Complete Camshaft Measurement System

Audie Technology, Inc.

23 North Trooper Road
Norristown, PA 19403
USA
Phone 610-630-5895
Fax 610-630-5894
www.audietech.com
support@audietech.com

Copyright 1999-2012, Audie Technology, Inc. All Rights Reserved Worldwide

CONTENTS
USING CAM PRO PLUS
License Agreement ......................................................................................... 2
Software Updates............................................................................................ 2
Installation & Configuration .......................................................................... 3
How to Measure a Camshaft on the Test Stand .......................................... 5
How to Measure a Camshaft in the Engine.................................................. 7
Measuring Order ............................................................................................. 7
Adding Notes to Data Files ............................................................................ 8
Editing Lobe Details ....................................................................................... 8
What Can I Do With the Lists? ...................................................................... 9
What Can I Do With the Graph? .................................................................... 9
Project Files ................................................................................................... 10
Measurement Setup ...................................................................................... 12
Report Setup.................................................................................................. 15
Graph Setup................................................................................................... 15
Measuring Options ....................................................................................... 16
Keyboard Entry / Edit ................................................................................... 16
File Import / Export ....................................................................................... 17
Raw Data Output ........................................................................................... 18

CAM PRO PLUS TECHNICAL TOPICS

Smoothing ..................................................................................................... 19
Locating TDC for On-stand Measurements ............................................... 19
Mating Lobes ................................................................................................. 19
Authorization Codes ..................................................................................... 20
Troubleshooting............................................................................................ 20

CAMSHAFT TECHNICAL TOPICS

Velocity, Acceleration, Jerk ......................................................................... 22
Flat Follower Contact Width / Minimum Flat Follower Size ..................... 22
Centerlines..................................................................................................... 23
Base Circle Runout ....................................................................................... 23
Pivoting Followers ........................................................................................ 24
Mushroom Tappets & Power ....................................................................... 25
Parts of a Lobe .............................................................................................. 26
Elements of a Cam Lift Curve ...................................................................... 26
Lobe Separation & Overlap ......................................................................... 27
Open, Close, Duration, & Area Under the Curve ....................................... 27
Cam Factor .................................................................................................... 28

LICENSE AGREEMENT
This software license agreement is being provided to you (Customer) before you use the software. Please
read it carefully. If you do not agree to it, do not use the Software. Return it and all its accompanying
documentation for a refund of your purchase price.
Audie Technology, Inc. grants you a non-exclusive license to use one copy of the Cam Pro Plus program
(Software) on one computer. The Software may not be copied, transmitted, or transcribed, except by the
original purchaser for his own convenience. The original and backup copies of the Software shall be used
only on one computer at a time. The documentation may not be copied.
The Software and its documentation are COPYRIGHTED. ALL RIGHTS ARE RESERVED.
Audie Technology, Inc. has made reasonable effort to prepare the Software and its documentation in an
error-free manner. The user accepts full responsibly for determining the suitability of the Software for a
particular application. In no event will Audie Technology, Inc. be liable for any damages arising out of
the Customer's use of the Software, including direct, indirect, consequential, or incidental damages.
Audie Technology, Inc. warrants that the disks on which the software is supplied are free from defects in
materials and workmanship under normal use for a period of 90 days after purchase.

SOFTWARE UPDATES
You can check the revision history and download the latest software update form the Audie Technology
website at: www.audieteh.com/updates.htm

Installation & Configuration

1. Install the Software.
Place the CD in your CD drive. If the installation program does not auto-start then run the SETUP
program located on the CD.
Plug the authorization key into your computer.

2. After installation is complete, run the CPPlus program.

3. Set the PC Connection.
a.
b.
c.
d.
e.

Click on the Edit menu.

Click on Graph & Measuring Options
Click on the Measuring tab.
Set the PC connection to USB or to the COM port that the sensors are using.
Click on OK

4. Enter the authorization codes for software options.

a.
b.
c.
d.

Click on the Edit menu.

Click on Authorization Codes
Enter the codes for options that you have purchsed.
Click on OK

5. Connect the Sensor Display Module to the PC's COM port.

Newer Display Modules connect by USB. Older ones use a COM port.
There are two different connectors used for COM ports on PC's. One is a 9 pin male D-Sub
connector, the other is a 25 pin male D-Sub connector. Your computer may have either or both (PC's
can have more than one COM port). The cable used to connect the sensor display module to the PC
is a standard serial port cable. Adapters to convert one connector to the other, longer cables, and
cables with different connectors (9 or 25 pin) are available from most computer stores. If your PC
does not have a COM port, a USB to COM adapter can be used.

6. Plug the rotary and linear encoders into the sensor display.
7. Connect the motor drive control.
Newer Display Modules also control the motor. Older ones require a separate motor control box. If
you have the motor drive option on an older system, plug the motor control box into the sensor
display module. Plug the motor control box into a 120 VAC 50/60 Hz supply.

8. Apply power to the sensor display module.

Apply power to the sensor display module with the wall transformer power supply. Newer systems
use a 24 VAC, 500 ma power supply. Older ones use a 250 ma (or greater), 9 VDC supply.

9. Test the PC Connection.

a.
b.
c.

Click on the Measure button (or Click on Measure menu and then on Measure).
When the file name dialog appears click on Open. (The file name does not matter now since
you wont be saving any data yet).
If the Sensor Display Module is on and properly connected, large numbers that match those on
the Sensor Display Module will appear to the right of the Lift and Angle labels.

