GP SYSTEM (SINGAPORE) PTE LTD - ZOLLER

The award-winning presetting and measuring "zenit" for milling cutters

ZOLLER »zenit« is the presetting and measuring device for milling cutters
with an ergonomic seated workplace. It is ideal for all multi-cutter tools,
particularly face milling cutters, »zenit« operates completely automatically
and absolutely precise to the micron. 2-axes CNC-controlled with autofocus.
Special measuring programs for presetting and measuring of milling cutters,
PKD cutters, right-angle and face milling cutters and round blanking dies.

Travel distance Z-axis	500 / 800 mm *	Setting accuracy	< 2 µ
Travel distance X-axis	250 mm	Display accuracy	1 µ
Diameter	500 mm	Positioning accuracy	± 1 µ
Repeatability	± 2 µ	Concentricity	2 µ
*) increased measuring range upon request

Tool holding fixture spindle

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 »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 2-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

	»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.

Options: Tool Identification »pilot 3.0«

	Manual read-/write station (Mechanics) • Separate, external read/write station for tool identification - for optional mountings on ZOLLER presetter and measuring machines for manual reading/writing of tool ID chips • Version is suitable for chips in pullstuds and driving slot of tool systems • Changeable holding fixtures for steep taper, shaft taper, Capto etc. • Hard- and software for tool identification not included

	Plastic insert MSLE • For steep taper SK • For hollow shank taper HSK • For Capto and many more

	Automatic read/write station (driving slot) HV (Mechanics) • Automatic height adjustment to compensate the different positions of tool ID chips in driving slot of tools • Pneumatic control for read/write activities

	Tool identification (Hardware) • Hardware tool identification consisting of evaluation electronics, read/write head and connection cable • Available for Balluff, Bilz, Euchner, Mazak, Pepperl&Fuchs, Kennametal, Big Daishowa, and many more

	Automatic positioning „Tool ID“ • Software to position the turnable tool holding fixtures automatically and to read/write on the tool ID chip in the driving slot of the tool • Autofocus and rotation generator »ROD« are necessary

	Tool ID write-/readable systems (Software) • Software tool identification for read/write systems • Software to read the code carrier (chip) and to automatically select the tool out of the tool library or the tool list • Software to write on the code carrier with the opportunity to read and edit

	Tool ID string (Software) • String (data string) in standard version. Tool nominal data and actual measured X and Z values are written onto chip according to customer requirements • Additional costs for special models with arithmetic operation

Accessories

	15“ TFT colour display »satellit« • Additional 15“-TFT display for industrial use (without touchscreen) for extra display of cutting edge illustration, counter and cutting edge shape • Light metal casing incl. hard- and software • EMC-tested • Suitable for shop floors (illustration shows 3-axes-version - option)
	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 to 240 Volt
	Laser printer „lists/graphics“ colour • Colour laser printer for hard copies of test reports and lists • 32MB storage • Print speed up to 16 pages per minute • 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
	Board for laser printer • To fix on machine table • Unneccessary for label printer
	Adapter board • For tool post, adapter, clamping elements, zero gauges and many more • To fix on the left side of the machine table
	Standing support • Stabile, black epoxy coated steel construction • Gas-filled spring device cover for the protection of dust and dirt • Low-maintenance polyurethane foam, breadth 320 mm • Adjustable height 680 to 920 mm
	Barcode reader • Barcode reader to memorize the article number • Big reading distance, high scanning speed, ergonomic and a design for industrial use • Readable codes: 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, ISBT 128 • For barcodes with width of < 80 mm

We have the right to make technical changes.

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