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ZOLLER

INSPECTION SOLUTIONS

Technical Description

CNC 5-axes Universal Measuring Machine

genius 3 / pilot 3.0


ZOLLER Universal Measuring Machine
»genius 3«

QUALITY &
PRODUCTION
Made in Germany

ZOLLER branded components

Uhing drives Cable carrier elements CCD camera systems Heidenhain measuring Bosch/Festo pneumatics THK guide systems
systems

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Table of contents
Universal measuring machine »genius 3«����������������������������������4 Measuring machine control »pilot 3.0« hardware�������������������12
At a glance�������������������������������������������������������������������������������4 Performance and data������������������������������������������������������������12
Technical data��������������������������������������������������������������������������5
»pilot 3.0« software�����������������������������������������������������������������13
Optics »high resolution«������������������������������������������������������������6 Standard functions�����������������������������������������������������������������13
Camera/lighting »micro«�����������������������������������������������������������6 Measurement program packages Basic / Advanced / Premium14
ZOLLER test report�����������������������������������������������������������������15
Tool holding fixture spindles for »genius 3«������������������������������7 Interface grinding machine controller / »genius 3«������������ 16/17
High-precision spindle SK 50 / vacuum / AF / ROD������������������7
High-precision spindle »ace« size I / AF / ROD Accessories�������������������������������������������������������������������������������18
or with hollow shaft encoder����������������������������������������������������7 Storage shelf��������������������������������������������������������������������������18
Wooden board D32 mm��������������������������������������������������������18
Spindle options��������������������������������������������������������������������������7 »genius 3« PVC turret for reduction sleeves����������������������������18
Autofocus with ROD����������������������������������������������������������������7 Printer for thermal adhesive labels������������������������������������������18
Hollow shaft encoder HLG for high-resolution C axis����������������7 Laser printer "Lists/Graphics" Color����������������������������������������18
Sit-stand���������������������������������������������������������������������������������19
Tool holding fixtures for high-precision spindles »ace«�������������8 Barcode reader or data-matrix code reader�����������������������������19
Tool post size I / expansion chuck D32 mm������������������������������8 Adapter or tool trolley������������������������������������������������������������19
Reduction sleeves D32 / d 3 – d 25 mm�����������������������������������8
Reduction sleeves D32 / d 3 – d 25 mm�����������������������������������8 Mains voltage���������������������������������������������������������������������������19
Holding fixture D32������������������������������������������������������������������8
Fastener for indexable inserts with support glass 35 mm����������9 QA, maintenance, service���������������������������������������������������������20
Collet chuck adapter D32���������������������������������������������������������9 Test mandrel ISO 9001�����������������������������������������������������������20
»Baby Chuck« fixture set with collet chuck adapter D32 mm������ 9 Radius gauge »Radius«�����������������������������������������������������������20
Calibration gauge A����������������������������������������������������������������21
Tool posts size I for high-precision spindle »ace«��������������������10 Angle gauge for incident light camera�������������������������������������21
Tool posts HSK A/C/E-B/D/F���������������������������������������������������10 Pine tree-shaped test gauge D32 mm - »CERT«����������������������21
Tool post steep taper��������������������������������������������������������������10 Measuring machine capability test »tethys«����������������������������21
Tool post Sandvik Capto���������������������������������������������������������10 Worldwide remote maintenance��������������������������������������������21
Tool post Kennametal UTS������������������������������������������������������10
Parameter list »genius 3s - pilot 3.0«�������������������������������� 22–25
Adapter for high-precision spindle SK 50/vacuum������������������11
Adapter SK 50 / expansion chuck D32�����������������������������������11 Overview���������������������������������������������������������������������������� 26/27
Adapter SK 50 / steep taper���������������������������������������������������11
Adapters SK 50 / HSK A/C/E-B/D/F (with tool clamping)��������11

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Universal measuring machine »genius 3«

Door query

Safety door
One-hand operation Image proces-
sing »pilot 3.0«
3D camera with LED ring light
Transmitted light
Image processing camera
Membrane keyboard (360°
spindle brake; 4 x 90° spindle High-precision spindle
indexing; tool clamping)

Tool turret for reduction Label printer


sleeves

Adapter tray »cockpit«

Measuring machine control Report printer

ZOLLER »genius 3« is the universal measuring machine for all ■■ CNC control unit in 5 or 6 axes (micro sensor optional), posi-
types of metal cutting tools, starting from fast checking of single tioning accuracy of 0.001 mm (linear) and 0.01° (rotating) and
criteria, such as the outer contour of your tools, to fully automa- repeatability of the measurements < 0.002 mm
ted and operator-independent complete control of special tool ■■ Separate and ergonomic control unit »cockpit« with 23“TFT mo-
geometries. The measurement results are documented in detail nitor for storing the keyboard, mouse, small parts and printers
and can be transferred to the grinding machines at the push of a ■■ »pilot 3.0« image processing for automatic transmitted light
button or printed out depending on the application. Therewith measurements with a field of vision 4 x 4 mm, camera HR70 high
the »genius 3« saves you valuable time during work preparation resolution and 50-fold magnification of the tool cutting edges
and programming, prevents troublesome rework and customer ■■ Image processing »pilot 3.0« for automatic incident light mea-
complaints and ensures quality results that convince both you surements with 8-segment incident light system with adjustable
and your customers. Besides, an integrated information system intensity. 200-fold magnification of the tool cutting edge, CNC
provides support in all areas of image processing at any time. A swivelling free from backlash in 0 – 90° for radial and axial mea-
wide selection of individual and modular measurement programs surements
allows you to tailor »genius 3« exactly to your needs and requi- ■■ Measuring machine capability: E = 3 + L / 250 µm
rements. ■■ The smallest measurable diameter in (2D) is 0.07 mm
■■ The smallest measuring area for incident light measurements in
Highlights »genius 3«: (3D) is 0.2 mm x 0.2 mm (micro 0.06 mm x 0.07 mm)
■■ Pneumatic slide clamping, electronic infinite micro adjustment ■■ The maximum measurable diameter for effective cutting angle
■■ Bellow covers over guides and measuring system measurements in (3D) is 75 mm.
■■ Brand name products such as Bosch pneumatics, Heidenhain
measuring systems, Sony camera, THK guide system and Uhing
drive
■■ Total encasement to avoid external influences and vibration re-
ducing device base
■■ Dimensionally stable and torsion-free construction consisting of 2D = transmitted light, 3D = incident light, *) = For sharp-edged
robust design elements cutting edges

