solut The o ion f ptimum or yo ur su ccess Prese t inspe & measu re, ct & m your cuttin anage g too ls The new generation of tool presetter and measuring machines smile CONTENTS 1 | ZOLLER overview Products and services oﬀered by ZOLLER 2 | Why ZOLLER tool presetter and measuring machines? ZOLLER eﬃciency ZOLLER application solutions 3 | ZOLLER »smile« tool presetter and measuring machine versions [hardware] ZOLLER »smile« – the universal tool presetter and measuring machine ZOLLER »smile/pilot 2.0« – getting started professionally ZOLLER »smile/pilot 3.0« – the solution for every challenge ZOLLER standard and options – all components perfectly matched ZOLLER »smile/CNC« – the fully automatic version ZOLLER »smile/tribos« – with the SCHUNK TRIBOS clamping unit* ZOLLER »smile/shrink« – with integrated shrink device ZOLLER »smile/EDM« – measure electrodes 4 | ZOLLER software ZOLLER »pilot 2.0« – as much as necessary, as little as possible ZOLLER »pilot 3.0« – quickly and simply equipped for any requirement 5 | ZOLLER precision and reliability ZOLLER tool holders – high concentricity with short change-over times ZOLLER precision – quality in every detail 6 | ZOLLER service and contact ZOLLER locations – there for you all over the world ZOLLER service – competent, personal, fast ZOLLER tool presetter and measuring machines – at a glance * SCHUNK TRIBOS is a registered trademark of SCHUNK GmbH & Co. KG ZOLLER increases your productivity ZOLLER helps companies to manufacture more eﬃciently by using tool presetters, tool inspection machines and tool management software. ZOLLER measures and presets tools to two-thousandths of a millimeter – quickly, simply, accurately and guaranteed! Accuracy means less waste, less CNC machine downtime and more proﬁt. Put more precisely: You Y can improve your productivity by at least 20% with ZOLLER. Trust in ZOLLER technology and proﬁt from the highest quality and reliability, top-innovation and competence as well as user-f r riendliness and exceptional customer service and support. Tool presetters T T Tool measuring and inspection machines Heat shrink presetters T Tool management software Consulting and service Do you work with cutting tools? If so, then ZOLLER is the right partner for you. ZOLLER – for your success »ZOLLER is today a the global expert and market leader in the ﬁeld of tool presetting, tool measurement and tool inspection for more precision and productivity in manufacturing companies. For more than 60 years, ZOLLER has developed innovative software as well as tool presetters and measuring machines to measure, inspect and manage cutting tools of all kinds. Our many years of experience and the close cooperation between our customers and partners give us the necessary expertise to deliver cutting-edge technology that is user-f r riendly and helps our customers to cope with the everyday a manufacturing challenges. The family business is in its third generation. Its headquarters and manufacturing are based in Germany and it is committed to the highest quality standards for true precision and the longest product life. Our ZOLLER locations and business partners throughout the world guarantee customer proximity and dedicated service in local markets. And it is our top priority at ZOLLER that the products carrying our family name exceed your expectations and contribute to your success. In order to achieve this ZOLLER goes to great measures for you.« The ZOLLER family Christoph Zoller, Alexander Zoller, Eberhard Zoller 1 | Products and services oﬀered by ZOLLER The ZOLLER »smile« product series Simple to operate, equipped with all the standard measuring functions, at an attractive price. The ZOLLER »smile« universal tool presetter and measuring machine has been designed speciﬁcally for measuring tools for manufacturing production. It can save you up to $15,000 per shift and machine over a year. Beneﬁts for you: Simple to use thanks to intuitive ZOLLER software interface and ergonomic operating elements Fast & precise thanks to powerful ZOLLER image-processing technology Robust & able to withstand shop ﬂoor conditions owing to special alloy and thermally optimized design Process-reliable through intelligent software and the highest safety standards Ergonomic thanks to functional, tried and tested design Versatile due to modular construction and extensive software from ZOLLER Economical thanks to an excellent price-performance ratio Environmentally friendly through use of recyclable materials and compliance with ISO standards »smile 400/pilot 3.0« Your needs – our solution ZOLLER eﬃciency With ZOLLER tool presetter and measuring machines, your tools are preset and measured before use. This means you can beneﬁt in every aspect, thanks to less waste and fewer machine crashes, lower production costs and higher productivity. For you, this means: more eﬃciency and thus more turnover and proﬁt. Your productivity increase with ZOLLER 20 % Capitalize on ZOLLER: your results – greater proﬁts! Less machine down-time Reduced scrap More eﬃcient processes Higher process-reliability Better production quality Increased productivity 2 | ZOLLER eﬃciency Your requirement: Our solution: Your requirement: Our solution: Your requirement: Our solution: Your requirement: Our solution: Measure and preset tools quickly, simply and accurately! ZOLLER »pilot 3.0« modular image processing software for every requirement ZOLLER »elephant« technology for measuring and presetting tools without data entry Special measuring programs with photorealistic input dialog for complex