Vision Engineering Falcon 3-axis Non Contact Measurement System
Introduction
Vision Engineering's Falcon is a compact 3-axis non-contact semi-automated measurement system, designed to provide cost-effective accurate results. The repeatable 5-position zoom optics offer users a high-resolution clear image of intricate parts. Accurate and repeatable results are achieved in X and Y axes via the NLEC calibrated stage, and in the Z axis through the unique camera iris control, which reduces the depth of field, thereby increasing accuracy, repeatability, and reproducibility of Z-axis measurements.
Health & Safety
Vision Engineering and its products conform to the requirements of the EC Directives on Waste Electrical and Electronic Equipment (WEEE) and Restriction of Hazardous Substances (RoHS). Compliance includes EN61326-1:2006, FCC Part 15, and EN60950-1:2001.
WARNING: ALL EQUIPMENT PLUGGED INTO THIS UNIT MUST BE APPROVED TO EN60950-1:2001 AND CHECK CURRENT RATING OF OUTPUT SOCKET IF USED.
Symbols observed: [WEEE symbol - crossed-out wheeled bin], [RoHS symbol - checkmark in circle].
Unpacking
The unpacking process involves carefully removing the main unit and its accessories from the shipping container. This is typically done in several steps, involving lifting out the main instrument, removing protective materials, and extracting various components and accessories such as the toolkit and dust cover.
Packing Contents
The Falcon system is supplied with the following main components:
Stand & Objectives
- Stand
- Low Magnification Objective lens
- High Magnification Objective lens
- LED ringlight
- Toolkit
Stage
- 150mm x 100mm stage
- 150mm x 100mm adapter
- 150mm x 150mm Stage
Microprocessor
- Quadra-check 300 microprocessor
- Microprocessor stand
- Control box
Assembly
Removing the transit protection
To remove transit protection, unscrew three securing screws and remove the transit plate. Unscrew the rear transit bolt from the rear of the stand. It is recommended to keep the transit protection for future transport and refit it when moving the system.
Attaching the LED array
Connect the flying lead socket into the fixed plug on the LED array. Position the array carefully and secure it by tightening the single securing screw using the supplied Allen key.
Stage assembly (150 x 150mm)
Ensure the base is stable using the stabilising foot. Remove all red transit protection from the stage. Check the stand base plate and the underside of the 150 x 150mm stage for cleanliness. Position the stage and secure it with the bolts and Allen key, but do not tighten them fully at this stage. The fourth mounting bolt should not be inserted until the system is set up and the stage is aligned.
Stage assembly (150 x 100mm)
Ensure the base is stable using the stabilising foot. Check the stand base plate and the underside of the adapter for cleanliness. Locate the adapter plate and secure it in position using the provided bolts.
Stage assembly (continued)
Remove any remaining red transit protection from the stage. Ensure the adjustable pad on the stage is retracted into the stage bottom plate. Check the top of the adapter and the underside of the stage are clean. Place the stage on the adapter, align the three bolt holes, and screw in the Allen bolts, but do not tighten them fully yet.
Objective lens attachment
Place the objective lens into the head and screw it into position.
Microprocessor assembly
Locate the microprocessor body onto its stand. Ensure the shoulder bolt is used on the left-hand fixing and the spacer and locking washer are correctly positioned on the right-hand fixing. Do not overtighten either fixing bolt.
Cable connection
Connect the necessary cables between the main unit, the QC-300, and the power supply. Ensure easy access to the mains socket is maintained for safety compliance.
Stage alignment
Switch on the Falcon and the QC-300. Follow on-screen instructions for crossing reference marks. Set the magnification control to 2 for high magnification objectives or 4 for low magnification objectives. Focus on the three horizontal lines in the centre of the alignment plate. Rotate the stage until the horizontal lines are parallel to the QC-300's horizontal crosshair. Use the X-axis control to ensure reference lines remain parallel. Tighten the stage bolts through the alignment plate using the Allen key. Remove the alignment plate. If the stage is removed, re-attach the alignment plate and ensure horizontal lines are parallel to the crosshair before removal.