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Technical data »genius 3«

Series »genius 3« Max. length


Diameter Snap gauge Transmitted Incident light
Height of machine: Z axis X axis Y axis incident light
D D1 light camera camera
2000 mm; Weight: 660 kg measurement
»genius 3s« 600 mm 175 mm ± 50 mm 340 mm 100 mm 470 mm 1:1/HR70 1 x 1 mm/HR50
»genius 3m« 600 mm 175 mm ± 50 mm 340 mm 70 mm 470 mm 1:1/HR70 0,5 x 0,5 mm/HR50

Effective cutting Face geometry


Diameter Diameter Draft angle Chamfer width
Length (2D) angle/flute depth (3D)
Snap gauge (2D) (2D) Perimeter (3D) Perimeter (3D)
(3D)
Z < 470 mm
Tool
0.1 – 100 mm 0.1 – 340 mm 0 – 600 mm Ø < 200 mm Ø < 200 mm Ø < 75 mm Ø < 230 mm
dimensions
Step < 35 mm

Accuracies Electrical data Pneumatics


Concentricity 2 µm Voltage 230 V ±10 %
6 – 8 bar
Compressed
Presetting 2 µm Frequency 50/60 Hz ±2 % (depending on the tool
air
holding fixture spindle)
Indication 1 µm Power < 1000 VA
Repeatability 2 µm Protective switch F6A (slow blow) Condition Dry, slightly oiled

Environment

Transport and storage 10 – 95 % Measuring operation 80 %


Humidity
not condensing not condensing

During normal operation the device reaches a level of < 45 dBA. When actuating the optionally available
Noise level
printer, this level can rise briefly to approx. 53 dBA according to DIN 45635.

Note: Weight 7100 N (including »cockpit«)

Subject to technical modifications. The depicted machines may include options, accessories and control variants.

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Optics »high resolution«

Optics carrier »genius 3 s«


1:1/HR70 transmitted light camera, Micro sensor
Transmitted light Incident light
incident light camera, standard (optional)
Snap gauge D = 100 mm

Field of vision 3.6 x 4.8 mm 1.0 x 1.3 mm 1.1 mm


Working distance 203 mm 45 mm 6.0 mm
Sony 1/3“ CCD Sony 1/3“ CCD
Camera chip type monochrome monochrome –
(HR70) (HR50)
Resolution 1024 x 768 pixels 640 x 480 pixels –

Optics carrier »genius 3 s« and »genius 3 m«


without micro sensor

Optics carrier »genius 3 m«


1:1/HR70 transmitted light camera, Micro sensor
Transmitted light Incident light
incident light camera Micro (optional)
Snap gauge D = 70 mm

Field of vision 3.6 x 4.8 mm 0.36 x 0.48 mm 1.1 mm


Working distance 203 mm 45 mm 6.0 mm
Sony 1/3“ CCD Sony 1/3“ CCD
Camera chip type monochrome monochrome –
(HR70) (HR50)
Resolution 1024 x 768 pixels 640 x 480 pixels –

Optics carrier »genius 3 s« and »genius 3 m«


with micro sensor

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Tool holding fixture spindles for »genius 3«

High-precision spindle SK 50 / vacuum / AF / ROD

The high-precision spindle SK 50 with autofocus and ROD encoder


shows concentricity of 0.002 mm. It has a vacuum clamping device,
spindle nose with integrated calibration edge and an indexing de-
vice 4 x 90°. To allow manual focusing of the spindle, it is equipped
with an ergonomic hand wheel. The membrane keyboard allows
pneumatic spindle clamping and further power-operated functions.

High-precision spindle »ace« size I / AF / ROD


or hollow shaft encoder

The high-precision spindle »ace« allows universal power operated


tool clamping for tools with steep taper, ANSI, CAT, MAS-BT, HSK,
Capto and KM. The tool post-quick change device allows a tool
post replacement with a changing accuracy of 0.001 mm in maxi-
mum 10 seconds. Furthermore, like the SK 50 spindle, the »ace«
spindle has an indexing device 4 x 90°, a membrane keyboard for
all power-operated functions on the spindle and a ROD encoder or
optional hollow shaft encoder.

Spindle options

Autofocus with ROD

Using the autofocus, the tool cutting edge is automatically focused


to the highest point and the angle position is determined.

»genius 3 « /
»ace« spindle

Hollow shaft encoder HLG for high-resolution C axis

The hollow shaft encoder is a direct angle measuring system on the


C axis (spindle).

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Tool holding fixtures for HGS »ace« size I

Tool post size I / expansion chuck D32 mm

The tool post size I with integrated calibration edge is designed to


fix tools with cylindrical shank surfaces. The tool holding fixture
is automatic and power-operated. The holding fixture is D32 mm.

Reduction sleeves D32 mm / d 3 – d 5 mm (standard)

The three slotted reduction sleeves are suitable for an expansion


chuck with diameter D32 and for a tool shank diameter
D3/4/5 mm. Special sizes are available on request.

Reduction sleeves D32 mm / d 3 – d 25 mm

The 12 slotted reduction sleeves are suitable for an expansion


chuck with diameter D32 mm and for a tool shank diameter
D3/4/5/6/8/10/12/14/16/18/20/25 mm. Special sizes are available
on request.

Holding fixture D32 mm

The holding fixture with locating shank D32 mm and with inte-
grated calibration edge is designed for scanning and measuring of
small workpieces in the incident light. The ground support surface
which can be adjusted using tool holders ensures a precise mea-
surement result.

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Fastener for indexable inserts with
support glass 35 mm

The fastener for bearing the indexable inserts with special glass
pane and a fixture shank diameter of D32 mm, a clamping arm and
integrated focus edge ensure interruption-free and fast fixture of
the outer contour (see data sheet 05WF033).

Collet chuck adapter D32 mm

Depending on the adapter size the collet chuck with a fixture shank
diameter D32 mm clamps tools with a diameter from 0.5 mm up to
maximum 9 mm (see data sheet 20.4.36).

»Baby Chuck« fixture set with collet chuck adapter


D32 mm

The »Baby Chuck« fixture set contains a collet chuck adapter with
a fixture shank diameter of D32 mm, a hook wrench and a collet
chuck set with a diameter from 0.5 mm to 8 mm (see data sheet
05B0046).

