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Genius Technical Description CNC 5-axis measuring machine »genius 3 - pilot 3.0« Technical Description (734) 332-4851 Page 1 www.zoller-usa.com [email protected] »genius« Technical Description I 06/2009 I Subject to technical modifications I Created and Printed in the USA »genius 3 - pilot 3.0« Table of Contents Table of Contents ............................................................................... 2 Overview .........................................................................................3-4 Tool Holding Fixtures ......................................................................5-6 Operating Software............................................................................. 7 Standard 2D Cutter Shapes ......................................................................................... 8 »elephant« Technology 8701311 ............................................................................... 9 Measuring program generator »expert« - MP800 8772700 ....................................... 10 »metis« tool inspection / measurement 8702003 ..................................................... 11 »metis« Generator 8772818 ...................................................................................... 12 »metis« Interpreter 8772819 ..................................................................................... 12 »FORED« 8701310 ................................................................................................... 13 Radius Contour »contur« 8772028 ............................................................................ 14 Radius Contour »contur« Sector 8772137 ................................................................. 14 Diameter -- Odd Number of Flutes 8772057 ............................................................ 15 Concentricity-wobble compensation 8772058 .......................................................... 15 Contour measuring »lasso« 8772080 ....................................................................... 16 Contour correction »CoCon« 8774024 ...................................................................... 17 Concentricity check 360 with graphics 8772049 ....................................................... 17 Drawing generator »sinope« 8702102 ...................................................................... 18 auto-edge-check »a.e.c.« 8702002............................................................................ 18 Chip space scan »genius 3« 8772703 ....................................................................... 19 Cutting edge preparation »s.k.p.« 8772702 .............................................................. 19 Data import/Export »XML« 8709000 ........................................................................ 20 Editable test report »apus« 8702100 ......................................................................... 20 Reporting and documentation........................................................... 21 Grinding Interfaces ........................................................................... 22 Accessories ....................................................................................... 23 Quality Assurance........................................................................24-25 Parameter list ...............................................................................26-31 Technical Specifications .................................................................... 32 (734) 332-4851 Page 2 www.zoller-usa.com [email protected] »genius« Technical Description I 06/2009 I Subject to technical modifications I Created and Printed in the USA »genius 3 - pilot 3.0« Overview Universal Measuring Machine »genius 3 - pilot 3.0« 5-axis CNC control High-quality components including Heidenhain measuring sys- tems, Bosch pneumatics, THK-guide system and Sony camera Fully enclosed with vibration absorbing machine base. Stable and torsion-free design 2D Imaging - Automatic transmitted light measurement: 4.0 x 4.0mm measuring window, high resolution HR70 camera, 50x magnification Pneumatic slide clamping, infinite micro adjustment Bellows covers for guide and measuring systems »cockpit pilot 3.0« 9500156.1 • Multifunctional operating unit • 17" TFT color display with touch screen operation • Keyboard, mouse and shelves for label and laser printers • USB port »genius 3s - pilot 3.0« shown with »cockpit« • Adjustable height »genius 3« Standard 3D Vision System Automatic incident light measurement Field of view: 1.0 x 1.0mm Automatic adjustment of incident light in 8 segments CNC controlled camera positioning 0-90° for radial and axial measurements »genius 3« Micro 3D Vision System V326229 Automatic incident light measurement: Increased illumination