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ZOLLER universal measuring machine »genius 3« with image processing technology "pilot 3.0"

The ultimate product for any tool manufacturing and resharpening company, allows fully automatic and user-independent tool measuring and inspection.

»genius 3« machine enables you to measure the outer contour of your tools quickly, simply and µ-precisely.  This is true for the manual inspection up to the complete inspection working fully-automatically and independently of the operator.  All measuring results are documented in detail onto test reports and can be transmitted control-specifically at a push of a button.

•  5 CNC-driven axes make it possible to carry out complex, precise and fully-
    automatic measuring procedures of every type.
•  The revolutionary image processing technology »pilot 3.0« can intuitively be
    operated by means of the graphical user interface and input dialogues.
•  An integrated information system gives support for every area of the image
    processing.
•  A various selection of software and measuring programs enable you to adapt
    the »genius 3« exactly to your requirements.


   Travel distance Z-axis 600 mm    Display accuracy 1 µ
   Travel distance X-axis 175 mm    Positioning accuracy ± 1 µ
   Travel distance Y-axis 100 mm    Concentricity 2 µ
   Measuring range longitudinal axis 570 mm    Machine weight 8000 N
   Diameter (2-D) 200 mm    Magnification incident light 200 fold
   Repeatability ± 2 µ    



    Tool holding fixture spindle

High precision spindle SK 50 / Vacuum
•  Concentricity truth 0.002 mm
•  Pneumatic spindle clamping
•  Vacuum clamping device
•  Spindle nose with integrated calibration edge
•  Indexing device 4 x 90°
•  Membrane keyboard for all power operated functions on the HP-spindle
•  Ergonomic hand wheel for manual focusing
High precision spindle »A.C.E.«
•  Concentricity truth 0.002 mm
•  Tool post quick change device
•  Universal, power operated tool clamping for tools with steep taper,
    ANSI, CAT, MAS-BT, HSK, Capto, KM
•  Tool post-changing accuracy 0,001 mm, change-over time max. 10 sec.
•  Indexing device 4 x 90°
•  Membrane keyboard for all power operated functions on the HP-spindle
•  Ergonomic hand wheel for manual focusing


    Adapters for High precision spindle SK 50 / Vacuum   (Options + Accessories)

Adapter SK 50 / steep taper
•  To fix tool shanks with steep taper DIN 69871
•  Integrated calibration edge
SK-size Loss in Z SK-size Loss in Z
SK 10 20 mm SK 30 20 mm
SK 15 20 mm SK 35 20 mm
SK 20 20 mm SK 40 20 mm
SK 25 20 mm SK 45 20 mm
     
Adapter SK 50 / VDI-straight shank
•  To fix tools with VDI straight shank DIN 69880
•  Manual tool holder clamping
•  Integrated calibration edge
VDI-size Loss in Z VDI-size Loss in Z
VDI 16 80 mm VDI 40 85 mm
VDI 20 80 mm VDI 50 95 mm
VDI 25 80 mm VDI 60 105 mm
VDI 30 85 mm VDI 80 175 mm
     
Adapter SK 50 / HSK A/C/E-B/D/F
(without tool clamping)
•  To fix tool shanks with hollow shank taper
    HSK DIN 69893
•  Face contact for HSK-tool holding fixture
•  Integrated calibration edge
HSK-size Loss in Z HSK-size Loss in Z
HSK 32-40 50 mm HSK 63-80 50 mm
HSK 40-50 50 mm HSK 80-100 60 mm
HSK 50-63 50 mm HSK 100-125 100 mm
     
Adapter SK 50 / HSK A/C/E-B/D/F
(with tool clamping)
•  To fix tool shanks HSK DIN 69893 with and
    without cooling tube
•  Manual eccentric clamping
•  Integrated calibration edge
HSK-size Loss in Z HSK-size Loss in Z
HSK 32-40 75 mm HSK 63-80 75 mm
HSK 40-50 75 mm HSK 80-100 105 mm
HSK 50-63 75 mm HSK 100-125 105 mm



    Adapters for High precision spindle »A.C.E.«   (Options + Accessories)

Tool post steep taper (I)
•  To fix tool shanks with steep taper
     DIN 69871
•  Integrated calibration edge
•  Changing accuracy 0.001 mm
•  Suitable for automatical lengthways
     setting »ASZA«
SK-size Loss in Z SK-size Loss in Z
SK 20 1) 50 mm SK 40 0 mm
SK 25 1) 0 mm SK 45 0 mm
SK 30 0 mm SK 50 0 mm
SK 35 1) 0 mm  1)   Special Size
     
Tool post HSK A/C/E-B/D/F
•  Power-operated tool clamping
•  Suitable for tool ID
•  Integrated calibration edge
•  Changing accuracy 0.001 mm
•  Changing time 10 sec.
•  Suitable for automatical lengthways
     setting »ASZA«
HSK-size HSK-size
25 - 32 63 - 80
32 - 40 80 - 100
40 - 50 100 - 125
50 - 63 125 - 160
     
