Technical Description · 2019. 9. 12. · Technical Description »smile« ZOLLER »elephant« The »elephant« measuring program assistant allows you to easily measure standard tools

ZOLLER PRESETTING SOLUTIONS

»smile«The Entry Level for Professional Tool Presetting and Tool Measuring

Technical Description

Technical Description »smile«

02

Note:

We reserve the right to make technical and optical changes to

the product during ongoing product development. The machines

shown may include options, accessories, supplemental compo-

nents and control variations, which differ from the configuration

of your product. Reproduction or dissemination of content to

third parties is not permitted without the express consent of

the author and manufacturer.

»smile / pilot 3.0«

CNC Cutting edge inspection*

Fully- automatic measuring*

Tool database*

Compatible interfaces*

Powerclamping

ErgonomicMulti sensor system*

Contactless measuring

Made in Germany

QUALITY & PRODUCTION

03


Contents»smile« Presetting and Measuring Machine

* optional

04»smile« Presetting and Measuring Machine

06»smile« SeriesVersions

08Control Units

09»smile« Drive Options

10Measuring Machine Control »pilot 3.0«»pilot 2 mT«»pilot 1.0«

11 Software»pilot 3.0« Image Processing Software

12 »pilot 3.0« – Standard Measuring Programs

14ZOLLER »elephant«

15Tool Management

16ZOLLER TMS Tool Management Solutions

17Software»pilot 2 mT« Image Processing Software

18 »pilot 2 mT« Standard Measuring Programs

19Software»pilot 1.0«Image Processing Software 20ZOLLER »elephant« for »pilot 1.0«

21Machine SpindlesSK 50 High-precision Spindle

22»pcs« High-precision Spindle

23HGV-UZ High-precision Spindle

24Spindle Functions

25Adapter Tool PostsAdapter Tool Posts for the »pcs« and HGV-UZ High-precision Spindles

27Adapters for SK 50 High-precision Spindle

29Accessories Adapter Board Thermo-label Printer Laser Printer

30Adapter / Tool TrolleyTFT Satellite MonitorUninterruptible Power Supply (UPS)

31 OpticsOptic Carrier - Standard Versions

33Technical Data

34Installation Dimensions

35Packaging and CommissioningRemote Maintenance

36Commissioning / Basic Training Operator TrainingFactory AcceptanceNetwork Integration


04

Adapter Board*

Optic Carrier

ZOLLER »eQ« Single-hand Operating Device

»pcs« High-precision Spindle, SK 50* or HGV-UZ*

Membrane Keypad

»smile« Presetting and Measuring MachineFast, precise, and offering intuitive operations, »smile« is the simple way to get started with professional tool presetting and measuring.

With precise measuring results, simple operations, and a robust and yet ergonomic design, »smile« offers everything your company needs to economically preset and measure tools. Made of a light metal alloy specially developed for measuring machines and under the exclusive use of high-quality brand components, the tool presetter and measuring machine stands for maximum ergonomics and longevity and can be arranged shop floor oriented right next to the CNC machine.

»smile 620« with »pilot 3.0« Image Processing

05

Adapter Board*

Measuring Device Control

Thermo-label Printer*

Brand name products like Bosch/Festo pneumatics, Heidenhain measuring systems, Uhing drive nuts, and THK guides Pneumatic slide clamping, 180 degree accessibility to the spindle, dynamic crosshairs for the Z and X axis Adjustment using the ergonomic single-hand operating device, fine setting*or CNC control* of up to 3 axes Cutting edge inspection with magnification of the cutting tool edges, depending on screen size, 22, 30, or 40 x

Highlights


* optional

»smile 620« with »pilot 3.0« Image Processing

Intuitive and ergonomic operation

Precise and repeatable measuring results

Simple integration into the production process

06


»smile« Series Versions

»smile 320«

»smile 320«

The »pilot 1.0«, »pilot 2 mT«, and »pilot 3.0« image processing technologies and their control units can be individually selected for every machine in the »smile« series. The following machine versions are available:

Max. Tool Diameter 320 mm

Max. Tool Length Z 350 mm

Measuring Range X 160 mm

Snap Gauge Diameter 0 mm


Max. Tool Length Z 350 mm



Table Version Monitor Bracket »cockpit«

»smile 320 / 420 / 620« with »pilot 1.0« X X -

»smile 320 / 420 / 620« with »pilot 2 mT« X X X

»smile 320 / 420 / 620« with »pilot 3.0« - X X

* optional

Exemplary Combination Possibilities:

Fig. shows »smile 320« with »pilot 1.0« Table Version

Fig. shows »smile 320« with »pilot 1.0« and Monitor Bracket

07


1) Measuring range Z axis 800 mm is only possible in combination with the Table System

»smile 620«


Max. Tool Length Z 420 / 600* / 8001)* mm




Max. Tool Length Z 420 / 600* / 8001)* mm



Fig. shows »smile 420« with »pilot 2 mT« and Monitor Bracket

Fig. shows »smile 620« with »pilot 3.0« and »cockpit«

Fig. shows »smile 320« with »pilot 1.0« and Monitor Bracket

»smile 420«

08


Control Units

ZOLLER »cockpit« The separate »cockpit« control unit brings together all control elements such as a panel PC, keyboard, mouse, and shelves for the operating instructions, small parts, thermo-labels, and a color laser printer in one compact location. The ergonomic construction guarantees comfortable and efficient work.

Monitor Bracket for Table This bracket for the measuring machine control is fitted on the machine table. The custom height adjustment, tilt, and rotation allows every user to work comfortably. Shelves for keyboard and mouse can be added.

Table Electronics All components in the table electronics can be placed directly beside the presetting and measuring machine.

Keyboard and Mouse

Keyboard and Mouse

Shelf for Operating Manual

Shelf for Thermo- label Printer

Shelf for Thermo- label Printer

Shelf for Color Laser Printer

09


»smile« Drive Options

The Z and X axes can be adjusted in three ways:

Manual Drive Using the »eQ« Single-hand Operating Device The ergonomic ZOLLER »eQ« single-hand operating device allows operators to reliably and quickly adjust the linear axis of the optic carrier to the desired position.

Manual Fine Adjustment of the Z and X Axes* Manual fine Adjustment is provided by the hand wheels on the tower (Z axis) and body (X axis).

CNC Control of the Z, X, and C Axis* The CNC control allows for axis adjustments in the Z, X, and C axis to be completed automatically.

Z+

X-X+

Z-

* optional

10


Measuring Machine Control

Features Anti-glare screen One-button data backup on USB stick Fast and shock-resistant solid-state disk drive (SSD) Fast software reaction time of 5 ms to axis movements Operating system: Windows 7®, 64 bit Dimensions: approx. 58 x 36 cm (24‘‘ screen diagonal) for »pilot 3.0« and »pilot 1.0«* approx. 33 x 27 cm (17‘‘ screen diagonal) for »pilot 2 mT« approx. 30 x 19 cm (13.3‘‘ screen diagonal) for »pilot 1.0«

»pilot 3.0«, »pilot 2 mT« and »pilot 1.0« Measuring Machine Control

The hardware of the »pilot 3.0« measuring machine control includes a mouse and keyboard. »pilot 3.0« image processing software is pre-installed allowing the operator to execute all software functions.Alternatively, the »smile« is available with the »pilot 2 mT« or »pilot 1.0« measuring machine control. With this option, the machine is controlled by touchscreen.

»pilot 3.0« Measuring Machine Control

»pilot 2 mT« Measuring Machine Control (optionally available with keyboard and mouse)

»pilot 1.0« Measuring Machine Control (optionally available with a 24” display and keyboard and mouse)

11


»pilot 3.0« Image Processing Software

»pilot 3.0« is the easy-to-operate and intelligent image processing software for presetting, measuring, inspecting, and managing tools.

Due to the modular design of the software, required functions can be added and optimally adjusted to the current measuring tasks and the production process. In addition, »pilot 3.0« can be expanded with modules for efficient tool data management.

Tool Name Current Image from the Camera Nominal Measured Value with Tolerance Figure Current Meter Readings Function Buttons

Dimmable Incident Light Movable Crosshairs

Main Menu with Function Buttons

Current Meter Readings

Cutting Edge Inspection Software Function

Software

Cutting edge inspection for wear inspection with movable crosshairs, dimmable incident light, and free radius placement. For seamless documentation, images of the cutting edge inspection can be saved and printed.

* optional

12


»pilot 3.0« – Standard Measuring Programs

This measuring program can be used to determine the theoretical tip of the tool using measuring points along the cutting tool edge.

This measuring program can be used to automatically determine the theoretical tip of a tool using the cutting edge form. Also suitable for countersink tools

This measuring program is used to measure cutting tool edges which exceed the field of view of the camera on the presetting and measuring machine. The cutting edge is recorded in two sections in the horizontal or vertical direction for this purpose.

