When visiting the halls of Schubert Fertigungstechnik GmbH, the large number of robots and automation solutions on the machines immediately catches the eye. The company is not a series manufacturer; typical batch sizes range from three to ten units and are sometimes fewer than 100 pieces. ‘We have been working for a long time to get 18 to 22 hours of autonomous machine time. This means we can run the machines around the clock without having to ask our employees to work night shifts,’ explains Jens Grieser, the managing director responsible for the technical division. ‘Ideally, we would make early and late shifts as unnecessary as possible. But we need to ensure the same high level of quality at all times.’

With this in mind, Erhard Strobel, sales engineer at Blum-Novotest, found a receptive audience in Bartholomä with FormControl X. Schubert was very interested in the BLUM software, a client server-based solution for the automated measurement and evaluation of machining processes. Ultimately four variants of a part are manufactured on one machine, with around 60 parts per variant and a cycle time of between 10 and 40 minutes per part – but only if the machines are running at full capacity. This means it is very important to keep an eye on quality, also during unmanned shifts. Thanks to FormControl X, specialists can be sure that all measured values are upheld. The advantage of measurement being performed during the process is that it is clear when a measured value begins to drift. Action can be taken long before the tolerance range is exceeded. It goes without saying that this is especially true for broken tool edges.

FormControl X is a client server-based software solution for the automated measurement and evaluation of machining processes. BLUM developed the software from scratch based on the tried-and-test FormControl software with a particular focus on the automation of measurement processes. A major advantage of the client server architecture is that the data in the FormControl X database can be accessed from multiple workstations or machines. This allows users to easily create complex measuring programs at their office workstations or review the measured values taken during the previous night. The operator can monitor the tolerance fluctuations of all measured values on a laptop near the machine. The display is generally very simple and can be viewed on a PC, laptop or tablet in a standard web browser.

The flexible options that can be used to influence the machine with FormControl X are very interesting: In one case, for instance, the manufacturing process is only stopped when the same deviation is measured on two parts in a row. This rules out the possibility of a chip adhering to the measuring point during the first measurement. ‘For example, it is possible to measure every fifth part. In the event of an outlier, instead of waiting to measure the next five parts, the machine immediately starts measuring again during the next machining process to rule out a chip at the measuring point,’ explains Erhard Strobel. ‘Only then does the program decide, based on the specifications, whether the next part will be machined, whether the machine will interrupt machining or whether it will switch to the production of another part using different tools.’

The Fanuc Robodrill machining centres are mainly used to manufacture components for tool changers for Schubert packaging machines. For instance, these tools can hold boxes into which a robot places chocolates. If a different package size or shape is required, the tool can be changed and the packaging line automatically switched over. Several pneumatically operated pistons with an H7 fit work in parallel in these tool changers. The bore holes in which the pistons run must be made very precisely and have to parallel to each other with the correct diameter. Measuring every part produced is necessary to ensure reliable operation later on. This is because a stoppage in a packaging machine can be extremely expensive, for instance with the chocolate production processes mentioned above: If the packaging line stops, the production of the sweets must also be shut down because the liquid chocolate and other ingredients will solidify and go bad. In addition, the pre-assembly processes at Schubert are synchronised, which means that deliveries must be made at very short notice. So a problem on the machine also affects processes at the parent company, which accounts for around 70 percent of orders. That is why the accuracy of the measurements in the machine was checked continuously during the beta test prior to the purchase of FormControl X – the deviations were in the range of a few thousandths of a millimetre.

The designers of the packaging machines specify dimensions that are crucial for proper functionality and have to be checked during production. The NC programs are then created in Bartholomä, and the measurement subroutines are incorporated at the appropriate points. ‘We work together here: We, the employees working on the machine, are responsible for quality, which is why we decide together with the NC programmers which dimensions are recorded with the BLUM measurement cycles and stored in FormControl X,’ explains Markus Maier, who supervises the RobodrillPlus Big K systems. ‘This also gives us the knowledge we need to understand the measurements and make improvements.’

During the introduction phase of FormControl X, we stayed in very close contact with the BLUM specialists: In addition to the dedicated support of the programmers during beta testing, Schubert was also impressed by the excellent training. Currently, a new part only needs to be programmed every two or three weeks in Bartholomä, but the employees still have a good experience with the software because it is very intuitive. FormControl X also helps them focus more on their actual work. For instance, in the past, time had to be spent in the morning checking the dimensional accuracy of the components manufactured overnight. Now a glance at the screen is all it takes: The graphical display of the FormControl X web client shows whether the tolerances have been upheld. This allows employees to react immediately or continue production straight away.

