Why is the ZOLLER »toolBalancer« more exact than competing balancing systems?

The »toolBalancer« is so exceptionally accurate because of the center offset during measurement. This advantage applies to every tool—but especially to smaller HSC tools.

»toolBalancer« control software in 25 languages

Intuitive software with a graphical user interface for quick and simple balancing in one or two levels, including a wide range of standard functions.

Convenient operation of the software via touchscreen.

Graphic display of the spindle's angular position on the monitor.

Balancing Correction “Various Weights”:Correction of unbalance by adding or removing weights (e.g., balancing screws). Includes the option to specify existing weight sets. Balancing Correction “ShiftWeights”: Compensates for unbalance by rotating balancing rings or slotted nuts. Balancing “RadialDrilling”: Provides correction for unbalance through radial drilling. Automatically calculates the number, angular position, and depth of the drill holes. Balancing correction “Milling”: Compensates for unbalance through radial, tangential, or axial milling. Balancing correction “AxialDrilling”: Compensates for unbalance through axial drilling. Automatic calculation of the number, angular position, and depth of the drill holes.

Display of the unbalance and correction position on the chuck via a laser beam.

Balancing on a level surface

For measuring and performing correction for unbalance on a single level (static).

Balancing in Two Levels

For measuring and performing correction for unbalance on two levels (dynamically).

LabelPrinting: Output of measurement results on one or two levels using a ZOLLER label printer. Reportprinting: Output of the measurement report as a printout on a laser printer or as a PDF file, including an editing function. Measurement Data Export: Automatic export of measurement data in CSV format.

I already have a balancing system. Can I use my balance adapter with the ZOLLER »toolBalancer«?

Yes, you can. What makes the »toolBalancer's« spindle especially versatile is its ability to accommodate both ZOLLER balance adapters and adapters from other manufacturers. You can use them in the spindle.

Is the ZOLLER »toolBalancer« easy to service?

Ease of use is the main difference compared to other balancing machines on the market. Starting with the »toolBalancer«’s »twinPanel« safety cover. If a part releases during balancing or the panel deteriorates due to contact with oil, you don’t have to replace the entire cover right away. The cover is designed with two panels, so you can exchange just the inner panel. That’s why we call it the “sacrificial panel.” Furthermore, you have simple access to the spindle, and all electronic components are carefully and securely installed in the control cabinet to ensure trouble-free operation. The positioning of the control cabinet, the drives, and the sensors ensures optimal accessibility for maintenance and service work.

How does the »toolBalancer« differ from competing balancing systems?

The »toolBalancer« is a newly developed product that features more advanced technology and a superior, more ergonomic design. This results in high precision, simple operation, and certified safety.

What is the exact nature of the unbalance correction process?

In this video, we'll show you exactly how the »toolBalancer«'s« unbalance correction process works.

I'd like a personalized consultation. What options are possible?

At ZOLLER, you’ll find a range of options for learning more about a specific product. For example, a one-on-one consultation with an expert in our virtual showroom. We’d also be happy to exchange information via Microsoft Teams or by phone. Or you can stop by our Smart Factory. Inquire now

Why is a »toolBalancer« needed?

A balanced tool assembly ensures a longer tool lifetime, low vibration, higher spindle speed, better surface finish on parts, and, above all, a longer spindle lifetime. Unbalance in a tool assembly generates excessive centrifugal forces that can damage the spindle bearings. Such damage reduces the spindle’s lifetime and can lead to costly unplanned downtime.

When using balanced tool holders of type G2.5 at 25,000 rpm, does the entire tool assembly still need to be balanced after the cutting tools/inserts have been assembled?

Cutting tools are sometimes asymmetrical, for example, due to flattening of the shaft (Weldon surface). Profile cutting tools may have an asymmetrical weight distribution. When such cutting tools are fitted in a balanced tool holder, this results in an unbalance in the tool assembly. Collet chucks, clamping nuts, stop screws, data chips, etc., also contribute to the unbalance of the tool assembly. Once these other components are added to the tool holder assembly, the tool holder may need to be rebalanced to correspond to ISO balancing specifications.

Do you have an adapter for clamping drill bits, such as wood cutters and tools with different shank sizes for profiling tools?

ZOLLER offers specialized adapters for clamping drill-milling cutters and tools with different shank sizes.

What is single-plane (static) unbalance and two-plane (dynamic) unbalance? How can we determine which method we should use for balancing the tool assembly?

