Why is the ZOLLER »toolBalancer« more accurate than competitor balancing systems?

Due to the center offset during measurement, the »toolBalancer« is extremely accurate. This advantage is effective with any tool - but especially with smaller HSC tools.

Operating software »toolBalancer« in 25 languages

Intuitive software with graphical user interface for quick and easy balancing in one or two planes, including extensive standard functions.

Convenient operation of the software via touchscreen.

Optical insertion aid

Graphic display of the angular position of the spindle on the monitor.

Balance correction "Various weights "Correction of unbalance by attaching or removing weights (e.g. balancing screws). Incl. presetting option for existing weight sets. Balance correction "Shift weights"Correction of unbalance by turning balancing rings or sliding blocks. Balance correction "Drilling radial"Correction of unbalance by radial drilling. Automatic calculation of the number, angular position and depth of the holes. Balancing correction "Milling"Correction of unbalance by radial, tangential or axial milling. Axial drilling" balance correctionCorrection of unbalance by axial drilling. Automatic calculation of the number, angular position and depth of the holes.

Display of the unbalance and correction position on the chuck via laser beam.

Balancing in one plane

For measuring and correcting the unbalance in a plane (static).

Balancing in two planes

For measuring and correcting the unbalance in two planes (dynamic).

Label printingOutput of the measurement results in one or two levels on ZOLLER label printers. Report printingOutput of the measurement report as a printout on a laser printer or as a PDF file including editing function. Measurement data exportAutomatic export of measurement data in CSV format.

I already have a balancing system. Can I use my balancing adapter in the ZOLLER »toolBalancer«?

Yes, you can. The special feature of the »toolBalancer« spindle is its universality. You can use ZOLLER balancing adapters in the spindle as well as adapters from other manufacturers.

Is the ZOLLER »toolBalancer«service-friendly?

The ease of servicing is one of the main differences to other balancers on the market. Starting with the »twinPanel« safety cover of the »toolBalancer«. If a part comes loose during balancing or the disk ages due to contact with oil, the entire cover does not have to be replaced straight away. The cover is made up of two panels. This means you can only replace the inner disk. We therefore call it the "sacrificial disk". Furthermore, you have easy access to the spindle and all electronic components are carefully and safely installed in the control cabinet to ensure trouble-free operation. The position of the control cabinet, drives and sensors allows optimum accessibility for maintenance and service work.

How does the »toolBalancer« differ from competitor balancing systems?

The »toolBalancer« is a new development and features more modern technology as well as a better and more ergonomic design. This results in high precision, simple operation and certified safety.

What exactly does the unbalance correction process look like?

In this video, we show you exactly how the unbalance correction process of the »toolBalancer« works.

I would like individual advice. What options are available?

At ZOLLER, you will find a range of offers to obtain individual information about a product. For example, the 1:1 expert discussion in the virtual showroom. We can also exchange information via Microsoft Teams or by telephone. Or you can drop by our Smart Factory. Enquire now

Why is a »toolBalancer« needed?

A balanced tool assembly ensures longer tool life, less vibration, higher spindle speed, better part finish and, most importantly, longer spindle life. Imbalance in a tool assembly creates excessive centrifugal forces that can damage the spindle bearings. Such damage reduces spindle life and can lead to costly unplanned downtime.

If balanced tool holders with grade G2.5 and 25,000 rpm are used, does the entire tool assembly still have to be balanced after the cutting tools/inserts have been fitted?

Cutting tools are sometimes asymmetrical, e.g. due to flattening on the shank (Weldon surface). Profile cutting tools can have an asymmetrical weight distribution. If such cutting tools are mounted in a balanced tool holder, this leads to an imbalance in the tool assembly. Collets, clamping nuts, stop screws, data chips etc. also contribute to the unbalance of the tool assembly. Once these other components are added to the toolholder assembly, the toolholder may need to be rebalanced to meet ISO balance specifications.

Do you have an adapter for clamping drill cutters, e.g. for wood cutters and tools with different shank sizes for profile tools?

ZOLLER offers special adapters for clamping drill cutters and tools with different shank sizes.

What is unbalance in one plane (static) and unbalance in two planes (dynamic)? How can we decide which method we should use to balance the tool assembly?

