Zoller GENIUS3 Universal measuring machine for cutting tools

Zoller Universal measuring machíne for cutting tools genius 3/pilot 3.0

The universal measuring machine genius 3
There aгe various measuring machines or metal cutting tools, but onIy one ZOLLER ugenius 3..,
This unique universal meazuring machìne gives you an evceIIert return on innestment as ìt saves you valuable time during work preparaüon and programming by preventing troublesome rework and customer complaints. On top of that, it ensures quality results that convince both you and your customers. See for yoanseIf - you will be ínspired.
ZOLLER .geаіuτ 3. is the universal measuring machine for metal cutting tools. From rapid testing of individual crŔeda to complete, ully automatic, operator-independent checks youг tools aze checked quickly, simply and extremely preciseiy. The measurement resuIts are documented in detail and can be transferred to the grínding machínes at the push of a button.
Fìnd out how sìmply ít all happens, as we  the other benefit .genius 3. can give you in the following pages.

The ZOLLER geníus 3
Híghlíghts
Compact structure and Iow ѕpace requirement Adjustable control center for ergoпomic layout Measure, test and save money Total encasemerıt to prevent dust aud extraneous light aѕ a standing or desk workstatíon
Dimenslonally stable design elements and hígh-tech materials , uníversal spindIe wíth power clampíng with the genius 3 for high stability and optimum suitability for use under pro- Automatic hydraulic expannion for tools
duεtion conditìons, even wíthout a climateгontrolled гoom Intelligent calibration and automatic search +pilot eIectronics and software CNCεontrolled, abílíty to pívot and backlash-free
5-axiѕ CNC con2ro1 unR and manual axis adjustment for quic i k ndexed cameгa for radial and axial meaвuгemeпtѕ
spot checks between 0 and 90
Fully automatic measuńng cycle Interactive configuratíon wizard for easy operation 17^ TFT гоloг display wíth touchscreen operation Extremely fast measurìng speed
Brand-name pгoduc such as Bosch pneunratics, Heidenhain Vlrtual joystick and ınembrane keytward
measuring systems, THK guide systems and maоy others software modules customized
Soпy cameгaѕ with telecentríc lenses elephant technology ìncident light, aułomatìcally adjustable in 8 segments swívellíng device and accessories
lnnovative technology and ergonomic operation
Speed and comfort during the testing and measuring process translates into pure profit every day in the form of a considerable increase ìn productivity and motivated, efficient employeeѕ.
ZOLLER stríves to make machine operation as sìmple and ergonomic aѕ possible aed to create the optimum baeís for a fully automatìc measuríng cycIe. Storage shelf 1 ZOLLER Cockpit
space-saving and easily accessib1e trays for accessories Adjustable control center for ergonomic layout as a ztan- such as changeable sleeves, adapterc and tool posts. dìng or desk workstation.
CNC-dríven, adjustable 3D CCD camera and LED lightíng

Rapid changing guaranteed
ZOLLER measures everyłhing - and dampѕ everytising, whether zteep oг hollow shank taper, sandvikLapto
oг i ennametaI. From the smaiieut to the largest shank, from diartıeters of 3 to 32 mm. The comprehensíve
ZOLLER system measures any type of tool and ís flexibilaty adapaable to the most recent developments in the
ZOLLER tool posts aгe aѕ quick, convenìent and reliable to change market, eveп јπ the future. 5o the matching tool posts are always avaílable, regardIess of whích tools you aѕ tools - and just as accurate. The beautìfully simple principIe of modular construction has convínced uners all over the world since have to measure now or in the future. At the same tíme, all t6e toot shatiks ue power-operated at the pusM 1968. The icing oо the cake: The spindle is fitted wıth a all bushing
into which all ZOLLER tool posts caп Ьe inserted with absolute of a button and thus always dainped wíth the same power and wíth repeatabte accuracy.
precisioп and above all without play. For you, this means: changíng
tool posts іп less than 10 seconds with an accuracy of mm.
Other convincing features of the tried asd tested system aгe íts
ѕmall ѕumЬeг of composents, low weíght and its absolute freedom
from wear. That makes the ZOLLER change system the flrst choice
not only technically but economicaIiy too.
Tool posts for spíndles I AvaiIabIe for aII tooIs used in the worıd
ZOLLER upiIot electronícs Software for all requirements
 ZOLLER measuring program generator expert

Position manually or by CNC, check the boxes of the parameters to be measured. All geometries which can be measured with 3+ are ordered under the headings: chip space, circumference, or end, and displayed graphically. Standard parameters are stored for each measurement operation and can be adapted as required. The measuring sequence determined for the tool is saved and is available at any time for subsequent measurements. Saved measurement programs can be edited and expanded. Simply select and deselect new parameters or measure individual parameters repeatedly in a targeted manner.