All dimensions with tolerances of less than a tenth of a millimetre are now measured automatically, as are shape and position tolerances. These are important because many parts are machined in two clamping operations, which means the position of the second machining process depends on the surfaces produced in the first clamping operation. This is another reason why FormControl X brings major improvements to everyday work processes: ‘The software takes care of the measuring tasks for me because they are automated. This means I can concentrate more on my actual work,’ reports Markus Maier. ‘Working on the machine is also more relaxed because the process is transparent and we always know where we are in terms of quality – that’s very reassuring. What’s more, I no longer have to work in shifts since I can finish my work during normal hours – that’s a huge advantage for me!’

The number of employees at Schubert Fertigungstechnik who are being ‘freed’ from shift work could rise soon: Thanks to the positive experiences at the Fanuc centres, there are plans to use FormControl X on many other machines with the aim of increasing productivity. After all, BLUM software is an important part of the automation of machining processes and is playing a decisive role in achieving a very high level of automation in Bartholomä.

FormControl X has proven its worth and entrenched itself at Schubert Fertigungstechnik: ‘For each production batch, the first and last measurement logs are printed out and filed, and apart from that, all measurements are available in the FormControl database. ‘This is useful for assessing the tool service life,‘ summarises Jens Grieser. ’And it’s also reassuring for me to be able to see where we are in terms of quality at any time. Of course, the machines and the range of parts have to be just right so we can get the most out of the software – and that’s the case for us.’

Winfried Weiland, Marketing Manager at Blum-Novotest GmbH, explains: “At this year’s EMO, everything at our booth will have to do with automation. This topic is often primarily associated with robotic solutions that insert raw parts into machine tools and remove the workpiece after machining. We at Blum-Novotest, however, take a more holistic approach; after all, the goal is to produce as many good parts as possible in the shortest possible time. That is why we will be demonstrating how intelligent production measurement technology combined with modern robot technology enables machining in a closed control loop live at our booth at the EMO”.

The highlight of this year’s presentation will be the FormControl X measuring and automation software, which will be shown interacting with a cobot at the BLUM booth. This is a clever solution for machining centres for machine-integrated quality control of workpieces in series production. The software enables automated monitoring of machining processes in line with the principle of statistical process control (SPC). The process is managed based on the recorded measured values and previously defined warning and control limits. To make sure that this also works perfectly in unmanned operation and in cooperation with robot solutions, FormControl X offers a clever approach with its alignment function. This feature detects the current workpiece position and alignment right after clamping and automatically adjusts the reference points of the machining program to the actual position of the workpiece. This also makes reliable automated machining of parts with small allowances possible. FormControl X also prepares the recorded data in graphic form. It can then be visualised and evaluated by the user using the web browsers of any end devices. FormControl X accelerates manufacturing processes and makes them more transparent, and the quality and manufacturing costs of the finished workpieces are optimised.

The second software solution that BLUM will present at the EMO is the latest version of the LC-VISION measuring and visualisation software. The application, which was developed specially for the laser measurement systems from BLUM, has been adapted even more closely to the needs of users and its usability has also been improved. For instance, the free standard scope has been expanded to include the “ToolControl” and “Stability” functions. ToolControl is an intuitive application which even users without NC programming knowledge can use to quickly and easily generate measuring sequences for the most common measuring tasks. The user can visualise measuring sequences for tool length and radius, including the tool-specific wear limits, directly on the control screen and take appropriate action. The stability function is used to determine the thermally stable spindle state for high-precision machining, to name just one example. If a machine is in the warm-up phase, the spindle elongation is measured at speed and the length value in the tool memory is updated after the thermally stable state is reached. For ambitious measuring tasks, there are also optional technology cycles available such as “ToolControl Advanced” or “SpindleControl”.

“The third highlight of the trade fair, the new TWIN technology, makes it possible to simultaneously operate two BLUM tool or workpiece probes with only one radio receiver. This technology is mainly used in dual-spindle machines, whereby a cycle time reduction of up to 50% can be achieved due to the omission of a second probing movement. The BRC technology used ensures secure transmission, and no line of sight to the receiver is required,” Weiland concludes.

Blum-Novotest, a leading provider of innovative and high-quality measuring and testing technology, is presenting FormControl X for process-reliable automation. “The basis of intelligent automation solutions is process data, which is evaluated live or very quickly and serves as a control variable for optimising the process. The automation reacts to the measurement result and readjusts it so that the process always stays within the predefined limits,” explains Wolfgang Reiser, Head of Technology at Blum-Novotest. “With the new FormControl X software, Blum-Novotest presents such a solution for machining centres, with which even more knowledge can be gained through continuous measurement of workpieces in the machining process.”