10. Set the software for your encoders.

a.
b.
c.
d.

The sensor display must be connected and communicating with your computer before changing
the encoder setting in the software.
While on the Measuring screen, Click on the Measure menu.
Click on Encoders.
Select the correct encoder. (The selections available change depending upon the abilities of
your sensor display. This is why the display must be connected and communicating.)
If your linear encoder is an Ono Sokki GS-332 or GS-133 choose Standard Encoder. If your
linear encoder is a Heidenhain choose Optional Encoder.
If your rotary encoder is a Heidenhain choose Optional Encoder, or Optional Encoder
(Fast). Optional Encoder (Fast) permits 4 times faster rotation when measuring a lobe. If
your rotary encoder is not a Heidenhain choose Standard Encoder.

Using Cam Pro Plus

How to Measure a Camshaft on the Test Stand
see also: Measuring Order

Mount the cam

1. Place the cam on the V-blocks. If the journals of the camshaft are different diameters, use spacers on
the V-block to raise the smaller journal so that the camshaft is level.
2. Use a little oil to lubricate the V-blocks.
3. Position the V-blocks so that each end of the camshaft can rest on a V-block. When tightening the
thumbscrews on the V-blocks or the follower support rod, pull the base of the V-block against the
bevel on the back edge of the base.
4. Tighten the hold downs so that the camshaft can not slip off the V-blocks.
5. Loosen the thumbscrews on the V-blocks so that the camshaft and V-blocks together can slide on the
base as one unit.
6. If using the universal cam adapter:
a. Position the adapter so that one of the jaws is at the top, and open the jaws.
b. Slide the camshaft into position, and lock the V-blocks in place.
c. Slightly loosen the wing nut that holds the rotary encoder assembly. Use one hand to hold the
rotary encoder assembly against the base, while tightening the adapter with the other hand.
d. Tighten the wing nut that holds the rotary encoder assembly.
e. Loosen the thumbscrews on the V-blocks, and then re-tighten them.
7. If using a standard cam adapter:
a. Slightly loosen the wing nut that holds the rotary encoder assembly.
b. Slide the camshaft into position, and lock the V-blocks in place.
c. Use one hand to hold the rotary encoder assembly against the base, while tightening the wing nut
that holds the rotary encoder assembly.
8. Adjust the hold downs so that they allow the camshaft to rotate while still keeping it from moving
around in the V-blocks.
9. If you are using a motor drive, set the direction switch on the motor drive control box so that the
camshaft rotates in the normal direction (i.e. that same direction it rotates in the engine).
10. Set the CW/CCW switch on the sensor display module so that rotating the cam in the normal
direction increases the rotary reading on the display.
11. Zero the rotary sensor. The zero position does not matter when measuring a cam on the stand, but
once zeroed you are not permitted to zero it again until you press CLEAR. This rotary zero lockout
feature prevents accidentally changing the zero in the middle of measuring a shaft. Changing the
rotary zero in the middle of measuring a shaft will cause errors.
12. Select the correct follower for your cam. Flat tappet cams all use the follower with the dowel pin.
Roller cams use a follower with a ball of the same diameter as the roller. Set the height of the
follower block so that the follower can sense the full range of follower motion and still clear the
journals when moving to the next lobe.

Measure the lobes

Move the highlight to the lobe you want to measure. Previously measured lobes will be yellow on the
diagram. The program will ask for confirmation before it lets you re-measure a lobe.

Rotate the cam in the normal direction until the follower is on the base circle (heel) of the lobe. Push the
MEASURE button. If you are using the motor drive, the drive will automatically start. When not using
the motor drive, slowly and smoothly rotate the cam until you hear a triple beep. If you rotate too fast for
accurate measurement, the sensor module will beep to warn you. When this happens it is still possible to
use the measurement but the accuracy may be suffer. To abort a measurement in progress press the
CLEAR button.
After completing the measurement, the program may change to the graph or report screens depending on
the action selected on the Measuring Options dialog. This dialog is on the Edit menu.
If the measurement order is active the highlight will automatically move to the next number in the order.
If you are not using the measurement order numbers, move the highlight to the next lobe. Move the linear
encoder to that lobe and repeat the measurement process. Do NOT change the rotary encoder zero
between lobes.

How to Measure a Camshaft in the Engine

see also: Measuring Order
Measuring in the engine differs from measuring on a stand in two ways:
1. Mounting the sensors.
2. The rotary encoder must be zeroed at overlap TDC of the #1 cylinder (see below for an exception).

Mount the Linear Sensor

Mount the linear sensor so that it can sense the full range of motion of the follower or valve stem. The
simplest way to accomplish this is with a machinist's magnetic base. More rigid mountings can also be
fabricated.

Mount the rotary sensor

The rotary sensor assembly mounts on the front of the engine as a fuel pump or dry sump pump would
mount. Various compatible mounting brackets are available from:
BLP Products
1015 W. Church St.
Orlando, FL 32805
Phone: (407) 422-0394
Use an old damper hub to attach the arbor to the crankshaft nose. Connect the pulley on the arbor to the
pulley on the sensor assembly with a standard 3/8 pitch by 1/2 inch wide belt (L050 series belts). Set the
CW/CCW switch on the sensor module so that rotating in the normal direction increases the rotary
reading on the display.
If this mounting system will not work on your engine, any system that drives the rotary sensor at a 1:1
ratio from either the camshaft or the crankshaft should work. Just be careful that the measurement setup
his the correct sensor location.