measurement tasks Use only 100 % perfect tools! Contactless inspection of metal cutting tools in incident light Measurement of tool geometries at the push of a button Extensive statistical and logging functions Manage data optimally! Tool management systems for the oﬃce or T directly on the tool presetter and measuring machine Central data storage in the ZOLLER system Interfaces to external systems Modular expansion options Perfect integration into the closed process chain Reduce production costs! Less machine down-time by presetting the tools outside the machine Control-speciﬁc tool data from the measuring unit directly to the machine tool Prevention of machine crashes through process reliability, e.g. zero point monitoring Optimized magazine space allocation with ZOLLER »cetus« software The right machine for your application ZOLLER provides the optimum solution ZOLLER tool presetter and measuring machines consist of hardware functions, e.g. the »smile« machine series, and are equipped with »pilot« image processing software. The world market leader ZOLLER can thus provide the optimum solution for all requirements. The following questions will help select the best one for you: What would you like to measure? (tools and parameters) This is important to decide what ZOLLER software and measuring What are the maximum dimensions of your tools? What tool holders are you using? Determine the maximum length This decides what spindle or functions. and diameter of the tools you adapter you should use in your ZOLLER »pilot 3.0« has a need to measure. The measuring tool presetter and measuring modular construction, thus lets range of the tool presetter and machine. you decide what modules you programs you need: ZOLLER »pilot 2.0« is our standard software with all the important measuring machine depends on need and allows you to retroﬁt this factor. additional features at any time. Our recommendation: Our recommendation: Our recommendation: For tools of up to 600 mm in If ISO/HSK or VDI tool holders For the most frequently needed length and 400 mm in diameter: are used: ZOLLER »smile« stan- measuring and inspection func- ZOLLER »smile«. dard equipment. tions: ZOLLER »smile/pilot 2.0«. For heavier and larger tools: For work with shrink-clamping For more demanding work and The ZOLLER »venturion« holders: ZOLLER »smile/shrink« versatility in the future: product line. or ZOLLER »redomatic«. ZOLLER »smile/pilot.3.0« For the TRIBOS clamping For measuring electrodes: system: ZOLLER »smile/tribos« ZOLLER »smile/EDM«. or ZOLLER »tribos«. 2 | ZOLLER application solutions Many requirements. One goal: The optimum ZOLLER tool presetter and measuring machine for your company. Use the navigator on the back fold-out page to ﬁnd the right tool presetter and measuring machine. Do you want to manage tools? Would you like to measure tools manually or automatically? All ZOLLER machines, whether With »pilot 2.0« you can add and sav a e adapters and tools. The How do you want to transfer the data? »pilot 2.0« or »pilot 3.0«, can advantage for you: For recurring tools you can simply call them Do you need interfaces, for example to machine tools or controls? up, select the saved measuring output the measurement results Manually or electronically sequence and thus get to the Do you want your tool presetter automatically and independently for integration into your measurement result even more and measuring machine to com- of the operator. Investment in network for error-f r ree data quickly. municate with other machine CNC control of the axes pay a s communication? Furthermore, »pilot 3.0« pro- controls or tool management for itself with reliable measuring This decides the appropriate vides you with comprehensive systems for highly eﬀective nett sequences, depending on the software. tool management, which can be working? extent of presetting. extended as required. Our recommendation: Our recommendation: Our recommendation: Our recommendation: For measuring contours: For manual data output: Tool For optimum tool management: Tool presetter and measuring machines ZOLLER tool presetter and presetter and measuring machi- Tool presetter and measuring with ZOLLER »pilot 3.0« plus individual measuring machines with CNC nes with ZOLLER »pilot 2.0«. machines with ZOLLER »pilot adaptation to your production process. control of the axes provide the For electronic data output: Tool 3.0« and ZOLLER tool manage- highest precision and automatic/ presetter and measuring machi- ment. operator-independent sequences. nes with ZOLLER »pilot 3.0«. The universal tool presetter and measuring machine for any user ZOLLER »smile« Whether you use it as a universal tool presetter and measuring machine for your entire production facility or dedicate it to an individual machine tool, the automatic tool cutting edge detection and the »pilot« software make presetting All basic elements of the ZOLLER and measuring your tools particularly precise, fast and simple. tool presetter and measuring machines are developed and de- The ZOLLER »smile« series can be equipped with the »pilot 2.0« or »pilot 3.0« signed in-house and manufactured in Germanyy and the USA. software, plus diﬀerent applications and options depending on your requirements. In any case – ZOLLER »smile«: Great performance at a small price. We only use renowned name-brand components noted for their precision, reliability and durability. This is why ZOLLER tool presetter and measuring machines have become the benchmark of quality known around the world for their extremely high levels of