While the previous FormControl version (without ‘X’) is based on a scenario in which a machine operator works on a machine with a laptop and processes the measurements at the same time, the trend today is towards the automation of such processes, so that this 1:1 relationship is increasingly rare. In addition, completely new areas of application open up with genuine automation of workpiece measurement. The goal with FormControl X was to enable real measurement automation on the basis of a modern client-server architecture – away from pure logging and towards process integration and automation with the help of the measurement data collected by the software.

In this way, workpieces can be measured directly after each processing, whereby the results already serve as a correction value and basis for optimisation for the next component. For this purpose, the user defines intervention limits when creating the project, according to which the software carries out a corresponding correction. Among other things, this allows tool wear to be compensated; FormControl X recognises the trend that, for example, bores become smaller over time when the tool in question wears out, and can take countermeasures accordingly. This expands the focus of the software: while FormControl focused on higher-priced parts in single-item production, FormControl X also aims at small, medium, and large series production.

Evaluated data and results can be accessed through a web interface via various end devices. The server communicates with the machines on which measurements are taken – this allows an operator to carry out measurement projects on many different machines and have them automatically evaluated. Complex measurement routines, such as the alignment function, can be used to adapt the reference points of the machining programme to the position and shape of the workpiece so that machining can run optimally. Another innovation in FormControl X is the management of measuring equipment and machines. Since this is now located centrally on the server, the data is available across all machines. The definition of the measurement is also very easy and intuitive thanks to a context assistant.

In addition, FormControl X now opens up the possibility of creating and evaluating data series over time. What ended up being a log of a single processing in FormControl can now be used to evaluate an entire processing series. This offers the operator completely new insights. In addition, the protocols resulting from the measurements can be extensively and very easily adapted, tolerance limits can be displayed as a number or image; red/green colouring can be defined; and much more.

FormControl X is a further step on the way to integrating measurement results from machine tools into company processes and making them usable in terms of Industry 4.0. “With a networked client-server architecture, the reusability of measurements and interaction with the machine, the new version of the software solution offers many new options for keeping processes transparent and continuously optimising them,” summarises Wolfgang Reiser. “Perhaps the most important aspect for many users, however, is that the machining process can be automated quickly and reliably with FormControl X, which is reflected 1:1 in productivity and in the quality of the finished workpiece.”

“Our core competencies in manufacturing are in milling, turning and grinding, as well as in logistics and assembly. We machine metal as well as plastic and, in doing so, achieve a high level of quality and reliably tight manufacturing tolerances,” reports Mario Maier, head of process planning at Scherzinger Pumps. “BLUM touch probes and laser light barriers, which we use in many machining centres, help us to accomplish that. The probes have an astonishingly long service life.” For example, a BLUM probe that ran in two-shift operation in one of the Heller machining centres was in use from 1998 to 2021. It was only replaced because BLUM had long since discontinued the series and the Furtwangen-based company wanted to remain flexible in case of an emergency. Even the oldest of the new TC50 probes have been in continuous operation for over 18 years – with virtually no failures.

In 2003, BLUM revolutionised probe technology for machine tools with the TC50 infrared probe and its integrated, innovative measuring mechanism. At Scherzinger, the TC50 probes are primarily used to measure bores and for workpiece zero-point detection. The housings for brine pumps, for example, are machined from two sides by rotating the clamped components in the machine. The drive is located on one side, while the two gear wheels of the actual pump are located on the other side. The through-hole of the drive axis is machined from the drive side in the first setup. After one side is finished – there are five housings per setup – the housings are swivelled by 180 degrees and the pump side can be machined.

To ensure that the two machining operations are precisely aligned with each other, the position of the through-hole is measured for all five housings after swivelling using the probe, which has been mounted in the machine spindle. The measured positions are then taken into account during the second machining operation so that, for example, the threaded holes for the cover can be precisely aligned, drilled and cut. In this way, the production specialists ensure that the housing, internal components and cover later fit together exactly and the pump achieves a long service life and runs as quietly as possible.

In other areas, the probes are used to ensure and document ongoing production quality. This is especially important when it comes to parts for the automotive industry. In addition, when measurements are performed in the machine, the measuring room is relieved. Apart from random quality checks, the parts can go directly from production to assembly. Process-integrated measurement at and the Furtwangen-based company also avoids unnecessary scrap.

The BLUM probes even deliver highly precise measurement results when operating in the presence of coolant, considering that the TC50 works absolutely reliably under the most adverse conditions. Scherzinger is also impressed by the measuring cycles supplied by BLUM, which can be readily integrated into the NC programs created: All that is required is to call up the macro for the probe and enter a few parameters. Then the NC program is created automatically. The BLUM NC modules reliably execute the measuring processes at up to 3000 mm/min. Thus, integration of the measurements generates almost no programming effort.

