To what temperature is the tool holder heated during the heat-shrink process?

This depends on the holder's geometry, the clamping diameter, and the taper size. While some standard holders have a 4.5-degree taper, slim holders have a 3-degree taper. Depending on the type, different temperatures ranging from 150˚C to 350˚C are used when the holder is shrunked.

The fume extraction system reliably removes fumes from the operator's working area. The established and patented fume extraction system above the induction coil has been extended to include an integrated extraction system inside the coil housing. The fumes are therefore extracted directly where they are produced. The filter unit has a safe place in the under-table.

What types of cutting materials can be used in shrink-fit holders for the shrink-fit process?

Steel, HSS, carbide, heavy metals, metal powders, collet extensions.

What is the required tolerance for the shaft diameter of the cutting tool during usage with a shrink-fit tool holder?

The shank tolerance of the cutting tool must amount to h6 or h5.

Is it possible to monitor the lifetime of the tool holder and the number of shrink cycles it has undergone?

With the ZOLLER »powerShrink«, it is possible to monitor the tool holder’s heating cycles using a unique tool holder ID number—for example, via ZOLLER »idChip« technology. Each cycle is monitored and recorded in the »pilot« software.

What are the minimum and maximum heating times?

The heating time depends on the geometry of the tool holder and the clamping diameter. For small diameters, it takes 2 to 3 seconds; for large diameters, 5 to 7 seconds.

What are the minimum and maximum cooling times?

ZOLLER offers two types of cooling systems: a non-contact cooling system with air cooling and cooling adapters. Depending on the tool diameter, the cooling time with cooling adapters ranges from 60 to 120 seconds. With »Zstream« air cooling, the process is called “conditioning,” during which the entire tool holder is cooled from the projection to the flange. The conditioning time depends on the diameter of the tool holder and ranges from 3 to 5 minutes.

Is an air-conditioned room required to install the »powerShrink« device?

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

How does (to) shrink work, and what kind of process takes place here?

The concept is simple. Each shrink-fit tool holder is manufactured with an inner diameter that is slightly smaller than the shaft diameter of the cutting tool. An induction heater is used to rapidly heat the nose of the tool holder in order to increase the inner diameter. At this point, the cutting tool can be used in the tool holder. The tool holder is then cooled, causing the diameter to shrink and applying force to the shaft of the cutting tool to hold it in exact position.

What is non-contact cooling and contact cooling?

When tool holders are shrunk without direct contact, the tool holder system is referred to as a contactless cooling system. This is achieved, for example, using cooling adapters or air cooling. When tool holders are cooled with a liquid after being heated, this process is called quenching. The tool holder’s lifetime is reduced, and it will rust if it continues to be used with liquids in direct contact with it. The coolant becomes contaminated after a short time and must be replaced; otherwise, it will break down, emit a strong odor, and contain harmful substances that are dangerous to human skin.

Is it possible to use the same shrink machine for standard diameters ranging from 3 to 32 mm and heavy-duty shrink holders for diameters greater than 32 mm?

Yes, it is possible with the ZOLLER »powerShrink 600«, which allows the 14 kVA induction coil and the 22 kVA induction coil to be quickly and simply exchanged using the quick-change interface.

Is it possible to adjust the total length of the tool after it has been shrunk with the »powerShrink« machine?

Yes, with the »eQset« and »liteSet« adjustment systems, it is possible to preset the total length of the tool on »the« »powerShrink«.

Air cooling »zStream«

With ZOLLER's air cooling »zStream« you obtain maximal flexibility and protection with the cooling of your shrink fit tool holder, independently of its contour or diameter. In addition, your shrink-clamping tools are cooled consistently and safely across their entire length – without the risk of being damaged. »zStream« is also ideally suited for cooling placed down tools.

Length adjustment »eQset«

The integrated length adjustment system is used to set the overall length or projection length and for tool replacement. The pneumatically activated quick adjustment and fine adjustment by handwheel enable fast, ergonomic and precise positioning of the probe head to the desired height.

Scan function incl. hand scanner

The »pilot« software scan function in combination with the hand scanner enables reliable selection of the appropriate shrink fit parameter by scanning the holder number on the shrink fit holder. Regardless of the manufacturer, all shrink fit toolholders with DataMatrix code (e.g. ZOLLER »idLabel«, ZOLLER »idChip«) are supported. In the »pilot« software, each heating process can be counted for each shrink fit chuck. In addition, a warning and wear limit can be stored in relation to the permitted heating processes.