Zero the Rotary Sensor at #1 TDC

There are two ways to zero the rotary sensor. You can push the ROTARY ZERO button to zero the
rotary sensor at its current position. Or, you can use a piston stop (this is the recommended method). To
use the piston stop method press PISTON STOP and follow the prompts. The system will set zero for
midway between each piston stop reading.
Once zeroed, you are not permitted to zero the rotary sensor again until you press CLEAR. This lockout
feature prevents accidentally changing the zero in the middle of measuring.
For specialized applications, the sensor can be zeroed at a different position. When this is done the
angular offset between the zero position and TDC must be specified in the measurement setup.

Measuring Order
Measuring order automatically moves the highlight to the next number in the order after each lobe is
measured. When measuring order is active the measuring order numbers will appear above each lobe. To
activate / de-activate the measuring order click Measuring Order on the Measure menu while on the
measuring screen.

Adding Notes to Data Files

Each Cam Pro Plus data file has a notes entry. There is one entry for the entire file. It is a good idea to
develop a standard format for the first line of your notes. When searching for a particular test file, it is
easier to find the data if it is always in the same spot in the notes.
Common items to include in the notes are:
Date
Camshaft manufacturer
Serial or unique numbers marking the cam.
Height of an intake lobe
Height of an exhaust lobe
The owner or engine number
To edit the notes for a file:
1. Move the highlight in the Lobe list to any lobe in that file.
2. Choose Edit Notes from the file menu.

Editing Lobe Details

To edit the details of a lobe:
1. Place the highlight in the lobe list on the lobe.
2. Choose Highlighted Lobe from the Edit menu.
Lash and rocker ratio are used compute valve motion from follower motion.
For more explanation of the other details see also:
Centerline
Centerline as Measured
Base Circle Runout
Base Circle Radius, Heel to Nose
Notes
Smoothing
Valve Train Adjustment (in the section on Measurement Setup)

What Can I Do With the Lists?

Relocate the lists
An entry on the Graph & Measuring Options dialog (on the edit Menu) allows you to position the Lobe
and Curve lists to the left of the graph or above the graph. To change the size of the screen window used
for each list, click and drag the bars that divide the screen windows.

Hide the lists

A command on the Window menu lets you hide/show the lists on the graph screen. This allows a larger
area for the graph.

Change lobe order

The command to change the order of the lobes in the lobe list is on the file menu.

Change column order

1. Click on the title of the column you want to move.
2. The column will change color to show your selection
3. Click on the new location for the column.

Change column width

To change the width of a column, click and drag the columns right edge in the title line.

Edit values
In the lobes list only, you can edit many values in the list just as if it were a spreadsheet. To edit a runout,
lash, rocker ratio, centerline, or smoothing value, click on the value in the list and then edit it in-place.

Tag/Untag
The Tag turns items on for graphing and/or chooses them for some action (such as inclusion in a report).
Double Click an item to tag/untag it. Pressing SPACEBAR will also tag/untag the highlighted item.
Double Click the column title for the tag mark to tag/untag all lines in the list.

What Can I Do With the Graph?

Setup Dialog
There are several options for configuring the graph on the Graph & Measuring Options dialog (on the edit
Menu).

Curve Color
Either list (but only one at a time) may use color to distinguish the curves that belong to each item in the
list. An entry in the graph setup dialog determines which list uses the color.

Blinking Curve
The curve identified by both the highlight in the curve list and the highlight in the lobe list will blink.
You may need to adjust monitor contrast and brightness to see blink.

Finding a Curve in the Lists

When you click on a curve, the highlight in both lists will move to the items that correspond to the curve
that you clicked on.

Zoom

To zoom in on part of the graph, click at one corner of the area to be enlarged. Then, while holding the
mouse button down, move to the opposite corner and release the mouse button. To remove the zoom
click the Un-Zoom button on the toolbar or choose Un-Zoom from the Window menu.

Hide the lists

A command on the Window menu lets you hide/show the lists on the graph screen. This allows a larger
area for the graph.

Marker Lines
The graph has 4 vertical lines which are used to select angular positions and boundaries. Two blue lines
mark the boundaries for the area under the curve and average columns in the lists. A green line marks the
position for the value column in the lists.
The red line, when activated, marks a reference so that the green line can measure relative values. To
activate/de-activate the red reference line right click its marker.
Each line has a marker in the short window just above the graph. You may move a line by dragging its
marker with the mouse. Each line also has a numeric entry above the graph. This entry shows its exact
location and can be used to set the location.
The lines can also be moved by these keystrokes:

KEYSTROKE
_ (underscore)
+
[
]
{
}
L
R
Up Arrow
Down Arrow

ACTION
Move green value line to right
Move green value line to left
Move blue right boundary line to left
Move blue right boundary line to right
Move blue left boundary line to left
Move blue left boundary line to right
Move both blue boundary lines to left
Move both blue boundary lines to right
If a numeric entry has the focus this has the same effect as
clicking the up arrow next to the numeric entry.
If a numeric entry has the focus this has the same effect as
clicking the up arrow next to the numeric entry.

The Step entry above the graph sets the amount of movement caused by a keystroke or a click on the
arrows next to the other numeric entries.