With the help of the BLUM touch probes, Scherzinger ensures high production quality and lower scrap production by detecting problems in the machine early on. “In addition, the precision we achieve thanks to the BLUM probes allows us to manufacture housings and covers independently of each other, which of course greatly simplifies logistics. Apart from random samples, the components can be sent directly to assembly,” Mario Maier concludes. “Because we obtain measurement data directly during machining, we can immediately incorporate it as feedback into the machining process, thereby saving time and effort. Thus, BLUM touch probes play a very central role in our processes and help to ensure the high quality of our products.”

BLUM TC64-DIGILOG touch probe as a measurement gauge for drive shafts at Schuler Pressen.

What can be done when the production machines for an essential component have been discontinued and the process simply takes too long? At the Schuler Pressen, the decision was taken to find a new solution: producing gears using profile cutters. This is where Blum-Novotest’s TC64-DIGILOG scanning touch probe came into play: It enables examination of the tooth interlocking and ensures that the process as a whole is consistent and verifiable.

At the Schuler AG, gears for large press driveshafts have only been produced with the aid of special gear cutting machines in the past. These machines exhibit good repeatability characteristics, but the time taken to manufacture a driveshaft is very long. Shaping the gears alone takes between 16 and 19 hours. Moving the parts weighing nearly 700 kilogrammes between the various processing machines was also complicated and contributed to the long production times.

As the tried-and-tested machines were no longer available on the market, Schuler Pressen had to find other ways of tackling the production bottlenecks that were looming. The solution came in the form of milling the driveshafts on a modern turning/milling machining centre using a specially manufactured profile cutter, together with carrying out measurements in the machine itself. “Previously, we had no way of directly measuring the form deviations of the tooth flanks,” explains Thomas Vujica from the production planning and NC programming department. “That wasn’t required with the gear cutting machines, in fact, because they are constructed in such a way that there is always an involute. The question of measurement only became an issue when the gear production migrated to the turning/milling centre.” A workaround was found that involved transporting the heavy driveshafts to another company where each individual shaft was measured on a special measuring machine. However, depending on order backlogs and waiting times, that took two to three weeks. And that cancelled out the advantage in time that the milling technique brought with it.

The solution found by Schuler Pressen was the Blum-Novotest TC64-DIGILOG touch probe. The advantage of the DIGILOG touch probe is that it can carry out both digital measurements as well as analogue scans. This means that it is possible to guide the probe over a surface and register measurement data continuously.

The complete measurement of a cogwheel consists of 144 individual measurements on a slanted track along the whole tooth flank – 36 teeth with two flanks each, and in both halves of the double helical gear. The complete measurement procedure only takes 13 minutes at a scan speed of 1.8 m/min. During this time, the DIGILOG touch probe records 570,000 individual measurement values. However, only the linear axes are used during the scan so as to exclude any errors of the rotation axes used for production.

Software developed by Thomas Vujica allows for rapid inspection of the driveshaft. Using the network, the software adopts the measurement data recorded by the DIGILOG touch probe and generates a report including diagrams by way of illustration. The report provides a simple means of establishing whether there are deviations from the ideal form, and if so how big they are. This makes it possible to assess the manufacturing quality. The machine operator can keep track of the measurements on the PC as they are generated and differentiate between outliers caused by impurities and genuine quality issues. Also, the automated measurement technique avoids errors that cannot be prevented in the course of manual measurement.

Thanks to Blum-Novotest’s DIGILOG probe, production today is backed up by reliable quality assurance, the delivery times are significantly shorter and the production department can be sure of fulfilling the required gearing quality. In fact, it is possible to manufacture and dispatch a driveshaft within a single day if necessary. Previously, such times were unthinkable; the measurement process alone took two to three weeks. This is extremely valuable in a sector in which customers depend on absolute reliability. So Thomas Vujica is able to draw a positive conclusion: “The cooperation with BLUM and the internal specialist departments was excellent. We developed the measuring sequence together, optimizing it steadily and integrating it into the process. Thanks to the DIGILOG touch probe we now have a very fast and reliable manufacturing process that means we no longer have to rely on the old special machines for this component. It also enables us to achieve high economic viability and shorter response times. What more could one ask for?”

The Schuler AG, headquartered in Göppingen, is a technological and global market leader in the metal forming industry. The company provides presses, automation solutions, tools, process know-how and services for the entire metal forming industry. Founded by Louis Schuler in 1839, the company began to manufacture sheet metal processing machines in 1852. Schuler customers include automotive manufacturers and their suppliers as well as companies from the forging, household equipment, packaging, energy and electrical sectors. Schuler leads the way in the production of minting presses and also provides system solutions for the aerospace, railway and large pipe manufacturing industries.