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Tool post size I
for high-precision spindle »ace«

Tool posts HSK A/C/E-B/D/F


HSK size
Description Item no.
A/C/E-B/D/F
25–32 6 016 925
■■ Power-operated
tool clamping 32–40 6 015 932
■■ Suitable for WZI 40–50 6 015 940
■■ Integrated calibration 50–63 6 015 950
edge 63–80 6 015 963
■■ Changing accuracy 80–100 6 015 980
0.001 mm 100–125 6 015 9100
■■ Change-over time 10 sec.
125–160 6 015 9125

Tool post steep taper


SK Loss Weight
Description Item no.
size Z - mm in kg
■■ For holding fixture of 25 0 2.60 6 201 2251)
tool shafts 30 0 2.55 6 201 230
acc. to DIN 69871
35 0 2.50 6 201 2351)
■■ Integrated calibra-
40 0 2.45 6 201 240
tion edge
■■ Changing accuracy 45 0 2.40 6 201 245
0.001 mm 50 0 2.00 6 201 250
1)
All adapters can be manufactured individually. Special sizes / additional costs
(please request the delivery time or additional costs)

Tool post Sandvik Capto


Description Size Capto Item no.

■■ Power-operated 3 6 001 C03


tool clamping
4 6 001 C04
■■ Integrated calibration
edge 5 6 001 C05
■■ Changing accuracy
6 6 001 C06
0.001 mm Change-
over time 10 sec. 8 6 001 C08

Tool post Kennametal UTS


Description Size KM / UTS Item no.

■■ Power-operated 32 6 003 K32


tool clamping 40 6 003 K40
■■ Integrated calibration
50 6 003 K50
edge
63 6 003 K63
■■ Changing accuracy
0.001 mm 80 6 003 K80
■■ Change-over time 10 sec. 100 6 003 K100

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Adapter for high-precision spindle
SK 50/vacuum

Adapter SK 50 / Expansion chuck D32

The SK50 adapter is designed for holding tools with cylindrical shank
surfaces. When using the expansion chuck insert with a holding fix-
ture diameter D32, the tool clamping is performed manually.

Adapter SK 50 / steep taper


Measuring
SK Weight
Description range loss Item no.
size in kg
Z - mm
10 20 2.70 6 300 210
■■ For holding
15 20 2.60 6 300 215
fixture of tool
20 20 2.50 6 300 220
shanks with
steep taper 25 20 2.40 6 300 225
DIN 69871 30 20 2.35 6 300 230
■■ Integrated
35 20 2.20 6 300 235
calibration
40 20 2.00 6 300 240
edge
45 20 1.45 6 300 245

Adapters SK 50 / HSK A/C/E-B/D/F


(with tool clamping)
Loss in
HSK size
measuring Weight
Description A/C/E- Item no.
range Z - in kg
B/D/F
mm
■■ For fixing of 32–40 75 4.80 6 302 932
tool shanks with
hollow shank 40–50 75 4.80 6 302 940
taper HSK DIN
69893 with and 50–63 75 5.40 6 308 950
without cooling
pipe 63–80 75 5.25 6 302 963
■■ Manual eccen-
tric clamping 80–100 105 6.65 6 302 980
■■ Integrated
calibration edge 100–125 105 6.85 6 302 9100

Further adapters or tool posts are available on request!


All other adapters or special sizes can be manufactured individually.
(Delivery time or additional costs depending on the effort)

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Measuring machine control »pilot 3.0« hardware

Performance and data

■■ Control and measuring electronics in five- or six-axes version


■■ Windows 7 operating system 64-bit with multilingual
User Interface (MUI)
■■ Measuring machine control with min. 3.06 GHz
■■ CE regulation (Europe) and FCC class A (USA) traceable
■■ Hyperthreading technology
■■ 4 GByte main memory
■■ Heat pipe with 6 embedded copper pipes for optimum
processor cooling
■■ 2 parallel interfaces
■■ 6 RS232 interfaces
■■ 12 USB 2.0 interfaces
■■ Hard drive with minimum 500 GByte
■■ Image software for hard-drive backup
■■ Industrial filter according to EN 779 data sheet 9700910-14
■■ Special cooling system for working at ambient temperature of
up to 50°C without performance drop
■■ Exclusive use of special industrial components
■■ Monitoring of temperature, fan and hard drive
■■ 23“ TFT color display, EMC certified
■■ Flexible operation via keyboard, mouse and touch screen
■■ Real-time measurement, 50-fold magnification
■■ Power factor (PFC), revised power supply unit for 100 - 240 V
■■ »cockpit« for 23“ TFT monitor, keyboard, mouse, printer, storing
places including USB connection

23“ TFT monitor with industrial casing

Measuring machine control and processor cooling »cockpit« for monitor, keyboard, mouse, printer, storing places

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»pilot 3.0« software

Standard functions

■■ Professional technology (.NET Framework)


■■ Graphical user interface
■■ Automatic recognition of cutter shape and measuring range
■■ Automatic zero point monitoring
■■ Dynamic crosshairs
■■ Projector function
■■ InPicture measuring and zoom
■■ Real-time measurement
■■ Analog, color focusing display
■■ Automatic transmitted light control
■■ Adapter management for 9,999 zero points and graphical indi-
cation for calibration procedure Automatic recognition of cutter shape and measuring range
■■ Machine management of all data for error-free measurement
and presetting of tools
■■ Handling of radius, diameter, difference dimension, incremental
dimension and counter stop for both axes independently from
each other (freely selectable)
■■ Switching from mm/inch
■■ Display accuracy 0.001 mm
■■ Adjustable intensity for projector function and cutting edge
inspection
■■ Generator for ID numbers
■■ Tolerance monitoring of all measured values
■■ User management
■■ Setup system Adjustable intensity for projector function and cutting edge inspection
■■ Concentricity measurement cutting edges
■■ Measuring procedure largest cutting edge
■■ Software Maxcontur »cris«
■■ Measurement program generator »expert« / »genius 3« (standard)
■■ Management of more than 15,000 tools
■■ Library for tool descriptions
■■ Multifunctional workstation
■■ Standard measurement programs: oversized radii, theoretical
point via cutter shape, angle via measuring points, radius via
measuring points, length/radius on chamfer, etc.
■■ Navigation system »compass« for manual axis adjustment for
fast and safe positioning of target values
■■ Help system Software Maxcontur »cris«
■■ Acceptance record
■■ Operation using touch screen, mouse and keyboard
■■ Printing of labels, lists and protocols
■■ SoftwareViewer Powerpoint, Word, Excel (MS®), Autodesk®,
Design Review (CAD 2/3D)
■■ and many more.

