Automatic Sliding Door

Before the measuring process starts, the sliding door of the measuring machine can be conveniently and simply closed automatically via the software using pneumatic systems, and opened once the measuring process is complete.

What is the main difference between presetting machines and inspection units?

An inspection unit is equipped with additional axes, sensors, and cameras to enable comprehensive measurement of cutting tools.

»elephant 2.0« – extremely simple to use

01. Selection of tool type, e.g., end mill > end mill with corner radius 02. Selection of the required parameters 03. Perform measurement, e.g., cutting contour corner radius 04. Measurement results (19 measurements, measured fully automatically without data entry or programming)

With a dead weight of approximately 650 kg and isolators, the solid vibration platform absorbs external vibration influences at the installation location. The isolators are supplied with compressed air at 6 bar.

Scanning measuring sensor

For electronic tactile measurement of, for example, the flank relief on taps. Available with Probe inserts ranging from D 0.3 mm to D 2 mm.

Measuring and Inspection Tools

For periodic on-site inspections of your measuring machine and to verify the accuracy of through-beam and reflected-light measurements, ZOLLER offers inspection tools that correspond to your machine, such as test mandrels, diameter gauges, and angle test gauges.

EMERGENCY STOP" circuit in »the cockpit«

Allows all motor-driven movements to be stopped simultaneously, further enhancing the high level of safety offered by Uhing drives. Voltage to the electronic components is maintained during this process, eliminating any danger of data loss.

Key control elements are located on the front of the measuring machine. This ensures that you always have unobstructed access to the emergency stop switch, the reset button, the membrane keypad, and the button for starting measuring processes.

Manual RFID Read/Write Station »mslz«

For manual writing to or reading from the code carrier on the tool holder using a handheld reader.

The UPS unit ensures that your computer shuts down properly in the event of power grid faults, thereby avoiding data loss. Mains voltages of 230 V~ (Europe) or 120 V~ (U.S.) are available.

Which tools are measured on ZOLLER machines?

All rotating cutting tools can be measured on ZOLLER inspection units. Additionally, stationary tools such as indexable inserts can be easily measured according to customer specifications using our specialized adapters.

Can I connect the inspection units to a grinding machine?

Absolutely—you can transfer the tool file from measuring machines to the grinding machine, or vice versa, via a network connection or a USB flash drive. For example, we offer a file interface for many programming systems.

Does it take a long time for the measurement of standard tools?

No, our software includes an automaticly installed program called ZOLLER »elephant«. With this program, you can simply measure basic geometries without having to adjust many settings.

What is the difference between »genius« and »threadCheck«?

ZOLLER »threadCheck« is based on the »genius« design but features an additional axis for horizontal swiveling and several specialized programs for measurement of threading tools. The swiveling capability allows the user to accurately focus on and measure the contour of the thread flanks without distortion.

Can I only use the inspection units to measure tools?

No, you can measure various objects, such as grinding wheels or, if necessary, the finished workpiece.

How large can the tools be in order to successfully measure them on ZOLLER machines?

Our inspection units can be equipped with various cameras upon customer request. For tool manufacturers, who usually manufacture tools larger than 3 mm in diameter, we recommend the standard camera for macro tools. For micro-tool manufacturers, we recommend a micro camera for tools with a diameter of 0.4 mm or larger.

Can even beginners quickly take tools on the inspection units?

Yes, we can save the measured tools in our z.One database and call them up at any time. This means that even operators with little experience can independently call up the saved programs. The tool is measured exactly according to specifications.

Does the installation require an air-conditioned room?

An air-conditioned room is not required. The device can be installed in a dust-free area in the machine shop.

Are there automation solutions available for the »genius»« series?

Yes, we can connect a »roboSet 2« automation system to all machines in the »genius« series.

