En Innovation Special 17-60-025 131i

8/10/2019 En Innovation Special 17-60-025 131i

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InnovationIssue 17, 5/2014

// Metrology Special

Measuring InnovationsZEISS XENOS, ZEISS CONTURA, ZEISS ROTOS


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Dear Reader,

ZEISS has been driving the progress of industrial metrology for more than

100 years. During this time, ZEISS has repeatedly challenged the constraints

of technology. And the future will be no different; we will continue to push

the limits of measuring technology.

The challenges in production technology demand a wide range ofenhancements to methods, machines and equipment. The quality and

thus the measuring technology play a key role. Now and in the future,

measuring technology will be vital to leading production companies.

Meeting the demands of our pivotal role requires us to enter uncharted

territory and to once again drive the progress of precision and dynamics.

For this reason, we have taken an entirely new approach to the

development and construction of the ZEISS XENOS measuring machine.

At the 2014 Control show, we are introducing a measuring machine

that enters a new realm of accuracy and dynamics with its innovative

technology. With length measurement error of just 0.3 micrometers,

the XENOS from ZEISS is now the new standard-bearer.

Editorial

2 Innovation SPECIAL Metrology 17


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The new ZEISS CONTURA line is now more flexible and modern. Proven time

and time again and now an essential piece of equipment in the measuring

labs of numerous customers, it provides precision, speed and analysis

possibilities that were only avai lable on high-end machines in the past.

One highlight is the new ZEISS ROTOS roughness sensor as an extensionof the multi-sensor system on the measuring machine. In the future, it will

enable you to measure size, form, location and surface quality on a single

machine, in one setting and documented in a single report. This optimized

workflow delivers quantifiable benefits thanks to its faster results and lower

workpiece idle times.

Our promise to you today and for tomorrow: advanced total solutions that

set new standards in precision, efficiency and reliabil ity.

Best wishes,

Dr. Rainer Ohnheiser

President and CEO

Carl Zeiss Industrielle Messtechnik GmbH

3Innovation SPECIAL Metrology 17


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02 Editorial

Product Report

06 XENOSThe new reference coordinate measuring machine from ZEISS

12 A Model of Success More Attractive than EverThe new ZEISS CONTURA

18 All Features, One Measuring Machine The new ZEISS ROTOS roughness sensor

24 Intelligent Tool for Optical InspectionZEISS Smartzoom 5

26 ABCs of Optical InspectionBook presentation and interview

28 What You See Is What You Get

Product design / MD&M / Germany

From Users for Users

36 Millions of Steps Acrossssur / Reykjavik / Iceland

42 A Race Against Time

Pankl Racing Systems / Bruck / Austria

48 Quality for Your EyesJun He Technology / Taiwan

54 Pursuing Excellence, Shaping the FutureBYD Precision Plastic Injection Tooling Factory / Shanghai / China

58 Micrometer PrecisionKWS Klle / Mauerstetten / Germany

63 Legal Information

Table of Contents



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5Innovation SPECIAL Metrology 17 5


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The New Standard

XENOS. The name conjures up images of superheroes. Fitting,considering that the new coordinate measuring machine from ZEISSis entering a new realm of accuracy and dynamics with its innovativetechnology. XENOS from ZEISS delivers length measurement errorof just 0.3 micrometers unbeatable accuracy in this machine class.

Bridge-type measuring machine / ZEISS XENOS

// Measuring innovation



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XENOS , the new reference measu ring machin e from ZEISS , wi ll be in troduced at the 2014 Con trol show



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New VAST gold probe for

maximum accuracy andreproducibility

Measuring range: 900 x 1500 x 700 mm

for a wide range of applications with smallor large parts

LED status display quicklydetermine what is going on

First use of linear drives inreference measuring machines:safe, dynamic and futureproof(through inherent intelligence)

The next generation of high-techceramics: silicone-carbide ceramics maximum rigidity for maximumprecision and reproducibility

Innovative mechanical design with optimalproperties for dynamics, weight ratios andreproducibility



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very fast acceleration, high positioningaccuracy and shear force-free drives.Thanks to an innovative overall concept,it was possible for the first time todecouple the force transmission ofthe linear drives of the guideways andmeasuring system. Taking into accountthe high-resolution scales on ZEISSXENOS, the new drive technologyresults in very high path adherence andextremely high positioning accuracyclearly below 100 nanometers. Forexample, the stylus deflection remainsmore constant, which results in higher

accuracy. Another benefit of the veryhigh path adherence is evident whenmeasuring curved surfaces: the morereliably and accurately a stylus followsthe specified path, the more preciselyerrors can be identified.

