the NIVELtrack program. All connectedsensors will then be displayed with the corresponding serialport number, sensor address, sensor type and serial number ofeach NIVEL20.

Should the Autoscan function not recognize the connectedsensors:● Check the power supply and all cable connections according

to chapter 1.5.1 and 1.5.2.● Close the dialogue and restart the Autoscan function as

described in chapter 3.5.4.● Check the sensor addressing with the NIVELtool function as

described in chapter 1.7.

Press this button to accept the current sensor configuration orto clear the dialogue.

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5.2 NIVELtrack main menuThe NIVELtrack measurement window will be displayed after asuccessful sensor initialization.

All connected sensors are displayed on the left in the treestructure of the data display. For each sensor its address (Nx),number of measurements recorded, the X,Y inclinations and the temperature values are continuously displayed. The defaultunits for inclinations are mrad (mm/m) and Celsius for thetemperature.

5.2.1 Sensor status

The icon displayed with each sensor is indicates the currentcommunication status. The status is automatically set to ON ifthe sensors are responding and communicating. The correspon-ding sensors are automatically set to OFF if an error or commu-nication time-out occurs. Each sensor may be turned ON or OFFmanually by clicking onto the status icon.

ON - The sensor is running and communicating

OFF – The sensor is turned off or not responding

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5.2.2 Recording status

The recording status dialogue contains all functions for commu-nication and time settings. Internal speed displays the internalcommunication speed in milliseconds, which is required toreceive the data from all involved sensors. An error messagewill be displayed in case of a communication failure if the“Alarm” option is checked.

Time interval: Sensor data will be stored continuously if no time interval isspecified. The fastest time interval for recording is the timeinterval indicated in the “Internal speed” data field.

Press this button to set a time interval for recording

Enter the required time interval into the entry boxes in hours,minutes and seconds. If no time interval is specified the internalspeed or fastest recording interval will be used automatically.

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5.2.3 Tracking file

A file name must be specified in order to store measurementdata in an ASCII file.

Press this button to specify a file name for data storage

The default location for storing measurement data is“C:\Niveldata”. Enter a file name in order to store the sensormeasurements. The file extension *.txt for the entered ASCII filewill be added automatically.

Storing sensor data is enabled as soon as a file name for datastorage is entered. To start a recording mark the checkbox ofthe “Save to file” option. Unmark this checkbox to stop therecordings.

Marked = saving data according to the specified time interval Unchecked = data display only – no data is stored

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The following data fields are continuously updated during therecording:

The number of records stored in the ASCII file

Time to the next recording

Current file size and remaining disk space for data recording

Stored measurement recordings with the file extension “*.txt”may be viewed and edited with the standard Windows applica-tions such as “Notepad” or “Wordpad”.

The data column headers from left to right: Recording # / usedCOM port / Sensor address / Date / Time / X-value / Y-value /Sensor temperature

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A logfile is generated with each recorded data file (*.txt). Thislogfile has the same file name with the extension “*.log”. Alogfile may be viewed and edited with the standard Windowsapplications such as “Notepad” or “Wordpad”. The data col-umn headers from left to right are: Date / Time / Recording # / Task name or message

Measurement data may be imported into Windows Excel forfurther analysis or graphical display. Refer to the Microsoft usermanual on how to import ASCII formats.

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6.0 Accessories and system components

The following accessories are available for use with NIVEL20inclination sensors. Customized or individual accessories areavailable on request.

Power supply 12V DC for RS232/485 network

The power supply is equipped with a switch for use with 110 or 220 V AC.Article number: 571 533

Battery 4 Ah / 12V DC

Working time with 2x NIVEL20 and data converter isapproximately 12 hours. Article number: 571 530

Battery charger

The charger is equipped with a switch for use with 110 or 220V AC.Article number: 571 534

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Signal converter RS232/485Required for applications with RS485 NIVEL20 sensors. Article number: 802 923

Data cables RS232/485The following standard cable types are commonly used.Customized cable lengths are available on request.

RS232, 1 m LEMO/DSUB9f Article number: 802 902

RS232, 5 m LEMO type Article number: 802 904

RS485, 1 m LEMO type Article number: 802 905

RS485, 5m LEMO type Article number: 802 906

RS485, 20 m LEMO type Article number: 802 907

RS485, 40 m LEMO type Article number: 99 113

Case for single sensor systemPadded case for storage of 1x NIVEL20 sensor, cables, batteryor power supply and base plate.Article number: 803 493

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Case for dual sensor systemPadded case for storage of 2x NIVEL20 sensors, cables,converter, power supply and base plate.Article number: 803 494

Base plate for NIVEL20Standard Leica base plate 150 x 150 mm. Three lapped circularcontact surfaces with a diameter of 15 mm. Customized baseplates of other dimensions available on request.Article number: 803 365

Remote control Infrared remote control I-Point for connection onto serial COM port of PC or laptop. Article number: 575 654

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NIVEL20 inclination sensors NIVEL20 sensors are available with 3 different data interfaces:

Analogue interface Article number: 801 451

RS232 interface Article number: 801 452

RS485 interface Article number: 801 453

Manual NIVEL20User manual for NIVEL20 sensors contains technicalinformation such as: ● Wiring diagrams of cables and sockets● Programming reference for sensor communication● Technical specifications● Languages English, German and FrenchArticle number: 803 592

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Re-certification of sensorsRe-certification encompasses a system inspection and includesa service certificate. The report certifies that the NIVEL20 is incompliance with its technical specifications. Re-certification is done at the Leica factory in Switzerland.For inquiries contact your domestic supplier or Leica Geosystems in Switzerland at <support.ims@leica-geosystems.com>

Article number: 99 112

Training and InstructionSW training and instruction through Leica personnel atcustomer site or at Leica Unterentfelden in Switzerland. Forinquiries contact your domestic supplier or Leica Geosystems inSwitzerland at <support.ims@leica-geosystems.com>

Article number: 99 113

Leica Geosystems AGMönchmattweg 5

CH-5035 Unterentfelden(Switzerland)

Telephone +41 62 737 67 67Fax +41 62 723 07 34

www.leica-geosystems.com

Illustrations, descriptions and technicaldata are not binding and may be changedwithout notice.Printed in Switzerland – Copyright byLeica Geosystems AG, Heerbrugg,Switzerland, 2000

714653en – II.2000