The following rule of thumb can serve as a guide for determining whether the tool holder should be balanced "statically" or "dynamically": Static: 1 Balancing on the level applies to tool holders with an operating speed of less than 20,000 rpm and where the total length of the holder is less than twice the maximum diameter of the tool holder. Dynamic: 2 Dynamic balancing applies to tool holders with an operating speed of more than 20,000 rpm, or when the total length of the holder is more than twice the maximum diameter of the tool holder.

What are G1, G 2.5, and G 6.3, and where are they applicable?

"G" indicates the balance grade. CNC machines, machine tool drives, and the tool industry have usage of G2.5 for finishing tools, G6.3 for roughing tools, and G1 for grinding wheels. These are the quality grades according to DIN ISO 1940-1.

What are the different balancing methods?

In balancing technology, there are three methods for correcting unbalance: Adding material using the screw method;removing material by drilling or milling; and shifting material using unbalance rings.

If the speed is only 2,000 rpm, does it still need to be balanced?

If the spindle is running at only 2,000 rpm because of vibrations and cutting noise, this lies with the usage of an unbalanced tool setup. When the tools are balanced, higher speeds and feeds can be used, thereby increasing profitability.

What does the unit gmm mean?

This is the unit used to measure unbalance. Unbalance is caused by a rotating mass located off-center from the axis of rotation. Unbalance is expressed as the product of this mass and the distance from the axis of rotation, e.g., in gram-millimeters (gmm) or kilogram-meters (kgm).

»toolBalancer«

Name: »toolBalancer«
Brand: Zoller

With optimally and highly precisely balanced tools, you can achieve longer tool life, extended spindle runtime, and better surface finish on your components. With »toolBalancer«, you can bring not only your tools but your entire manufacturing process into perfect balance between sustainability, efficiency, and progress.

Request more information now

The unique balance of functionality and ergonomics for exact measurement results: That’s precision and certified safety for your manufacturing process.

Frank Hartstein, member of the »»toolBalancer«« product development team

We, the technology company ZOLLER, have focused our experience and expertise on this new product development, thereby setting another milestone and rounding out the ZOLLER product portfolio. Typical ZOLLER: Everything from a single source.

Christoph Zoller, Managing Director

The perfect combination of design, ergonomics, and technological intelligence. The ZOLLER solution with certified safety for resource-efficient application in your manufacturing operations.

Alexander Zoller, Managing Director

TÜV and UL/CSA inspected

500 kg solid base

Best balancing results: < 0.4 gmm

»twinPanel« Safety Cover

»twinPanel« Safety Hood

Corresponds to DIN ISO 21940-23 Class C60 for maximum safety.

The internal “sacrificial pane” records contaminants such as residues of cooling lubricants and damage caused by component detachment. This takes into account the very important—and often overlooked—process of protective pane aging resulting from daily use. By allowing for quick and cost-effective exchange of the sacrificial pane, the ZOLLER »twinPanel« guarantees the long-term safety of your operators.

high-precision spindle

High-Precision Spindle

Accommodates virtually any tool holder with the appropriate balance adapter. Depending on the weight of the tool, the spindle rotates it at an adjustable speed ranging from 400 to a maximum of 1,200 revolutions per minute and measures the unbalance with an accuracy of < 0.4 gmm.

In designing the high-precision spindle, ZOLLER placed especially great focus on a safe and certified adapter-changing process. A special design feature avoids accidents and damage caused by balance adapters that are not securely fastened in the spindle.

Adapter Compartment

Adapter compartment with a swivelling front flap

Three storage places for ergonomic, back-friendly, and quick adapter changes without having to bend down.

Fork cutout

Fork Slot

For flexible installation and simple transport of »the« »»toolBalancer«« in your production facility using a pallet truck.

ZOLLER Control Software

Simple ZOLLER Operating Software

The structured, graphic representation intuitively guides the operator through the measurement and balancing process.

The machine is set up by providing the tool geometry data as input. All data is stored in the database and remains available for later use.

»Cockpit« Control Unit

Separate »Cockpit« Control Unit

It is adjustable in height and position, and the monitor’s inclination can be adjusted; it can be simply shifted to the required position, making the use of software as convenient as possible.

In addition to touch operation, the »cockpit« offers the option to input data via mouse and keyboard, as well as storage compartments for label and laser printers, handheld scanners, and tools such as Allen keys.