CHIRON Group first presented the FZ 16 S five axis machining center at AMB in
Stuttgart, Germany in September 2018. An important factor for high productivity
is the fast, automated change of the up to 162 tools in a pick-up process. But
what about the path of the tools in and out of the machine? How can we ensure that the right tool is equipped? How can tools be changed with the
maximum level of security and efficiency?
are questions which ZOLLER and the CHIRON Group have investigated and for which
they have found convincing answers as part of a cooperation project true to the
motto »better together«. The approach: Integrating the CHIRON FZ 16 S five axis
machining center into the ZOLLER Smart Factory in Pleidelsheim, Germany to
jointly test innovative procedures for moving tools into the machine and
develop these for series production.
Traditional and critical: Manual data entry
is the traditional way of doing things: The
operator prints a label at the setting device, walks to the machine with the
tool and enters the data. However,
statistics indicate that every 20th keystroke is a typing error, with a 4
quickly becoming a 1, or a 5 turning into an 8. It sounds harmless, but during
production this can lead to machining problems and even a machine crash.
»In the Smart Factory, we combine the know-how of machine manufacturers like the CHIRON Group with our expertise. This enables us to expand on issues like connectivity, digitization and automation, develop these further in real circumstances and also experience them live.«
Head of Sales Automation at ZOLLER
Smart solution, part 1: Secure data transfer to replace paper
A core competence of ZOLLER is setting and measuring
prepared tool assemblies. The first step of the smart solution is connecting setting and measuring devices to machining centers.
The data can be transferred via RFID tags, which is very secure but also quite
costly. Just as secure but easy and affordable to implement for small companies
is the new data transfer via DataMatrix code.
process is incredibly simple: The code on the tool holder is read with a hand
scanner at the setting device, the tool is measured and the actual data is
stored in the central tool database. There is another code reader on the
machining center which is used to clearly identify the tool. The machine
control system then obtains the measuring data including all other required
tool information directly from the tool database and inputs these into the
machine – clearly, automatically and free from errors.
data transfer is just one of the benefits: The »flash« production analysis
software offered by the specialists from Pleidelsheim makes it possible to
check the tool service life in real time based on a traffic light concept. If
the tools reach the warning limit, a message is generated in the tool setting
space, the new tool can be prepared and equipped in good time.
Smart solution, part 2: Communication, protection
and dynamic action via ProtectLine
Another result of the
cooperation between ZOLLER and the CHIRON Group is the integration of the full
tool modeling data in ProtectLine. The digital machine
twin is supplemented with the complete tool data – including tool geometry and
tool holder geometry – fully automatically. This creates a highly efficient
process for generating digital twins, which forms the basis in the system for
preventative collision protection for the machine via ProtectLine. »The fully
automatic integration of tools therefore creates significant added value,« explains Pascal Schröder, Development
Coordination Digitalization at the CHIRON Group.
scan is generated for the digital tool twin on the Zoller pre-setting device
and automatically provided to the CHIRON Group machining centers in the right
»The fully automatic integration of tools in ProtectLine creates significant added value. On the one hand, it significantly increases user convenience. On the other hand, a main source of errors – wrong or faulty tool data in the digital model – is excluded.«
Development Coordination Digitalization at the CHIRON Group
Smart solution, part 3: Automated tool handling with
working with difficult-to-machine materials, such as Inconel or titanium, the
tools need to be changed in a quick rhythm. Frequently changing order sequences
also require correspondingly frequent set-up processes. This takes up work and
machining time – just a few minutes each, but these add up over time and across all machinery. With »cora«, the cooperative robot assistant from
ZOLLER, in combination with the CHIRON Group machining centers, potential for
rationalization can be exploited and clear gains in efficiency can be
time thanks to automated tool handling on the setting device
- Optimized production thanks to automated tool logistics
- Continuous data transfer for maximum security
and stock transparency
- Avoid tool-related spindle downtime
- Highly productive even with small tool magazines
Excellent solution, pioneering, super digital …
great tool, many application options: This is just a small selection from the
all-positive feedback received for the webinar led by Bernd Schwennig on behalf
of the CHIRON Group Sales department.
you experience the solution for yourself? Make a personal appointment for an
online presentation or stop by for a visit at the Smart Factory in Pleidelsheim. To do so, please contact your responsible sales
employee from the CHIRON Group or contact ZOLLER.
As an alternative, you
can also have a first look at the OPEN HOUSE ONLINE during the innovation talk of ZOLLER on the topic »Save
time and ensure quality– Integrated tool management and innovative data
transfer in practice«.
»At ZOLLER, we generally look at tools with a systematic approach that includes identification, pre-setting, measurements, inspection, automation, storage systems, software, data transfer and digital twin solutions. All this is perfectly implemented in the cooperation project with the CHIRON Group.«
Head of Sales Automation at ZOLLER
Expect great measures
the motto of E. Zoller GmbH & Co. KG, which offers innovative setting and
measuring devices, software for measurements, inspection and management of
machining tools and automation solutions.
Founded in 1945 by Alfred
Zoller, the company remains an independent family business to this day and
focuses on solutions for greater profitability in machining.
There are currently around
42,000 setting devices and software solutions deployed worldwide, supported by
service and sales branches in the most important markets and partners in 59
countries. Development and assembly are completely »Made in Germany« and based
at the headquarters in Pleidelsheim near Stuttgart. Here, ZOLLER opened a new
building right in time for its 75th anniversary in 2020, and now operates on an
area of 37,000 m2. The building is equipped with geothermal energy,
solar power, water power and a green roof and therefore designed for
sustainability. It offers ideal conditions for around 400 employees and for
training courses held at the ZOLLER Academy. At the heart lies the innovative
technology and customer center, the Smart Factory.