accuracy, low maintenance costs and long service life. Y Your beneﬁts of a »smile« tool presett t er and measuring machine with »pilot 2.0« or »pilot 3.0« softw t are vailable in up to seven selectable measuring ranges in Z and X axes ISO 50 high precision spindle with integrated calibration edges, 4 x 90° locking device, spindle brake Membrane keyboard for power-ope r rated spindle clamping and spindle braking Electronic ﬁne adjustment of X and Z axes Light metal construction with optimum heat-conducting properties for use on the shop ﬂoor Heidenhain glass scales for a high level of measuring accuracy CCD camera with telecentrical objective ZOLLER »pilot 2.0« or »pilot 3.0« image processing software (see pages 20–25 for range of functions) Dynamic cross-hairs in the entire measuring window Analog focusing display a for focusing the tool cutting edges Automatic cutting edge recognition, including those greater than 90° Cutting edge inspection with 20 x magniﬁcation Manual projector function Adapter and tool management Zero point monitoring for process reliability Numerous measurement programs such as concentricity and run-out Machine table (standard for »smile/pilot 3.0«) Technical information subject to change. All tool presetter and measuring machines shown can include options, accessories and control system variations. 3 | ZOLLER »smile« tool presetter and measuring machine versions or larger measuring range requirements, we recommend ZOLLER »venturion« »smile 400« »smile 600« »smile 800« »smile 400« »smile 400/6« »smile 400 / RA 140« »smile 600« »smile 600/4« »smile 600/4 / RA 140« »smile 800«1) Measuring range Z 400 mm/15.7" 400 mm/15.7" 400 mm/15.7" 600 mm/23.6" 600 mm/23.6" 600 mm/23.6" 800 mm/31.5" Measuring range X 200 mm/7.8" 300 mm/11.8" 130 mm/5.1" 300 mm/11.8" 200 mm/7.8" 130 mm/5.1" 300 mm/11.8" 400 mm/15.7" 600 mm/23.6" 260 mm/10.2" 600 mm/23.6" 400 mm/15.7" 260 mm/10.2" 600 mm/23.6" – 100 mm/3.9" 140 mm/5.5" 100 mm/3.9" – 140 mm/5.5" 100 mm/3.9" Diameter Snap gauge Ø 1) Uhing drive Heidenhain measuring system Machine table is a prerequisite (included as standard with »pilot 3.0«) THK linear guidance system with recirculating linear ball bearings High-precision and reliable axis adjustment, Ultra-precise positioning in X and Z axes Superr light sliding with no stick/slip eﬀect manual or CNC controlled. thanks to Heidenhain. thanks to ﬁve THK guide systems. The professional introductory package to get you started ZOLLER »smile/pilot 2.0« The basis for your work. ZOLLER »pilot 2.0« software gives you all the measuring and presetting f df our day a -to-day a unctions you tools quickly d ideally for use and for the tool medium batch »smile/pilot 2.0« options Image processing system with telecentrical objective 32 Bit ARM9 processor 4 USB 2.0 interfaces RJ45 network connection 12.1" TFT color display a with touch-screen 800 x 600 pixel screen resolution Linux operating system 256 MByte working memory Memory for at least 3,000 adapters and tool steps Virtual keyboard ISO 30, ISO 40, HSK, KM high precision spindle Vacuum spindle Manual length adjustment, linear or rotary, to adjust the length of tools Center height measuring device List and label printer Electronic data output 3 | ZOLLER »smile« tool presetter and measuring machine versions The solution for every challenge ZOLLER »smile/pilot 3.0« Made to measure for your requirements. »pilot 3 0« allows you to select from lot 3.0« options Image processing system with telecentrical objective IPC computer with Intel®Core TM2 Duo 1.80 GHz 2 GByte main memory 17" TFT color display a with touchscreen 1,280 x 1,024 pixel screen resolution Windows XP Professional for Embedded Systems operating system 6 serial interfaces 2 parallel interfaces 12 USB 2.0 interfaces 2 RJ45 network connections Hard disk with at least 80 GByte DVD-RW burner for data backup Integrated hard disk monitoring – detects the ﬁrst signs of a possible hard disk crash Flexible operation using keyboard, mouse and touch-screen ntrolled X and Z axes us and/or rotary encoder for ding ﬁxture spindle (C axis) ISO 40, HSK, KM cision spindle clamping Manual length adjustment, linear or rotary, to adjust the length of tools Center height measuring device List and label printers Electronic data output T Tool identiﬁcation Special measuring programs such as reamers, grinding wheels T Tool management All components perfectly matched ZOLLER standard and options ZOLLER tool presetter and measuring machines set high standards, such as ergonomic design, cutting edge inspection or machine table, for eﬃcient and healthy working. Added to this are numerous options such as adapters, printers or data communication, with which you can match your ZOLLER tool presetter and measuring machine optimally to the requirements of your production process. So you are best-equipped for any task and still remain versatile. Cutting edge inspection – standard High precision spindle – standard Machine table – standard for »smile/pilot 3.0« Cutting edge inspection for checking tool cutting With integrated calibration edge, without a separate Precise and secure positioning with leveling elements. edges in incident light. zero gauge for better accuracy and ease of use*. Including support arm for ergonomic use of monitor, keyboard and mouse. Adapter with integrat ated calibration a edge – optional Label printer – optional List printer – optional Case-hardened, bronzed and ground with integrated For printing out measurement results for length, For printing out measurement results calibration edge (where technically possible). diameter, radius, angle 1 and 2 onto thermo labels**. or cutting edge inspection **. * optional vacuum clamping ** may a diﬀer from model shown 3 | ZOLLER »smile« tool presetter and measuring machine versions Center height measuring device – optional For measuring the center height of turning tools. Tool identiﬁcation – optional for »pilot 3.0« T Separate read/write station for manually reading and writing the tool ID chip. Tool length adjustment – optional T Manual adjustment device for setting the length of tools either by using the stop pin or rotating the setting screw. Shelf for label printer – optional Adapter shelf and shelf for list printer Data communication – optional – optional Shelf for label printer, ﬁxed in place. Shelf for adapters, for up to nine ISO 50 holders. Data communication from the tool presetter and Shelf for list printer, with anti-slip coating. measuring machine to the machine tool for data transfer without errors. With »pilot 2.0« and »pilot 3.0«. The fully automatic version ZOLLER »smile/CNC« For milling and turning machines. or CNC control in three axes, see product overview pp. 30/31 Speed and precision with ease of use and maximum process reliability are standard in the ZOLLER »smile/CNC«. A special, tried and tested drive design allows rapid, operator-independent r and micron-precise positioning of all axes. The decisive advantage of the »smile/ CNC« with autofocus is: You Y can create your repeat orders, deﬁne measuring sequences and call them up again and again. For you, this means: Producing each batch eﬃciently, proﬁtably, on time and with perfect quality. »smile/CNC« options Autofocus and/or rotary encoder for tool holding ﬁxture spindle (C axis) For further options, see p. 11 ZOLLER »pilot 3.0« / /p CNC control in linear axes Z and X Optional autofocus in the C axis for fast and precise measurement results ZOLLER USB Motion »CoNCept« drive for fast and process-reliable tool measurement Uhing drive with sliding clutch for micron-precise positioning and user safety – the user can stop the CNC controlled axes manually at any time 3 | ZOLLER »smile« tool presetter and measuring machine versions With SCHUNK TRIBOS clamping unit ZOLLER »smile/tribos« One workstation for all tasks. Universal tool presetter and measuring machines for all kinds of tools are one thing, those for the SCHUNK TRIBOS system are something else. Really? Not at ZOLLER! Because with ZOLLER »smile/tribos« you hav a e a high precision tool presetter and measuring machine for absolutely any kind of tool – including SCHUNK TRIBOS chucks. The integrated device for presetting, measuring and clamping SCHUNK TRIBOS tools means that you only need one workstation for all the tasks in your company and you can beneﬁt from the exceptional eﬃciency of this ZOLLER tool presetter and measuring machine. »smile/tribos« options Digital print display a Wooden shelf for »tribos« inserts »ASZM« tool length adjustment or »ASZR« rotary tool adjustment For further options, see p. 11 ZOLLER »pilot 3.0« »smile 400/tribos/pilot 3.0« »smile 400« »smile 600/4« Measuring range Z 400 mm/15.7" 600 mm/23.6" Measuring range X 200 mm/7.8" 200 mm/7.8" 400 mm/15.7" 400 mm/15.7" Diameter Clamping, presetting and measuring SCHUNK TRIBOS chucks Swiveling and lowerable SCHUNK clamping unit Analog print display a T Tool diameter: 6–32 mm Hydraulic clamping pressure: max. 400 bar With integrated shrink device ZOLLER »smile/shrink« Manual – in combination with ZOLLER »pilot 2.0« or »pilot 3.0« All in one machine: the ZOLLER »smile/shrink« tool presetter, measuring and shrink machine is speciﬁcally designed for shrinking, presetting and measuring all kinds of tools. With »smile/shrink« ZOLLER provides a cost-eﬀective combination machine, its purchase price being much lower than that of two individual machines. Based on the »smile«, a shrink device has been integrated with an induction coil and a water cooling system. Get your hands on a »smile/shrink« for easy presetting, measuring and shrinking – all in one machine. Shrink tools to a desired length 1. Insert the shrink-ﬁt chuck into the tool holding ﬁxture 2. Insert the adapter into the shrink-ﬁt chuck 3. Insert the tool into the adapter 4. Adjust the tool to desired length (optional) 5. Remove adapter and tool 6. Swivel in shrink unit 7. Heat the shrink-ﬁt chuck 8. Move the optic carrier to the safety position 9. Insert the tool into the shrink-ﬁt chuck 10. Cool the shrunk tool in the »showerCooler« Result Detailed overview of measurement results with tolerance check e versions For CNC sequences, we recommend ZOLLER »redomat a ic« Measuring range Z Measuring range X Diameter 400 mm/15.7" 600 mm/23.6" 200 mm/7.8" 200 mm/7.8" 400 mm/15.7" 400 mm/15.7" Y Your beneﬁts Space-saving, a swiveling shrink unit. Separate »showerCooler« cooling unit. Optional tool re-adjustment to shrink tools to desired length Low temperature due to short heating time and induction energy over a wide area. This prevents structural changes in the shrink-cla k mping ﬁxture and protects your tools for a longer service life The »showerCooler« cooling unit cools the shrunk tools rapidly using water/emulsion Integrated swiveling shrink unit Safety standard met: Optional integrated fume extraction provides protection from vapors and gases Short cycle times for eﬃcient working Ergonomic design for convenient operation and ideal storage options for »shower-Cooler« r and shrinkk ﬁt accessories »smile/shrink« options »showerCooler« Fume extraction »ASZM« linear tool readjustment