The following rule of thumb can serve as a guide as to whether the tool holder should be balanced "statically" or "dynamically": Static: 1 Level balancing applies to tool holders that have an operating speed of less than 20,000 rpm and where the overall length of the holder is less than twice the maximum diameter of the tool holder. Dynamic: 2 Level balancing applies to tool holders with an operating speed of more than 20,000 rpm or if the total length of the holder is more than twice the maximum diameter of the tool holder.

What is G1, G 2.5 and G 6.3 and where is it applicable?

G indicates the balancing quality class. CNC machines, machine tool drives and the tool industry use G2.5 for finishing tools, G6.3 for roughing tools and G1 for grinding wheels. These are the quality grades according to DIN ISO 1940-1.

What different balancing methods are there?

In balancing technology, there are three methods for correcting unbalance: Adding material using the screwing method.Material removal by drilling or millingMaterial displacement using unbalance rings.

If the speed is only 2000 rpm, does it still need to be balanced?

If the spindle only runs at 2000 rpm because of vibrations and cutting noise, this is due to the use of an unbalanced tool arrangement. If the tools are balanced, higher speeds and feeds can be used and profitability is increased.

What does the unit gmm mean?

This is the unit used to measure the unbalance. The reason for an unbalance is a rotating mass outside the axis of rotation. The unbalance is expressed as the product of this mass times the distance from the axis of rotation, e.g. in gram-millimeters (gmm) or kilogram-meters (kgm).

»toolBalancer«

Name: »toolBalancer«
Brand: Zoller

With optimally and highly precisely balanced tools, you achieve longer tool life, longer spindle life and a better surface quality of your components. With »toolBalancer«, you can achieve the perfect balance of sustainability, efficiency and progress not only for your tools, but also for your entire production process.

Inquire now

The unique balance of functionality and ergonomics for exact measurement results: This is precision and certified safety for your production.

Frank Hartstein, part of the »toolBalancer« product development team

We, the technology company ZOLLER, have focused our experience and expertise on this new product development, setting another milestone and completing the ZOLLER product portfolio. Typical ZOLLER: everything from a single source.

Christoph Zoller, Managing Director

The perfect combination of design, ergonomics and technological intelligence. The ZOLLER solution with certified safety for a resource-saving application in your production.

Alexander Zoller, Managing Director

TÜV and UL/CSA approved

500 kg solid base

Best balancing results: < 0.4 gmm

»twinPanel« safety cover

»twinPanel« safety hood

Complies with DIN ISO 21940-23 class C60 for maximum safety.

The internal "sacrificial disk" absorbs dirt caused by e.g. The internal "victim disk" absorbs dirt, e.g. residues of cooling lubricants and damage caused by component detachment. This takes into account the very important and often overlooked process of protective disk switching that occurs through daily use. The ZOLLER »twinPanel« guarantees the safety of your operators in the long term thanks to the quick and cost-effective replacement of the sacrificial screen.

High-precision spindle

Accepts almost any tool holder with an appropriate balancing adapter. Depending on the weight, the spindle rotates the tool at a variably adjustable speed of 400 to max. 1200 revolutions per minute and measures the unbalance with an accuracy of < 0.4 gmm.

When designing the high-precision spindle, ZOLLER placed a particular focus on the safe and certified adapter changing process. A special design element prevents accidents and damage caused by unbolted balancing adapters in the spindle.

Adapter storage compartment

Adapter storage compartment with hinged front flap

Three storage spaces for ergonomic, back-friendly and quick adapter changes without bending your knees.

Fork recess

For flexible installation and easy transportation of the »toolBalancer« in your production facility using a pallet truck.

ZOLLER operating software

Simple ZOLLER operating software

The structured, graphical display guides the operator intuitively through the measuring and balancing process.

The machine is set up by entering the tool geometry data. All data is stored in the database and is also available at a later date.

»Cockpit« control unit

Separate »cockpit« control unit

Can be adjusted in height and position and the monitor can be tilted. It can be easily moved to the desired position, making operating the software as convenient as possible.

In addition to touch operation, the »cockpit« offers input options via mouse and keyboard, as well as shelves for label and laser printers, hand scanners and tools such as Allen keys.