Project Files
Most of the settings by which you customize the program and a list of which lobes are open in the
program are stored in a project file. Project files are similar to INI files, but they have a PRJ file
extension. The program will always start with the project file that was in use when you last exited the
program. By this means Cam Pro Plus is able to restore the program to the state you left it in the last time
you used it.
Project files can also be used to quickly switch from working on one project to working on another
project. For example, you can have one project file for the large V8 cams you work with during the
week, and another for your sons kart engines that you work on on the weekends. Use the Project menu
and the Exit - no PRJ write item on the file menu to manage your project files.

10

Measurement Setup
Use TDC Offset
TDC Offset is an adjustment to the position of the rotary sensor zero. In-engine tests expect the rotary
encoder zero (after applying the offset) to be at number one cylinder TDC.
For on-stand tests the position of the rotary encoder zero is normally ignored. A virtual TDC is
established by splitting the difference between the intake and exhaust centerlines, and then applying your
cam advance entry. If "Use TDC Offset" is checked, then the rotary encoder zero (after applying the
offset) is taken as the number one cylinder TDC. The usual procedure when using TDC Offset on the
stand, is to place the dowel pin on the front of the cam against a stop before zeroing the rotary encoder.
You will need to fabricate your own stop and determine how much offset it needs.

Piston Included Angle

This is the included angle between the right & left bank piston bore centerlines.

Opposed Engines
For opposed engines use V-Block and set the included angle to 180 degrees.

Linear Sensor Reverse Direction

This setting affects how the program processes linear encoder readings when measuring valve motion.
Normal motion has minimum extension of the encoder tip (and maximum linear reading) when the valve
is closed. Reverse motion is the opposite.

Lash & Rocker Ratio

Lash and rocker ratio are used compute valve motion from follower motion. They are not used when
valve motion is measured. These values are those given to a lobe when it is measured. Each individual
lobes values can be revised at any time in the future.

Follower Bore vs. Piston Bore Angles

Angles are the trickiest part of working with camshafts. When a cam is measured on the stand instead of
installed in an engine, the lifter centerline may not be positioned at the same angle as it is in the engine. If

11

all you are interested in is the profile of a single lobe this does not matter. But if you are interested in
lobe separation, overlap, or correct positioning of lobes from cylinder to cylinder, it is necessary to know
the angles of the follower bores in the engine relative to the follower on the stand.

Example: Small Block Chevy

Let's consider the small block Chevy as an
example. The piston bores have 90 degrees
between each bank. Both intake and exhaust lifter
bore centerlines have only 82 degrees between
each bank. The difference is 8 degrees (90 - 82 =
8). Half of the difference is appears on the left
bank and half on the right. Thus the Follower
Bore C/L vs. Piston Angle is -4 degrees for the
left bank and +4 degrees for the right bank.

Example: Big Block Chevy

The big block Chevy is a little trickier because
exhaust lifter bore centerlines are not positioned
the same as intake lifter bore centerlines. The
exhaust lifter bore centerlines and the piston bores
both have 90 degrees between each bank. Thus
the exhaust follower bore C/L vs. piston angle for
each bank is 0 degrees. Intake lifter bore
centerlines have 77.5 degrees between banks. The
difference between them and the piston bore
centerlines is 12.5 degrees (90 - 77.5 = 12.5).
Half the difference appears at each bank. Thus
the follower bore C/L vs. piston angle is -6.25
degrees for the left bank and +6.25 degrees for the
right bank.

12

Camshaft Diagram
Identify each position on the diagram.
Journal
Enter J
Intake Lobe
Enter I followed by the cylinder number
Exhaust Lobe
Enter E followed by the cylinder number
Keyway / Dowel Pin
Enter K
On multi-valve engines, where each valve has its own lobe, use a, b, and c to distinguish the lobes for
each valve. Examples: I1a, I1b, E2a, E2b

Firing Order
Enter the firing order with each cylinder separated by a dash. Always start with cylinder number 1. For
example: 1-4-3-2 is a typical 4 cylinder firing order.

Crank Throw Angles

The program will calculate crank throw angles for even fire engines based upon the firing order and
cylinder numbers that you enter. For odd fire engines you must enter the crank throw angles. Number
one cylinder must always have a crank throw angle of 0.

Valve Train Adjustment

Valve Train Adjustment is an extra cost option. If you do not have this option the only valid selection is
"No Adjustment". This option compensates for overhead valve trains that have pivoting followers. It
handles both cam on rocker arm (CORA), and finger followers. The option can also convert lift data
measured with one diameter roller follower to what it would be if a different diameter roller were used.
No Adjustment
C Lift is the data as measured with the runout subtracted.
V Lift = (C Lift x Rocker Ratio) - Lash.
Different Size Follower
C Lift is the data adjusted to what it would be if a different follower were used.
V Lift = (C Lift x Rocker Ratio) - Lash.
End Pivot, Center Pivot
C Lift is the data as measured with the runout subtracted.
V Lift is the motion that would be produced at the valve using the specified geometry.
End Pivot & Knife Edge Follower, Center Pivot & Knife Edge Follower
C Lift is the data adjusted to what it would be if a knife-edge follower were used.
V Lift is the motion that would be produced at the valve using the specified geometry.

14

Report Setup
See Also:

Checking Height, Open, Close, Duration & Area Under the Curve
Cam Factor
Overlap

Checking Heights
The Lift by Lobe and Lift by Lift reports can include up to 20 checking heights. While it is not necessary
to enter the checking heights in order it is a good practice.

Customized Report
The customized report is a flexible multi-column format that lets you designate the contents of each
column. You can define ten different variations of the customized report. Give each one a unique title so
that you can identify it on the Custom Report sub-menu.