Based on its 30 years of experiencewith precision drives, ZEISS is nowintroducing the patented, virtual centraldrive. The full incorporation of dynamicmass distribution is enabled by the

latest generation of controller andalgorithm.

ZEISS has repeatedly pushed the limitsof contact measuring with systemssuch as ZEISS PRISMO, ZEISS UPMCultra or ZEISS F25. Today, they serve asreference machines in national institutesaround the world.

0.3 micrometers per cubic meterWith a measuring volume of aroundone liter, the F25 from ZEISS can onlymeasure small parts. By comparison,ZEISS XENOS offers a measuring rangeof just about one cubic meter(900 x 1500 x 700 mm). The engineers

at ZEISS took a new approach for thedevelopment of XENOS in order toset a new standard in precision withthis measuring volume, while alsoincreasing the measuring speed. "Allstandard measuring machines canonly be optimized up to a certainlevel. Sooner or later, this potential isexhausted," explains Konrad Werner,ZEISS XENOS Product Manager. Thismachine is a new innovation fromZEISS. XENOS from ZEISS stands for

accuracy and future proofness thanks tothe use of innovative technologies and

materials, which also pushed the limitsof technology.At first glance, the new measuringmachine clearly distances itself from theprevious top model ZEISS PRISMO ultra.The mechanical concept was derivedfrom the successful ZEISS CenterMaxinline system: the reference machinefor production measuring technologysince 2001. The fixed side wallsprovide extreme stability throughoutthe system. Because only the uppercross bar moves in the Y direction, themoving weights are reduced, which

remains always constant in comparisonto a machine strategy with a movingworkpiece. Together, the weightreduction and constantly movingmasses enable optimal coordination ofthe drives regarding acceleration andmaximum speed.

Virtual central driveUnlike other systems, the ZEISS XENOSuses linear drives on all axes insteadof friction drives. Until now, these

have been rarely used on measuringmachines. The benefits: high speeds,



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The new VAST gold probe from ZEISS was

developed to meet maximum demands on

sens iti vit y, accu racy and reproducib ili ty

has been clearly reduced throughthe improved decoupling and a newelectronics concept.

The foundation for precisionXENOS features standard ZEISS floatingZerodur scales. Zerodur is a glassceramic material with virtually nothermal expansion. Thermal expansionon steel scales must be compensated.The temperature sensors and theestimated expansion coefficient wouldbe sources of uncertainty that areavoided on ZEISS XENOS from the start.Product Manager Werner: "Some time

ago, someone mentioned completelycompensating mechanical invariancemathematically. Our approach with

Silicon-carbide high-tech ceramicsIn the past, ZEISS used aluminumoxide ceramics or CARAT-treated

aluminum for the parts of the machinestructure relevant to accuracy. Theseare known for their lightness, rigidityand invariance regarding temperaturefluctuations. With ZEISS XENOS, ourengineers have once again raised thebar. As a result, an innovative silicone-carbide ceramic is being used for thefirst time on a measuring machine.Until now, this material has rarelybeen used for a comparable part sizeor accuracy. Compared to the white

standard ceramic, the black silicone-carbide ceramic exhibits around 50percent lower thermal expansion, up

to 30 percent higher rigidity and 20percent less weight. Compared to steel,it delivers twice the rigidity at half the

weight.

New VAST gold probeZEISS XENOS features various othernew equipment in addition to thepreviously mentioned innovations. Thisincludes the enhancement of the VASTgold reference probe and its optimalintegration for better accuracy andrepeatability. Optimized air bearingswith considerably improved integrationenhances stability and also contributes

to better accuracy. The influenceon precision of moving cables onall coordinate measuring machines



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ZEISS XENOS was to uncompromisinglypush the limits of mechanical precision,to eliminate hysteresis influences and to

use the computer only for the last bit.We are certain that this course of actionhas enabled us to achieve maximumprecision with ideal repeatability."