Measurement program generator »expert« / »genius 3« (standard)

13
Measurement program packages Basic / Advanced
Premium

ZOLLER software package »Premium« includes the software pac-


kages »Basic« (standard) and »Advanced« as well as additional im-
portant measurement programs for transmitted light, incident light
and contour measurement (the »Advanced« package includes the
»Basic« package). It will give you a complete software package for
the tool inspection and measurement in the transmitted light and
incident light mode as well as for the automatic and operator-inde-
pendent nominal/actual comparisons.

The »Premium« software package includes the fol-


lowing measurement programs (MP) and software
functions (SF):

Measurement program package »Basic« (standard):


■■ SF Editable test report »apus« item no. 8702100
■■ SF Collective report item no. 8702115
■■ SF Auto-edge-check »aec« item no. 8702002 SF Incident light measurement »metis« item no. 8702003
■■ MP 16 Theoretical point via measuring points item no. 8772016
■■ MP 28 Radius contour »contur« item no. 8772028
■■ MP 32 Snap gauge diameter item no. 8772032
■■ MP 36 Angular calculation item no. 8772036
■■ MP 42 Cylindricity item no. 8772042
■■ MP 44 Chamfer width/length/angle item no. 8772044
■■ MP 45 Helical pitch/angle item no. 8772045
■■ MP 47 Axial angle item no. 8772047
■■ MP 56 Single-edged tool diameter item no. 8772056
■■ MP 57 Diameter uneven number of cutting edges item no. 8772057
■■ SF Concentricity /wobble compensation, item no. 8772058
■■ MP 89 Cutting edge radial run-out item no. 8772089
■■ MP 102 Pitch item no. 8772102 MP 80 »lasso« contour measuring item no. 8772080
■■ MP 145 Point angle (hollow grind) item no. 8772145
■■ MP 166 Theoretical intersection point item no. 8772166
■■ MP 470 Cylindricity / Taper item no. 8772470
■■ MP 555 »apus-Rechner« item no. 8772666

Additional measurement programs in the »Advanced« package


(optional):
■■ SF Electronic contour projector »telesto« item no. 8702001
■■ SF Drawing generator »sinope« item no. 8702102 MP 52 Flank diameter MP 171 cutting edge radial run-out,
■■ SF 22 Die sinking cutter »cris« item no. 8772022 item no. 8772052 drill item no. 8772171
■■ MP 49 Concentricity check, graphical item no. 8772049
■■ MP 88 Die sinking cutter without radius item no. 8772088 ■■ MP 260 Run-out (indexing) item no. 8772260
■■ MP 137 Full radius end milling cutter item no. 8772137 ■■ SF »Fräser« expert template item no. 8772750
■■ MP 149 Point angle/hollow grind item no. 8772149 ■■ SF »Bohrer« expert template item no. 8772751
■■ MP 440 Intersection point at the taper milling cutter item no. 8772440 ■■ SF »metis« generator item no. 8772818
■■ SF »metis« interpreter item no. 8772819
Additional measurement programs in the »Premium« package ■■ SF File logging item no. 8702204
(optional): ■■ SF Statistical measured values item no. 8703005
■■ SF Incident light measurement »metis« item no. 8702003 ■■ MP 43 Helical pitch/angle item no. 8772043
■■ MP 52 Flank diameter item no. 8772052 ■■ SF Contour correction »coCon« item no. 8774024
■■ MP 80 »lasso« contour measuring item no. 8772080
■■ MP 171 Cutting edge radial run-out drill item no. 8772171 Note: All software packages are available starting from »pilot 3.0«
■■ MP 212 Flank diameter uneven number of cutting edges version 1.10.0. Please observe the individual measurement pro-
item no. 8772212 gram prerequisites!

14
ZOLLER test report »apus«

ZOLLER test report can be created individually and informative for ■■ Corporate logo
each customer and meaningful for documentation and traceability. ■■ Tool graphics
The following object data or parameters can be saved in the test ■■ Full article designation
report: ■■ Inspector including date
■■ Different measurement parameters including tolerance
specifications
■■ Graphics which are created/measured in »pilot 3.0«
■■ and much more

Measure protocol 1 / 1

»genius Standard« 13-08-2014


User zoller 13:25:26

ID no. GW-009
Desc. Vollradiusfräser

Remark

Tester

Step Result Nom. value U. tol. L. tol. Act. value


Diff. value Tolerance

2 Radius 3.000 0.020 -0.020 2.978 -0.022

3 Diameter 6.000 0.000 -0.048 5.969 -0.031

4 Center offset 0.000 0.100 0.000 0.068 0.068


4 Axial relief angle 1 12.00 0.50 -0.50 11.69 -0.31
4 Axial land width 0.350 0.025 -0.025 0.350 0.000
4 Radial rake angle @ 0,3500 5.00 0.50 -0.50 6.34 1.34
4 Core diameter 3.100 0.050 -0.050 3.070 -0.030
4 Flute depth 1.450 0.025 -0.250 1.467 0.017
4 Helix angle 30.00 1.00 -1.00 30.10 0.10
4 Radial relief angle 1 9.00 0.50 -0.50 7.71 -1.29
4 Radial land width 1 0.750 0.050 -0.050 0.741 -0.009

All length units in Millimeter, all angle units in decimal degree

E. Zoller GmbH & Co. KG - Gottlieb-Daimler-Str. 19 - D-74385 Pleidelsheim


Tel. +49-7144-8970-0 - Fax +49-7144-8060807 - post@zoller.info - www.zoller.info

15
Interface grinding machine controller / »genius 3«

Interface grinding machine controller / ZOLLER »genius 3« means


that a tool is programmed at the grinding machine controller only
once. From these grinding machine data ZOLLER software »pilot
3.0« automatically creates the measurement program for measuring
and inspecting the ground tool. This means time and cost savings
and gives a significant competitive edge.

Data communication
The NC program for tool grinding is transferred to the NC grinding
machine. At the same time the programming system sends a mea- Open the interface and enter the nominal data.
surement data file to »genius 3« from which ZOLLER generates a
fully automatic measuring cycle.

