Measuring crankshaft milling cutters at an unprecedented speed

Are you still measuring, or have you started milling already?

For the layman, at first glance, the crankshaft cutter is just a large and heavy disc cutter with many blades. However, professionals know that crankshaft milling cutters are extremely demanding and have special requirements for radial runout and axial runout of the cutter.
A set of crankshaft milling cutters usually costs up to five digits. Therefore, people always hope, or more precisely, always demand that such expensive tools work properly on the machine. What's more, they must achieve the expected service life. To achieve this goal, crankshaft cutters must be used on the machine in the right way, that is, the crankshaft cutter must be preset and measured first.

However, how much cost will these tool preparations require? The simplest and most risky situation is that people blindly believe in the capabilities of the tool manufacturer, the quality of the indexing blade, or the operation of the assembly worker. However, we all know that this will not work. In addition, who dares to take such a huge risk today? Perhaps the easiest way to test and measure a crankshaft cutter is to use a granite slab with a meter. Although this ancient method appears to have obvious advantages in terms of cost, it is completely incapable of satisfying the complex requirements of today's crankshaft milling cutters. Therefore, this method is also very expensive in terms of the accuracy of the measurement results. The whole measurement process is actually more of an estimate. It is not only influenced by the operators but it is also very time consuming and it cannot be proved in writing at all.

Measuring crankshaft milling cutters with presetting and measuring devices equipped with image processing technology, to a certain extent, can be automated measurements that are not affected by the operator. However, in this area, the difference in system performance is also very large. Once a traditional device encounters a multi-blade tool (ie, the spacing between the blades is small), there is a huge problem with the display of the blade. This is because, for a certain indexing blade, the blurred image produced by the blades located in front of and behind it covers the blade of the indexing blade. The process of aligning and focusing a large-weight, multi-blade tool is also very complicated, and most measurement systems cannot handle this demanding operation. In this case, is it impossible to measure the crankshaft milling cutter? Of course not!

Venturion
As the world's leading manufacturer of precision tool presetting and measuring equipment, ZOLLER introduced the Â»geminiÂ« (inset 2) and venturion 800 for crankshaft milling and turning tool presetting and measurement more than ten years ago. With the ZOLLER tool presetter, it is possible not only to fully position, focus and measure the crankshaft cutter, but also to fully clean the blade.

Gemini
ZOLLER has also achieved targeted improvements through the development and launch of new control electronics units and software Â»pilot 3.0Â«, focusing and measurement technology for multi-blade tools. This is definitely good news for the "Crankshaft" products. When measuring a crankshaft cutter with a ZOLLER device, the milling cutter is placed on the measuring device and fixed, then the data set is loaded into the current tool and the measurement starts.

Unique results:

E.g:

Measure 120 blades (rows of blades) in 70 seconds with Î¼ level accuracy

Measurement items:

- The vertical dimension of each blade
- Lateral dimensions of each blade
- Blade radius per blade
- Blade angle of each blade
- Radial runout
- axial runout

The measurement results will be displayed on the display for the operator to read. At the same time, the Â»pilot 3.0Â« software visualizes the measurement results in the form of tables or charts. After complete automatic measurement of the blade, the user can correct any blade that is out of tolerance. After the corresponding blade is selected, it is automatically positioned within the field of view of the camera. This allows the indexing blade to be cleaned, replaced, rotated, or reset.
ZOLLER's advanced technology in crankshaft milling presetting and measurement can also be applied to various precision tools. With the introduction of the new control and electronic unit Â»pilot 3.0Â«, ZOLLER technology experts from Leidelsheim can provide users with numerous unmatched innovations and unique and perfect solutions, creating great value for users!
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