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A Model of Success More Attractive

than EverThe new ZEISS CONTURACONTURA the broad platform from ZEISS for flexible, reliable anduncompromising quality assurance. The latest generation is even moreprecise and offers a large package of optical sensors on top of a largermeasuring range. Outstanding scanning technology, CALYPSO referencesoftware and a highly tuned overall concept enable ZEISS CONTURA tocement its place as the standard in its class.

Bridge-type measuring machine / ZEISS CONTURA

// Measuring innovation



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CONTURA is the best-selling coordinate measuring machine from ZEISS



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Thanks to its robust design, CONTURA from ZEISS can also be used near production



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Depending on the configuration,ceramic or CARAT guideways areused on CONTURA for high rigidity,low thermal expansion and minimalmoving weights. Covered guidewayscontribute to smooth operation in the

workshop. The floating glass ceramicscales are practically expansion-free andtherefore do not require any additionaltemperature sensors or mathematicalcompensation.

Proven ZEISS softwareZEISS CONTURA runs on CALYPSO,the powerful measuring and analysissoftware from ZEISS that is knownfor its simple, icon-based operation.Furthermore, the entire softwareoffering from ZEISS is available,including GEAR PRO for geargeometries, BLADE PRO for turbineblades and PiWeb for quality datamanagement.

A reliable measuring system is the resultof the interaction of its components:design, sensors, software and serv ice.With ZEISS CONTURA, customersreceive a well-balanced system fromZEISS and thus a guarantee for stable,reproducible precision. In other words:

results they can rely on.

results obtained from fast scanning.Active scanning is a unique sellingpoint of ZEISS. navigator technologyfrom ZEISS, which enables a tangentialapproach without a stop & go, as wellas circular or helical scanning, delivers

additional speed for the active sensors.ZEISS CONTURA aktiv comes standardwith navigator, thus joining the ranksof ZEISS PRISMO, ZEISS ACCURAand CONTURA from ZEISS whichalready integrate this technology. TheQuickChange option, which enables thefast change-out of stylus systems, isnow also available for ZEISS CONTURAaktiv for the first time.

Up to 1200 x 2400 x 1000millimetersAnother new feature is the range ofmeasuring volumes. CONTURA fromZEISS is now available around the worldin eight different sizes starting with ameasuring volume of 700 x 700 x 600mm up to 1200 x 2400 x 1000. In mostcases, this enables ZEISS to offer itscustomers the right size machine fortheir workpieces and not have to dowithout certain technologies.

From a design standpoint, CONTURA

from ZEISS is based on proven features:its efficient, highly precise air bearingsare an in-house development.ZEISS AirSaver can also be integratedfor additional savings. This technologyreduces compressed air consumption byup to 60 percent depending on how itis used.

The new LineScan

More precision

More vision

Three versions

Extend the functionality of your new

CONTURA from ZEISS with the new

LineScan. It enables the fast optical

measurement of features.The new LineScan is available in

three different measuring ranges:

25 mm, 50 mm and 100 mm.

The corresponding accuracies are

12, 20 and 35 50 m MPE(PF). This

requires the new ZEISS CONTURA with

the RDS articulating probe holder.



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All Features, OneMeasuring MachineThe new ZEISS ROTOS roughness sensor

ROTOS from ZEISS, the new roughness sensor, enables the standard-compliant inspection of roughness and waviness on a single coordinatemeasuring machine (CMM) for the first time. Therefore, all features of atechnical drawing can be fully captured with one CMM and displayed inone report. It is no longer necessary to transfer to a surface measuringinstrument. Various measuring positions can be reached withoutrechucking and a fully automatic run is possible without the operatorinfluencing the surface measurement. The benefit: a simplified workflowfor added measuring certainty and enormous time savings.

Sensor / ZEISS ROTOS// Measuring innovation



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ZEISS ROTOS is idea l for power trai n component s



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Can be flexibly positionedZEISS ROTOS can be positioned veryflexibly to reach all surfaces on a partwithout rechucking. Fur thermore,the sensor features a rotating/tiltingaxis. The rotary axis can turn a full360 degrees. The sensor can be tiltedperpendicularly downward, plus anadditional five degrees via the tilt axis.It can tilt upwards by 65 degrees. This

results in a tilt range of 160 degrees.The 36 millimeter long st ylus armcan be inserted into boreholes with adiameter of at least 11 millimeters. Theentire sensor is so compact that it fits ina 75 millimeter cylindrical borehole.