The most advanced member of the tool setting probe series
Blum-Novotest, the leading supplier of innovative and high-quality measuring and testing technology, introduces the new ZX-Speed tool setting probe at the Intec (hall 5, booth D16) and Moulding Expo (hall 5, booth D32) trade fairs. As a result, the company’s 3D tool setting probe series for machine tools now includes three new compact systems for tool measurement of length and radius as well as for tool breakage detection.
Wolfgang Reiser, Technical Director at BLUM explains: “The new ZX-Speed is aimed at customers who wish to profit from automatic, quick and economical tool measurement and monitoring. The tool length measurement and breakage detection processes are carried out while the tool is stationary. Only large tools such as facing mills, which must be measured acentrically, as well as radii are measured under rotation with the help of cutting edges that rotate in reverse. The measurements are performed, for example, after a new tool has been loaded or for control measurements between machining steps. This is a reliable method of avoiding costly rejects due to undetected tool breakage, wear and poorly adjusted tools.“
The wired BLUM ZX-Speed combines impressive economic efficiency with a compact and rugged design. Optionally, a nozzle is available for tool cleaning.
Extremely compact ZX-Speed with cable connection of Blum-Novotest GmbH
A particularly noteworthy feature of the new ZX-Speed is the modern, multi-directional measuring mechanism of the latest generation: Unlike standard probes, its rotationally symmetric design offers constant and extremely precise measuring characteristics in all measuring directions without a preferred direction. This allows the measurement of even very small tools starting from a diameter of 1 mm with an ultra-precise repeatability of 0.4 µm 2σ. The trigger signal generation system used by the BLUM tool measuring probe is also remarkable because it is based on optoelectronics and the shading of a miniature light barrier rather than a simple micro-switch. This wear-free system guarantees consistently high measurement accuracy even after millions of switching cycles.
The new tool setting probe is available in three versions: wired, infrared and radio transmitting. The highly economic wired version is recommended if it is possible to mount the probe at a fixed location in the machine room without causing disturbance. It is supplied as standard with a highly flexible connection cable and 1.5 m steel spiral protective hose.
The new ZX-Speed IR is particularly easy and cost-effective to retrofit, for instance, if a BLUM workpiece touch probe with infrared transmission is already installed.
3D tool setting probe ZX-Speed IR with infrared transmission of Blum-Novotest GmbH
If a BLUM workpiece touch probe is already fitted to the machine or if wired installation is not possible, wireless variants are available. The ZX-Speed IR is the perfect solution for machines with pallet changers: Via infrared transmission, the trigger signal is forwarded to the IR-receiver IC56. When operated in “DUO-Mode”, it allows two measuring systems to approached sequentially using only one IR-receiver.
The ZX-Speed RC with BRC radio technology is used if a direct line of sight between the probe and receiver cannot be guaranteed. One advantage of the new transmission technology is that each single bit of the radio signal runs across the entire width of the frequency band, thus making transmission particularly resistant to interference. The proven BRC radio technology also allows sequential activation of up to six BLUM radio measuring systems with one receiver as well as the simultaneous use of two radio measuring systems on a single machine operating in TWIN mode.
“Thanks to its robust construction according to protection class IP68, the ZX-Speed is perfect for the tough demands of machine tool applications,” says Reiser. It is also worth mentioning that the newest addition to the BLUM tool setting probe series is comparatively compact, making it ideal for use in machines offering limited space. To meet the needs of each customer, BLUM offers a comprehensive range of accessories for the probe systems. This includes replaceable measuring surfaces, different mounting plinths as well as blow nozzles for cleaning the tool and measuring surface.

Q) Blum-Novotest has a wide range of high-precision measuring and testing technology. Tell us more about your product offerings like the Micro Component NT, Digilog Touch Probes, Roughness Gauges, Tool Setting Probes, among others.
A) Blum-Novotest is a global leader in technology and innovation in measuring and testing technology and a reliable partner to the global machine tool, automotive and aerospace industries. Talking about our products: –

• Blum Laser Micro Compact NT, High Speed Probe System TC 50, Z-Nano, ZX Speed & FormControl Software are our well established products in India in Part Manufacturing and Die & Mold Segments with large customer base Pan-India.
• Blum New Technology products Roughness Gauge TC64-RG for Roughness Measurement, TC 64-DIGILOG Touch Probe with revolutionary shark360 measuring mechanism  for Workpiece Inspection & Contour Scan and Bore Gauge BG60 for Diameter Measurement are being offered to our industry.