»expert« – smart, simple, brilliant

»expert« is the specialist for measurements on precision tools—based on ZOLLER’s »pilot 4.0« software. The intelligent software generates the optimal measurement sequence based on the selected parameters. Fully automatic, reproducible, and with photorealistic parameter selection. Using check boxes, the parameters to be measured can be selected easily, quickly, and in a tool-specific manner for the measuring program. Simply select the parameters to be measured and confirm—and the measurement sequence starts right away.

360° Concentricity Check

To automatically determine the radial run-out of circular surfaces (e.g., tool shanks) and graphically evaluate the entire contour.

Point angle with hollow grinding

For drills and hollow-ground tool cutting edges, this is determined by contour tracking from the start point (major diameter) to the tool tip or the defined end point.

Groove chip space scan

Automatically scans the groove/chip space contour without contact and represents it graphically.

Radius »contour« with graphic

For the automatic determination of concave and convex radii on the outer contour of tools, including adjustable angular sectors with graphic evaluation.

Rake angle on radius cutters

Calculates the rake angle within the Radius segment based on the specified angles. Suitable for Die cutters, corner cutters, and full radius cutters.

Contour profile measurement (»lasso«)«

To scan any tool or workpiece contours and perform a nominal/actual comparison or dimension the contour.

»Metis« Tool Analysis

Measures and documents any contours, radii, angles, distances, and defects (wear and tear) using incident light.

Editable »apus« inspection report

To represent all measurement results—including designations, nominal values, tolerances, and much more—in a table format with a flexible layout.

The virtual measuring machine for the PC workplace, used to externally configure the testing and measurement sequence—including measuring programs, nominal values, and tolerances—based on the 3D model of the tool, even before it is manufactured.

»»genius«« – Technical Specifications

Name: »»genius««
Brand: Zoller

Maximum tool length Z 600 mm

Maximum tool diameter D 400/260 mm

Maximum snap gauge diameter d 100 mm

Number of axes: 5–6

Weight ~ 820 kg

application

2D Parameters: Incident light
Default Diameter 2–100 mm	Basic
Microtools 0.1–10 mm	optional
3D parameters: Incident light
Partial	Basic
Area-Based	Basic
Measuring Tasks
Threading Tools	optional
(not available for all models)

Sensor Configuration

Optical Transmitted Light
HR70 Transmitted Light Camera, Field of View approx. 4.0 x 3.6 mm²	Basic Model
5 Mpx Transmitted Light Camera, Field of View approx. 4.4 x 4.0 mm²	Optional
WF Transmitted Light Camera, field of view approx. 15.5 x 14.1 mm²	optional
Optics – Incident Light
HR50 Standard incident light camera, field of view approx. 1.1 x 1.0 mm²	Basic
HR50 Micro incident light camera, field of view approx. 0.4 x 0.4 mm²	Optional
Tactile
Scanning measuring sensor	Optional

Measuring Machine Configuration

Spindle
High-Precision Spindle »ace«	Base Model
High-Precision Spindle SK 50	Optional
ROD	Base Model
Hollow Encoder	Optional
Linear Actuator
Swivel Axis (Incident Light)	Standard
Swivel Axis (Incident Light & Transmitted Light)	Standard
Optics Drive
Swivel Axis (Incident Light)	Standard
Swivel Axis (Incident Light & Transmitted Light)	Optional
Vibration Damping
Leveling Element on machine feet	Base
Active Vibration Decoupling	optional
Material
Light-metal alloy	Base

accuracy

Exy = 2.5 μm + (L/250 mm) μm	Base
Ex = 1.5 μm + (L/300 mm) μm	Base

Inspection & Measuring: Your Advantages

Find out what is possible with ZOLLER for tool inspections. Process-related inspections or high-end analyses through to SKP, roughness and the creation of digital twins.

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Christoph Zoller — 1:1 Expert Meeting

The individual exchange about your goals and our ideas for achieving them. Online advice from ZOLLER directly from the Smart Factory. Arrange your appointment now.

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Inspection & Measuring: Your Advantages

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