or »ASZR« rotary tool readjustment For further options, see p. 11 ZOLLER »pilot 3.0« Measure electrodes ZOLLER »smile/EDM« Manual or CNC controlled – in combination with ZOLLER »pilot 3.0« Measures your electrodes before use in the erosion machine: no waste, more production precision. And it's the same for your metal-cutting tools such as drills, reamers and milling machines. The solution for die and mold-making ZOLLER – the perfect result in a ﬂash. tools: The ZOLLER »smile/EDM« tool presetter and measuring machine for measuring electrodes and metalcutting tools. Where several machines would hav a e been used previously, the ZOLLER »smile/EDM« now carries out all measuring tasks: precise measurement results in the shortest possible time. For all those who want to measure EDM electrodes and metal-cutting tools quickly and simply. Measure electrodes in less than 1 minute 1. Determine reference measurement for adapter 2. Determine oﬀset angle 3. Determine X/Y mismatch 4. Determine length: Sample highest measurement point Result Detailed overview of measuring results with tolerance check 3 | ZOLLER »smile« tool presetter and measuring machine versions ce 600/26 800 600 mm/23.6" 800 mm/31.5" Measuring range X 300 mm/11.8" Diameter 600 mm/23.6" 260 mm/10.2" 600 mm/23.6" 260 mm/10.2" 600 mm/23.6" 130 mm/5.1" Measuring range Y Snap gauge Ø Y Your beneﬁts Simple, fast and accurate measurement of electrodes and metal-cutting tools All the important parameters of an electrode can be measured in less than 1 minute The following electrode parameters can be measured, regardless of shape and application: – Oﬀset angle – Mismatch in X and Y axes – Length in Z axis – Renishaw measuring sensor for measuring electrode parameters Photorealistic measuring programs for measuring electrodes Graphical instructions guide the user step-by-step through the electrode-measuring process The solution for die and mold-making tools. 300 mm/11.8" 130 mm/5.1" 300 mm/11.8" ± 50 mm/1.9" 20 mm/0.8" »smile/EDM« options Electrode adapter av a ailable for all EDM holding ﬁxture systems, e.g. Erowa, System 3R, Hirschmann, etc. Autofocus for C axis Control-speciﬁc measurement data output for the CNC erosion machine For further options, see p. 11 ZOLLER »pilot 3.0« As much as necessary, as little as possible ZOLLER »pilot 2.0« software Behind ZOLLER's software development are people whose declared goal is simple and practical operation and the long-term sustainability of ZOLLER tool presetter and measuring machines. ZOLLER »pilot 2.0« software is a cost-eﬀective solution, The ZOLLER »smile« product series can be equipped with the »pilot 2.0« which has been developed speciﬁcally for the shop ﬂoor. software. You Y will then have dynamic cross-hairs for automatically measuring True to the motto: as much technology as necessary, but as little as possible. and manually presetting tools. »pilot 2.0« also has the most frequently For the highest quality at an excellent price-performance ratio. »pilot 2.0« standard functions Graphical user interface – intuitive and clear, with self-explanatory symbols for the easiest operation »compass« navi a gation system for simple positioning (Fig. 1) Presetting and measuring without manual ﬁne adjustment – quickly and precisely Fine adjustment of axes not necessary thanks to »pilot« intelligent image processing. The dynamic cross-hairs follow the cutting edge and the current measurement is continously display a ed Automatic detection of cutting edge shape and measuring area of tool cutting edges – fully automatically and in seconds (Fig. 2) Analog focusing display a – a colored bar indicates to the user when the cutting edge is focused and thus ready for measurement or presetting Five automatic measurement results: tool length, diameter, cutting edge radius and two cutting edge angles (Fig. 3) Operator-independent r measurement results – repeating accuracy with tolerance check (Fig. 4) Automatic zero point monitoring to prevent machine crashes (Fig. 5) Cutting edge inspection – 20 x magniﬁcation in a live image for checking cutting edge quality (Fig. 6) Measurement programs and »C.R.I.S.« measurement function (Figs. 7–8) Counter switchover to X and Z axes as required: radius/diameter absolute measure, diﬀerence dimension, incremental dimension and counter stop. In particular for measuring step drills, distances, etc. Unit switchover – e.g. degrees/rad/ mm/inch T Tool step management – create and manage several steps for fast measurement of complex tools »libra« help system – sophisticated help system supports the user step-by-step in up to 14 languages needed measuring functions. User-friendly operation Developed for the shop ﬂoor Simple, eﬃcient working 1. »compass« navigation system – a convenient navigation 2. Automatic measurement of cutting edge geometries of 3. Dynamic cross-hairs – the dynamic cross-hairs are used system, which makes positioning the axes on the cutting all kinds – even cutting edges of > 90° are measured to measure cutting edges automatically without time- edge a child's play. automatically in all 4 quadrants. consuming ﬁne adjustment of the axes. 4. Tolerance check – when the predeﬁned tolerance is exceeded, a message appears after the measurement. 7. System-controlled measurement programs with photo- 5. Automatic zero point monitoring – the current zero point 6. Cutting edge inspection – indentations and wear is indicated before each measurement. To prevent machine marks can be detected for right-hand cutting tools crashes, tool breakage and scrap parts. in a live image. 