Next generation tool presetting and management takes machining technology to thenth degree of high precision

Citation

(2007), "Next generation tool presetting and management takes machining technology to thenth degree of high precision", Aircraft Engineering and Aerospace Technology, Vol. 79 No. 4. https://doi.org/10.1108/aeat.2007.12779dab.002

Next generation tool presetting and management takes machining technology to thenth degree of high precision

Next generation tool presetting and management takes machining technology to thenth degree of high precision

Acknowledged throughout the high- tech manufacturing industries such as aerospace, automotive, metrology, etc. are the remarkably high levels of accuracy, precision and software control, set by E. Zoller GmbH & Co KG, Freiberg, Germany, in one technologically-demanding niche area of production engineering, namely tool presetting, measurement, inspection and tool management.

A new modular system for tool presetting, measurement and inspection, sets the benchmark for the next decade, claims ZOLLER UK Ltd, Braintree. An extravagant claim? May be, were it not for the fact that the maker is one of the world leaders in its field with more than 60 years of research and development experience behind them. Certainly, one needs only a quick look at the new ZOLLER “venturion” array of high-technology hardware, advanced software and a host of new, user-benefit design features, to accede to the undoubted validity of the claim (Figure 3).

Figure 3 The Zoller “Venturion” new generation toll presetter and measuring machine

Accuracy and inbuilt precision

The distortion free, special hardened, light metal alloy frame is one factor that ensures that within the measuring ranges 450-1,400mm vertical and diameter 350-1,000mm horizontal repeat, accuracies are as fine as ^0.002mm, positioning to ^0.001mm and setting accuracies of ,2m.

Only the best components available on the world market are accepted for incorporation into the Venturion” presetter, such as Heidenhain's ultra- precise positioning systems for both linear and rotary axes; Sony superior imaging; THK stick-slip free recirculating ball guides; Bosch pneumatics, etc. all of which bring the benefits of consistently high precision and reliability direct to the end-user (Figures 4 and 5).

Figure 4 Operator seated at the variable control unit

Figure 5 Operator seated

Modular, highly-flexible system or basic machine

ZOLLER claim that the “venturion” new generation range of machines can be so closely optimised, with features suited to any customer's individual needs, that they can be virtually guaranteed to increase profitability from day one of their introduction.

They even calculate that an increase of at least 15 per cent in overall CNC productivity can be realized following the installation of the new “venturion”.

Drawing on the company's 60 years of experience to adopt a modular approach to the new product, instead of constantly adding features to provide the best of all machines to all users, offered is a highly effective basic model for those seeking such a quality machine but without having to pay for unwanted features.

With this standard model, customers might wish to take advantage of the photorealistic input dialog and automatic cutting edge detection, the automatic zero point control and the measuring capability check (Figures 6 and 7).

Figure 6 Tailstock mechanism

Figure 7 Induction shrink fit system

Customers with special needs, however, can choose from a full list of options, equipments, measuring ranges and high-precision spindles for their tool fixtures sufficient to customize a machine to meet any specific configuration without paying for under-utilised capabilities. Among the many options that can be specified are:

^• tailstock mechanism for holding reamers between centres;

^• the unrivalled ZOLLER induction system for heat-shrink fitting and removal of tools;

^• automatic TRIBOS polygon clamping technology;

^• swivelling incident light camera assembly for tool inspection at “goods inwards” and for controlling and documenting own- manufactured tools.

“Metis” software will measure and inspect tools in transmitted light, incident light, radially and axially and in any angular position;

^• automatic tool identification suitable for all popular systems can include automatic height regulation for the read/write head to accommodate different height positions of the tool identification chip; and

^• additional “centre height” CCD camera for contactless measuring and setting in incident light and with perfect illumination for precise measuring and setting through multi-LED light (Figures 8 and 9).

Figure 8 Schunk TRIBOS polygon clamping system

Figure 9 Optimum access to the high-precision spindle

Unique functions

A unique foolproof measuring function, “elephant” gives the user automatic identification and measurement of any standard cutting tool type at a press of a button.

The ZOLLER “pilot 3.0” software, says UK Sales Manager, David Evans, “as well as providing all the functions expected for optimum machine controls, can even be used as a tool for “reverse engineering” because highly accurate measurement scans can be made of tools from which the ZOLLER produces a 3D tool drawing” (Figures 10 and 11).

Figure 10 One-hand control knob

Figure 11 ZOLLER “pilot 3.0” software system

Other practical possibilities include the use of the “Delta” measuring program for setting reamers, using the snap gauge or oversize principle; a “Metis” software module for the fully- automatic measurement and inspection of ground and spark-eroded cutting tools and “in screen” software for contactless measuring and the setting of tools to centre height (Figures 12 and 13).

Figure 12 Automatic tool identification

Figure 13 Additional “central height” CCD camera

The user first and foremost

Economically the new “venturion” is not only of distinctive award-winning design, but is also set apart from its predecessor – and most, if not all, of its contemporaries – by the full 1808 access permitted to the work area.

So well designed is it, in fact, that the operator can remain seated throughout the entire pre-setting/measurement sequence.

The keyboard/display console is mounted on wheels so that it can be positioned to suit the operator's wishes and even has a variable-height adjustment incorporated to ensure that easy viewing is possible, no matter whether the operator chooses to stand or be seated.

Every stage of the operation is clearly depicted on-screen and the “Venturion” operator does not need to be an IT specialist in order to set up the program or interpret its status at any point in the process (Figures 14 and 15).

Figure 14 Swing-out boards

Figure 15 Swing-out lens assembly

Another good example of having the user in mind is the provision of a “one- hand control knob” to automatically clamp/release the slide and then position the measuring head single- handedly to where it is needed (Figure 16).

Figure 16 Pull-out controllers

A membrane keyboard is conveniently-placed on the front of the machine that enables all power- operated functions of the high- precision spindle to be set in motion by a single, light keystroke.

The company has wholly-owned subsidiaries in UK, USA/Canada, France, Austria, Spain/Portugal, China, India, Mexico and Asia/Pacific, with additional sales and service representation in more than 30 countries around the globe.

Details available from: ZOLLER UK Ltd Tel: +44 (0)1376 331335; Fax: +44 (0)1376 331651; E-mail: evans@zoller-d.com; web site: www.uk.zoller.info