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Transferring information from NC programmers to machine setters on paper can be a time-consuming, error-prone process. With ZOLLER TMS Tool Management Solutions, you can extensively digitize this data transfer with Manage Setup Sheet and Fixtures software modules.
Short throughput times and maximum flexibility are critical if local manufacturers want to be internationally competitive. Extensive digitization helps with both, especially when it comes to transferring data from NC programmers to machine setters and the overall organization and management of tools, devices, and measuring and testing equipment.
Christoph Zoller, Managing Director of E. ZOLLER GmbH & Co. KG in Pleidelsheim, a family and technology company for the efficient handling of cutting tools, says: "Digitally transferred data has several outstanding advantages. It is usually generated automatically and therefore error-free, it is immediately available to all parties involved, and it enables traceable corrections to be made at any time."
Traditionally, a collection (folder) of forms and data on paper has been handed out and passed manually from NC programmers to machine setters. But transferring data digitally has become a faster and more reliable option. This applies to the NC programs, information on required tools, and materials and dimensions of blanks.
How does it work?
In order to digitize and optimize this process, ZOLLER has integrated the Manage Setup Sheet module into its TMS Tool Management Solutions software. The contents of the digital setup sheet can be flexibly adapted to specific requirements. And thanks to interfaces to 30 different CAD/CAM systems, the setup sheets are largely created automatically during CAD/CAM programming. NC programmers simply select the CNC machine to be used.
The digital setup sheets contain NC programs and the data required by the machine setter for tools, devices, and blanks. As an option, commercial data on main, auxiliary, and set-up times can be added.
As Robin Bender, Project Manager for the TMS Tool Management Solutions software at ZOLLER, explains, additional information can also be easily integrated into the digital setup sheets. "This includes, for example, comments, drawings, photos and 3D models of fixtures and clamping situations, but also videos of complete processes, such as the setup of clamping fixtures and clamping of blanks," he explains.
With this detailed information and instructions, the digital set-up sheets avoid time-consuming queries and tedious searches for the necessary equipment and auxiliary tools, ensuring greater process reliability.
Additionally, depending on the expansion level and installation of the entire software, information on clamping fixtures and tools can be called up at the touch of a button. This means that additional information is available to the personnel involved as needed, including the assembly and testing of clamping fixtures and the assembly, adjustment, and measurement of complete tools.
Bender explains that comprehensive data being available immediately is another significant advantage.
"The entire package of information is available on demand not only on CNC machines, but also in other areas such as tool preparation. Digital setup sheets also benefit the personnel involved in setting and measuring as well as assembling complete tools and clamping fixtures," he reports, adding: "Digital setup sheets from the ZOLLER TMS Tool Management Solutions software contain all the information and data required to manufacture a component. They are therefore ideally suited to significantly accelerate internal processes from NC programming to the first machining of a workpiece and, above all, to make them extremely reliable. Everyone involved always works on the basis of the same, approved data."
It is important to provide suitable and tested clamping fixtures quickly, especially with repeated production orders in series production. The fixtures software module contributes to this significantly. In it, fixtures are each given an ID number so that they can be precisely assigned at any time. All data on specific components, required standard elements (screws, nuts, bolts), and special accessories, such as required hand tools, are stored in a data record. Further information, such as photos and videos on construction and assembly, can also be created.
This means that at the touch of a button, work planners at terminals receive all the information required for the correct assembly and installation of clamping fixtures. Information is maintained centrally by authorized specialist personnel, ensuring maximum process reliability so that fixtures are always set up in the optimum configuration. In addition, measurement logs, measurement, test and schedules for repeated measurement, testing and calibration of fixtures can be saved and displayed. This ensures that only suitable and approved devices are used in production.
To ensure that fixtures are available at short notice once they have been assembled, the fixtures software module can be linked to the sophisticated warehouse management of ZOLLER's TMS Tool Management Solutions software, so storage locations for jigs and fixtures can be organized and managed just as easily as for tools.
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