Because the entire measurementwith ZEISS ROTOS is CNC-guided,the risk of operator errors has beenconsiderably reduced. Unlike manualroughness sensors, measurements on

a CMM are more reproducible and themeasurement location is verifiable. Thismakes it easier to find the measurement

Today, roughness is usually measuredusing contact stylus instruments such asZEISS SURFCOM in the measuring lab. Inproduction, mobile devices such as theZEISS HANDYSURF (skid probing system)and ZEISS SURFCOM 130 (free probingsystem) are frequently used. Theycan be quickly positioned at variousareas on the workpiece for a surfacemeasurement. However, the reliability of

manual measurements depends on theexpertise and diligence of the personoperating the equipment. Furthermore,the results of mobile devices with askid probing system generally do notcorrespond to the standards for surfacemeasurements and are thereforenot always accepted for conformityassessments.

New workflowThe new ZEISS ROTOS roughness sensor

enables a new, simpler workflow inquality assurance. It is intended forusers that inspect size, location or form

on a coordinate measuring machineand also need to measure roughnessand waviness on the same workpiece.Instead of transporting the workpieceto a contact stylus instrument andclamping it, ZEISS ROTOS is used via thestylus changer interface on the probeof the coordinate measuring machine under full CNC control. This takes just afew seconds compared to the previous

several minutes. Because it is no longernecessary to transport and clampthe part, the susceptibility to errorsthroughout the process and operatorinfluence are eliminated. The timesavings with ROTOS from ZEISS becomeeven more obvious when multipleroughness measurements in differentorientations are required. On a contactstylus instrument, this means rechuckingthe workpiece every time or CNC-guidedmovement of the workpiece. On the

coordinate measuring machine, theworkpiece can generally remain in onesetting for the entire process.

Very mobile: the swivel range of ZEISS ROTOS

encompasses 360 horizontal and 160 vertical



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75mm

12mm

location again. As a free probingsystem, ZEISS ROTOS is also suitablefor standard-compliant conformityassessments for external parties.

AccuracyThe accuracy of ZEISS ROTOS covers thequality of all machined surfaces. Thesensor is therefore ideal for the qualityinspection of powertrain components.

ZEISS ROTOS is connected to themeasuring machine via the VASTline of active probes, which dampeninterferences from the machine and

environment, and also determinethe measuring position of ROTOS.Measurement data from ZEISS ROTOS istransmitted via Bluetooth to the analysiscomputer. The data is then importedinto ZEISS CALYPSO CMM software viaa machine driver and can be exportedwith other measurement data in acommon report.

In short, the three key benefits ofa workflow with ZEISS ROTOS are:

improved measuring productivity,reliable and fully automatic measuringruns, and the common report. They

are based on the seamless interactionbetween the sensor, measuringmachine and software. As a systemsmanufacturer, ZEISS guarantees theperformance and precision of the entiresystem, which, after all, is what it's allabout.

Thanks to the slim design, the interior of

boreholes can also be inspected



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At a glanceZEISS ROTOS

Improved measuring productivitythrough integrated CNC roughnessmeasurement on the coordinatemeasuring machine

Enables fully automatic measuringruns for size, form, location andsurface quality

Free probing system with 2 mand 5 m stylus radii

Sensor is carried by the ZEISS VASTgold, VAST XT gold and VAST XTRgold active probes

Two continuous rotation axes toreach many measurement positions



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Intelligent Tools

for Visual Inspections

// Product ReportSmartzoom 5

In an industrial environment, a visualinspection is an important part ofproduction-related quality testing.Parts such as screws, printed circuitboards, and metal elements need tobe examined for defects. However,companies often do not have the timeto inspect these parts, nor do theyalways have expert microscope users.

