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Z|magazine 01.2015
Foto: Lufthansa Technik
State-of-the-art technology on
board – and behind the scenes
Next to safety, an extremely high level
of quality is paramount in the mecha-
nical manufacturing in the business
division „VIP & Executive Jet Solu-
tions“. The individual requirements
include the production of high qua-
lity components with new geomet-
ries daily. To this end, a tool pool of
approximately 2000 different comple-
te tools is available. The sophistica-
ted NC programs for these complex
geometries are programmed with the
Edgecam CAM system since the year
2000, and since 2009, also with si-
multaneous 5-axis operation. These
are used for milling both prismatic
parts and free shapes.
More and more tool data
Over the years, new requirements
were added which accumulated in
even greater volumes of tool data.
Distributed over several data bases
(for example, Edgecam, machine con-
trols as well as Zoller), this resulted in
redundant data storage leading to
increased inefficiency and possible
sources of errors due to multiple ma-
nual data entry.
Safety, quality and flexibility
Against this background and the
purchase of a state-of-the-art ma-
chine pool, investment was also made
into high-tech peripherals. The ob-
jective was not only to increase pro-
cess safety, but in particular to en-
sure maximum flexibility to respond
to market changes. Up to this point in
time, only a single manual tool pre-
setting machine was in use, the la-
bels were printed and the data were
entered manually into the machine.
Expandable solutions
Since 2007, the CNC-controlled tool
presetting and measuring machine
»venturion 450« is in operation. „Fol-
lowing a cost-benefit analysis, the
decision to go with ZOLLER was made“,
explains Mr Frank Pieterwas, Planning
Engineer. „Crucial for us was the ex-
pandability and the linking to the ma-
chines.“ In addition to the outlook of
introducing a system-superimposed
tool data base, there were also a num-
ber of details in favor of ZOLLER. „For
example, the graphic user guidance for
fine drill tools which is normally quite
elaborate, or the fact that I can view
the cutting edge perfectly with a ma-
gnifying glass“, says Mr Jan Horn, CAM
specialist at Lufthansa Technik.
A leading tool data base
The basic machine was built up suc-
cessively over the years and Tool Ma-
nagement Solutions was introduced.
„We wanted the ZOLLER data base,
being the leading system“, says Jan
Horn. „If a new tool is to be set up,
then it should be entered in the ZOL-
LER Tool Management data base, so
that the name is correct, as well as the
description and the T-number. Thus,
once generated, it is used across the
entire process by all employees in a
uniform and consistent manner.“ Al-
ready in 2011, CAMTECH developed the
interface between Edgecam and the
ZOLLER Tool Management Solutions. In
2013, the Edgecam CAM system, the
tool stores of the CNC machines and
the ZOLLER tool presetting and measu-
ring machine were linked via the ZOL-
LER data base.
Data consistency ensures operator
independence
This ensured data consistency from
the CAM system through to the ma-
chine. All data are saved in the TMS Tool
Management Solutions and are acces-
sed by the CAM system. The measuring
specifications are saved directly next
to the tool in the data base and are
available at the measuring machine.
Professional measurement is perfor-
med at the push of a button and the
tool data are passed to the machine.
This ensures consistency and all sour-
ces of errors, such as through manual
entry, are thus eliminated. Multiple
storing of data was thus abolished.
Programming with real data
The tool data are now saved in the ZOL-
LER TMS data base, being the leading
data base, according to DIN4000 and
are thus available in the Edgecam CAM
system as exact, real envelope con-
tours. The system programs with real
data and outputs the data of those
tools with which simulation was per-