Parameters such as horizontal and vertical dimensions, angle 1 and 2, radius, concentricity, and axial runout (for multi-blade tools) can be determined using “automatic cutting edge form recognition” in the standard measuring program.

This measuring program is used to measure tool radii which exceed the field of view of the camera on the presetting and measuring machine. The radius in the horizontal or vertical direction in subsegments is recorded for this purpose.

This measuring program is used to calculate the measured dimensions (horizon-tal and vertical dimensions) of a tool before outputting results with a pre-set correction value “A-dimension.”

Standard Measuring Programs Length Correction Value “A-dimension”

Oversized Radius Measuring

Theoretical Tip Using Cutting Edge Forms

Theoretical Tip Using Measuring Points

Measuring Oversized Cutting Edges

Maximum tool contours can be measured with this »cris360°« (circular-response-image-sampling) software function.

»cris 360°« Software Function

* optional

13


This measuring program can be used to calculate any number of angles on cutting edges using measuring points.

This measuring program can be used to determine angle intersection points in various calculation variations.

The software function »focus 360°i« can be used for rotary measuring of all the cutting edges of a tool. The measured values determined for each cutting edge are presented in graphic or table-based form, including a tolerance range.

This measuring program is used to determine the theoretical circle center point for convex and concave tools, including radii, using individual measuring points.

This measuring program can be used to determine the length and the radius on the chamfer of this tool. The measuring point in the longitudinal axis is determined from the difference of the measure length and a set value.

Angle Using Measuring Points Theoretical Circle Center Using Measuring Points

Angle Calculation

»focus 360°i« Software Function »fored« Software Function

Length / Radius Using Chamfer

Cutting edge forms and measuring ranges are automatically recognized in the »pilot« image processing software.

Automatic Cutting Edge Form Recognition

The »fored« tool measuring program library offers a way to quickly and easily select all standard measuring programs.

14


ZOLLER »elephant«

The »elephant« measuring program assistant allows you to easily measure standard tools without entering target data. Graphic selection dialog boxes can be used to select the desired tool categories and activate a concrete measuring task. Various measuring modes and parameters are available for selection. The operator receives graphic support in positioning the cutting edge and measuring point when making measurements in the »elephant« measuring program assistant. The parameters to be measured are displayed graphically — for tool measurements without any advanced knowledge. Measuring results are then printed on a thermo-label.

Complete measuring processes without advanced knowledge

Graphic selection dialog for choosing tool categories Various measuring modes to choose from

Highlights

Step 1: After starting »elephant«, select the tool category Step 2: Select measuring task and select one of the suggested measuring modes

Step 3: Complete the measuring tasks either manually or via CNC controls, with output of measuring results

15


* optional

Tool Management*Tool Management InterfaceInterface to connect to the ZOLLER TMS Tool Management Solutions Software or the Tool Management Standard software module. The interface can be used to access tooling sheets and complete tools from z.One, the central ZOLLER tool database. Requirements:• Presetting and measuring machine with »pilot 2 mT« image

processing version 1.12.0.0 or higher• ZOLLER TMS Tool Management Solutions or »pilot 3.0« Tool Ma-

nagement Standard software module

Tool Management Standard Software ModuleThis software module is used for structured and trans-parent management of single components, complete tools, and tooling sheets in »pilot 3.0« directly on the presetting and measuring machine itself. This ensures that all tools needed in the production process are provided, including documentation. Option: 1 x floating license for Tool Management on the »pilot 3.0« software, on one external workstation Requirement:• Presetting and measuring machine with »pilot 3.0«

image processing version 1.10.0.0 or higher

Interfaces to Production Management or Tool Management Systems

Interfaces to systems by COSCOM, FASys, SOFLEX, TDM Systems, WinTool, ZOLLER TMS Tool Management Solutions, and many others are available. This allows for consistent, cross-system tool data management.

Requirement:• Presetting and measuring machine with »pilot 3.0«

16


ZOLLER TMS Tool Management Solutions

* optional

Efficiency Right Down the Line: from Order Receipt to Delivery.

With a central tool database, ZOLLER combines virtual and real tool data, ensuring that the right data is available everywhere and at all times.