8. »C.R.I.S.« function – measurement of the eﬀective cut- 9. Center height measuring device – the center height is realistic input dialog, e.g. largest cutting edge on milling ting area of rotationally symmetrical tools. Corresponds measured without contact, and the oﬀset of the cutting heads, concentricity and runout, theoretical point on to the distortion-free dimensions, which the tool creates edges in the Y direction is determined using an additional drills, etc. in the material during production. incident light camera (optional). Quickly and simply equipped for any requirement ZOLLER »pilot 3.0« software »pilot 3.0« image processing software sets standards: The design of the input menu follows the tasks, which the user has to complete. The beneﬁt to you: Simple orientation and use of the software according to the functional area and its requirements. The following pages will give you a simple introduction to the world of tool Thanks to the modular construction, you can grow with your future needs. measurement using the ﬁve menu buttons of the input menu. You Y will gain a ﬁrst »pilot 3.0« meets all production demands with its comprehensive functionality impression of the performance potential of »pilot 3.0«. However, it would be even and yet remains user-f r riendly. better if you tested the software live e.g. in one of our showrooms, by simply bringing your tools with you. Measuring + presetting Experience new ease of use »elephant« technology for measuring and presetting without any data entry or prior knowledge Measurement programs with photorealistic input dialog for measurement of complex tool geometries Over 200 cutter shapes to measure any cutting edge geometry Automatic cutting edge shape recognition for fast and precise measurement results Production Deﬁne production processes eﬃciently Here you can ﬁnd all the functions of the tool presetter and measuring machine to make your production process more eﬃcient: Measure lists of tools at the push of a button and transfer them directly to the machine tool »cetus« tool exchange list for calculating the tool requirement on the machine tool and for determining the tools to be exchanged on the machine tools Advantages of the new menu interface Extremely simple operation Get started quickly Direct access to numerous functions Inspection Trust is good, control is better Adjustable intensity LED lighting for brilliant cutting edge display and inspection Inspect and measure tools in transmitted and incident light with »metis« tool inspection and measurement Simple creation of test reports for detailed documentation Manage Create order by organization Management of: Individual components Tools Tool lists Graphics DIN 4000 subject characteristics NC programs Storage Ordering systems (suppliers, currencies, etc.) The correct setting Here you can carry out system settings and ﬁnd useful information: User settings User rights management Data import/export settings Parameter settings for special functions Information on servicing and maintenance ZOLLER »pilot 3.0« software Highlights »sinope« »sinope« drawing a generator For automatically generating tool drawings from the measured actual values and steps »compass« »compass« navigation a system For fast and safe manual axis adjustment to the nominal position of the tool cutting edge »cetus« »cetus« tool exchange list For calculating the tool requirement on the machine tool and for determining the tools to be exchanged on the machine tools T Tool net requirement calculation saves approx. 50 % on tools Data output Control-speciﬁc data output From individual tools or complete tool lists via DNC, network or USB stick to the machine tool for fast, error-f r ree data communication Presetting and measuring at the push of a button Ingeniously simple! Insert tool. Press start button. The »elephant« technology will do the rest: Simple measurement and presetting without data entry Intelligent measuring tasks Can be operated without prior knowledge It's as simple as this: All measuring sequences can be saved, adapted as required and repeated. The ﬁgures show a CNC controlled measuring sequence. ZOLLER »pilot 3.0« »elephant« technology Select tool type from the overview on screen. Image catalogue of standard tools – two-ﬂute cutter selected. Conﬁrm measuring sequence. Selection of measuring task. Start measuring sequence, done! Detailed overview of measurement results. High concentricity – short change-over times ZOLLER tool holding ﬁxtures ZOLLER tool holding ﬁxture spindles are suitable All ZOLLER spindles are optionally av a ailable with autofocus and ROD rotary encoder for all the usual tool shanks and allow rapid tool changeovers while maintaining a high level of accuracy. Standard: ISO 50 high precision spindle ZOLLER standard – ISO 50 high precision spindle The pneumatic 4 x 90° lock for turning tools and the spindle clamping for tool presetting are actuated using the membrane keyboard. 