Securing the stage (150 x 150mm)
Loosen the floating stage foot securing screw. Insert and screw in the last stage bolt and tighten fully. Then, tighten the floating stage foot securing screw.
Securing the stage (150 x 100mm)
Set the adjustable pad using a flat-headed screwdriver. Adjust the screw until it just touches down; do not use force, as over-tightening can distort the base plate.
Fitting the stage glass
Fit the stage glass into its recess, ensuring its rear right-hand corner is located against the location springs and on the supports. This procedure applies to both stage types.
Stage glass levelling
Use the X and Y axis controls to bring the rear right-hand corner of the stage glass into view. Use the stage focus control to bring the glass surface into sharp focus. Use the axis controls to bring the front right-hand corner into view and adjust the glass support to achieve sharp focus. Repeat this process for the remaining two corners until all four corners are in focus.
Product Family
The Falcon system is part of a broader range of Vision Engineering products. The family tree illustrates the core instrument and its various configurations and accessories:
- Falcon Bench Stand complete with Quadrant ringlight (F-001)
- Standard Core Instrument
- Objective Lenses: High Mag F-004, Low Mag F-003
- LED Ringlight (F-010)
- Optional Filter (FIL-1570)
- Adapter for 100mm x 150mm Stage (F-008)
- LED Substage Illuminator (F-009)
- Precision Measuring Stage 100mm x 150mm (6"x4") (F-005)
- Precision Measuring Stage 150mm x 150mm (6"x 6") (F-006)
- QC-300 2-axis Microprocessor (H-049)
- Control Box Including Cables (F-002)
- Footswitch (K-016)
- Dust Cover (F-011)
Operation & Setup
Main system controls
The Falcon system features several key controls:
- 1 Zoom Control
- 2 Surface Illumination Iris Control
- 3 Substage Illumination Iris Control
- 4 Y Axis Control
- 5 X Axis Control
- 6 Fine Z Axis Rocker Control
- 7 On/off switch
- 8 Camera gain control
How to Use Your Falcon Measuring System
Start up
Power on the Falcon, ringlight power supply, and QC-300. Follow the on-screen instructions to set up reference marks. Adjust illumination via the Light tab and slidebar. Use the front stand control to move the head and focus on the subject, then adjust zoom. Optimize illumination and optics for the best image. Substage illumination is for profile measurement, while surface illumination is for surface features. Adjust for a clear, bright image with good contrast for accuracy and repeatability. Contact Vision Engineering for assistance.
Iris controls
The camera and substage have adjustable iris controls (5 positions: 1-4 and Z). Adjusting the iris changes the aperture, affecting light and depth of field. Position Z is used for height measurement. The substage iris helps achieve sharper edge definition on profiles.
Objective lens
The system uses interchangeable objective lenses. A magnification table provides details:
| Part No. | Description | Zoom Ratio | Total System Magnification | Working Distance | Field of View |
|---|---|---|---|---|---|
| F-003 | Low Magnification Objective | 1 - 5x | 10x - 50x | 91mm | 2.7 - 13.5mm |
| F-004 | High Magnification Objective | 1 - 5x | 20x - 100x | 61mm | 1.35 - 6.75mm |
Illumination options
Substage illumination is used for measuring holes, profiles, and edge features. Adjust its intensity via the Substage icon on the Light toolbar. It can be used in conjunction with surface illumination.
Ringlight (surface) illumination is used for surface features and blind holes. Adjust its intensity via the Ringlight icon. Quadrants can be switched on or off to create shadows and enhance contrast for difficult edges. This can also be used with substage illumination.
Best practice
For accurate measurements:
- Do not adjust magnification or camera/substage iris once the image is optimized.
- Avoid leaning on or shaking the instrument's upper arm.
- For Z-axis measurements, use the same approach direction for references to achieve clear focus.
- When locating measurement features, focus at maximum magnification and then select lower magnification if required.
The Z-axis is controlled by a sensitive variable speed switch for fine adjustment. Light pressure provides fine adjustment, while increased pressure increases speed. Select the correct magnification based on component size and field of view. Focus on the subject using the front control, then adjust zoom. Regular routine maintenance and calibration are recommended.