"In this context, the microscope is one ofmany tools, just like pliers or a wrench.And it must work just as intuitively andreliably," says Wolf Jockusch, productmanager for ZEISS Smartzoom 5. Thedevice is the first integrated completesystem from ZEISS comprised of anoptical engine (which itself consists of azoom system, camera and illumination

With the microscope's swing arm users can view

structures on the sample surface at cont inuously

adjustable angles between -45 and +45

Smartzoom 5 the smart d igital microscope

system that s ideal for quality assurance

applications in virtually every field of industry

Even without training, users of Smartzoom 5

can quickly and easily produce digital images

and 3D reconstructions of macroscopic and

microscopic structures

Smartzoom 5 is the first automated digital microscope from ZEISS.It stands out thanks to its one-of-kind operating concept, which

makes it as easy to use as possible.

source), a stand with sample stage,objective lenses, the operating unit andsoftware.Smartzoom 5 is also suitable for failureanalyses, i.e. the close examination ofa defective part, as well as for routineinspections, during which the samematerial sample needs to be repeatedlyinspected using the same workflow.Once quality inspectors have placed thesample under the microscope, they nolonger have to switch back and forthbetween the device and the software,but can carry out all the necessarysteps right on the screen. They can alsosave this workflow so that it is alwaysavailable at a later time: "This makes theanalysis reproducible and independent



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of the user," says Jockusch. Furthermore,the Best Image feature allows userswithout any prior knowledge to achieveoptimal results the system shows apreview of different illumination options,and the user only needs to select thebest one. In addition, the device iscalibrated at the factory and can beused immediately without any furtheradjustments.

For more information, please visit:www.zeiss.com/smartzoom



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The practice-oriented volumes in thisbook series concisely, clearly and vividlypresent well-defined engineering,economic and scientific topics.

Authors Dr. Timo Bernthaler, Tim

Schubert and Christian Weisenbergerfrom Aalen University explain industrialmicroscope measurement and analysistechniques in several chapters. Intheir introduction, they address thegeneral meaning of optical inspection.This is followed by a chapter on theprinciples of optical measurement withmicroscopes. Here the authors explainthe fundamentals of optical imaging aswell as image errors and how to avoidthem. In the next section, they address

digitization of optical information. Inaddition to the operating principle

ABCs of Optical

Inspection

of digital cameras and influencevariables, the second step deals withtechniques for improving images. Thenext part addresses the calibration andmeasurement accuracy of an opticalsystem. From the calibration process,

the authors move on to measurementuncertainties and the causes of commonoptical measurement errors. Thesubsequent chapter on measuring withmicroscope systems presents commoninteractive measurement parametersand properties. Finally, the authorsdiscuss areas of application such asaccident investigations, structuraltesting, surface inspection, residueanalysis and structural assessments.

// Book presentation and interview

On 30 April 2014,Sddeutscher Verlag onpactreleased thescientific book Optical Inspectionas part of its Bibliothekder Technik series in collaboration with Aalen University, oneof ZEISS' long-running cooperation partners. The book isavailable in German, English and Chinese.



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Co-author Timo Bernthalerdiscusses what led to the bookand his personal motivation forcooperating on the project.

Mr. Bernthaler, please tell us a

little bit about your work.I am one of the directors of theMaterials Research Institute (IMFAA)at Aalen University. The Institute wasfounded in 2010 and is associatedwith the surface technologies/newmaterials degree path. As a result,we achieve tremendous synergy inour day-to-day research, our use anddevelopment of laboratories andour acquisition of research projects.Various industrial partners participatein our projects, representing, forinstance, the analytics, automotive andmechanical engineering industries. Wework on issues that will later becomeimportant to industrial applications.For instance, our team is currentlyconducting intensive research to identifyalternative, high-power, magneticallyhard materials. This is where thecollaboration with ZEISS comes intoplay. Light and electron microscopesprovide information about the magnets'intrinsic properties and therefore their

capacity and quality. Above all, it is vitalfor us to constantly and methodicallydevelop materialography and materialmicroscopy as key interdisciplinaryengineering technologies for theresearch, production and processingof materials for components. It's a lotof fun to be able to work with a teammade up of students, young engineersand seasoned researchers.

What led you to work on this

book?In education, I have often noticed thatstudents are uncertain about taking

measurements and sometimes they lackbasic knowledge above all with thegrowing presence of digital technology.Nowadays an image is produced veryquickly unfortunately, sometimestoo quickly. The goal of this book is to

clearly define terms and to convey basicknowledge. I wanted it to be a kindof textbook and manual that would behelpful not only for students but also alarger audience. I was also interestedin explaining what constitutes a goodmicroscope image, what conditionshave to be met for that to happen andhow common mistakes can be avoided.