Analysis Report
The analysis report compares all tagged lobes to determine their consistency. This can be useful in
judging the quality of a camshaft. The report layout is flexible. You designate the contents of both the
rows and columns. You can define ten different variations of the analysis report. Give each one a unique
title so that you can identify it on the Analysis Report sub-menu.

Graph Setup
To edit the graph setup choose Graph & Measuring Options from the Edit menu.

Y-Axis Scales
The Y-axis (vertical) scale is selected from the Graph & Measuring Options dialog. Grid lines always
match the scale on the left side of the graph. When using both right and left side scales, try to adjust the
scale top and bottom values so that the grid lines, which are controlled by the scale on the left, also work
well for the scale on the right.
Keep in mind that lift is measured in inches, not thousandths. Thus four hundred thousandths is 0.400,
not 400.
Velocity, acceleration, and jerk scales are in units of inches (or mm) per degree, inches (or mm) per
degree2, and inches (or mm) per degree3 respectively. This differs from the DOS version of Cam Pro Plus
where the units were thousandths per degree, ten thousandths per degree2, and hundred thousandths per
degree3 respectively. The new units are in line with common practice in the camshaft industry.

Grid Threshold
The spacing of grid lines is automatically adjusted every time the screen is redrawn. Grid threshold
controls the point at which the program decides there are too many grid lines on the screen and the grid
needs to be thinned out. A lower grid threshold will result in a finer grid. Most people find a setting of 3
or 4 works well.

15

Measuring Options
To edit measuring options choose Graph & Measuring Options from the Edit menu.

File Name Increment

Test data is stored in disk files. You must provide a name for the file when you start a new test. The
Increment Name on New Data Files option advances the name you used for the last test and provides
that name in the entry blank. For Example: CHEVY009 becomes CHEVY010, BUICK04C becomes
BUICK04D. If the name increment is not active then the last test's file name is provided unchanged.

After Measuring Go To
These options control what the program does each time it finishes a lobe. When the program goes to
another screen (graph or report) the measuring screen is still active. Click the measure icon on the tool
bar or choose Measure on the Window menu to return to the measuring screen.

Measurement System

(English inches vs. Metric mm)

This selection affects lift, runout, velocity, acceleration, jerk, and area under the curve values throughout
the whole program. Only the display of the data is affected by this setting. Internally, and in the files, the
data is always stored in inches. If you create a report and then change the measurement system, you must
re-create the report in order to show values in the new measurement system.

Lobe Centerline Method

There are a variety of methods for computing lobe centerline. The standard Cam Pro Plus method
calculates lobe centerline by averaging the points that are .003, .006, and .009 down from maximum lift.
Another method is to average the points that are .050 (or 1 mm) down from maximum lift. Many cam
cards use the method. The centerline method is applied when the lobe is measured. It is not possible to
change it after the lobe is measured.

Keyboard Entry / Edit

Description
The Keyboard Entry / Edit creates Cam Pro Plus data files from keyboard entered lift data. Data may be
from a blueprint or manual measurements. For symmetrical lobes enter one half of the lobe and then use
one of the Mirror buttons to create the other half.
Keyboard Entry / Edit is an extra-cost option. Contact your software vendor to order this option.

Angle Spacing
In fixed angle spacing mode, the angle step size can be set for 1, 2, 3, 4, 5, or 6 cam degree steps. When
not in fixed angle spacing mode, you must enter every angle, but you are allowed a random step size. The
program will interpolate the data to 1 degree spacing when it is saved. Some operations (such as mirror)
may also cause the data to be interpolated to 1 degree spacing.

Curves
Lift and velocity curves are drawn as you enter the data. No smoothing is used. Use these curves as a
visual check for keying errors.

Centerlines
Regardless of how the data is entered, the highest lift entry will define the centerline. Just as with other
Cam Pro Plus data files, the data will be stored with the centerline at TDC and then shifted to match the
specified centerline when the file is accessed.

Details

16

Click the Details button to access entries for the centerline, runout, notes, etc.

File Import / Export

Description
Cam data file import extracts cam data from other file formats and saves it in a Cam Pro Plus data file.
Cam data file export saves cam data from Cam Pro Plus files in other file formats. The S96 and Doctor
Doctor files are ASCII file formats. Cam Pro and Cam Pro Plus files are binary file formats.
Except for importing files from Cam Pro (the predecessor of Cam Pro Plus), the file import & export
functions are an extra-cost option. Contact your software vendor to order this option.

Import
The import commands are on the File menu. Data can be imported from Cam Pro files, Doctor Doctor C1
files, and S96 files. The Cam Pro Plus files created by the import functions are in the same folders and
have the same name as the source files, but with a CPP file extension.
Cam Doctor C1 files can also be imported using the Doctor Doctor import function, but the lobe
centerlines will be incorrect. After importing you can adjust the centerlines to correct values just as you
can adjust the centerline of any lobe.
Because S96 files do not contain centerline information, imported S96 files always have a centerline of 0.

Export
The export commands are on the File menu. Data can be exported to S96 files, 4StHead files, and Doctor
Doctor C1, INC, and EXC files. The lobes to be exported must be opened in Cam Pro Plus before
exporting.
When exporting to Doctor Doctor files the type of file created depends upon how many lobes you select
for exporting. If you select only one lobe an INC (for intake lobes) or an EXC (for exhaust lobes) will be
created. If you select two or more lobes the first two selected lobes will be exported to a C1 file.
When exporting to S96 files each lobe you select will be converted into an S96 file. S96 files can hold
only one lobe. Centerline information will be lost because S96 files do not contain centerline
information.