Tool post Sandvik Capto
•  Power-operated tool clamping
•  Integrated calibration edge
•  Changing accuracy 0.001 mm
•  Change-over time 10 sec.
•  Suitable for automatical lengthways
     setting »ASZA«
Size Capto Size Capto
3 6
4 8
5  
     
Tool post Kennametal UTS
•  Power-operated tool clamping
•  Integrated calibration edge
•  Changing accuracy 0.001 mm
•  Change-over time 10 sec.
Size KM / UTS Size KM / UTS
32 63
40 80
50 100
     
Tool post VDI straight shank
•  To fix tools with VDI tool shank DIN 69880
•  Automatic tool clamping
•  Integrated calibration edge
•  Changing accuracy 0.001 mm
VDI-size Loss in Z VDI-size Loss in Z
VDI 16 90 mm VDI 40 99 mm
VDI 20 95 mm VDI 50 105 mm
VDI 25 95 mm VDI 60 120 mm
VDI 30 95 mm    
     
Tool post Hydraulic chuck
•  Adapter Toolpost Expansion Chuck
     D 32/size I (Autom.)
•  Expansion chuck D 32 mm, automatic
     clamping of tools. Suitable for Nikken
     reduction sleeves.
•  Loss in measuring range 113 mm in Z-axis.



    Electronics   »pilot 3.0«
  Hardware
•  Control- and measuring electronics in 5-axes version
•  Operating system Windows XP-Professional with Multilingual User Interface (MUI)
•  IPC-computer with at least 3.2 GHz
•  CE-specification (Europe) and FCC class A (USA) verifiable
•  Hyperthreading Technology
•  Heat-Pipe with 6 embedded Copper-Pipes for an ideal cooling of our processor
•  1 Centronics interface
•  3 RS232 interfaces, 8 interfaces USB 2.0
•  DVD-RW-drive for data backup
•  Hard disk with minimum 80 GByte
•  Image-Software for hard disk backup
•  Industrial filter according to EN 779
•  Special cooling system makes working possible at ambient temperatures up to 50°C without loss of power
•  Exclusive use of special industrial components
•  Temperature-, fan- and hard disk monitoring
•  17“ TFT colour display, EMC-tested, industrial housing
•  Flexible handling via keyboard, mouse and touchscreen
•  Measurement in real time, 50-fold magnification
•  Efficiency factor (PFC) revised power supply for 100 - 240 V
•  Cockpit for 17“ TFT-monitor, keyboard, mouse, storing places - incl. USB-connection
 17“ TFT monitor with
 industrial housing
 
 IPC computer and
 processor cooling
 
 »cockpit« for monitor,
 keyboard, mouse,
 storing places
 Graphic operating screen
Real-time measuring
 Automatic recognition of
 cutting edge shapes
Security service
 Measuring sequence
 biggest cutting edge
ZOLLER inspection report
 Navigator »compass«
In-picture measuring and zoom
 Dynamic cross-hairs
The max-contour »C.R.I.S.«
 Cutting edge inspection
Projector functions
     
  Standard Functions
•  .NET Framework technology
•  Graphic operating screen
•  Automatic recognition of cutting edge shape and
measuring range
•  Dynamic cross-hairs, Projector function
•  InPicture-measuring and zoom
•  Measurement of real time
•  Analogue, coloured focusing display
•  Automatic incident light setting
•  Adapter management for 9.999 zero points and
graphic display for calibration
•  Management for at least 15.000 tools
•  Automatic zero point monitoring
•  Machine management with all data for an
accurate measuring and presetting of tools
•  Radius, diameter, difference dimension,
incremental dimension or counter stop function
can be selected for both axes
•  Touchscreen-, mouse- and keyboard operation
•  Switch between mm / inch
•  Display accuracy 0.001 mm
•  Cutting edge inspection with adjustable intensity
of light
•  Identification number-generator
•  Library for tool descriptions
•  Tolerance check for all measuring results
•  User management, Setup System
•  Concentricity measurement cutting edges
•  Measuring sequence “biggest cutting edge”
•  Maxcontur »C.R.I.S.«, Multifunctional workstation
•  Standard measuring programs:
•  Oversized radii
•  Theoretical point over cutting edge shape
•  Angle over measuring points
•  Radius over measuring points
•  Length/radius on chamfer and many more
•  Navigation system »compass« for manual axis
adjustment for a fast and safe positioning of the
nominal value
•  Performance capability test for measuring
machines »tethys«
•  Acceptance record
•  Printing of labels, lists and protocols
•  SoftwareViewer Powerpoint, Word, Excel (MS®),
Autodesk®, Design Review (CAD 2/3D)
•  Help system, Remote maintenance
•  and many more

  
  Axle Drives

Autofocus
•  Mechanics, hard- and software to focus tool cutting edges automatically,
    independent of the operator and process-reliable
•  Fully automatic measuring of multi-insert cutting tools (run of cutting edges)
•  Automatic rotation for Maxcontur »C.R.I.S.«
 
CNC-base/joystick »a.e.p.«
•  Automatic search run and positioning of tool cutting edges in length Z and
    diameter X (only in connection with autofocus)
•  Driven/automatic positioning of measuring slide to the tool cutting edge
• »pilot 3.0 virtual joystick« with continous speed control
•  Automatic positioning to nominal value Z/X according to specification of
    nominal value in »pilot 3.0«
•  Linear, CNC-driven basic version
  
  Standard Softwares

  Adapter Management
  The ZOLLER-adapter management shows you the name of the adapter, the
  zero point number, the zero point measures of the adapter, and further more
  an information about the calibration interval.  It is shown coloured, when the
  adapter has to be calibrated new. Therewith the quality is ensured.
 