Camera gain control
The Falcon system features camera auto gain control, which can be deactivated. This is useful for viewing low contrast parts with high illumination or for profile measurements using substage illumination.
Taking basic measurements
Measurements are made using four capture tools: Straight and Offset crosslines (not used by Falcon), Single Edge tool (for single points), and Multi Edge tool (for multiple points). Points are captured by aligning the tool over the feature and pressing 'enter', or automatically by keeping the tool stationary. The multiedge tool captures points inside or outside the field of view. For features outside the field of view, capture three points for a circle or two for a line, and follow the on-screen arrow to capture remaining points.
Measuring features
The system can measure geometric features:
- Point: Measured by capturing a single point.
- Line: Measured by capturing a minimum of two points.
- Circle: Measured by capturing a minimum of three points.
- Slot: Measured by capturing five points.
For measuring feature form, it is recommended to take at least 8 points for better results.
Measurement Microprocessor Settings and Advanced Features
The Falcon system is configured to work with the supplied measurement microprocessor. Standard factory settings include calibrated magnifications. Refer to the microprocessor user manual for details on setting up and editing features, archiving images, writing measurement routines, and other advanced functions.
Getting the most from your Falcon
Routine maintenance
Wipe down the instrument to remove dirt and dust. Check instruments and accessories for loose or damaged components. Protect the Falcon with the dust cover when not in use.
Consumable & replacement parts
| Description | Specification | Part Number |
|---|---|---|
| Stage glass | 150mm x 100mm | K-018 |
| Stage glass | 150mm x 150mm | 201-B0686 |
| Surface light LED array | 20 LEDs, 1,100 lux (filtered) | F-001 |
| Substage LED | 330 lux (filtered) | MN-006 |
Environmental considerations
For optimal accuracy and repeatability, position the Falcon on a firm, rigid, and level table. Avoid sources of vibration, radiators, heat sources, cold temperature sources, direct sunlight, or areas with bright reflections.
Routine Maintenance
Substage lamp changing
Disconnect the unit from the mains supply. Turn the stand on its side. Remove the two bolts from the Substage Illuminator base plate and remove it with the illuminator unit. Disconnect the inline connector and remove the unit. Fit the new unit by reversing the procedure.
LED Ringlight replacement
Using the Allen key, unscrew the securing screw at the rear of the ringlight assembly. Lower the assembly and disconnect the inline connector. Reverse the procedure to replace the LED ringlight.
Other Solutions From Vision Engineering
Vision Engineering offers a range of stereo inspection and non-contact measuring systems. Visit their website for more product information.
Stereo inspection systems
| Product | Features | Description |
|---|---|---|
| Lentis |
|
A state-of-the-art bench magnifier for inspection, manipulation, and material rework. |
| Mantis |
|
The Mantis family is a unique range of optical systems without eyepieces, for intricate tasks requiring superb quality viewing over long periods of use. Available with universal arm or rigid bench stand option. |
| Alpha |
|
Expanded Pupil eyepiece stereo zoom microscope. Available in boom and bench stand configuration with a wide range of optional accessories (e.g., lighting, cameras). |
| SX 45 |
|
Designed as an affordable stereo zoom microscope, the SX45 with its long working distance, precision optics, and compact design is the perfect solution for many industrial and biological applications. With a wide array of options and accessories, the SX45 allows further tailoring to individual requirements. |
| Lynx |
|
Advanced eyepieceless stereo zoom microscope. Available in boom and rigid stand configuration with a wide range of optional accessories (e.g., lighting, cameras). |
Non-contact measuring systems
| Product | Features | Description |
|---|---|---|
| Kestrel |
|
Entry level, 2-axis measuring system. Ideal for shop floor gauging applications. |
| Hawk manual |
|
Advanced manual measuring system, offering increased accuracy and capacity. Operates with QC-200 and QC-300 microprocessors. |
| Hawk precision |
|
High accuracy measuring system for 2 and 3 axis measurement. Operates with QC-200 and QC-300 microprocessors or QC-5000 PC software. |
| Hawk automatic |
|
Automated measuring system combining optical viewing head with PC based Video Edge Detection. 2 and 3 axis motorised stage movement controlled by QC-5000 PC software. |
Service & Calibration Record
Record details of service and calibration for the Falcon system.