17

Raw Data ASCII Output

Description
Cam Pro Plus saves 360 lift readings for each lobe. The measuring process collects more data than this.
The amount of extra data collected depends upon the resolution of your rotary sensor. The extra data is
used to establish lobe centerline and then is discarded. The Raw Data ASCII Output function creates an
ASCII file with all the data gathered when a lobe is measured. This data may then be used by other
software.
The Raw Data ASCII Output function is an extra-cost option. Contact your software vendor to order this
option.

Use
Use the Raw Data Output command on the measuring screens file menu to configure and enable or
disable this function. The command will have a check mark nest to it when the Raw Data Output is
enabled. The regular CPP data files are always created regardless of whether the Raw Data Output is
enabled.

Files
Raw Data files are created in the same folder as the regular CPP data file. One file is created for each
lobe measured. The file name is the CPP data file name with a lobe name added and a TXT extension.
For example: If the CPP data file is MyCam.CPP then the Raw Data File for the number one intake
lobe is MyCamIntake1.TXT
The first line of each file describes the file. It will read something like: Cam Pro Plus raw data file for
Intake 1. The rest of the file will be the data with one lift reading per line. The number of lines depends
upon the resolution of your rotary sensor. There will always be 360 degrees of data.

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Cam Pro Plus Technical Topics

Smoothing
While the sensors used on Cam Pro Plus have a high resolution they are digital devices and as such have a
limited resolution. Consider the standard linear sensor which has a resolution of 1 micron (.00003937
inch). It can measure 20 microns and it can measure 21 microns, but it can not measure 20.4 microns. A
lift of 20.4 microns will be reported as 20 microns. This small error can create a large amount of hash in
the velocity, acceleration, and jerk curves.
The answer to this hash problem is to smooth the lift data before it is used to generate velocity,
acceleration, and jerk. Cam Pro Plus smoothes a copy of the lift curve so that smoothing will not affect
the lift data. The smoothing algorithm which Cam Pro Plus uses is mild, but it can be applied repeatedly
to gain any desired degree of smoothing. When you change the smoothing for a lobe, you are changing
the number of times that the smoothing algorithm is applied.

Locating TDC for On-stand Measurements.

When a camshaft is measured in the engine, the operator must zero the rotary sensor at cylinder #1
overlap TDC. This allows CPP to correctly locate each lobe. But when a camshaft is measured on the
stand there is no piston and therefore no real TDC. Cam Pro Plus creates a virtual TDC to take its place.
The procedure used to find this virtual TDC is:
1. Find the lowest cylinder number for which both the intake and exhaust have been measured. Set
TDC with not advance equal to midway between the intake and the exhaust centerlines. Then adjust
TDC for the advance specified in the measurement setup.
2. If no cylinder is found by step 1 and this is a multi-valve engine, consider other lobes from the same
cylinder. For example: Allow lobe 2Ia and lobe 2Eb to be a match. Set TDC with not advance equal
to midway between the intake and the exhaust centerlines. Then adjust TDC for the advance
specified in the measurement setup.
3. If steps 1 and 2 both fail, locate TDC so that the lobe that was measured first has its centerline at 100
degrees (ATDC for intakes, BTDC for exhausts).
If "Use TDC Offset" is selected in the measurement setup then the TDC for cylinder 1 is placed at the
specified offset from the zero location of the rotary encoder. The virtual TDC method described above is
not used.

Mating Lobes
Lobe separation and overlap are characteristics of a pair of lobes rather than a single lobe. In Cam Pro
Plus the process of identifying which lobes form a pair is called mating. While a lobes mate in a real
engine is a fixed characteristic of the lobe, Cam Pro Plus allows you to mate any lobe to any other lobe.
If two lobes that are mates in a real engine are opened in the same open operation, Cam Pro Plus will treat
them as mated. To change the current mating, select Mate Lobes on the File menu.

Authorization Codes
Authorization codes activate special options which are available at extra cost. Contact your software
vendor to order these options.

Troubleshooting

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No communication
If there is no communication between the Sensor Display Module and your PC, the rotary and linear
values on the measuring screen will display as a row of dashes. The most common causes of failed
communication are:
1. Com Port setting on the Graph & Measurement Dialog (on the Edit menu) is incorrect.
2. Cable between the Sensor Display Module and the PC is loose or plugged into the wrong
connector on the PC.
3. No power to the Sensor Display Module.
4. Com Port on the PC is defective.

Upside-down lobes
The cam lift curve appears to be upside-down. Instead of looking like a mountain it looks like a valley.
The centerline is not even close to being correct and the durations are very long.
To correct this change the Reverse Motion setting for the Linear Sensor and measure the lobe again. This
setting is on the General tab of the Measurement Setup dialog.

Wrong centerlines
There are many possible causes for wrong centerlines.
1. Zeroing the rotary sensor between lobes.
2. Rotating the camshaft the wrong direction.
3. Incorrect Crank Throw angle entries in the measurement setup. These entries are on the Engine
Map tab of the Measurement Setup dialog.
4. Incorrect Follower Bore vs. Piston Bore angle entries. These entries are on the General Tab of
the Measurement Setup dialog. These entries are only used when testing in done on the stand.
5. Incorrect Piston Included Angle or Reverse Rotation entries. These entries are on the General
Tab of the Measurement Setup dialog. These entries are only used when testing in done on the
stand for V-block engine camshafts..
6. See also the answer to the Upside-down lobes question above.