»pilot 3.0« image processing software can be combined with ZOLLER TMS Tool Management Solutions. This combination is used to add all tools and tool components to z.One, the central tool database, and manage them through the entire production process. The functions included in the BRONZE package can be used to organize complete tools, single components, and accessories in an economical manner. The SILVER package adds to the BRONZE package by providing effective warehouse management and standardized manufacturing data management with organized tool management. The GOLD package offers additional functions for full cost control and transparency across the entire process chain. Option:ZOLLER »toolOrganizer« tool cabinet

Requirement:Presetting and measuring machine with »pilot 3.0«

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»pilot 2 mT« Image Processing Software

ZOLLER myTouch »pilot 2 mT« operating technology concentrates on the most important functions for presetting and measuring tools.

»pilot 2 mT« can be operated quickly and easily, without extensive training. The integrated slide function can be used to adapt the user interface for specific users and measuring tasks.

Current Meter Readings (mm or inch)

Tool Designation

Measuring Specifications

Nominal Measured Value with Tolerances

Time and Selected

Measuring Units

Current Camera Image

Actual Measured Values with Tolerance Deviations

Function Buttons

Automatic cutting edge form and measuring range recognition

Cutting edge inspection illuminator dimmable lighting

»cris360°« (circular response image sampling) software function for measuring the maximum tool contour

»compass« navigation system for manual positioningto the saved nominal measurement

Software

18


»pilot 2 mT« – Standard Measuring Programs

This measuring program can be used to measure length, transverse dimension, width, and the center of the cutting edge. Cutting edge forms are suggested automatically during the measuring depending on measuring position.

Parameters such as horizontal and vertical dimensions, angle 1 and 2, radius, concentricity, and axial runout (for multi-blade tools) can be determined using “automatic cutting edge form recognition” in the standard measuring program.

This measuring program can be used to determine the theoretical tip of a tool by extending the cutting edge to the theoretical intersection. The measuring program is also suitable for reverse countersink tools.

Standard Measuring Programs

»contur« Radius Contour

Side Milling Cutter – width top/bottom

Theoretical Tip Using Cutting Edge Forms

Angle Using Measuring Points

This measuring program can be used to automatically determine concave and convex radii on the outer contours of tools.

This measuring program can be used to determine any number of angles using measuring points.

19


Software»pilot 1.0« Image Processing Software

ZOLLER »pilot 1.0« image processing software provides all the functions needed to quickly and precisely preset and measure standard tools. Standard parameters such as length, diameter, radius, angle, concentricity, and axial runout can be measured in seconds in a user-independent manner with easy touchscreen operation. The “projector function,” “cutting edge inspection,” and »cris360°« for determining real effective tool dimensions, are also included standard.

Cutting Edge Form Recognition of over 100 Cutting Edge Forms

Dynamic Crosshair Pointer for Automatic Measuring

Free Angle and Crosshair Positioning

Cutting Pattern in Incident Light

Display Precision 0.001 mm Detailed Tool Designation Including Nominal Data Input

Dimmable Incident Light

Clear and intuitive software interface

Immediate comparisons of standard parameters

Precise and repeatable measurement results

View of Projector Functions

20


ZOLLER »elephant« for »pilot 1.0«

This measuring program assistant is a standard component of the »pilot 1.0« image processing software.

This manual measurement program assistant supports the operator in selected measurement program sequences and makes the measurement of standard tools easier. Tool categories can be easily selected and standard measurement routines can be performed quickly and easily.

Graphic selection dialog for tool categories

Standard measurement tasks to choose from Support in cutting edge / measuring point positioning

Highlights

Easy selection of measurement tasks Favorite list for quick tool selection

Precise and user-independent nominal value positioning using the »compass« navigation system

Table-based and graphic analysis of measured values

21


Machine Spindles

Spindle FunctionsSpindle functions are activated and controlled using the ZOLLER membrane keypad. The vacuum clamping device* creates negative pressure between the SK 50 spindle base and the tool chuck for steep tapers. This gives the tool additional stability and ensures even more precise measuring. The spindle brake stops the spindle in the current position. Spindle indexing can be used to lock the spindle in one of 4 x 90° possible positions.

SK 50 High-precision SpindleThe ZOLLER SK 50 (steep taper 50) high-precision spindle impresses with its concentricity of 0.002 mm, a pneumatic 4 x 90° indexing for positioned holding of adapters, and a spindle nose with integrated calibration spheres. All pneumatic functions of this spindle are controlled using the membrane keypad. The autofocus* and rotation sensor (ROD)* functions can be added to the SK 50 high-precision spindle.