Tool measuring
The tool is ground at the CNC grinding machine. Then the tool is
immediately measured at ZOLLER »genius 3« fully automatically.
Your benefit: No time required for programming of a measuring
procedure at ZOLLER »genius 3«.

Transfer of the measured actual values


The measured tool actual data are transferred by ZOLLER »genius 3«
back to the programming system. The NC program can be corrected
Generating and performing the measurement.
there on the basis of these data.

Corrected tool data


Based on the actual tool data, the optimized NC program can be
transmitted to the machine, the tool is ground correctly.

Production start
The production of the tools can start. ZOLLER »genius 3«
measures and records the ground tools. No programming
effort at ZOLLER »genius 3«!

Measurement results and resending of data.

Overview of interface grinding machine controllers:

16
Interface grinding machine controller / »genius 3«

Transfer of corrected
tool actual data
CNC grinding machine/s
grinding of tools with the generated opti-
NC programming system
mized NC program
programming/definition of the tool in NUM,
MTS, Anca, Schütte, etc. Transfer of NC data

Transfer of
measurement
data files to
»genius«

New tool Start of serial


measuring production

Retransfer of the
measured tool actual
data Shipment
of finished
tools

Random sampling
according to test protocol

Generation of ZOLLER test report

ZOLLER »genius« | Automatic measurement of tools

■■ Automatic generation of the measuring procedure for measuring


and inspecting tools from grinding programs
■■ Fully automatic contour correction for form tools »coCon«
■■ Fully automatic measurement and data transfer
of the grinding wheel sets
■■ Marginal programming requirements for regrinding of
metal cutting tools
■■ Complete documentation with automatically generated
and saved test reports

17
Accessories

Storage shelf

The storage shelf is designed for storage of tool posts, tools, reduc-
tion sleeves, etc. At »genius 3« it is fastened on the total encase-
ment on the left side of the device.

Wooden board D32 mm

The wooden board (for storage in the storage shelf) has 16 slots
for proper storage of the reduction sleeves with external diameter
D32 mm.

»genius 3« PVC turret for reduction sleeves

Swivelling PVC turret with 15 slots for the storage of reduction


sleeves with external diameter D32 mm. The installation is per-
formed on the left at the genius casing.

Printer for thermal adhesive labels

This printer is suitable for thermal adhesive labels (text and bar-
code). It has a print density of 8 dots/mm, print width of 108 mm,
maximum print repeat range of 1000 mm and USB interface. Mains
voltage of 100 - 240 Volt is required.

Laser printer "Lists/Graphics" Color

The color laser printer for report and list printing has a memory
of 128 MB (can be upgraded to 640 MB), printing speed of up to
20 pages/minute, resolution of max. 1200 x 1200 dpi, universal
paper cartridge for 250 sheets (DIN A4 and smaller), USB interface
and network connection. Mains voltage of 230 V is required. The
printer can also be used as a monochrome printer.

18
Sit-stand

The ergonomic sit-stand consists of a stable, black steel construc-


tion and makes the work at the tool presetter and measuring ma-
chine easier. A gas spring cover protects from dust and dirt. The
PU-foam seat is easy to maintain, it is 320 mm wide and can be
adjusted to a height from 680 mm to 920 mm.

Barcode reader or data-matrix code reader

The barcode reader or data-matrix code reader allows easy scan-


ning of identification numbers or other data, such as actual tool
data from long reading distances. The barcode reader has a design
fitted for industrial purposes and high scanning rate; it is ergono-
mic and survives 50 falls from a height of 2 m. Readable codes are:
code 2/5 family, code 39, EAN/UPC, EAN 128, code 128, code 93,
CODABAR, TELEPEN, PLESSEY, code 49, CODE MSI, code Delta
IBM, code 11, CODABLOCK, code 16K, ISBN/ISSN and ISBT 128.
The barcodes may be maximum 80 mm wide.

Adapter or tool trolley

The adapter trolley consists of:


a) Transport unit
b) Tool changing frame
c) Pair of frame stretchers
d) Fluted rubber storage place
e) Adjustable shelf with frame

For further information refer to data sheet 22.21.

Mains voltage

Type of voltage Countries

230 V EN

115 V US

230 V CH

240 V GB

230 V CN

100 – 200 V JP

19
QA, maintenance, service

Test mandrel ISO 9001

The test mandrel ISO 9001 is designed for the start-up and conti-
nuous control of ZOLLER measuring machines. The test mandrel
ISO 9001 (calibration certificate) is packed safely in a wooden box.
Thus, flawless checks or independent calibrations can be performed
at the measuring machine at any time. The shank fixture depends
on the type of the tool holding fixture.

Design L (mm) D (mm) Item no.


SK 30 300 32 9 100 085
SK 40 300 40 9 100 024
SK 45 300 40 9 100 225
SK 50 300 50 9 100 020
SK 50 500 50 9 100 140
SK 50 1400 40 9 100 198
SK 60 300 50 9 100 084
Tool post size I 300 40 9 100 022
Tool post size I 500 50 9 100 162
Tool post size I 1000 40 9 100 081
Tool post size I
300 50 9 100 055
Front clamping
Tool post size II 300 40 9 100 021
Tool post size II 500 50 9 100 066
Tool post size II 1000 50 9 100 031
Tool post size III
600 50 0 5B0 205
Front clamping
HSK63 300 40 9 100 238
HSK100 300 50 9 100 123

Radius gauge »Radius«

The radius gauge can be used for testing during start-up, measuring
and for continuous control. The calibration certificate ISO 9001
and a wooden box for proper storage are enclosed. The shank fix-
ture depends on the type of the tool holding fixture.

Ø sphere Item no. SK 40 Item no. SK 50 Item no. Shank D 32


3 9 100 064 - -
5 9 100 063 9 100 161 9 100 426
10 9 100 062 9 100 191 9 100 427
15 9 100 121 - -
20 9 100 120 9 100 219 9 100 428
25 9 100 119 - -
30 9 100 118 - -
35 9 100 117 - -
40 9 100 122 - -

20
Calibration gauge A

The calibration gauge A is designed for recalibration of 2D and 3D


camera directly at the installation location. The following parame-
ters are recalibrated (see data sheet 9100368):

■■ Adapter center 2D and 3D camera in the horizontal position


■■ Adapter center 3D camera in the vertical position
■■ Positioning offset of the camera 2D to 3D

Angle gauge for incident light camera

The angle gauge checks the angle measurement accuracy in the


incident light. The following angles are certified and can be deter-
mined with high accuracy (see data sheet 9100311):

■■ Draft angle
■■ Effective cutting angle
■■ Front clearance angle

Pine tree-shaped test gauge D32 mm - »CERT«

The pine tree-shaped test gauge is designed for inspection, verifi-


cation and correction of the absolute accuracy in the diameter. The
ground diameters include 5 mm to 98 mm. The locating shank has
a diameter of 32 mm. The pine tree-shaped test gauge is supplied
together with the test certificate for safe storage in a wooden box.