Wrong lobe separation

1. Zeroing the rotary sensor between lobes.
2. Rotating the camshaft the wrong direction.
3. Incorrect Follower Bore vs. Piston Bore angle entries. These entries are on the General Tab of
the Measurement Setup dialog. These entries are only used when testing in done on the stand.
4. See also the answer to the Upside-down lobes question above.

Wrong durations
1. Base circle runout can change duration, especially duration at low lifts. Raising the runout
number will lower the duration.
2. See also the answer to the Upside-down lobes question above.

No Graphs
1. There are two lists on the graph screen. One list has lobes, the other has the various curves that
can be plotted (Lift, Velocity, Acceleration, Runout). Each list has a narrow column which will
be blank or have a black X. The rows with a black X are tagged (turned on). Only tagged items
appear in the graph. Thus, in order for anything to appear in the graph you must have something
tagged in both lists. See the topic "What Can I Do With the Lists?" for more information on tags.
2. In addition to the information on tags, you should be aware that a lobe that is measured at the
valve (instead of at the follower) has no C Lift, C Velocity, C Acceleration, or C Jerk curves.

20

3. You may have accidentally zoomed into a portion of the graph that has no curves. It is possible
to unintentionally do this by accidentally moving and clicking the mouse. Look carefully at the
horizontal and vertical axis scales. See the topic "What Can I Do With the Graph?" for more
information on zoom.
4. The graph scales may be configured so that the curves are off screen or so small that they can not
be seen. To get to the entries for setting the graph scales, choose "Graph and Measuring Options"
from the graph screen's Edit menu. Keep in mind that lift is measured in inches, not thousandths.
Thus four hundred thousandths is 0.400, not 400.

21

Camshaft Technical Topics

Velocity, Acceleration, Jerk
Velocity is the rate at which position changes. In most applications it is expressed in terms of distance vs.
time (miles per hour, feet per second, etc.). When dealing with camshafts, time is replaced by degrees of
camshaft rotation. This allows us to study camshaft profiles independent of engine speed. Thus camshaft
follower velocity is usually expressed in units of inch/deg (as in Cam Pro Plus) or thousandths/deg (as in
Valve Pro). Metric units are mm/deg (as in Cam Pro Plus) or micron/deg (as in Valve Pro).
The maximum velocity a flat tappet cam profile may have is limited by the diameter of the follower.
Exceed this limit and the contact point between the follower and the cam will move off the face of the
follower. This will very quickly destroy the cam as the edge of the follower digs into the cam.
Acceleration is the rate at which velocity changes. It is expressed in units of inch/deg 2 or
thousandths/deg2. Manufacturing issues and tolerable stress levels combined with the diameter of the
follower and the diameter of the base circle limit the maximum acceleration a roller follower cam profile
may have.
Jerk is how fast acceleration changes. It is expressed in units of inch/deg3 or thousandths/deg3. Cams
with higher maximum accelerations and jerks are harder on the valve train. When examining the
acceleration and jerk curves high negative values of acceleration and jerk are as important as high positive
values.
The question is often asked, How much velocity/acceleration/jerk is too much? The answer is, It
depends. Maximum engine speed, the type of valve train, the mass and stiffness of valve train
components, and the characteristics of the valve springs all affect the answer to this question. Usually
experience is used to establish practical limits. The one exception is the earlier mentioned maximum
velocity limit of flat tappet followers.

Flat Follower Contact Width / Minimum Flat Follower

Size
The formula for computing the movement of the contact point on the face of the lifter relative to the
contact point when on the base circle is:
MOVEMENT = VELOCITY / 57.296
Other factors that need to be considered are:
1. Opening and closing velocity move the contact point in opposite directions.
2. The width of the lobe
3. Chamfer on the edge of the follower reduces the effective diameter of the follower
4. A safety margin

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Centerlines
There are a variety of methods for computing lobe centerline. The standard Cam Pro Plus method
calculates lobe centerline by averaging the points that are .003, .006, and .009 down from maximum lift.
Another method is to average the points that are .050 down from maximum lift. Many cam cards use the
method. A third method is to average the points that are .050 above the base circle. This is the centerline
reported as ".050 Lift C/L" in the Lift by Lobe reports. You can select the centerline method on the
Measuring tab of Graph and Measuring Options. The centerline method is applied when the lobe is
measured. It is not possible to change it after the lobe is measured.

Base Circle Runout

If a cam lobe had no lift it would be round, like a journal. If you accurately measure the profile of a
round lobe you would still find some spots that were higher than others because of runout. Automotive
cam lobes have a portion of the lobe that is supposed to be round, which is called the base circle..
Before we can measure a cam lobe we must address the issue of how to mount the camshaft for
measuring. Cams are mounted on centers for grinding, but they run on the bearing journals in the engine.
Unless the journals and the centers are perfect (nothing is ever perfect) the mounting method will make a
difference in the runout. Cam Pro Plus mounts the camshaft on the bearing journals because that is how
the camshaft is used.
Cam lifts are measured from a point called "zero lift." Zero lift is defined as the lift on the base circle.
But now we have a problem because the lift on the base circle varies due to runout. What point should be
considered zero? Should the lowest point on the base circle be zero lift? Or do we want to figure out
where the ramps are and do some sort of averaging to define zero? This is an important issue because the
zero lift point affects many commonly used camshaft parameters including total lift, duration, timing
angles, and area under the curve.
Cam Pro Plus finds the lowest point on the base circle and calls that zero. It also scans the base circle to
find the highest point. The difference between these two points is the base circle runout. Cam Pro Plus
subtracts the base circle runout value from the measured lift values and uses the result as lift (except for
the base circle runout graph). The Cam Pro Plus base circle runout graph shows the lift curve of the base
circle.
Any camshaft can experience a change in measured base circle runout because camshafts seldom stay
straight. It is common for runout to change as the stresses in the metal introduced by the different
manufacturing processes work themselves out over time. Thus while quality cam manufacturers strive to
limit base circle runout to .001 inch (and some even limit it to .0005 inch), you may see runouts up to four
times these values when you measure a camshaft.