  Machine Management
  The machine management manages the zero point of the necessary adapter,
  the data record for the control specific data output as well as the string for
  the system tool identification.
 
  User Management
  The user management manages the user database, desktop locking and
  password protection ensuring the system operation will be secure.
 
  Measuring programs »Standard«
  The image processing technology »pilot 3.0« offers a variety of standard
  measuring programs for the current tools and measuring methods.
  The measuring programs are displayed thanks to the photo-realistic input
  dialogue in a self-explanatory way.

  Application: Drills, Countersinks, Milling cutters, Chamfer tools and Lathe
  cutting tools
 
  Measuring program generator »expert«
  Global measuring program to measure tools in incident and transmitted
  light, in chip space, at circumference and front.
 
  Measuring programs »reamers«
  Software to measure and preset reamers.
  Simple, precise measurement and presetting of cylindrical and conical reamers.
  Measurement in snap gauge and oversize principle.
  Photo-realistic input dialogue.
 
  Measuring programs »univer«
  Software to measure and preset milling heads.
  Included are measuring programs to preset the attitude of the end face to the
  major cutting edge, to determine difference dimensions regarding a reference
  cutting edge, to preset and measure milling cutters with both roughing and
  wiper/finishing inserts and others more.
 
  Concentricity and wobble compensation
  Software for an automatic concentricity and wobble compensation for tools
  with cylindrical surfaces.  It makes automatically a revaluation of the tool
  centerline of tools with cylindrical surfaces.  The newly calculated centerline
  is a basis for further diameter- and length measurements.


   DNC data input/output

  Data Output
  Measure and output tool lists

  Data Input / Output
  For the input and output of control-oriented data

  CNC output formats
  Control-specific calculation of actual data

  DNC Interfaces
  Interfaces to exchange target / actual tool data


   Optional Softwares

  Radius contour »contur«
  Measuring program for end milling cutters with corner or full radius to measure
  the radius in any adjustable angle range.  During measurement analysis the
  nominal and actual radius as well as the different measuring points of the
  contour (by using a tolerance range) are graphically displayed.   Measured
  values such as the centre of a circle, transition intersection, the maximum
  external and internal deviation with the corresponding angle positions and
  more are also displayed.
 
  Chip space scanning
  Software for automatic chip space scanning of tools.  Graphic output with
  editable and measuring function.
 
  Tool inspection and measurement »metis«
  Software for universal measuring of contours, radii, angles, distances,
  wear, in incident light and for documentation
 
  Incident light measurement »antila«
  Software for fully automatic measuring of either worn or eorded tools
 
  »metis« Generator
  Software to create automatic »metis«-measuring procedures/measuring
  programs.  The generator stores every work step, for example creation of
  measuring elements, automatic measurement, switchover of display and
  thus creates a fully automatic measuring program.

  Tool inspection and measurement »metis« required
 
  »metis« Interpreter
  Software for the automatic execution of »metis«-measuring programs in
  the »pilot 3.0«-measuring program ambience.

  Tool inspection and measurement »metis« is not required
 
  Contour measuring »lasso«
  With the contour measuring »lasso« every tool or workpiece geometries can
  be scanned, measured and analysed by a nominal/actual comparison.
  Nominal/actual comparison, distance measurement, zoom and print function
  are only a few possibilities which can be carried out by using »lasso«.
  A basis-CAD-function is integrated into this program, in order to process,
  measure and manage scanned contours.
 
  Editable test report »apus«
  Documented quality and dimensioned drawings with variable layout
 
  Automatic cutting edge inspection »a.e.c.«
  Enabling simultaneous inspection and measurement
 
  Drawing generator »sinope«
  Software for automatic generation of a tool drawing from measured actual
  values of tool/tool steps with dimensioning.  After the measurement is carried
  out the software then calculates the theoretical contour of the tool by means
  of the individual steps.  Via the quick-scan-function the tool contour or a free
  selectable sector can additionally be scanned and the actual contour can thus
  be adapted.


  Accessories

Printer for labels  
•  Printer for thermal-adhesive labels in plain text and barcode
•  Resolution 300 dpi, printing width 60 mm
•  USB-interface
•  Mains voltage 100 - 240 Volt
Laser printer „lists/graphics“ colour  
•  Colour laser printer for hard copies of test reports and lists
•  32MB storage
•  Maximum resolution 2.400 X 600 dpi
•  Universal paper box for 150 pages (DIN A4 and smaller)
•  USB-interface
•  Mains voltage 230 Volt
•  Can also be used for monochrome printer

Key deposit  
•  Turret for key deposit
•  Can be fixed to the machine table or to the support arm
•  Scope of delivery without key


We have the right to make technical changes.


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