How long have you been working

in this field?

I have been working on materialcharacterization since 2000, primarilyin material microscopy, and automatedand quantitative material analysis. Ibegan working with industry while Iwas still in school. I was able to domy first direct research assignmentfor Bosch which was very exciting!Starting out as a project engineer, Iwas then able to help establish veryapplication-oriented research at AalenUniversity in close cooperation withindustry (for instance, Bosch, Audi, GE,

Mapal, ZEISS). But what's also attractiveabout Aalen University is the fact thatthe demands that regional and trans-regional companies make on freelancersthrough service contracts sometimeschange daily.

What is the most exciting industrial

application that your research has

contributed to?

Developing a completely newmicroscopic quality assurance system for

a mass-produced, multi-position ceramiccomponent. That had never existedbefore. The most exciting thing about

that was that we were able to go froma thesis project to other developmentwork to designing an extremelysophisticated preparation and imageanalysis so smoothly that it is nowbeing used more than five years later in

industrial settings. That is the kind ofapproach we want to pursue.

What happens next? What are your

next projects?

The goal is to continue to strategicallydevelop materials research andmaterialography at Aalen University intoa prestigious research and educationinstitution. I'd like to contribute tothat. As far as projects are concerned,we want to accelerate and enhanceautomated material microscopy forquality assurance measurement tasksand to understand the functionalconnections between manufacturingand properties for strategicallyimportant energy efficiency materials,for instance magnets for electricalmachines, energy storage or lightweightconstruction materials.

Are you interested in optical inspection?For more information, please go to:www.zeiss.com/opticalinspection



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What You See IsWhat You Get

Product designers at MD&M designed new measuringmachines and sensors for ZEISS. Walter Matuschek, Presidentof MD&M, told us about his brand-oriented approach andwhat is behind the designs of ZEISS XENOS, ZEISS CONTURAand ZEISS VAST XTR.

Product design / MD&M / Germany

// About Us



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Walter Matuschek has access to 250,000 material and paint samples



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Walter Matuschek is an imposing figure:tall, stout, walrus mustache, direct.While discussing his work, he alsoshowed us his softer side, explainedthe touch and feel of paint, and thedifferent ways of implementing brandvalues in product design.

He earned his degree as an industrialdesigner in 1988. After 15 years as aproduct designer, he was appointedin 2003 as Chief Design Officer ofSiemens mobile in Munich, Beijing andSan Diego. In this position, he wasresponsible for the design of all newSiemens mobile telephones for a periodof three years. In 2006, he and twopartners founded the MD&M productdesign agency. It has now designed thenew ZEISS XENOS and ZEISS CONTURA

measuring machines, as well as theZEISS VAST XTR sensor.

In light of his global activities atSiemens, Matuschek ironically describeshis current base in Aalen as the boonies.However, he did not abandon his globalperspective upon returning to hishometown: "We go toe to toe with thebest product designers in the world,"he says, and refers to numerous designawards, including multiple iF and Red

Dot awards. Matuschek's office in Aalenis also very international. "We speakEnglish most of the time," he grins.

MD&M currently has 10 employees.External designers help out whennecessary.

"We are not off-the-shelfdesigners"Matuschek promises his customersa design that fits the brand, clearlyseparating his work from the approachof many well-known product designers:"When you go to Luigi Colani, you getsomething streamlined, at Philip Starcksomething that looks like a lemonpress." At MD&M, the focus is always onthe brand.

Consequently, Matuschek starts withthe brand when coming up with adesign. The defined brand values puthim and his team in the right direction.

"However, many brands coincidewith their values. Things like quality,innovation and customer focus allmean the same thing," he emphasizes.Therefore, he has to dig a little deeperto find out just what is behind thesevalues. One method is picture mapping:"We show our customers various imagesand let them choose the pictures thatbest fit their brand," he explains. "Evencompanies with similar values can endup with completely different images."

Together with his customers, Matuschekdevelops a feeling for the brand and avision of how to present it in the future.