0.002 mm concentricity, easily turned, ergonomic hand wheel. Optional – vacuum clamping device: Membrane keyboard for all powerr operated functions of the tool holding ISO 50 high precision spindle with integrated calibration edge, ﬁxture. Spindle brake, vacuum clamping so that separate zero gauges are not necessary. (optional), 4 x 90° lock. The high precision spindle is av a ailable with a vacuum clamping device. The vacuum clamping device is conveniently actuated using the membrane keyboard. The right adapter for every tool shank Optional: Adapter All our adapters are case-hardened, bronzed, ground and, where technically possible, equipped with an integrated calibration edge. Steep taper adapter HSK hollow shank taper adapter VDI straight shank adapter ISO 10 to ISO 60. HSK 25 to HSK 125. VDI 16 to VDI 80. Optional: Spindle with manual front clamping ISO front clamping spindle. HSK front clamping spindle. KM front clamping spindle. Optional – manual tool clamping directly on the spindle Do you continuously use one tool holder shank size, e.g. only ISO 40 in your production process? Then ZOLLER also has the right solution for this: direct manual clamping of your tools to the spindle. This spindle version is av a ailable for the most common holding ﬁxture systems and guarantees you all the advantages of the standard tool holding ﬁxture. 5 | ZOLLER precision and reliability Quality in every detail ZOLLER precision Length measurement systems by Heidenhain Cable carrier elements for ideal cable routing and a long service life Balance weight with linear guide Transmitted light with centered cold light source Single hand operation device and automatic regulation with unique ergonomics Linear guidance systems with recirculating linear ball bearings CCD camera 2 units in the Z and X axes and and multi LED ring light with telecentrical objective 4 track carriages per axis Ideal linear behavior Linear axis adjustment of the X and Z axes according free from play and wear to thermal analysis due to with the UHING drive special light metal alloy. Tensile strength: 32kg/mm² ZOLLER IPC electronics with network connection, USB interfaces and active cooling system ZOLLER high precision spindle with pneumatic clamping and Machine table system 4 x 90° lock made of stable design components and with leveling elements model may diﬀer from diagram shown Bosch pneumatics for all power-operated functions The highest quality marks every detail. Which means: Micron-precise results every time. For motivated employees, eﬃcient working and increased productivity. All beneﬁts to you. There for you around the world ZOLLER locations ZOLLER branches all around the world bring our knowledge and expertise to where you are. Therefore, accessibility is not just a promise, but a reality. Germany European contact addresses HEAD OFFICE E. Zoller GmbH & Co. KG Einstell- und Messgeraete Gottlieb-Daimlerr Straße 19 D-74385 Pleidelsheim T +49 7144 8970-0 Tel: Fax: +49 7144 8060-807 email@example.com www.zoller.info AUSTRIA ZOLLER Austria GmbH Einstell- und Messgeraete Haydn a straße 2 A-4910 Ried im Innkreis T +43 7752 87725-0 Tel: Fax: +43 7752 87726 oﬃce@zoller-a.at r www.austria.zoller.info ZOLLER NORTH E. Zoller GmbH & Co. KG Service and Sales Center Wohlenbergstraße 4 c D-30179 Hannover T +49 511 676557-0 Tel: Fax: +49 511 676557-14 firstname.lastname@example.org r www.zoller.info FRANCE ZOLLER S. à. r. l. 12, rue de la Faisanderie F-67380 Lingolsheim T +33 3 8878 5959 Tel: Fax: +33 3 8878 0004 email@example.com www.zoller.info SPAIN P + PORTUGAL ZOLLER Ibérica S.L. Balmes 188 4º 1ª E-08006 Barcelona T Tel: +34 932 156 702 Fax: +34 935 198 014 firstname.lastname@example.org www.zoller.info ZOLLER AGENCIES BELGIUM ISRAEL SLOVAKIA V BULGARIA ITA T LY L SLOWENIA CROAT A IA THE NETHERLANDS SOUTH TYROL CZECH REPUBLIC NORWA WAY SWEDEN DENMARK POLAND SWITZERLAND FINLAND ROMANIA TURKEY HUNGARY R RUSSIA UK 6 | ZOLLER service and contact Overseas contact addresses USA ZOLLER Inc. North America Regional Headquarter 3753 Plaza Drive USA-48108 Ann Arbor, MI T +1 734 332 4851 Tel: Fax: +1 734 332 4852 email@example.com r www.zoller-usa.com r CANADA ZOLLER Canada 5659 McAdam Road Unit A2 CAN-L4Z 1N9 Mississauga, ON T +1 905 712 0100 Tel: Fax: +1 905 712 1623 firstname.lastname@example.org r www.zoller-usa.com r ZOLLER Inc. / West Coast Oﬃce 4025 Spencer St., Suite 202 USA-90503 To T rrance, CA T +1 424 247 0180 Tel: Fax: +1 424 247 0184 email@example.com r www.zoller-usa.com r MEXICO ZOLLER Mexico Calle 53, LT LT-24, C-21 Bosques de la Hacienda MEX-C.P. 54715 Cuautitlan Izcalli Estado de México T +52 55 5817 4654 Tel: Fax: +52 55 5817 4565 firstname.lastname@example.org r www.zoller-usa.com r ZOLLER AGENCIES ARGENTINA KOREA AUSTRALIA MALAY A SIA BRAZIL P STAN PAKI T UNITED ARAB EMIRATES A CHILE SINGAPORE VIETNAM COLUMBIA SOUTH AFRICA INDONESIA T WAN TAI W IRAN THAILAND CHINA ZOLLER Shanghai, Ltd. Asia Paciﬁc Regional Headquarter No. 1588 ZhuanXing Road Xin Zhuang Industry Park Min Hang District 201108 Shanghai T +86 21 3407 3978 Tel: Fax: +86 21 6442 2622 email@example.com r www.zoller-cn.com r HONG KONG ZOLLER Asia Paciﬁc, Ltd. 10A Seapower Industrial Centre 177 Hoi Bun Road, Kwun Tong T Kowloon, Hong Kong T +86 21 3407 3978 Tel: Fax: +86 21 6442 2622 firstname.lastname@example.org r www.zoller.info SINGAPORE ZOLLER Singapore Pte. Ltd. 7500A Beach Road #04-320 the Plaza Singapore 199591, Singapore T +91 20 2749 6118 Tel: Fax: +91 20 2749 6114 email@example.com www.zoller.info INDIA ZOLLER India Private Ltd. Plot No. RM 104, 'G' Block Sanjeevani Complex, Shahu Nagar, Near KSB Chowk, Chinchwad, Pune 411019 Maharashtra, India T +91 20 2749 6118 Tel: Fax: +91 20 2749 6114 firstname.lastname@example.org r www.zoller.info JAPAN P ZOLLER Japan KK 5-14, Kawagisi-Cho Suita-Shi, Osaka 564-0037, JAPAN P T +81 6 6170 2355 Tel: Fax: +81 6 6381 1310 email@example.com r www.zoller-jp.com r Competent. Personal. Fast. ZOLLER service At ZOLLER, delivering quality means being there for you after the purch hase, too. With personal advice and high-quality maintenance programs for your ZOLLER tool presetter and measuring machines. The