Setting with ZEISS CALYPSO preset

from an EDM machine to an automated cell

 Let your EDM machines do the production ­­­–
we'll take care of the measurement.

Streamline your processes and use a coordinate measuring machine

With a ZEISS coordinate measuring machine and ZEISS CALYPSO to achieve more eroding throughput and measure more accurately.
preset software, you'll be able to preset your electrodes quickly + + + +
and safely. You thus will benefit not only from shorter machine
PRODUCTIVITY & ACCURACY & WORLDWIDE PREREQUISITE
setup times, but also from greater accuracy and a considerably MACHINE EFFICIENCY PROCESS STABILITY COMPETITIVENESS FOR 24/7-
increased productivity. Invest in your production of the future PRODUCTION
step-by-step.
Increase in productivity of all EDM Higher quality and process reliability In addition to faster delivery dates The integration in automation
machines through optimal use of the via the use of a CMM in a batch and a better adherence to schedules, processes is supported by close
existing capacity. Shorter production size 1 production process and the reduced production costs and costs cooperation with the integrators
times of the EDM machine with a generation of ZEISS quality data. per component also are achieved. and with ZEISS.
higher throughput.

Do you still clamp electrodes and workpieces and align them Your first step towards With a step-by-step upgrade of an The ZEISS measuring system is a fixed
manually? Do you achieve a maximum of 1000 erosion hours enhanced efficiency EDM machine which already integrates constant within the complete cell; the
per year and thus tie down a specialist completely? With a ZEISS coordinate measuring a ZEISS solution at an early stage, both offset data are thus automatically sent to
ZEISS CMM with
machine and ZEISS CALYPSO preset, you the generation of traceable quality the job manager. The logging and use
ZEISS CALYPSO PRESET
can perform presettings more efficiently data and a simultaneous reduction of the quality measurements take place
and more safely. Achieve shorter set-up of manual activities are achieved. in a closed loop.
times, more flexibility and much higher This leads to increasing throughput
utilization. Measurement on the EDM and decreasing costs with a higher
machine and manual data handling productivity.
have thus been eliminated.

Standard EDM machine Automated EDM cell

with zero-point clamping system and process control system

1.000h 1.800h 5.600h This process step unites all aspects into a self-sustaining and
efficient overall system: the automated EDM cell. As an
production production production
time per year option, a robot also can be used for the parts handling.
time per year time per year
Robot
01 02 03 + 04 05 loading

Measuring machine and program Automatic electrode changer Job manager

with graphic user guidance Standard EDM machine with A job manager controls all processes, regulates
One essential rationalization step is additional electrode changer. the control and monitors the EDM cell.
the use of a measuring machine and
the corresponding software. The Automatic parts identification Job manager
Eroding, manual alignments and measurement on an presetting of the electrodes can be The parts identification (ID) ensures a
EDM machine means longer machine downtime, performed easily with the determined unique assignment and selection of the parts
EDM machine
long setup times, inaccurate results and inefficient processes. values. marked with the chips.

Automate the processes and workflows step-by-step

Step 1 Step 2 Steps 3 und 4 Step 5
by upgrading your existing EDM machine.
Manual presetting and measurement on the CMM Fully automated EDM cell
ZEISS DuraMax vs. EDM machine – a direct comparison With the ZEISS DuraMax, ZEISS CALYPSO preset & job manager

