tool presetting

Optimising production with
tool presetting
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Zoller’s range of tool presetters
preset for efficiency
(from left – right)
»venturion 450«
»venturion 600«
»venturion 800«
Cummins engineers saw that valuable production time could be saved by investing in
Zoller tool presetting and heat shrinking technology. Cummins estimates it is achieving
about 20% greater efficiency in production, thanks to the Zoller off-line presetting.
The plant now changes its heat-shrink cutting tools and accurately sets key dimensions
to within microns without interfering with production.
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Unleash the full capacity of your machine tools
preset for success
At Zoller, we are often asked why there is a need for a dedicated tool presetter, when tools can
be set on-machine. The simple answer is that machine tools should be in operation as much as
possible in order to ensure an efficient manufacturing process. Even three minutes while setting
tools is time wasted. Consider a typical machining operation:
Each tool change takes 3 minutes.
Quality and accuracy relies on a good optical system
There are 20 tool changes in an 8-hour shift.
with auto-focus capability, a robust mechanical
The result is a whole hour of manufacturing
structure and comprehensive support software.
lost because of tool setting. On every machine.
If that tool setting were carried out on a Zoller tool
presetter, then manufacturing would be improved
by 12.5% - where else could you gain that level
of improvement?
A high-accuracy tool presetter is therefore a must,
because a machined component can only be as good as
the tool cutting it. An inaccurate presetter will transfer
inaccurate tool data to the machining operation.
The latter is important so that data is interpreted
correctly, thus removing operator subjectivity.
The process needs to be fully integrated, i.e. no
translation – data should be sent in native format
directly to the CNC. These areas mark out Zoller’s
range of tool presetters as the pinnacle of precision
in the industry.
You probably strive for the most efficient
manufacturing process. You probably want the most
precisely-set tooling. You definitely need a Zoller.
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Our most popular presetters. See the full range at www.zoller-uk.com
»smile«
Smile
A general-purpose presetter with guaranteed
accuracy and repeatability.
The Smile is Zoller’s general-purpose presetter for tool weights
up to 30kg. It provides excellent levels of accuracy and
repeatability thanks to its unique CNC spindle with genuine
auto-focus capabilities. Zoller’s telecentric optics further enhance
performance while making the system easier to operate.
Data can be seamlessly transferred to machine tools thanks to
Zoller’s unrivalled control-specific output or via RFID.
This ensures that operator intervention is eradicated. All of these
unique and industry-leading capabilities at a price-point to meet
the most demanding budget.
»smile«
»redomatic«
Advanced tool presetting with an automatic heat
shrink capability.
The Redomatic is built around the proven Venturion structure, with
integrated heat shrinking functionality. Redomatic fully automates the
shrink process – setting tools to within 10 microns on tool lengths.
Productivity is increased compared to traditional shrinking
techniques, thanks to the fully integrated process.
»redomatic«
Our most popular presetters. See the full range at www.zoller-uk.com
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»venturion«
An advanced presetter with unique functionality and
enhanced performance.
The Venturion has been designed with enhanced structural integrity
to accommodate tooling weights up to 200kg. Integral to the
machine is the Auto Clamping Element (ACE) spindle, which provides
accuracy up to 2 microns. The spindle receives all tool workholding
systems, which ensures the ultimate in flexibility.
The Venturion systems have a measuring envelope up to 1600mm
in the Z-axis and can handle diameters up to 1250mm.
The Venturion has a wealth of options that meet all of your tool
setting and measurement requirements.
»venturion 600«
»hyperion«
Horizontal presetter for use with turning
and shanked tools.
The Hyperion is the most advanced system available for
measuring, presetting and inspecting static and dynamic tools.
Hyperion incorporates an Auto Clamping Element spindle.
This allows all tool workholding systems to be measured.
Genuine auto-focus and auto edge-detection ensures the
ultimate accuracy and repeatability. Furthermore, Hyperion is
»hyperion«
capable of measuring Y-Axes offsets within a range of
+/- 50mm. Control-specific data is output to machine tools to
streamline the production process.
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Tool management
solutions
Optimise tool and stock management.
Zoller Tool Management Solutions (TMS) centralises all
tooling information allowing collaboration across an
entire enterprise.
Tool data, including parametric, stock and cost information
is stored in a networked database that can be accessed by
Computer Aided Manufacturing, Planning, Manufacturing,
Warehousing and Purchasing departments.
TMS benefits an organisation by providing a holistic view of
stock quantities and location. In addition, TMS delivers work
schedules to the tool room ensuring production requirements
and tooling changeover is performed in a timely and
planned manner.
TMS stock control can track both components and assemblies
Tool life data can be automatically accessed and managed
giving pictorial indicators leading operatives straight to the
with the TMS reporting on performance and return
required storage locations.
on investment. Redundant tooling can be identified and
brought back into production reducing costs whilst
TMS delivers efficiencies in both cost and labour giving a rapid
enhancing performance.
return on the investment.
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Machine tool
integration
Machine Tool Integration
Zoller presetting processes provide huge productivity gains by preparing tool assemblies
for immediate use.
Tooling measurement and offset data is delivered
This integration ensures that there are no
directly to the production machine controller by
translation complications. Furthermore, it eliminates
network connectivity or a RFID chip system. Tooling is
possible errors caused by manual data entry.
set and checked against preset tolerances so that only
accurate tooling assemblies and correct data is sent to
Automatic connectivity is yet another example of
the production operation.
how Zoller aids process optimisation and streamlines
production processes whilst eliminating possible errors.
Zoller configure the data in native format for a wide
range of controllers, including:
Siemens
Heidenhain
Fanuc
Mazak
And many more...
Accurate data, delivered in real time, equals accurate
parts in double quick time.
»Would you like to maximise your manufacturing productivity?
»Then get in touch for a free assessment from our
tool management experts.
Faraday House
Woodyard Lane
Foston
Derby
Derbyshire
DE65 5DJ
Tel: 01283 585933
Email: [email protected]
www.zoller-uk.com
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