Q) What will Blum-Novotest showcase at the upcoming show IMTEX 2017? How do you plan to leverage on the event?
A) We will be showcasing: –

• Blum Laser Micro Compact NT, TC 50, Z-Nano, ZX Speed & Form Control Software demonstrated on the STM 850 Vertical Machining Centre
• Blum New Technology products TC64-RG, TC 64-DIGILOG and Bore Gauge BG60 as displayed as Technology Cell on a Makino Slim3n Machine

We aim to create a strong presence in Indian industry with the help of our technology products focus on the service.

Q) Tell us something about your R&D activities.
A) Blum futuristic R&D department has innovated TC64-RG, TC 64-DIGILOG and Bore Gauge BG60 in the recent past and the same has been implemented in the manufacturing industry and industry-integrated R&D department has constant endeavor to develop high quality & reliable products to address the demands of the manufacturing sector.

Q) How is the response for such high tech solutions in the Asian market especially in India?
A) The metrology requirements in manufacturing are on a constant rise to address the tight tolerances. The automation in combination of achieving Zero defect necessarily needs to incorporate the high technology and reliable metrology.

Q) What makes Blum-Novotest unique, given the fact that there are several measuring and testing solution providers globally.
A) Blum-Novotest is a global company with synchronized operations across the world. High quality & reliable products, well-trained service team, continuous improvements, innovations, new product developments are some of the main factors that are driving manufacturing excellence globally.

Advance technology, high quality and reliability makes Blum-Novotest unique and keeps it ahead of other solution providers. The growing customer base is an evidence of the products performance and services to the customers.

Q) How is the business outlook in India?
A) Indian industry has large indigenous and overseas market, which makes Indian industry a global industry. The Make in India initiative of the government is expected to further boost the manufacturing sector.

As stated earlier, the production metrology implementation is growing exponentially and looking at the positive growth of the industry it can be said that business opportunities are on a positive trend.

Touch probes automate the production of hand-held measuring equipment

The production of hand-held measuring equipment means large volumes and high demands on the accuracy of the workpieces. In this context, the production measurement technology used is faced with the challenging task of working fast and with a high degree of precision. The solution chosen by HELIOS-PREISSER is BLUM touch probes which are used in the machining centres for continuous measurements integrated into the process.

In 2008, HELIOS-PREISSER, a manufacturer of high-quality hand-held measuring equipment for professional use, became aware that the capacity of its three machining centres previously used for production was no longer sufficient – they were operating around the clock in three shifts. Due to its positive experience with the existing machines, the company based in Gammertingen decided once more to rely on the products of Heller, a machine tool manufacturer in Nuertingen.

A 14-metre long pallet magazine connects the machining centres, which are supplied with clamped workpieces by a robot. This ensured the automated supply, but an opportunity to satisfy the high quality requirements was still lacking. The HELIOS-PREISSER employees already had many years of good experience with BLUM touch probes in the old machining centres which are still operating with great reliability today. The new four-axis machine was also equipped with a BLUM measuring probe. It was only the five-axis centre which used a probe from another manufacturer. However, this did not meet with great approval at HELIOS- PREISSER. “Where possible, I endeavour to make regional purchases. In BLUM, we have found a partner that can offer us high-quality products and corresponding service within a close distance,” emphasises CEO Siegfried Lorch. “Particularly as, wherever possible, we would like to have just one point of contact. In addition, we have been extremely satisfied with the BLUM touch probes for years.” In the end, BLUM’s sales representative Erhard Strobel proposed a solution –  an engineer would install the probe and receiver in the new machining centre. 

HELIOS-PREISSER uses TC50 and TC60 touch probes. The first transmit data via infrared, the latter via radio technology. The touch probes are fitted on tool holders and can be substituted if necessary, in order to execute measuring tasks before, during and after machining. The infrared system can always be used when a line of sight can be guaranteed between the touch probe and receiver. A measuring system with radio transmission is installed on the five-axis machining centre. This reliably transmits the signals from the touch probe to the receiver – even when the line of sight is disrupted by the large swivel head.

The BLUM touch probes are used for a whole range of tasks in Gammertingen. For example, they check whether the workpieces are correctly clamped prior to the commencement of machining. “We also use the probe to measure the result of the machining. After casting, the dimensions of the cast blanks are often very different,” explains Tobias Weber, foreman of the milling shop. “This is why, prior to machining, the position of the blank is captured using the probe and the compensation values for the NC program are transmitted to the machine controller. Thanks to the BLUM touch probes, we have been able to reduce the rejection rate for these components from ten percent to one to two percent.”