Measuring machine capability test »tethys«

»tethys« provides software functions for testing of ZOLLER tool


presetter and measuring machines, which are recognized world-
wide. The measuring machine capability is verified according to Cg/
Cgk, R&R or Cmr. The measuring machine capability test does not
include any repairs or calibrations on ZOLLER tool presetter and
measuring machines. The procedure is performed according to flyer
K000010.

Worldwide remote maintenance

Remote maintenance software for connection of the universal


measuring machine to the worldwide ZOLLER service on-site as-
sistance via Internet.

21
Parameter list »genius 3s - pilot 3.0«

The following parameters are measured by means of ZOLLER »genius 3s - pilot 3.0«:

Distance contour - contour Alignment cutting edge - face


(face, perimeter, chip space) ■■ Edge detection
■■ Edge detection ■■ Repeatability 0.01°
■■ Repeatability 0.01 mm ■■ Duration: 6 sec
■■ Duration: 5 sec ■■ Standard
■■ Standard

Distance contour - center Alignment SE - face


(face, perimeter, chip space) ■■ Edge detection
■■ Edge detection ■■ Repeatability 0.01°
■■ Repeatability 0.005 mm ■■ Duration: 7 sec
■■ Duration: 4 sec ■■ Standard
■■ Standard

Distance line - line Cut-out length


(face, perimeter, chip space) ■■ Edge detection
■■ Edge detection ■■ Repeatability 0.01 mm
■■ Repeatability 0.01 mm ■■ Duration: 11 sec
■■ Duration: 5 sec ■■ Standard
■■ Standard

Alignment HP - face Cut-out angle


■■ Edge detection ■■ 3D measurement
■■ Repeatability 0.02° ■■ Repeatability 0.05°
■■ Duration: 7 sec ■■ Duration: 4 sec
■■ Standard ■■ Standard

Diameter D / snap gauge Draft angle face 3/4)


■■ 2D measurement (draft angle 1 / 2 / 3)
■■ Repeatability 0.002 mm ■■ 3D measurement
■■ Duration: 3 sec ■■ Repeatabilities 0.15°
■■ Software 8 772 032 5) ■■ Duration: 4 sec
■■ Standard

Facet width, length, angle 1)


■■ 2D measurement Draft angle, perimeter 3)
■■ Repeatabilities: (draft angle 1 / 2 / 3)
■■ Facet width 0.005 mm ■■ 3D measurement
■■ Facet length 0.005 mm ■■ Repeatabilities 0.15°
■■ Facet angle 0.05° ■■ Duration: 4 sec
■■ Software 8 772 044 5) ■■ Standard

22
Chamfer width Relief radius
(face, perimeter, chip space) 2) ■■ 3D measurement
■■ Edge detection ■■ Repeatability 0.25 mm
■■ Repeatability 0.01 mm ■■ Duration: 5 sec
■■ Duration: 3 sec ■■ Standard
■■ Standard

Flank face differences Core diameter


■■ 3D measurement ■■ 3D measurement
■■ Repeatability 0.01 mm ■■ Repeatability 0.01 mm
■■ Duration: 3 sec ■■ Duration: 4 sec
■■ Standard ■■ Standard

Head length Flute depth


■■ Edge detection ■■ 3D measurement
■■ Repeatability 0.01 mm ■■ Repeatability 0.01 mm
■■ Duration: 6 sec ■■ Duration: 4 sec
■■ Standard ■■ Standard

Length Z Opening angle


■■ 2D measurement ■■ Edge detection
■■ Repeatability 0.002 mm ■■ Repeatability 0.05°
■■ Duration: 2 sec ■■ Duration: 9 sec
■■ Standard ■■ Standard

Line center offset Run-out / cutting edge radial


■■ Edge detection run-out
■■ Repeatability 0.01 mm ■■ 2D measurement
■■ Duration: 6 sec ■■ Repeatability 0.002 mm
■■ Standard ■■ Duration: 10 sec
■■ Software 8 772 227

Minor cutting edge angle Chisel edge length


■■ 3D measurement ■■ Edge detection
■■ Repeatability 0.05° ■■ Repeatability 0.01 mm
■■ Duration: 5 sec ■■ Duration: 9 sec
■■ Standard ■■ Standard

23
Chisel edge radius Radius 1
■■ Edge detection (face, perimeter, chip space)
■■ Repeatability 0.02 mm ■■ Edge detection
■■ Duration: 5 sec ■■ Repeatability 0.02 mm
■■ Standard ■■ Duration: 3 sec
■■ Standard

Chisel angle Radius 3


■■ Edge detection (face, perimeter, chip space)
■■ Repeatability 0.05° ■■ Edge detection
■■ Duration: 5 sec ■■ Repeatability 0.02 mm
■■ Standard ■■ Duration: 8 sec
■■ Standard

Chisel angle, sharp Radius End gash


■■ Edge detection ■■ 3D measurement
■■ Repeatability 0.05° ■■ Repeatability 0.02 mm
■■ Duration: 5 sec ■■ Duration: 5 sec
■■ Standard ■■ Standard

Radius / Cross dimension 1) Concentricity


■■ 2D measurement ■■ 2D measurement
■■ Repeatability 0.002 mm ■■ Repeatability 0.002 mm
■■ Duration: 2 sec ■■ Duration: 7 sec
■■ Standard ■■ Software 8 772 049 5)

Cutting edge via center Point angle / cutting edge angle1)


■■ Edge detection ■■ 2D measurement
■■ Repeatability 0.01 mm ■■ Repeatability 0.05°
■■ Duration: 6 sec ■■ Duration: 6 sec
■■ Standard ■■ Standard

Cutting height differences Axial rake angle


■■ 2D measurement ■■ 3D measurement
■■ Repeatability 0.004 mm ■■ Repeatability 0.15°
■■ Duration: 8 sec ■■ Duration: 4 sec
■■ Standard ■■ Standard