Hand wheel

Tappet

Calibration Spheres

Hollow Taper

clamping button*

Spindle brake

Spindle indexing

22


»pcs«* High-precision Spindle »smile 420« and »smile 620«The ZOLLER »pcs« (power clamping system) high-precision spindle facilitates power-activated tool clamping for almost all tools with cylindrical shafts, steep taper SK in accordance with ANSI, CAT, MAS-BT, VDI, hollow taper shank HSK, or the Coromant Capto and KM tool systems. The autofocus* or rotation sensor (ROD)* functions, and a length limit system can be added to the »pcs« high-precision spindle.

Ball Bushing

Hand Wheel

Indexing Lever

Exchange precision of adapter tool posts of ≤ 0.001 mm Maximum exchange time for adapter tool posts is 10 seconds Tool clamping power 2000 N

Highlights

* optional

Note: The following adapter tool posts can be used with this spindle: SK from SK 25 to SK 50 HSK from HSK 25 to HSK 63 Coromant Capto from C 3 to C 6 VDI from VDI 16 to VDI 60 KM/from von KM 32 to KM 63 Hydro from D 32 to D 63

23


Ball Bushing

Hand Wheel

Indexing Lever

HGV-UZ High-precision Spindle*The ZOLLER HGV-UZ high-precision spindle has a specially designed quick-change collet to facilitate power-activated and universal tool clamping for almost all tools with cylindrical shafts, steep taper SK in accordance with DIN, ANSI, CAT, MAS-BT, VDI, HSK hollow taper shanks, or the Coromant Capto and KM tool systems. In addition, various kinds of head bolts can be clamped with the exchangeable chucks with a tool clamping of 1000 N. The autofocus* and rotation sensor (ROD)* functions can be added to the HGV-UZ power-operated high-precision spindle.

Quick change adapter tool posts and tension elements (clamping jaws) like SK 40, SK 50, HSK 63 ensures stable and powerful tool clamping.

Power Clamping with Clamping Tool

Note: The following adapter tool posts can be used with this spindle: SK from SK 25 to SK 50 HSK from HSK 25 to HSK 63 Coromant Capto from C 3 to C 6 VDI from VDI 16 to VDI 60 KM/from von KM 32 to KM 63 Hydro from D 32 to D 63

24


Spindle Functions*AutofocusAutofocus is used to equip the spindle with a CNC drive (motorized C axis). This automatically focuses the cutting tool edges to the highest point of the cutting tool edge.

Spindle Rotary Encoder (ROD)The spindle rotatry encoder, which is available for ZOLLER high-precision spindles, facilitates highly precise position determinations for cutting tool edges in the C axis. The position is displayed in degrees as a third axis in the »pilot« image processing software. This axis position is required for measurements intended to determine angle positions, slopes, or pitches on tools.

»aszm« Length Limit System in Z AxisThe length limit system in the Z axis can be used to manually readjust tools to the desired length. The adjustment is made either on a linear basis using a limit pin, or on a rotational basis using an adjustment screw (hexagonal with various wrench sizes).

ZOLLER offers two variations: Manual: • »aszm«-lin (linear)• »aszm«-rot (rotary - hexagonal)

Note: The length limit system is available for »smile 420 / 620« with an SK 50 high-precision spindle in the electronic variations »pilot 2 mT« or »pilot 3.0«

»aszm«-lin linear length limit system on the SK 50 high-precision spindle

* optional

25


Adapter Tool Posts*Adapter Tool Posts for the »pcs« and HGV-UZ High-precision Spindles