ZOLLER service team is always a on standby for you with technicians who hav a e been trained in-house at ZOLLER. For low downtime and ﬁrst-class service. Testing of every ZOLLER tool presetter T and measuring machine with certiﬁed test bars and gauges traceable to national measurement standards. Proof of geometries, measurement reliability and performance are also part of the inspections. Quality-critical parts are purchased from the best manufacturers on the world market, such as Bosch, Heidenhain or Sony Full service maintenance contract ISO 9000 check with calibration certiﬁcate Measuring machine performance capability test to Cg/Cgk, CMR, R & R and proof of accuracy Machine calibration with laser interferometer and ZOLLER FKM gauge Software updates and hardware upgrades Conversion and retroﬁtting of mechanical, optical and electronic components Training in diﬀerent ﬁelds of application ZOLLER TMC Tool T Management Consulting for lean, eﬃcient production processes We would be glad to send you more detailed information ZOLLER application solutions. At ZOLLER you will ﬁnd the best tool presetter and measuring machine for every requirement. With versatile equipment, matched to your needs. Y can ﬁnd a complete overview on You the right. More information on ZOLLER tool presetter and measuring machines is a ailable at www.zoller-usa.com av r You can rely on ZOLLER! We keep our promises. on maintenance programs and prices or to answer Find out for yourself – and arrange a personal conversation with us. any of your questions. Just call us: Phone: +1-734-332-4851 More products at a glance »venturion TOOL INSPECTION / CHECKING GRINDING SHARPENING ZOLLER tool presetter and measuring machines MEASURING | PRESETTING MEASURING | PRESETTING | SHRINKING MILLING TURNING »venturion THE SPECIALISTS 450« Vertical tool presetter and measuring V machine series 3 axis manual/CNC 450« »smarTcheck« »genius 3« & »genius 3 micro« Measuring machine for the most demanding requirements with 2D measurements: 4 axis manual/C / NC Universal measuring machine for fully automatic complete tool measurement: 5 axis CNC »venturion 600/800« »hyperion 250/400/700« Vertical tool presetter and measuring machine series 3 axis manual/CNC Vertical machine series for large, heavy a tools: 3 axis manual/CNC Horizontal machine series for turning and milling tools: 4 axis manual/CNC »powerShrinkset« »redomatic« »tribos« Manual shrinking machine with length adjustment Presetting, shrinking and measuring combination: 4 axis manual/CNC Vertical universal tool prese V r tt t er and measuring machine series with TRIBOS clamping system: 4 axis manual/CNC »gemini« »zenit« »phoenix« CNC tool presett t er/ r measuring machine for crankshaf a t cutt t ers and turning/broa r ching tools CNC tool presetter/measuring machine for milling heads and shafts Tool presetter/measuring machine for measuring T tools between points: 3 axis manual/CNC At a glance ZOLLER »smile« product series ZOLLER »smile« basic The basic structure of every »smile machine is the same: Brand name components for a solid perforr mance. Page 9 ZOLLER »smile/pilot 2.0« Standard measuring functions – as much technology as necessary, but as little as possible. Pages 10 | 20 | 21 ZOLLER »smile/pilot 3.0« Modular construction, select software functions according to your needs, stay a versatile, whatever happens. Pages 11 | 22–25 ZOLLER »smile/CNC« Automatic axis positioning for even more productionreliable tool presetting and measuring. Page 14 ZOLLER »smile/tribos« The ideal manual tool presetter and measuring machine for all those who are using SCHUNK TRIBOS tool holders. Page 15 The CNC controlled alternative: ZOLLER »tribos«. Page 31 ZOLLER »smile/shrink« The ideal manual tool presetter and measuring machine for all those who are using shrink-ﬁt chucks Pages 16 | 17 The CNC controlled alternative: ZOLLER »redomatic a « Page 31 ZOLLER »smile/EDM« The ideal tool presetter and measuring machine for all those who want to measure and preset electrodes. Pages 18 | 19 Our duty: Customer satisfaction ZOLLER Quality Continuous and consistent quality management at ZOLLER guarantees mechanically, electrically and electronically convincing product quality. The exclusive use of brand name components makes ZOLLER tool presetter and measuring machines virtually maintenance-free in use throughout their long service life. Satisﬁed customers around the globe beneﬁt from the highest manufacturing quality, saving a not only time, but also money. And ZOLLER quality does not stop at the product, but continues with the service. You Y can rely on our quality and expertise! »The bitterness of poor quality lingers long after the sweetness of low price is forgotten.« John Ruskin » A thriving, independent, family business in its third generation with locations worldwide. » » With ZOLLER you set the standard. The ZOLLER seal of quality guarantees precision and quality, reliability and eﬃciency. That's what ZOLLER stands for. ZOLLER has the know-how in development, sales and service. » More than 25,000 tool presetter and measuring machines have been sold worldwide since 1968. » ZOLLER is there for you – all over the world. The ZOLLER seal of technology stands for the highest level of innovation: ZOLLER is developing the technologies today that you will need tomorrow. » ZOLLER has the best solution. BRSMI.00–US. 06/2010. Subject to technical changes. Equipment without obligation. Concept & design: www.absicht.ag » With ZOLLER you lead the way.
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