24
Effective cutting angle Land depth / free grinding depth
■■ 3D measurement 2)

■■ Repeatability 0.15° ■■ 3D measurement


■■ Duration: 5 sec ■■ Repeatability 0.01 mm
■■ Standard ■■ Duration: 4 sec
■■ Standard

Helix angle Full radius - contour


■■ Edge detection ■■ 2D measurement
■■ Repeatability 0.02° ■■ Repeatability 0.002 mm
■■ Duration: 10 sec ■■ Duration: 5 sec
■■ Standard ■■ Software 8 772 028 5)

Angle of a line Angle between 2 lines


(face, perimeter, chip space) (face, perimeter, chip space)
■■ Edge detection ■■ Edge detection
■■ Repeatability 0.05° ■■ Repeatability 0.05°
■■ Duration: 5 sec ■■ Duration: 8 sec
■■ Standard ■■ Standard

Centering radius Cylindricity / Taper


■■ 2D measurement ■■ 2D measurement
■■ Repeatability 0.005 mm ■■ Repeatability 0.004 mm
■■ Duration: 2 sec ■■ Duration: 8 sec
■■ Standard ■■ Software 8 772 470

Note: Legend:

All specified values depend on the surface structure. The specified 2D = transmitted light measurement
accuracies assume that the measuring machine is not exposed to 3D = incident light measurement
vibrations and is installed in an environment with stable ambiance 1) Depending on the quality of the contour and object size
conditions. Different measurement methods for the same para- 2) Depending on the transition contrast Draft angle 1–2
meter may not be compared since calculations which are different 3) Starting from measuring window 0.35 mm
technologically or mathematically may lead to different measure- 4) At step tools up to maximum 30 mm step length
ment results. The acceptance and verification of the specified ac- 5) Included in »FORED-Grind«, item no. 8 701 310
curacies is performed only at the certified ZOLLER apprenticeships:
ZOLLER step gauge (2D) item no. 05B0031
ZOLLER angle gauge (3D) item no. 9100116

25
Designation »genius 3«
»genius 3 - pilot 3.0«
»genius 3 - pilot 3.0«/1:1/USB according to brochure and technical description
Casing »genius 3« USB motion is included in the basic price
Upstream transformer 90 VAC - 240 VAC/230 VAC, data sheet RE30.2.1
Optics carrier »genius3 s«/1:1/HR70, incident light camera (standard), snap gauge D = 100 mm
Optics carrier »genius3 m«/1:1/HR70, incident light camera (micro), snap gauge D = 70 mm
»genius3 s«/micro sensor/1:1/HR70, transmitted light camera (standard), micro sensor, incident light camera (standard),
snap gauge d = 100 mm, data sheet G600405
»genius3 m«/micro sensor/1:1/HR50, micro sensor and micro incident light camera, snap gauge D = 70 mm, data sheet G600405
»genius3 m«/micro sensor/1:1/HR50, micro sensor, incident light camera (micro), snap gauge D = 70 mm, data sheet G600405
»genius3 s«/micro sensor/1:1/HR70, micro sensor, incident light camera (standard), snap gauge d = 95 mm, data sheet G600405
Tool holding fixture spindles
High-precision spindle SK 50/vacuum/AF/ROD, concentricity 0.002 mm, vacuum clamping device, spindle brake, 4 x 90° spindle locking
devices, autofocus, rotary encoder
High-precision spindle »ace« size I/AF/ROD, concentricity 0.002 mm. Universal, power-operated tool clamping for steep taper/ANSI/CAT/
MASBT/HSK/Capto/KM. Autofocus, rotary encoder.
High-precision spindle »ace« size I/AF/HLG, concentricity 0.002 mm. Universal, power-operated tool clamping for steep taper/ANSI/CAT/
MASBT/HSK/Capto/KM. Autofocus, hollow shaft encoder for high-resolution C axis.
Tool holding fixtures
Adapter SK 50/expansion chuck D32, data sheet 20.4.29
Tool post size I/expansion chuck D32, automatic tool clamping, data sheet 20.2.6
Reduction sleeves metric or inches, different sizes, for example ø 3 – 25 mm
Collet chuck adapter D 32 data sheet 20.4.36
Reduction sleeve set D 32/d 3-d 25 D 3/4/5/6/8/10/12/14/16/18/20/25, data sheet 20.4.30
Reduction sleeve set D 32/d 6-d 25 D 6/8/10/12/14/16/18/20/25, data sheet 20.4.30
Reduction sleeve set D 32/d 3-d 5 D 3/4/5, data sheet 20.4.30
Holding fixture D 32 to hold small workpieces for measuring in the incident light
Fastener for indexable inserts with support glass 35 mm x 45 mm, clamping arm and integrated focus edge, fixture shank diameter 32 mm,
adjustment travel Y axis 16 mm, data sheet 05WF034
Adapter
Adapter SK 50/steep taper, data sheet 20.4.1
Adapter SK 50/HSK A32-F125 (with tool clamping), data sheet 20.16.26
Tool post
Tool post size I/HSK A25-F125, data sheet 20.16.25
Tool post size I/steep taper, data sheet 20.2.3.1
Electronic system
ZOLLER data backup service. Before shipment of the measuring machine, an image of the computer hard drive is created and saved on a USB flash drive.
Electronic axis management
ZOLLER measuring machine control »pilot 3.0« USB motion, Windows 7 operating system 64-bit, according to data sheet 9700910-14
Control unit »cockpit-pilot« with 23“ TFT color display, touch, keyboard, mouse and storing places for label and laser printer
Software
Standard functions »pilot 3.0«, flyer 8701000
»expert« measurement program generator for tool measurement in the transmitted and incident light (MP800), flyer 8772700
Basic measurement program package »pilot 3.0« for measuring and logging of tools, measurement programs with photo-realistic input dialog,
detailed logging of measurement results, flyer 8701331
Advanced measurement program package »pilot 3.0«, measurement programs for comparison of nominal and actual contours, generation of
tool drawings based on the actual dimensions and much more. Basic measurement program package is included in the price. Flyer 8701332
Premium measurement program package »pilot 3.0«, measurement programs for tool check, photo-realistic input dialog, tool inspection and
measurement with transmitted and incident light measurement. Automatic nominal/actual comparisons. Flyer 8701333
»elephant«/»genius« technology, flyer 8701311
Editable test report »apus« – software for editing, printing and outputting the measured values, flyer 8702100
MP »apus-calculator« measurement program and software for calculation of measurement results in the test report »apus« (»apus» is not
included in the price), flyer 8772666
Concentricity /wobble compensation, ROD encoder required, flyer 8772058
Chip space scan »genius«, flyer 8772703
Cutting edge preparation »s.k.p.«, software for measuring the edge rounding with incident light camera, flyer 8772702
Effective cutting angle - ball nose cutter, measurement program for measuring the effective cutting angle in different segments of the radius,
flyer 8772870
Customized test report, report layout according to customer specifications
Profil-assistent »pilot 3.0«, software for convenient creation of tool profiles in the DXF format for automatic nominal/actual comparison
and dimensioning with »lasso« function, single license, flyer 8702012
NUMROTO®plus interface, interface for tool grinding machines with »NUMROTOplus« software starting from software release 2.6.2., flyer
8774003 plus perimeter on NUMROTO®plus side