SK 25 to SK 50 Steep Taper Adapter Tool Post

Description SK SizeLoss

Z - mm

• For Holding Tool Shanks with Steep Tapers DIN 69871-1

• Integrated Calibration Spheres

25 0

30 0

35 0

40 0

45 0

50 0

HSK 25 to HSK 63 Hollow Shank Taper

DescriptionHSK Size

A/C/E–B/D/FLoss

Z - mm

• For Holding DIN 69893 Tool Shanks with Hollow Steep Tapers

• Integrated Tool Clamping• Integrated Calibration Spheres

25 - 32 50

32 - 40 50

40 - 50 50

50 - 63 50

Coromant Capto* Adapter Tool Post C 3 to C 6

DescriptionCoromant Capto

SizeLoss

Z - mm

• For Holding Coromant Capto Tool Shanks

• Suitable for Tool Readjustment• Suitable for Tool Identification

C 3 52

C 4 52

C 5 52

C 6 52

26


* optional

Adapter Tool Post VDI Cylinder Shaft VDI 16 to VDI 60

Description VDI SizeLoss

Z - mm

• For Holding Tools with VDI DIN 69880 Cylinder Shafts


16 7020 7525 7530 7540 7950 8560 100

KM/UTS KM 32 to KM 63 Adapter Tool Post

Description KM SizeLoss

Z - mm

• For Holding KM/UTS Tool Shanks

• Suitable for Tool Identifica-tion with Stop Ring


32 45

40 55

50 60

63 67

Adapter Tool Post Hydro Expansion Chuck D 32 to D 63

Description DiameterLoss

Z - mm

• For Holding Intermediate Bushings and Tools

30 90

32 80

32 66

40 90

42 137

50 100

63 100

Note: Machine-specific variations (Index, Sauter, etc.) also available

27


Adapters*Adapters for SK 50 High-precision Spindle

SK 50 Adapter / SK Steep Taper

Description SK SizeLoss

Z - mmWeight

in kg

• For Holding Tool Shanks with Steep Tapers DIN 69871-1


10 20 2.7015 20 2.6020 20 2.5025 20 2.4030 20 2.3035 20 2.2040 20 2.0045 20 1.40

SK 50 Adapter / HSK Hollow Shank Taper A/C/E-B/D/F (with eccentric clamp)

DescriptionHSK Size

A/C/E–B/D/FLoss

Z - mmWeight

in kg

• For Holding DIN 69893 Tool Shanks with and without Coolant Delivery Tube


25 - 32 90 4.00

32 - 40 75 4.80

40 - 50 75 4.80

50 - 63 75 5.40

63 - 80 75 5.20

80 - 100 105 6.60

100 - 125 105 6.80

SK 50 Adapter / VDI Cylinder Shaft (with Manual Tool Holder Clamping)

Description VDI SizeLoss

Z - mmWeight

in kg

• For Holding Tools with VDI DIN 69880 Cylinder Shafts


16 80 4.1020 80 3.9025 80 3.9030 85 3.7040 85 4.5050 95 4.9060 105 5.6080 175 11.00

28


* optional

SK 50 Adapter / Coromant Capto (with Eccentric Clamping)

DescriptionCoromant Capto

SizeLoss

Z - mm

• For Holding Tools with Coromant Capto

• Manual Tool Clamping Approx. ¾ Rotations

• Adapter Does not Have to Be Taken out of The Spindle to Clamp Tools

• SK 50 DIN 69871

C3 75

C4 80

C5 90

C6 107

C8 127

ISO 50 Adapter / Coromant Capto (with Axial Clamping)

Description Coromant Capto Size Loss Z - mm

• For Holding Tools with Coromant Capto

• Manual Tool Clamping with Clamping Bolt

• Without Calibration Spheres

• SK 50 DIN 69871

C3 30

Replaced by Coromant Capto (with Eccentric Clamping) C4

-


-


-

C8X 70

C10 150

29


Accessories*

Adapter BoardAdapter boards can be attached in a variety of positions on the table of the presetting and measuring machine, and serve as storage for adapter tool posts, adapters, tools, intermediate bushings, and much more.

Thermo-label PrinterThe thermo-label printer prints labels with a width between 25 and 108 mm (printing length 75 mm and print thickness (8 dots/mm). Various parameters such as ID, T, inventory, as well as adapter numbers, designations, Z, X, radius, angle concentricity, axial runout dimensions, and/or QR, line, dot matrix, or bar code printing is available, depending on customer requirements. Mains voltage: 100 to 240 VAC.

Laser PrinterThe color laser printer for report and list printing has a memory of 128 MB (upgradeable to 640 MB), a printing speed up to 20 pages/minute, maximum resolution of 1200 x 1200 dpi, universal paper cassette for 250 pages (A4 and smaller), USB interface, and a network connection. A mains voltage of 220 to 230 VAC (Europe) or 110 V to 127 VAC (USA) is required. The printer is also monochrome (b / w) capable.