Chip space select menu:
Select menu for measuring at circumference:  
Example: effective cutting angle  
Example: head length  
ZOLLER electronics

Highlights  
How good a machine control system is can be seen in its application. When it’s not a matter of theory, but of practice, in day-to-day work, where user-friendliness, time-saving, and precise results are indispensable. This is where ZOLLER electronics show their strengths: because they have features that make work easier for the user. A small selection of examples can be found below - but that’s not all, not by a long way. We would be glad to show you personally how you can solve your specific problems quickly and easily.

The groove/chip space contour is scanned automatically, without contact, and displayed graphically. It can be exported as a DXF/XML file and subjected to a nominal/actual comparison.

ZOLLER elephant  
Extremely easy to operate

Select menu for measuring at the end:  
Configuration menu for user-specific settings:  
Example: chisel edge angle  
Example: distance measurement  
Example: effective cutting angle/illumination

A 3D model of the scanned cutting edge is generated and output for evaluating the contour profile. Chip space measurements are output not only as measured values but also as surface models for checking and assessing the profile of the scanned area. The data can then be used in the machine control system or programming system for correcting the erosion or grinding path.

From practice
Application examples

Step measurement with Sinope automatically generates drawing segment graphical evaluation with methods for any desired parameter.

Automatic nominal/actual comparison between DXF and tolerance band with lasso.

Grinding wheels
For measuring grinding wheel and grinding wheel package profiles easily and reliably, and transmitting the results conveniently to the machine control system, there is ZOLLER Corvus. Contour recording takes place by rotation to account for wheel wobble errors and to determine exactly the contour produced on the tool during the grinding process. Predefined measurement macros for 24 FEPA wheel types make fully automatic measurement easier. Combined with the pilot package generator, individual grinding wheel packages can be generated according to requirements. So that they are also available for future measurements, they are stored and managed in a pilot, in groups if required. It couldn’t be easier.

Seamleѕѕ documentary proof thanks to test reports
Documentation
The quality o the precìsion tools delivered ìs critìcal or your cuі2omeгѕ. Provìng this qualíty is criticai
for you: Because you are covered 100 in the event of a complaint thavks to airtight test reports,created with ZOLLER measorement technology whích i5 recognisnd oп the market. No ìfs, ands, oг buts 
Meaníngful documentałion s the best way to show your customers how the delivered tools Wíth this seamless documentation you caп demovstrate your hìgh quality to your customers and thus have been sharpened oг manufactured. In the event of a complaínt, the test reportu can be used
to prove that the goods are іе order. Free deIiveries of repIacement tools or even disagreements staiid out clearly from youг cornpetitors.
with the customer are ru1ed out, your company s reputation is beyond any doubt. Can there be aпy better reasons for seamless documentation?
>apus test report Graphical evaluat πrr Sзvíng of ineasured valııes
Fditable apus test repvrt foı adaptabon of destrip  evaluation of conceotricity and radial runout ot The measured va1ues of saved tools are recvrdnd automaticly and ucope of the pńnted measured vaiues aѕ requíred. The the cutting edges wíth automatic cuttíng edge correctjon for cally wìth eacfi measurement, can 6e evaluated statistically manufacturer address and compaоy logo cav be included if multi-insert cutting tools τaw b1ades, milling headz . and called up at any time.
desired.

Save and export function measurement and test reports* 
Display on monitor, output via network or USB stick.

Tested quality thanks to ZOLLER:
Optimally checked and tested tools are your guarantee for high quality, on-schedule delivery, and a low number of complaints. Use it for yourself.

For smooth operations, interfaces are a prerequisite for paperless and process-reliable production in the grinding and sharpening business. How helpful it is that ZOLLER interfaces to grinding machine controls allow precisely this kind of automation. ZOLLER interfaces open up whole new worlds of saving potential to you: With the grinding program, the data set for .genius 3. is generated and the fully automatic measuring cycle is produced. The measured data is then transferred back to the programming system or grinding machine, depending on the type of interface, and the grinding program is temporarily corrected. Programming time and machine downtimes are reduced to a minimum in this way. You save time and costs - and also avoid errors when inputting data and creating a new grinding program.

