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INSPECTION SOLUTIONS
Technical Description
QUALITY &
PRODUCTION
Made in Germany
Uhing drives Cable carrier elements CCD camera systems Heidenhain measuring Bosch/Festo pneumatics THK guide systems
systems
2
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
3
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)
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
4
Technical data »genius 3«
Environment
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.
Subject to technical modifications. The depicted machines may include options, accessories and control variants.
5
Optics »high resolution«
6
Tool holding fixture spindles for »genius 3«
Spindle options
»genius 3 « /
»ace« spindle
7
Tool holding fixtures for HGS »ace« size I
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.
8
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).
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).
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).
9
Tool post size I
for high-precision spindle »ace«
10
Adapter for high-precision spindle
SK 50/vacuum
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.
11
Measuring machine control »pilot 3.0« hardware
Measuring machine control and processor cooling »cockpit« for monitor, keyboard, mouse, printer, storing places
12
»pilot 3.0« software
Standard functions
13
Measurement program packages Basic / Advanced
Premium
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
ID no. GW-009
Desc. Vollradiusfräser
Remark
Tester
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Interface grinding machine controller / »genius 3«
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«.
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«!
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«
Retransfer of the
measured tool actual
data Shipment
of finished
tools
Random sampling
according to test protocol
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.
The wooden board (for storage in the storage shelf) has 16 slots
for proper storage of the reduction sleeves with external diameter
D32 mm.
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.
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.
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Sit-stand
Mains voltage
230 V EN
115 V US
230 V CH
240 V GB
230 V CN
100 – 200 V JP
19
QA, maintenance, service
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.
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.
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Calibration gauge A
■■ Draft angle
■■ Effective cutting angle
■■ Front clearance angle
21
Parameter list »genius 3s - pilot 3.0«
The following parameters are measured by means of ZOLLER »genius 3s - pilot 3.0«:
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
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
24
Effective cutting angle Land depth / free grinding depth
■■ 3D measurement 2)
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
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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
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