Standard Option

26
Designation »genius 3«
Software
Data import/-export XML
Contour measuring »lasso/Auflicht«, flyer 8772884
»lasso office« (external version »lasso«) can be supplied in combination with a »pilot 3.0« tool presetter and measuring machine incl. dongle,
flyer 8772900
»CAZ« - the virtual measuring machine/DL+AL, software for external definitions of measuring procedures directly on 3D tool drawings using
the transmitted light (DL) and incident light measurement method (AL), flyer 8702205
»CAZ«- workstation license, license for another workstation, prerequisite: software module 8702205, flyer 8702205
Microsoft SQL »pilot 3.0«, connection to Microsoft SQL server, data sheet DB8715004
Software maintenance »pilot 2 mT / 3.0«, costs per year 15 % of the software costs (€ ...), installation support per day Euro 1,200.00 plus
travel expenses
Accessories
Storage shelf
Wooden board D34, data sheet 22.7.2
Printer for thermal adhesive labels, print width of 25 mm to 108 mm, standard labels 25 x 75 mm, flyer 8702111
Color printer in laser technology for lists and graphics, 220 V-240 V AC, 50/60 Hz
Color printer in laser technology for lists and graphics, 110-127 V AC, 50/60 Hz (US)
Accessories for laser printer
Accessories for color printer in laser technology
Sit-stand/gas spring height adjustment, data sheet 22.71
Air spring insulator/System Bilz, leveling elements FAEBI, 100 SystemBilz/4 pieces
Cleaning agent »genius« for tool cutting edges
UPS system 700 VA/230 V
Uninterruptible power supply, UPS system 120 V/750 VA
Tool tag tray at cockpit, data sheet 61.10.1
Barcode reader tray at cockpit, data sheet 61.10.1
Open-end spanner tray at cockpit, data sheet 61.10.1
Cup holder tray at cockpit, data sheet 61.10.1
Base tray at cockpit, data sheet 61.10.1
USB camera »pilot 3.0« for fast and simple recording of tool images directly at the tool presetting and measuring machine, flyer 9734845
Network preparation WLAN via USB adapter
Protective cover
Heidenhain/Enhancement of type of protection, overpressure system for Heidenhain measuring systems, enhancement of type of protection
Spindle protective cover for high-precision spindle SK-50 and size 1 SK50
QA, maintenance, service
Test mandrel size I/300 »CERT« with a wooden box and certificate, flyer »KDI«
Test mandrel SK 50/300 »CERT«, with wooden box and certificate, flyer »KDI«
Radius gauge „Radius“/SK 50 »CERT«, data sheet 20.15.17.
Calibration gauge A »genius« for recalibration 2D and 3D cameras at the installation location, incl. packaging box, data sheet 9100292
Pine tree-shaped test gauge D32 »CERT«, data sheet 20.15.11.2
Measuring machine capability test »tethys«, flyer K000010
Measuring machine capability test »tethys« - CG/CGK, at your facilities, flyer K000010
Measuring machine capability test »tethys« - R&R, at your facilities, flyer K000010
Measuring machine capability test »tethys« - CMR, at your facilities, flyer K000010-3
Vibration analysis/measurement technology, costs according to the effort according to applicable installation specifications, data sheet
K000016
Remote maintenance »pilot 2 mT / 3.0«, flyer 8708004
»Rundumsorglospaket« »genius«, full service maintenance, software maintenance, »pilot 3.0«, hotline and standard quality check according to
DIN EN ISO 9000, costs per year in Germany
»genius«-FSW, full service maintenance for ZOLLER »genius« measuring machine, costs per year in Germany
Hotline contract »genius«, costs per year according to hotline contract no. 8700V10
Software support contract »genius«, costs per year according to software support contract 8700V01
Start-up/training
Start-up/basic training, costs per 8-hour day for three employees/at your facilities (Germany), travel expenses shall be charged additionally, if
several visits are required on customer request, data sheet „INB“
Interface test, functional check of ZOLLER interface in combination with the customer machine and control unit, costs according to effort,
daily rate Euro 800.00 plus travel expenses, data sheet INB_ROW
Support »90«, support during integration of ZOLLER measuring machine in your production process, the costs include 6 full-day service
assignments including travel expenses, within 90 days after delivery and start-up
Network integration, costs per 8-hour day at your facilities (Germany), travel expenses shall be charged additionally, if several visits are requi-
red on customer request, data sheet „INB“
Factory acceptance/preliminary acceptance, costs per day for 3 persons

Standard Option

27
ZOLLER solutions
PRESETTING SOLUTIONS SOFTWARE SOLUTIONS

Rev. 2014-06-10/tr (ci_TBGEN.01-EN) Subject to technical modifications.


Presetting & measuring Managing tools

INSPECTION SOLUTIONS BUSINESS SOLUTIONS


Inspection & measuring from A-Z

ZOLLER solutions - comprehensive optimization of your manufacturing operations. For


improval of the quality, efficiency and productivity Zoller combines hardware, software
and services to customized system solutions. As a customer of Zoller you benefit not only
from our know-how as market leader in the field of tool measurement technology, but
equally from our claim as a family-run business to guarantee you sustainable competitive
advantages and thus make a measurable contribution to your success.

www.zoller.info
E. Zoller GmbH & Co. KG | Presetter and Measuring Machines
Gottlieb-Daimler-Straße 19 | D-74385 Pleidelsheim
Tel: +49 7144 8970-0 | Fax: +49 7144 8060-807
post@zoller.info

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