30


* optional

Adapter / Tool TrolleyThe adapter / tool trolley is used to safely store adapter tool posts, adapters, and tools. The trolley consists of the following components: 1. Transport unit (1 piece) 2. Tool cradle (3 piece) 3. Frame girder pair (3 piece) 4. Shelf with ribbed rubber surface (1 piece) 5. Adjustable base with girder (1 piece)

Options: 1. Plastic inserts for SK 30 to SK 50 adapters 2. Plastic inserts for VDI 30 to VDI 60 adapters 3. Plastic inserts for D1 3/4mm; D2 mm and D2 1/4 mm 4. Plastic inserts for a variety of adapter tool posts like SK, HSK, VDI, KM, and others. Wood inserts D32.5 mm and D42 mm

Uninterruptible Power Supply (UPS) The UPS unit for uninterruptible power supply is used to ensure the power supply to the presetting and measuring machine in case of an interruption in the power grid. Mains voltages of 220 to 230 VAC (Europe) or 110 V to 127 VAC (USA) are available.

TFT Satellite Monitor The 17” TFT satellite monitor is placed optimally behind the high-precision spindle on the table to allow for efficient and ergonomic adjustments of cutting tools such as reamers or cutter heads. The TFT satellite monitor is delivered in a high-quality industrial design without touchscreen functionality.

Note: Available for »pilot 3.0«

31


OpticsOptic Carrier StandardThe optic carrier can be adjusted using the ZOLLER »eQ« fine setting single-hand operating device* or CNC control* and aligned to the tool.

Optic Carrier

Transmitted Light Camera

Including Cutting Edge

Inspection

Camera Type Transmitted Light

View Field 7.3 x 6.7 mm

Working Distance 100 mm

Camera Chip Type 1/3" CCD Monochrome

Cutting Edge Inspection Illuminator 12 red LEDs

Optic Carrier

Transmitted Light Camera

Including Cutting Edge

Inspection

Center Height Measuring

Camera

Camera Type Transmitted light Incident light

View Field 7.3 x 6.7 mm 6.5 x 8.7 mm

Working Distance 100 mm 73.5 mm

Camera Chip Type 1/3" CCD monochrome 1/3" CCD monochrome

Cutting Edge Inspection Illuminator 12 red LEDs 12 red LEDs

Optic Carrier Standard with Center Height Measuring System*

Note: The standard optic carrier with center height measuring is available for »smile 420« and »smile 620«

32


* optional

Optic CarrierTransmitted Light Camera Including

Cutting Edge Inspection

Swiveling Incident Light Camera

-30° / 0° / 90°

Camera Type Transmitted light Incident light

View Field 7.3 x 6.7 mm 6.5 x 8.7 mm

Working Distance 100 mm 73.5 mm

Camera Chip Type 1/3" CCD monochrome 1/3" CCD monochrome

Cutting Edge Inspection Illuminator 12 red LEDs 12 red LEDs

Optic Carrier Standard with Tool Inspection

Note: Available for »pilot 3.0« with fine setting or CNC control

View of tool face geometry

33


Technical Data

Max. Tool Length Z 350 / 420 / 600* / 800*1) mm

Measuring Range, X Axis 160 / 210 / 310* mm

Max. Tool Diameter 320 / 420 / 620* mm

Snap Gauge Diameter 0 / 702) / 100 mm

Display of Meter Axes (Precision) 1 µm

Precision3) 2 µm

Concentricity4) 2 µm

Setting Accuracy to Nominal Value 2 µm

AxesDepending on machine equipment, up to 3 axes (longitudinal axis Z, transverse axis X, spindle axis C*)

Alternating Current 100 – 120 / 200 - 240 V~

Connection Socket with protective ground contact

Power 600 VA

Frequency 50 / 60 Hz

Circuit Breaker 6 A (thermic)

Compressed Air Supply 6 – 8 bar

Operating Pressure of the Pneumatics 6.0 bar

Quality of Compressed Air dry, lightly oiled

Ambient Temperature during Operation 5 °C - 35 °C

Relevant Humidity during Operation 5 % – 90 % (non-condensing)

Use in Operations Indoors

Noise LevelDuring operation the product reaches a noise level of < 45 dbA. When using the printer, which is available as an option, the noise level may briefly rise to < 54 dbA according to DIN EN ISO 1683:2015-09.