Another example are the tail stocks of the bench centres. Here, a hole must be positioned accurately to one hundredth for a channel on the same part. Previously, there had always been fluctuations, often due only to the temperature response of the machine. If the dimension was correct in the morning with a cold machine and hall, by noon with a hot machine and warm weather the dimension would be outside the tolerance. At HELIOS-PREISSER, the channel is now machined and measured before finally being drilled using the measurement data. This enables the desired precision to be reliably achieved despite the effects of temperature.

The large volumes manufactured in Gammertingen require short cycle times, so measurement must not take too long. BLUM touch probes are designed for maximum measuring speed and are not sensitive to the widely used coolant, which is simply pushed away by the high measuring pressure. Measurements can also be taken directly after machining. “The touch probe is moved at a top speed of 60 metres per minute until shortly before measuring point; touching then takes place at up to 3 m/min – so not much time is lost. After machining, we check almost all fits using the BLUM touch probe,” reports Tobias Weber. “Our manufacturing process has now become so precise, that we no longer have to grind many parts. Previously, in contrast, many parts were milled with an allowance and then ground to the finished size on grinding machines in order to be able to achieve the required precision for our measuring equipment – this saves a great deal of time.”

If a machine determines that a tolerance has not been complied with, the pallet is automatically removed and placed in the pallet store with an inspection record. The next morning it can be inspected to determine where the fault is and, in the meantime, the machine can continue to process further pallets. With respect to unmanned production, the touch probes from Blum have completely proven themselves at HELIOS-PREISSER: “Overnight, and often for parts of the weekend, the machines run unmanned. We only operate one shift, but we produce more than we previously did in three shifts,” concludes Siegfried Lorch. “The systems run very reliably during unmanned operation, which relieves the pressure on us and makes it possible to manufacture the required volumes without needing a night shift. The BLUM probes are essential to unmanned operation, especially as we are also very satisfied with the service offered by BLUM.”

 BLUM LaserControl at MTU Aero Engines GmbH in Munich, Germany

“When your car develops engine problems, you simply pull over and wait for a mechanic. But when jet engines fail in an aircraft, the lives of several hundred people are potentially at risk. That is why we at MTU attach the highest priority to quality! All our components must satisfy the close tolerances we specify – often to within just a few hundredths of a millimetre,“ explains Walter Strohmeir, user support representative for NC engineering with MTU Aero Engines in Munich. In addition to supporting machine operators with virtually every aspect of NC machining, his responsibilities include the programming of CNC routines and procuring machines and the peripherals to go with them.

To fully meet the exacting production engineering demands of aero engine manufacture, the machining centres of MTU rely on non-contact laser measuring systems supplied by Blum-Novotest, for whose operability Walter Strohmeir is also responsible. In simplest terms, LaserControl NT is an optical measuring system for tool setting and tool monitoring. As well as providing basic tool breakage detection, LaserControl NT systems capture data such as tool length, radius, wear, cutting edge bursts and spindle and tool carrier accuracy at nominal spindle speed. The systems also compensate for spindle displacement at high speed, and can detect and correct tool clamping errors.

“Way back in the mid-nineties, LaserControl NT won out against strong competitors in the selection process at MTU Aero Engines as being the system with the most know-how. MTU subsequently purchased the first laser system, and its existing machines were gradually upgraded, while new machines were acquired with LaserControl NT already installed,“ says Daniel Czujek from the Technical Sales Department of Blum-Novotest and MTU support engineer. Today, MTU Aero Engines in Munich has over 100 BLUM laser systems in use across the company. Around 300 to 350 MTU employees work with LaserControl NT in three-shift operation. A number of machines are also equipped with contact touch probes supplied by BLUM. In terms of quality assurance, the BLUM systems make a major contribution to the manufacture of all MTU engines. They include the new GP7000 family of aero engines which the Munich firm produces together with industry partners, with MTU taking responsibility for the low-pressure turbine, the intermediate turbine casing and the high-pressure turbine components. The GP7000 family of aero engines has been used in the long-haul sector, including scheduled services of the Airbus A380 since August 2008. In its class, this jet engine is a benchmark in terms of reliability, fuel consumption and noise emissions.

A major role in aero engine manufacture is played by so-called ‘blisk machining’. Blisks – the term is a blend of the words ‘blade‘ and ‘disk’ – marry maximum performance to minimum weight. The process involves integral rotor construction in which disk and blade form a one-piece component, rendering blade roots and disk grooves superfluous. “The chief advantages of blisks are their substantial weight saving, increased service life, decrease in the number of components through higher stage loading and the reduction in the amount of maintenance that is required. Most parts are made from titanium. For tool setting and monitoring, we deploy LaserControl NT throughout the entire blisk production line,“ explains Heinz Baumgartner, blisk production team leader for the medium-pressure compressor for the TP400 engine programme. He supervises virtually all of the machining operations that are involved in ‘blisking‘. Almost half of his team of 19 work with Blum systems.