Set-up table for »powerShrink 400«

As an alternative to installation on a workbench, the »powerShrink 300« and »powerShrink 400« can be positioned on a set-up table with ergonomically optimal working height. This provides a tidy place for the cooler and flue gas suction device. The table is optionally available with sturdy rollers and an ergonomic handle to allow variable positioning.

Configurations for »powerShrink 400 | 11«

There are 3 basic configurations for the induction coils to choose from: 1. combination of any 14 kVA induction coil with quick-change interface, changing the induction coil from one induction coil axis to the other depending on the shrink chuck length 2. combination of any 2 14 kVA induction coils without »shrinkbyLight« and without quick-change interface 3. combination of any 14 kVA induction coil with a 22 kVA induction coil with quick-change interface

With your »powerShrink«, you will receive a receiving pot as standard. Additional pots can be ordered for parallel heating and cooling. The work surface is perfectly matched to the receiving pot and ensures convenient and quiet movement.

The different mounting rings allow flexible changeover between different mounting interfaces. For all common tool holder types and sizes up to SK 50, HSK 100 and PSC 10.

Special cooling adapter

Cooling adapter for special shrink fit chuck shapes and sizes (e.g. also for D3 mm to D5 mm). Suitable for cooling bells D14 mm to D16 mm or D25 mm to D32 mm.

Storage board for mounting rings and special cooling adapters The storage board provides space for storing four mounting rings and six special cooling adapters size I or three special cooling adapters size I and size II. Tool trayFor storing socket tools at the shrinking workstation. The position of the tray can be freely selected by the operator. Shelf for cleaning brushesA shelf with all brush diameters is available for storing cleaning brushes, which can be attached to the device in any position using magnets. The brushes for cleaning the mounting hole of shrink fit chucks are also available from ZOLLER - for shaft diameters D3 mm to D32 mm, optionally made of brass or plastic. Split shielding discs with trayAn optional set of shielding discs (5 pieces) in a split design including the corresponding disc tray can be ordered for shrink-fitting offset tools.

Coil operating handle

For optimum user-friendliness, the operating handle, which is fitted on the left as standard, can be fitted on the right or on both sides. Each operating handle is equipped with two function buttons - for moving the coil and activating the heating process.

Shrinking device »toolEx«

»toolEx« helps you to remove tools from the shrink fit chuck that cannot be pulled out by hand or with pliers, such as broken tools. The set includes a holder and six ejector rods.

Length adjustment »liteSet«

Use »liteSet« to set the projection length of the tool to be shrunk. The maximum projection length is 150 mm. The set contains four clamping prisms for shank diameters D3 mm to D32 mm.

»powerShrink« – Features

Name: »powerShrink«
Brand: Zoller

With ZOLLER’s »powerShrink«,« shrink-fitted tools are ready for use in no time: thanks to the intuitive »pilot« software, the intelligent induction system, and continuous monitoring of the steps.

The »powerShrink« technology ensures the shortest possible process cycles. Even inexperienced operators can achieve the resulting short process times after just a brief training period. The »pilot« operating software guides you through all steps and controls many processes fully automatically. For each step, the software displays the component required and provides visual support through graphic displays on the screen and the pioneering ZOLLER »actbyLight« user guidance concept—the light-guided user guidance designed for the safe and efficient use of »the« »powerShrink« in your company.

Use the shrink fit holder; select the heating parameters (manual/automatic via »»idChip««)

Shielding system: Use the disc or »»varOct«« (manual/motorized) for alignment

Move the coil down until it rests on the shrink fit holder

Start the heating process; the heating progress is represented in the software

After the heating process, raise the coil and use the cutting tool in the shrink fit holder

Slide the mount onto the green-flashing cooling bell and place it on top

The cooling process starts automatically; when it ends, a blue light is displayed

After the cooling process is complete, remove the cooling bell from the shrink fit holder

The clearly structured graphic interface of the ZOLLER »pilot« software guides operators intuitively and reliably step by step through the input dialog using large function buttons and a well-designed color scheme. The 12.5-inch monitor delivers a razor-sharp representation.

Main Menu – large function areas with clear figures: Shrink-fit chuck selection, parameter selection, or scan code.

Parameter Selection – The required heating parameters can be selected simply and reliably using clear and intuitive software interfaces.

Scan Function – All parameters corresponding to the shrink fit holder are loaded automatically, regardless of the manufacturer. Monitoring of the number of heating cycles and viewing of information for each shrink fit holder is possible.