Field of view: 0.4 x 0.4mm Automatic adjustment of incident light in 8 segments CNC controlled camera positioning 0-90° for radial and axial measurements Climate-controlled room required (734) 332-4851 Page 3 www.zoller-usa.com [email protected] »genius« Technical Description I 06/2009 I Subject to technical modifications I Created and Printed in the USA Overview Electronics “pilot 3.0” - Hardware (CNC-version) 9 700 934.1 Machine Control Technical Specifications Patented ventilation system Control and measuring electronics for all five axes Windows XP-Professional Operating system with Multilingual User Inter- face (MUI) IPC-computer with IntelR Core.2 Duo 1.80 GHz CE-specification (Europe) and FCC class A (USA) verifiable Hyperthreading Technology Rugged, 17” touch-screen monitor 1 GByte DDR2 6 interfaces COM 2 interfaces LPT 12 interfaces USB 2.0 2 RJ45 network socket SATA-hard disc with at least 80 GByte SATA-DVD-RW-burner for data backup Image-Software for hard disk backup Industry filter according to EN 779 Exclusive use of special industrial components IPC-computer with special industrial Temperature, fan and hard disk monitoring components Measurement in real time Efficiency factor (PFC) revised power supply for 115 - 240V (734) 332-4851 Page 4 www.zoller-usa.com [email protected] »genius« Technical Description I 06/2009 I Subject to technical modifications I Created and Printed in the USA »genius 3 - pilot 3.0« Tool Holding Fixtures High precision spindle “A.C.E.” size I / AF / ROD V 440 591.1 Concentricity 0.002 mm Quick change tool post system Universal, power-operated tool clamping for tools with steep taper, ANSI, CAT, MAS-BT, HSK, Capto, KM, or custom (adapters required) Tool post change-over accuracy of 0.001 mm, change-over time ~10 sec. 4 x 90° indexing Membrane keyboard operation for all power-operated functions of the high- precision spindle Autofocus and rotary encoder Tool post size I / expansion chuck D32 6 006 Y32.3 To hold tools with cylindrical shanks Automatic, hydraulic tool clamping Compatible with standard D32 mm straight collets Integrated calibration spheres Bushing set D32 - Metric Z 05D 44XX Available sizes: D 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 20, 25mm Special sizes available upon request Bushing set D32 - Inch Z 05D 45XX Available sizes: 1/8, 3/16, 1/4, 5/16, 3/8, 7/16, 1/2, 9/16, 5/8, 11/16, 3/4, 7/8, 1” Special sizes available upon request (734) 332-4851 Page 5 www.zoller-usa.com [email protected] »genius« Technical Description I 06/2009 I Subject to technical modifications I Created and Printed in the USA »genius 3« Tool holding fixtures Tool post size I / Steep Taper VHSKUZ Specify size: 30, 35, 40, 45, 50, Other Compatible with standard CAT, SK & BT specifications Integrated calibration edge Locking device for positioning holding fixture Case-hardened, gunmetal finish Change-over accuracy: 0.001mm / Change-over time: ~10 seconds Tool post size I / HSK VHHSKSE Specify size: 25, 32, 40, 50, 63, 80, 100, 125, Other Specify type: A/C/E or B/D/F Conforms to HSK DIN 69893 Integrated calibration edge Integrated tool clamping Case-hardened, gunmetal finish Change-over accuracy: 0.001mm / Change-over time: ~10 seconds Tool post size I / Capto VHSACA Specify size: C3, C4, C5, C6, C8 Suitable for tool adjustment Integrated tool clamping Integrated calibration edge Case-hardened, gunmetal finish Change-over accuracy: 0.001mm / Change-over time: ~10 seconds Other adapters available upon request (734) 332-4851 Page 6 www.zoller-usa.com [email protected] »genius« Technical Description I 06/2009 I Subject to technical modifications I Created and Printed in the USA »genius 3 - pilot 3.0« Operating Software »pilot 3.0« Standard functions 8701000 Operation via touchscreen, mouse Display individual cutting edge or keyboard values (and automatically reposition to specific cutter on Graphical tool, component, and CNC controlled machines) machine libraries »C.R.I.S.« function to calculate Secure, SQL database the maximum dimensions of a Intuitive, graphical operating interface Automatic recognition of cutting tool when rotated 360° edge shape and measuring range Standard measuring programs: Real-time measurements • Oversized radii Automatic incident light adjust- • Theoretical point via cutting ments based on illumination edge shape required • Angle via measuring points Adapter management for 9,999 • Radius via measuring points zero points and graphical display for calibration • Length/radius on chamfer etc. Management of more than 15,000 Performance capability test Display individual cutting edge tools (and associated measuring values procedures) »tethys« for measuring machines Automatic zero point monitoring Acceptance record Toggle between radius
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