Inspection systems get friendly

Good parts cannot be machined without good cutting tools — that is, tools that are made accurately and in satisfactory condition. And neither makers nor users of tools can know whether they are what they should be without good inspection and measurement equipment.

In recent years, manufacturers of this equipment have been working hard to make hardware and software better and easier to use. As a result, tool inspection and measurement systems today have unprecedented capabilities that are accessible to shop floor personnel.

One such system is the »genius« universal measuring machine from Zoller Inc. in Ann Arbor, Michigan. For this month, the company has planned a virtual introduction of its new version of the »genius« in North America. The latest »genius« includes a five-megapixel camera for measuring microtools and revealing more details about tool surfaces. In addition, the new design removes heat-generating electronics from the main machine to guarantee the highest accuracy, said Dietmar Moll, director of business development.

The new »genius« also features the latest version of Zoller’s image processing software, »pilot 4.0«. Among other things, »pilot 4.0« offers an intuitive user interface that is completely customizable to make it easier for each user to run the »genius«.

The »genius« universal measuring machine provides interfaces for different grinding machine manufacturers. Image courtesy of Zoller

“In the past, it was basically the same user interface for different users,” Moll said. “Now the software can be customized by the user to make (the interface) even more friendly. So if John Smith was the last operator and now Mike Jones comes in, he finds a completely different user interface that he is used to.”

A customized interface can make things easier for an operator. He pointed out that »pilot« software has functions on up to four different levels. So if Jones normally measures batches of tools and produces batch reports, he can move the button for this function from a lower level in the software up to the top level, meaning he doesn’t need to make several clicks to find the button every time he needs that function.

The task of reaching the right screen or function in »pilot« software is made faster and easier by customizable shortcut icons called widgets. Although not a unique software feature, widgets are new to the inspection industry, Moll said.

No Programming Needed

Less expensive than the high-end »genius« are PG1000 cutting tool inspection systems from PG Inspection Technologies LLC in Waukesha, Wisconsin. One of the main selling points of the »genius« is that it’s an automated measuring system, said Max Mueller, president of PG Inspection Technologies. But he said an automated system must be programmed by a trained person to measure a tool. The PG1000, however, requires no programming.

“It was designed to be simple to use,” he said. “Most people can start using the functionality after playing around with it for a few minutes.”

Made for shop floor environments rather than quality labs or clean rooms, the PG1000 typically is located near one or more tool grinding machines. Mueller said the PG1000 quickly checks all tool dimensions of interest to manufacturers with accuracy down to the micron level.

“You grab a tool from the grinder, put it into a V-block, inspect it and then get back to work,” he said, adding that the company’s goal is to allow users to get the measurements they need in less than 30 seconds.

PG1000 machines come with PG Inspection Technologies’ Reaction software, which digitally analyzes 5 million pixels and sorts over 16 million colors at a rate of 15 times per second to find patterns and shapes.

Reaction software is designed solely for cutting tools.

Users of the latest Microset tool presetters can take advantage of a number of new capabilities. Image courtesy of Haimer

“In CAD-based software, you might have 100 icons but primarily use only three of them,” Mueller said. “What makes ours easy to use is we have eliminated all the stuff you see in other software that is unnecessary for cutting tool inspections.”

With Reaction, users can take measurements using 1 µm (0.00004″) linear scales and hand wheels or by using a mouse to click points on the screen. To take a screen measurement of an angle, he said a user might click three or four points on the picture of a tool shown on the screen, and the desired measurement will appear in a matter of seconds.