Numerous sketchesSeveral designers at MD&M thenuse this brand image for the draftphase. They intentionally take a broadapproach to cover an entire spectrumwith various drafts. "Five employeedrew sketches for two weeks straightfor the XENOS," remembers Matuschek."People have a lot of trouble describinghow something new should look, butas soon as they see something, theycan tell you immediately if they like itor not," he says, justifying the time-consuming method.

The draft sketches from MD&M arecreated the old-fashioned way byhand. "This enables us to discuss thedrafts and inspire each other." Beingable to draw is a basic requirement

in his agency: "All our designersare outstanding artists." The draftsprovide the foundation for the ongoingnegotiations with customers. Manydrafts are organic, others technical innature; some are very clever, othersstreamlined. The many versions allowMD&M to develop a precise objec tivein close cooperation with the customer.The next step is to turn the favoritesinto a more concrete draft.

Then it is time to turn to the computers.MD&M creates a true-to-scale, detailedCAD model. The designers use this

Hand-drawn sketches are a basic element of the design process a t MD&M



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3D form data to generate a realisticrendering from different perspectives.This gives the designers and customersa precise idea of how the finishedproduct can look, including colors, lightand shadow, and surface texture.

Focusing on the essentialsPrecision, quality and human were key

aspects for the design of the measuringtechnology products of ZEISS: "Ourjob was to bring these values to life,to dramatize them and to focus on theessentials." This led MD&M to use a lineleading to a point to embody precision.Such lines on the front of the VAST XTRpoint to the stylus tip. The ram designon the new ZEISS CONTURA has asimilar arrow effect.

Because the new ZEISS XENOS

represents a superlative of measuringtechnology, the design had to besomething special. Matuschek describes

his vision as a "Swiss watch the size of aroom or a cathedral of measurement."In fact, the side openings on the ZEISSXENOS conjure up thoughts of theupward-pointing windows of a Gothiccathedral. The sculptural magnificenceof this measuring machine makes itappear as an oversized piece of jewelry.

"In addition to the overall quality of theform, the details also play a key role inconveying the quality of the system,"adds Matuschek. Master craftsmanshipand the surface texture are vital tothis level of design. His considerationsextend all the way to the paint, withwhich the product will be finished.The new ZEISS VAST XTR sensor, forexample, features a special paint that isusually reserved for mobile phones. Thisconveys higher quality. By comparison,

an older sensor without special paintfeels cheap.

Matuschek has an archive of paintand material samples in his officeto help select the right paint, colorand materials, or to just simply findinspiration. The team has 250,000samples at their fingertips. It took twoemployees a full year to fill this archive.

More design work

The work that goes into a design fromMatuschek and co., even for technicalinvestment goods, has also increasedin recent years due to the risingdemands on designs. "Every machineoperator today owns a well-designedsmartphone. Considering that theirwork equipment costs several hundredthousand euros, they expect similarquality," says Matuschek. A square-shaped, gray hull is no longer enough.

Matuschek is convinced that productdesign is now vital to the mechanicalengineering and toolmaking industry

Pointed lines indicate the precision of the VAST X TR

sensor f rom ZEISS



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for anyone that wants to be successful.Moreover: because the design of aproduct makes the first impression, it isa key element of the decision-makingprocess. Matuschek states it directly:"What you see is what you get."

Red Dot Awards forZEISS sensors

MD&M and ZEISS won Red Dot Awards in 2014 for the design of

various optical and contact probes. The Eagle Eye, LineScan,

VAST gold (two configurations), VAST XTR gold, VAST XT gold and

VAST XXT sensors from ZEISS were honored in the Winners class.



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// FLEXIBILITYMADE BY ZEISS


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Millions ofSteps AcrossWith its high-tech prosthetics, Icelandic company ssurwould like to enable people to live without limitations.The company manufactures most of the components forthe artificial limbs at its own production facilities inReykjavik. To ensure the quality of the highly complexprosthetics, ssur uses two coordinate measuringmachines from ZEISS in production. All measured data isgathered in PiWeb software, which generates analyses anddocumentation at the push of a button.

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// From Users for Users

ssur / Reykjavik / Iceland



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Reykjavik, Iceland. 400 people workin the worlds northernmost capital toremove barriers for patients around theglobe. One of them is Lukas Kalemba,a slim, athletic man who lost his leftleg at the age of 19. The now 29-year-

old German nonetheless moves aboutwithout a problem. Although his worldwas turned upside down in an accident10 years ago, he now enjoys all that lifehas to offer. He likes his job, does sportsin his free time and he is discovering hisnew home: Iceland. "My new leg hashelped me regain the quality of life thatwas taken from me back then."