Weight approx. 180 - 225 kg

»cockpit« Weight approx. 50 kg

»smile« Series

1) Max. Tool Length Z 800 mm is only possible in combination with the table system2) With the selection of the optic carrier Standard with tool inspection 3) Proof with measurement standard4) Inside the tool holding fixture

34


Installation Dimensions with Monitor Bracket

Installation Dimensions with »cockpit«

* optionalNote: P air connection E electronic connection

Dimensions »smile 420 / 620« Table Versions

Z (mm) Xa (mm) Xb (mm) H1 (mm)

420 210 310 ~1050

600 210 310 ~1250

800 210 310 ~1450

Dimensions »smile 320 / 420 / 620« with

»cockpit« or Monitor Bracket

Z (mm) Xa (mm) Xb (mm) H1 (mm)

350 160 - ~1600

420 210 310 ~1750

600 210 310 ~1950

800 210 310 ~2150

Dimensions »smile 320« Table Version

Z (mm) Xa (mm) H1 (mm)

350 160 ~870

35


Packaging and Commissioning

Packaging

Standard transportation packaging consists of cardboard or shock-resistant wooden panels. Corrosion protection foil is included.

Both packaging types can also be packaged as seaworthy packaging for overseas transport.

Note: Accessories or options will change the gross weight. 1) Gross weight corresponds to the weight of the presetting and measuring machine, with packaging material.See the Technical Data for net weight.

Remote Maintenance*

Remote maintenance software to connect the presetting and measuring machine to the ZOLLER service location in Germany via internet can be installed. Requirements:• ZOLLER »pilot« image processing from Windows XP®

• Network integration art. no. 9700471• Internet connection at a download speed of at least

2,048 kbits/s and an upload speed of at least 192 kbits/s• Open port 5000• Unhindered access for the remote maintenance software

through the firewall

Note: Further device-specific QA or maintenance concepts available on request

approx. dimensions (W x D x H) Gross Weight 1) Cardboard Gross Weight 1) Wood

»smile 320« approx. 1760 x 900 x 1950 mm approx. 250 kg approx. 325 kg



ZOLLER »cockpit« approx. 900 x 900 x 1800 mm approx. 125 kg approx. 150 kg


35 36

Commissioning / Basic Training

Professional commissioning and final acceptance (8h/day) is carried out by a ZOLLER service technician at the customer’s location. After commissioning (approx. 4h), basic training is completed for the rest of the day.

Presetting and Measuring Machine Operator Training*

Training (8h/day) for three employees will be provided by a ZOLLER service technician at the customer’s location, or directly at a ZOLLER location if necessary.

Factory Acceptance / Preliminary Acceptance*

The customer has the option to witness the factory acceptance / preliminary acceptance (8h/day) at ZOLLER in Pleidelsheim. This will be completed by a ZOLLER service technician.

Network Integration and Service*

Integration of the measuring machine control for the presetting and measuring machine into the customer’s company network. Completed by a ZOLLER service technician (8h/day).

0 1 0 1 0 1 0 1 0 1 0 1 00 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 00 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

0 1 0 1 0 1 0 1 0 1 0 1 0

Note: Additional options for tool data transfer on request.

* optional


37

ZOLLER – At Your Service Worldwide

Our sales and service provides know-how, fast and where you need it – in 56 countries.

Our customers have been putting their trust in ZOLLER for decades because of both, the quality of our products as well as excellent customer service. As with all our other product offers, service adds to the efficiency and quality of your manufacturing. You can rely on the longevity of ZOLLER products, low maintenance costs and the continuous development of new application solutions. ZOLLER Head Office GermanyE. Zoller GmbH & Co. KG | Tool presetter and measuring machinesGottlieb-Daimler-Straße 19 | D-74385 PleidelsheimTel: +49 7144 8970-0 | Fax: +49 7144 [email protected] | www.zoller.info

Parent company Headquarters Branch office Representative

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E. Zoller GmbH & Co. KG | Tool Presetting and Measuring Machines

Gottlieb-Daimler-Straße 19 | D-74385 Pleidelsheim

Tel: +49 7144 8970-0 | Fax: +49 7144 8060-807

[email protected]

www.zoller.info

ZOLLER solutions

ZOLLER solutions are synonymous with comprehensive optimization of your manufacturing operations. ZOLLER combines hardware, software and services in individual system solutions to improve quality, efficiency and productivity. As a ZOLLER customer you benefit not onlyfrom our know-how as market leader in the field of tool measuring technology, but equally from our claim as a family-run business, guaranteeing you sustainable competitive advan- tages and making a measurable contribution to your success.

AUTOMATION

TOOL MANAGEMENTPRESETTING & MEASURING

INSPECTION & MEASURING

Parent company Headquarters Branch office Representative

Documents

Technical Description · 2019. 9. 12. · Technical Description »smile« ZOLLER »elephant« The »elephant« measuring program assistant allows you to easily measure standard tools