Programming/definition of the tool  
Communication  
CNC grinding machines  

Production and final inspectionThe NC program for grinding the tool is transferred to the CNC grinding machine and executed automatically. The tool data is recorded by the ZOLLER genius 3. The ZOLLER product optimizes the NC program, and the tool grinding starts. ZOLLER genius 3 measures and corrects any deviations, saving programming time and ensuring accurate measurements.

Outer contour
Cut-out ength
ZOLLER flgenius 3 Cut-out angle
with elephaпta Programmíng system CNC grínding machíne s
Díameter
Coгпeг radius
Drop
Chamfer width
Chamferlength
Chamfer angle
Axіal chamfer width
Radìa chamfer width
і Flank fact dífference
Axіal cleanaece aogIe 1+ 2
Radial c earance angle 1+ 2
Relief diameter

**Recognition of unknown tools: 3 NC programming and measurement of the ground tools**

**Relief radius**  
A worn tool is scanned and tracked fully automatically with the ZOLLER. This programming system receives the measured parameters from the CNC. The ground tools are brought to the safe position on .genius 3s recognizing the tool dimensions/ .genius 3 and the programming is maintained. The NC program is transferred to the CNC grinding machine, and the tool is re-ground to a new tool and logged there fully automatically.  
Measured outputs are transferred to the machine control system for the CNC grinding machine. The tool is measured and corrected automatically using the programming terminal, such as M75, NUM, Schütte, etc. The same data is used in the measurement sequence in .genius 3.

**Relief angle**  
The measured values are transferred to the machine control and CNC grinding machine. The tool is reground into a new tool and logged fully automatically. The measured outputs are transferred to the machine control system for the CNC grinding machine.

**Core diameter**  
Cone angle  
Centre offset  
Flute depth  
Opening angle  
Chisel edge length  
CAD drawing or tool pattern  
Programming system  
CNC grinding machines

**Chisel edge centre offset**  
Chisel edge radius  
Chisel edge angle  
Tooth distance  
Axial offset  
Cutting edge preparation  
Protective chamfer height  
Protective chamfer angle  
Effective cutting angle  
Helix angle  
Point angle  
Pitch  
Web length  
End gash width  
End gash position  
Recording of all contours via NC programming  
The measured data can be stored and recalled for later use

End gash radius  
Axial rake angle  
Step length  
The last ground tool is automatically recorded on the .genius 3, and a program which takes into account grinding sequences is automatically created.

Detailed examination in the programming system  
Measurements are stored in DXF format, which includes nominal/actual comparison. The contour is examined using .genius 3, and the nominal comparison is calculated. The results are transferred to the programming system, and corrections can be automatically made using the control system. Corresponding angles and measurements are compared and stored.

Graduation tolerance
Taper  
Full radius - contour  
Tooth geometry  
Tooth face width  
Centring radius  
And many more  
Number of transferable parameters depends on interface configuration.

Save and export function measurement and test reports
Display on monitor, output via network or USB stick.

Tested quality thanks to ZOLLER:  
Optimally checked and tested tools are your guarantee for high quality, on-schedule delivery, and a low number of complaints. Use it for yourself.

ZOLLER interfaces
For smooth operations, interfaces are a prerequisite for paperless and process-reliable production in the grinding and sharpening business. How helpful it is that ZOLLER interfaces to grinding machine controls allow precisely this kind of automation. ZOLLER interfaces open up whole new worlds of saving potential to you: With the grinding program, the data set for .genius 3. is generated and the fully automatic measuring cycle is produced. The measured data is then transferred back to the programming system or grinding machine, depending on the type of interface, and the grinding program is temporarily corrected. Programming time and machine downtimes are reduced to a minimum in this way. You save time and costs - and also avoid errors when inputting data and creating a new grinding program.

Programming system
Programming/definition of the tool  
Communication  
CNC grinding machines  

Production and final inspection

The NC program for grinding the tool is transferred to the CNC grinding machine and executed automatically. The tool data is recorded by the ZOLLER genius 3. The ZOLLER product optimizes the NC program, and the tool grinding starts. ZOLLER genius 3 measures and corrects any deviations, saving programming time and ensuring accurate measurements.

Unique sellin points
The ZOLLER seal o qualIty guarantees quatIty
and precision, reliabiliη and cost-effectwenes .
That 5 what ZOLLER stands for.
The ZOLLER seal of technology stands for the hrghest level innovation: ZOLLER is developing the technologies today which you wìll need tomorrow.