crankshaft cutters and reamers for high-precision com- ponents as well as milling cutters developed especially for FCA/VM. These special tools require very particular qualifi ed measurement technology and, accordingly, place high demands on the mechanics and the software of the measuring devices. More than 10 years ago, VM Motori began relying on Zoller
products to set and measure its machine tools. The FCA/VM machine toolroom is equipped with two Zoller “venturion 600” machines as well as one “gemini” unit. The “venturion 600” vertical presetter features autofocus for automatic user-inde- pendent focussing of tool cutting edges and fully automatic measuring of multi-insert cutting tools. The Zoller “ace” spindle toolpost for steep tapers, hollow shaft tapers, CAPTO and Kennametal KM holders can be changed via one ball bushing with guaranteed changeover precision of 0.001 mm. The “gemini” is a presetter and measuring machine for auto- matically presetting, measuring, and checking crankshafts. “The experience with our fi rst Zoller presetter has been very positive. So far it has been running smoothly 24 hours a day,” said Alberto Verri, head of the toolroom used for the engine block and crankshaft production line at FCA/VM. Strong growth required the company to expand its preset- ting and measurement technology. The fact that Zoller had branch offi ces worldwide, including one near the company in Italy, was an important consideration. “To measure the cranfkshaft cutter, we were looking for an easy-to-use machine specifi cally for this type of machine tool,” said Verri. “An important requirement was and is that the measuring procedure be able to be performed reliably and quickly.” The special and extremely ergonomic mechan- ics of the “gemini” are designed to handle these heavy tools simply and conveniently. They are easy to load from the front and come with an enclosed protective housing to keep the operator as safe as possible during operation. At FCA/VM, the “gemini” is particularly important for the
pre-owned crankshaft cutters and those newly equipped with cutting blades. “It enables us to manage the precision of our machine tools throughout their entire service life,” said Stefano Mestieri, machine operator. “In the past, cutting blades were not always correctly installed. Now we are able to reliably correct errors and thereby ensure that the machines are equipped with crankshaft cutters correctly measured and preset. It is also very fast, measuring 100 cuts per minute.”
FCA/VM uses the “venturion 600” for the highly
productive, yet diffi cult-to-set reamers that are frequently used in the automotive industry. In addition, all other tools individually produced for FCA/VM are preset and measured on both “venturion 600” measuring machines. Circular runout and runout are also checked. To ensure future machine tool performances, the “lasso” measurement program checks the exterior contours because the machine tools are delivered without a test report. The measurements are performed operator- independent and without contact, so that there is automatic compensation for potential axial eccentricity.
Reamers for machining diesel engines are measured with Zoller’s “venturion 600” presetter at FCA/VM.
“The Balluff industrial RFID ensures that all relevant tool
data are accurately transmitted to the machines. The data are written directly and without contact to the toolholder and im- mediately stored on the data medium, thus ruling out data en- try errors,” said Filippo Perletti from Multicontol, Zoller’s branch offi ce in Italy. “It is now a more integrated and reliable process. The machines are set, measured and the data transmitted via the Balluff RFID to the control systems for 30 machines,” said Verri. The result is the complete integration of the Zoller mea- suring and presetting machines into the production process on the engine block and crankshaft production line. Due to its strong performance, reliable processes, and working with partners like Zoller, FCA/VM has for years suc- cessfully maintained its preeminent position among diesel engine manufacturers in Europe, both in the toolroom as well as in the production process, but most importantly, on the highway among engines that generate up to 275 hp.
Edited by Yearbook Editor James D. Sawyer from information provided by Zoller Inc.
81 — Motorized Vehicle Manufacturing 2015
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