Falcon Serial Number: ________________
Stage Serial Number: ________________
| Service Type | Comments | Date of Service | Date of Next Service | Company | Signature |
|---|---|---|---|---|---|
Warranty
This product is warranted to be free from defects in material and workmanship for a period of one year from the date of invoice to the original purchaser. If during the warranty period the product is found to be defective, it will be repaired or replaced at facilities of Vision Engineering or elsewhere, all at the option of Vision Engineering. However, Vision Engineering reserves the right to refund the purchase price if it is unable to provide replacement, and repair is not commercially practicable or cannot be timely made. Parts not of Vision Engineering manufacture carry only the warranty of their manufacturer. Expendable components such as fuses carry no warranty.
This warranty does not cover damage in transit, damage caused by misuse, neglect, or carelessness, or damage resulting from either improper servicing or modification by other than Vision Engineering approved service personnel. Further, this warranty does not cover any routine maintenance work on the product described in the user guide or any minor maintenance work which is reasonably expected to be performed by the purchaser.
No responsibility is assumed for unsatisfactory operating performance due to environmental conditions such as humidity, dust, corrosive chemicals, deposition of oil or other foreign matter, spillage, or other conditions beyond the control of Vision Engineering.
Except as stated herein, Vision Engineering makes no other warranties, express or implied by law, whether for resale, fitness for a particular purpose or otherwise. Further, Vision Engineering shall not under any circumstances be liable for incidental, consequential or other damages.
For More Information
Vision Engineering has a network of offices and technical distributors around the world. For more information, please contact your Vision Engineering branch, local authorised distributor, or visit our website.
Vision Engineering Ltd. (Manufacturing)
Send Road, Send, Woking, Surrey, GU23 7ER, England
Tel: +44 (0) 1483 248300
Fax: +44 (0) 1483 223297
Email: generalinfo@visioneng.com
Vision Engineering Ltd. (Commercial)
Monument House, Monument Way West, Woking, Surrey, GU21 5EN, England
Tel: +44 (0) 1483 248300
Fax: +44 (0) 1483 248301
Email: generalinfo@visioneng.com
Vision Engineering Inc. (Manufacturing & Commercial)
570 Danbury Road, New Milford, CT 06776 USA
Tel: +1 (860) 355 3776
Fax: +1 (860) 355 0712
Email: info@visioneng.com
Vision Engineering Inc. (Commercial West Coast USA)
745 West Taft Avenue, Orange, CA 92865 USA
Tel: +1 (714) 974 6966
Fax: +1 (714) 974 7266
Email: info@visioneng.com
Vision Engineering Ltd. (Central Europe)
Anton-Pendele-Str. 3, 82275 Emmering, Germany
Tel: +49 (0) 8141 40167-0
Fax: +49 (0) 8141 40167-55
Email: info@visioneng.de
Nippon Vision Engineering (Japan)
272-2 Saedo-cho, Tsuduki-ku, Yokohama-shi, 224-0054, Japan
Tel: +81 (0) 45 935 1117
Fax: +81 (0) 45 935 1177
Email: info@visioneng.jp
Vision Engineering Ltd. (China)
11J, International Ocean Building, 720 Pudong Avenue, Shanghai, 200120, P.R. China
Tel: +86 (0) 21 5036 7556
Fax: +86 (0) 21 5036 7559
Email: info@visioneng.com.cn
Vision Engineering Ltd. (France)
1 Rue de Terre Neuve, ZA Courtaboeuf, 91967 Les Ulis Cedex, France
Tel: +33 (0) 164 46 90 82
Fax: +33 (0) 164 46 31 54
Email: info@visioneng.fr
Vision Engineering Ltd Italia (Italy)
Via Cesare Cantù, 9, 20092 Cinisello Balsamo MI, Italy
Tel: +39 02 6129 3518
Fax: +39 02 6129 3526
Email: info@visioneng.it
Vision Engineering (SE Asia)
Email: info@visioneng.asia
Distributor
Visit our multi-lingual website: www.visioneng.com