Blisk facts and figures are impressive: It takes between 15 and 60 hours to make one workpiece, depending on the size of the component and the type of machining that is required. The parts that are produced are worth between 30,000 and 60,000 Euro. This makes the constant monitoring of the tools that are used to machine them so vital, for if there is a problem in the production process because of a faulty, worn or incorrectly fitted tool and the work is scrap, things can quickly get very expensive. Each component can require the use of about 10 different tools – from the humble twist drill to expensive special-purpose tools. At MTU in Munich, there was the odd occasion when the wrong tool was fitted in error, resulting in substantial losses. With the laser they can now be confident that such mistakes cannot happen again.

The laser systems also help maximise the utilisation of the machines. After all, in modern production facilities of the kind found at MTU where manning levels are low, there is not an operator on every machine all of the time. One operator is often responsible for several machining centres, so without a reliable monitoring system, it can take a long time for the fault to be found if there is a problem with a tool. The tool may be broken or it may be worn or its cutting edge may have burst, ruining the surface of the component. This is particularly true on weekends when running the machines unmanned on Saturdays and Sundays is essential because of the production costs of the products. “Our ultimate goal – to achieve the greatest possible machine utilisation – means working toward the industry standard of 5,000 hours per annum. The longer the machines run, the more we can keep costs down. This can only be achieved by working unmanned weekends,“ explains Heinz Baumgartner – “And with the support of LaserControl NT,“ adds Winfried Weiland, Sales Engineer at Blum-Novotest.

The excellent process stability which the laser systems offer benefits other areas as well – most of the machines that are equipped with LaserControl no longer require devices for tool presetting. Some machining centres are operated in parallel, but MTU‘s objective is to dispense with tool presetters altogether in future, so when the machines are fitted with new tools, the laser will capture the tool data to the nearest µm directly on the machine. This will eliminate human error when operators manually enter tool data that has first been logged on the presetter, such as keying errors and transposed numbers. Measuring directly on the machine is in any case much more accurate, as the data are recorded in the actual clamping situation and at working speed. All kinds of tools are measured with the laser measuring systems. The smallest has a diameter of just 1.2 mm, while the largest cutter head is currently 250 mm.

MTU also sees significant benefits from the NT technology introduced by BLUM in 2003 which has completely eliminated occasional problems previously caused by coolant. “On this basis we can now theoretically move to the laser with the tool dripping with coolant and it still works perfectly. Together with the tool cleaning jets which were installed a few years ago, this solution represents a real quantum leap in process reliability. The good direct contact which we have established over the years with BLUM is a major contributing factor. The same goes for the custom cycle which BLUM have written to allow special-purpose tools with their non-standard profiles to be measured,“ says Walter Strohmeir.

“For us, it is the process reliability which LaserControl NT offers that is its most important feature. The excellent co-operation with BLUM is another vital factor for our business because they understand what we want and can deliver it quickly. And they always give us useful suggestions, like how we can measure the tools even faster. Above all, however, the laser measuring systems give us the reliability and confidence we need for our machining processes,“ Walter Strohmeir sums up with evident satisfaction. Passengers should enjoy the peace of mind, too, thanks to the high quality standards set by MTU Aero Engines, at least whenever their flights are powered by engines from MTU.

Universal touch probe systems for extremely fast measurements under the harshest conditions in medium and large machine tools. Superior precision and speed due to modern, multi-directional measuring mechanism with optoelectronic switch signal generation.

TC50 | TC60 touch probes – Manufacture more productively with measuring speeds of up to 3 m/min

Highlights:

• Wear-free, optoelectronic signal generation
• High-precision, rotationally symmetrical measuring mechanism
• Reliable and proven transmission technology

Application:

Touch probe systems by BLUM can be used for the most varied measurement and monitoring tasks in machine tools. Fast determination of current workpiece position (workpiece zero point) prior to machining or after resetting using digital (switching) measurement. The touch probe systems are ideally suitable for fast and highly accurate measurement on machine tools used in single and mass production.

Features:

• Max. probing speed: 3 m/min
• Repeatability: 0.3 µm 2σ
• Protection class: IP68
• Approach directions: ±X, ±Y, -Z

Accessories

• Receiver Systems
• Quickstart measuring cycle packages
• FormControl measurement software

For further details Click Here