Zoller brings sophisticated presetting within the budget of smaller subcontractors

Despite the price, Smile presetters share the rigid build quality, Heidenhain glass scales, THK linear guidance systems and the same Zoller Pilot software as other models in the Zoller range. The only discernable difference relates to the spindle. Whereas a Zoller Venturion features single point contact, the Smile series deploys an ISO 50 high precision spindle with integrated calibration edges that utilise adaptors to match customer requirements. Zoller calculates that based on three machines, Smile off-machine presetting could provide a 10-20% boost in productivity, while experience shows that confidence provided by the system's advanced image processing, allows the user to move straight to production without the need for preparatory cutting trials. In short, because tools are preset and measured before use, there is less waste and fewer machine crashes. Zoller Smile series machines can be supplied in either manual or automatic configuration. The reward for investment in CNC control of the axes comes from reliable measuring sequences and depends on the extent of presetting undertaken. However, even manual models offer advanced functionality such as true auto-focus capability. Available in up to seven selectable measuring ranges, the Smile series offers a Z-axis measuring range between 400 and 800 mm, X-axis measuring range between 130 and 300 mm, and diameters ranging from 260 to 600 mm. Standard Zoller Pilot 2.0 software features all the important functions for tool presetting, and allows users to add and save adapters and tools. This means that for recurring tools, users simply call them up, select the saved sequence and start measuring. Pilot 2.0 is designed for the tool requirements of small to medium batch sizes. Zoller Pilot 3.0 has a more modular construction whereby users decide what modules are required, allowing extra features to be retrofitted at any time. Pilot 3.0 also provides users with comprehensive tool management, which can be extended as necessary. Smile series configurations can also accommodate Schunk Tribos toolholding systems, and an integrated shrink-fit device with an induction coil and a water cooling system. In the case of the latter, the Smile/Shrink provides a cost-effective combination machine at a far lower cost than that of two separate machines, says Zoller. Similarly, the Smile/EDM allows toolmakers to measure electrodes before they get used in erosion machines. A detailed overview of electrode measuring results with tolerance check can be performed in less than 60 seconds.