GP SYSTEM (SINGAPORE) PTE LTD - ZOLLER - GENIUS3 MICRO PILOT 3.0

ZOLLER universal measuring machine »genius 3 micro« 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 micro« 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.

The »genius 3 micro« is specially designed to measure micro tools down to
0.1 mm. Equipped with a 500-fold magnification incident light camera the
»genius 3 micro« can automatically inspect tools smaller than a match.

Due to microscopic dimensions of tools and the 500-fold magnification of 3D
camera connected therewith »genius 3 micro« presetter and measuring machine
must be installed and operated in the climatised room.

• 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 micro« exactly to your requirements.

Travel distance Z-axis	400 mm	Display accuracy	1 µ
Travel distance X-axis	75 mm	Positioning accuracy	± 1 µ
Travel distance Y-axis	100 mm	Concentricity	2 µ
Measuring range longitudinal axis	370 mm	Machine weight	8000 N
Diameter (2-D)	140 mm	Magnification incident light	500 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, 80-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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