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Pivoting Followers
There are two broad categories of Camshaft followers: translating and pivoting. Pivoting followers are
also known as CORA (Cam On Rocker Arm). A translating follower is constrained, usually by riding in
a bore, so that it can only move in a straight line. Pivoting followers operate about a pivot point. The
follower on the Cam Pro Plus stand, and on every other general purpose cam measuring stand, is a
translating follower.

Camshafts are designed so that, regardless of the type of follower used, the valve motion produced has a
somewhat symmetrical lift curve. The lift curve produced by measuring a camshaft designed for a
pivoting follower on a stand using a translating follower is asymmetrical. It is strongly tilted to one side.
While this lift profile is not useful in understanding the valves motion or it finding centerlines or timing
points, it can be used for comparing a camshaft with a known good camshaft.
With pivoting follower camshafts it is common practice to measure the valve motion in the engine. You
can also create a custom stand from an old head.
The Valve Train option can convert a profile measured using a translating follower into the valve motion
produced by a pivoting follower. See the section on Measurement Setup for more information on the
Valve Train option.
Audie Technologys Valve Pro program can also convert a profile measured using a translating follower
into the valve motion produced by a pivoting follower. It also deals with the intricacies of valve train
geometries.

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Mushroom Tappets & Power

Contrary to what you may have heard, mushroom tappets by themselves don't make more power. They
do, however, allow the use of cams with higher velocities.
At any instant, the contact point of the cam on the follower face is directly related to the velocity of the
cam profile at that instant. When velocity is zero the contact point is in the center of the follower. The
higher the velocity, the further from center the contact point will be. It is possible for the velocity to be so
high that the contact point moves off the face of the follower. If this happens, the edge of the follower
gouges into the cam and quickly destroys it. Thus a higher velocity (and possibly higher power) cam may
require a larger diameter lifter or a mushroom lifter. The lifter by itself will not make more power, but
when used with a high velocity cam profile it may be a winning combination.

Let's consider the relationship between contact point and velocity some more. The cam can be thought of
as a lever that raises the lifter. The fulcrum of the lever is the center of the cam. The contact point
establishes the effective length of the lever (figure 1). Figure 2 shows two levers, a long one (A) and a
short one (B). Both are also shown after the cam has rotated a few degrees. The long lever will produce
more lifter movement for the same amount of rotation (i.e. it will move the lifter faster). Another way to
say this is the long lever produces higher lifter velocity.

25

Parts of a Lobe

Elements of a Cam Lift Curve

26

Lobe Separation and Overlap

Open, Close, Duration, & Area Under the Curve

27

Cam Factor
In theory an ideal cam would instantly open the valve to full lift, hold the valve open for the desired
duration and then instantly close the valve. Such a cam would have a rectangular profile. Of course, it is
not physically possible to create such a cam, and even if you could the valve train would never survive the
rough ride that it would produce. Cam factor compares a cam profile's area above the checking height
with the area of the ideal cam. Cam factors are expressed as percentage and are always less than 100%.

Since cam factor depends upon the checking height used, a cam factor specification is not complete
without specifying the checking height. The most commonly used heights are 0.050 inch (American) and
1 mm (metric). If you find a cam factor without a checking height specified it is probably one of these.

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Revisions
2-17-00
Add Analysis Reports to Report Setup.
Might be some other changes that were not noted.
6-17-00
Add TDC offset for In-Engine Measurement to How to Measure in Engine.
Remove last sentence of Raw ASCII Output (now outputs mm or inch).
1-26-01
Add Installation & Configuration section. (page 3-4)
2-2-01
Add Finding a Curve in the Lists to What Can I Do With the Graph section. (bottom of
page 8)
1-4-02
Add Hide the Lists to What Can I Do With the Lists section. (pg. 8)
Add Hide the Lists and Zoom to What Can I Do With the Graph section. (pg. 9)
4-2-04
Revised "Mount the Cam" instructions (pg. 5)
Add "Valve Train Adjustment" to the list at the bottom of page 8.
Add TDC Offset (pg 12).
Add Valve Train Adjustment (pg. 14)
Add "(or 1 mm)" to Lobe Centerline Method (pg 16)
Add 4StHead to File Export (pg. 17)
Revised the last 2 paragraphs in the section on Pivoting followers (pg 23).
3-13-06

Added "No Graphs" to section on troubleshooting.

Revised page numbers in Table of Contents.
Revised "Centerlines" in Camshaft Technical Topics.
Adding warning that lift units are inches, not thousandths to Graph Setup.
Revised centerlines in Measuring Options.
Added paragraph about TDC Offset to Locating TDC for On-stand Measurements.
7-19-12
Changes to adapt to Rev. G sensor boxes.

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