Electrode and workpiece magazine

Offset data trans- Washing machine

mission is ongoing Robot

Milling

EDM machine

EDM machine ZEISS DuraMax with ZEISS CALYPSO preset In the fully automated cell, measurements are
performed on an integrated coordinate measuring
Job manager
Manual offset measurement on The accuracy of the measurement is quality information, and finally, an machine in addition to the EDM machine and incl.
robot loading, tooling and job manager.
the EDM machine less precise in direct comparison to a excessively low machine throughput.
ZEISS DuraMax with ZEISS CALYPSO preset
The offset of electrodes and workpieces coordinate measuring machine. The
often is still measured directly on the quality of the workpiece thus decreases. A ZEISS solution for your
EDM machine. But this method poses production that pays off as previously produced by four EDM One more step towards overall productivity. The most efficient
problems. While the EDM machine is In addition, the quality of the electrode's The illustration on the right side depicts machines. The CMM thus enables the an efficient solution expansion stage is a fully automated cell.
measuring the offset, it is not producing shape, which directly affects the quality production without using coordinate EDM machine to achieve a much higher Manual measurement on a coordinate In it, a process control system performs
any parts. of the workpiece produced, cannot be measuring machines (CMMs), (see Fig. 01). degree of utilization while at the same measuring machine already pays off with all work. The key component of such an
examined with this method. The result Four EDM machines are used for produc- time decreasing production and invest- your first EDM machine: shorter setup EDM cell is the job manager. It assumes
Because this measurement on the EDM is long setup times during which the tion here. In the bottom illustration (see ment costs. times, considerably longer machine run- the complete interaction between soft-
machine takes a lot of time, the producti- machine is not producing anything, long Fig. 02), only two EDM machines are re- ning times, increasing throughput and the ware and hardware such as e.g. auto-
vity of the machine decreases drastically. throughput times in production, missing quired to produce the same annual volume generation of quality data increase your mated removal from the magazine and
robot-supported loading and unloading
of electrodes and workpieces.
01 //
EDM machines
without CMMs

= lower efficiency
Increased production figures and throughput (components/year)
Decreased production time (min/component)

02 //
EDM machines
+ CMM in use

= increasing
productivity with
decreasing costs

Increased production figures and throughput (components/year)

Decreased production time (min/component)
Decreasing production and investment costs
Measurement on the EDM machine yields a lower production volume, Manual measurement on an additional coordinate measuring machine
since long EDM machine setup times result. resulting in higher productivity while at the same time reducing costs.
Simple offset and quality measurement:
from the electrode to the workpiece and the clamping system

ZEISS DuraMax ZEISS CALYPSO preset

02 ZEISS CALYPSO preset features a large

library of electrodes for presetting and
a large number of predefined electrode
shapes for selecting the respective
application.

Hardware and software comprise a ZEISS CALYPSO preset workpiece. In the next step, a file featuring the
single unit and a direct connection The software offers a complete library offset data is available, which can be exported
to the EDM machine. of all current macros for presetting directly to the EDM machine. All current EDM
From manual pallet placement right electrodes and workpieces. A graphic machines can be connected directly.
up to the fully automated process con- user guidance helps to configure the
trol system, the ZEISS CMM and ZEISS measuring run. Data export is supported for all relevant quality measurement. ZEISS CALYPSO
CALYPSO preset let you measure offset manufacturer-specific formats. As an alter- preset is compatible with job manager
and rotation when exchanging electrodes What ZEISS CALYPSO preset can do native to the connection to a job manager, software from Zimmer & Kreim, Georg
and workpieces in a matter of minutes. The software is used to simplify the the offset data and all relevant quality data Fischer/System 3R, Röders and
The ZEISS software has open interfaces to presetting and quality inspection of can be transferred to the latter. The task of EROWA / CERTA and many more.
which it transmits the offset data with a electrodes and workpieces. First of all, the job manager software here is to start the
direct connection to the EDM machine. If the zero point is set on the clamping measurement and receive the offset data in
a job manager is integrated, it transmits system. You can then select a macro order to subsequently send the data to the
the offset data directly to the machine. and probe the electrode as well as the production systems and log the data of the

01 ZEISS CALYPSO preset features 03 Definition of the measuring

simple handling with an interactive points in the first step, simple
user interface in addition to offset quality measurement of electrodes
measurements of electrodes and against the CAD model with a sub-
workpieces. sequent presentation of the results.
The measurement plan is created
automatically; the undersize of the
electrode also is considered.
 Subject to changes in design and scope of delivery and due to ongoing technical development.
EN_60_010_0009I Printed in Germany. AW-CZ-VIII/2018 Noo

© Carl Zeiss Industrielle Messtechnik GmbH

Carl Zeiss Carl Zeiss

Industrielle Messtechnik GmbH Industrial Metrology, LLC
73446 Oberkochen/Germany 6250 Sycamore Lane North
Sales: +49 7364 20-6336 Maple Grove, MN 55369/USA
Service: +49 7364 20-6337 Phone: +1 763 744-2400
Fax: +49 7364 20-3870 Fax: +1 763 533-0219
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www.zeiss.de/imt www.zeiss.com/metrology