High-tech for a self-determined lifeKalembas left leg is now powered bya mini-computer, inside an aluminumframe with a plastic shel l cover. A metaltube connects it to an ssur artificialfoot made of two carbon plates boltedtogether. He wears an ssur siliconeliner on what remains of his thigh,which protects his leg and also providesdirect contact to the prosthetic via a pinconnector. An electric brake inside theartificial knee replaces the lost musclesweight bearing function. A computerand a fluid that becomes viscousthrough electrical impulses allows the

leg to react automatically to movement:it locks in place and provides supportwhen Kalemba uses it for standing, andadapts to his natural motion when hewalks. Kalemba is now also activelyhelping to advance this technology:at ssur, the manufacturer of hisartificial leg, he works in Reykjavik as anorthopedic technician and test personfor new developments.

Small, light and very strong

Icelandic company ssur is striving toenable "A life without limitations." Tofulfill this dream for its customers, the

company is relying on three principles:ongoing development, direct contactto people missing limbs such as LukasKalemba, and on excellent productquality.

A prosthetic leg has to carry the bodyclose to one million steps every year.For this to be not only safe, but alsocomfortable, every single componentmust deliver what the design demands from the simple aluminum tube andcritical components made of titanium upto the electronic elements for complete

"My new leg helped me to regain a bit of the quality of life that I had lost," says orthopedic technicianLukas Kalemba, who lost his leg 10 years ago

A prosthetic leg must be able to bear the weight ofthe user nearly one million times a year

computer-controlled knee prosthetics.Most of the parts for leg prostheticsare manufactured at the companysheadquarters in Reykjavik. "Our partsmust be small and light, but very strongand durable at the same time. This, ofcourse, leaves little room for error,"explains sgeir Pll Gstafsson, CMMspecialist at ssur.



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The Tolerances for some of thecomputer-controlled knee componentsare just 10 micrometers. QualityAssurance requires precise measuringtools to ensure compliance. Theseinstruments must also be able tocorrectly display complex geometries.The artificial knees, for example,feature concave and convex surfaces something that would be impossible tocorrectly measure manually. Therefore,two coordinate measuring machinesfrom ZEISS in the measuring lab nearproduction are used for in-processrandom sampling measurements.

The Power Kneehigh-tech prosthetic can replacethe muscle activity of people whose legs wereamputated above the knee

Each component of a prosthetic must meet the designrequirements exactly

Gumundur Jakobsson, Certified Prosthetist/Orthotist at ssur's Icelandic workshop, explains the indi-vidual fit of a prosthetic leg

The measuring machines must also correctly displaycomplex geometries



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Avoiding "Error 45""When all production machines arerunning, we measure at least 17different parts every hour," saysGstafsson. The machine operatorstarts the measurements at the push

of a button. Measuring technicianGstafsson and his colleague preparethe required measurement programsand clamping devices so that theircolleagues can position their workpiecesproperly on the coordinate measuringmachine without any difficulties andselect the corresponding measuringprogram. The sensor then automaticallyscans the workpiece and determines thedefined form and location data.Measurements with manual measuringequipment, on the other hand, arebeing gradually eliminated at ssur:

"The main problem with manualmeasurements is something that wecall Error 45, or an operator error," saysGstafsson, adding that "they alsotake up time that could be better usedelsewhere." Therefore, ssur now onlymanually measures the most simpleparts.

10 years ago this was a lot different.Before buying its first coordinatemeasuring machine in 2004, ssurwas not even able to measure thegeometrically complex parts. Theelaborate knee components with curvedsurfaces, for example, were purchasedfrom an outside source. The companyhas grown quite significantly sincethen. In addition to additional lathe andmilling machines, the new equipmentincluded a ZEISS CONTURA coordinatemeasuring machine that is still in use.Soon there will hardly be any partswhose details cannot be measured onthe coordinate measuring machine.Therefore, company managementdecided to invest in a second measuringmachine. "We considered another ZEISS

machine because we were so satisfiedwith the ZEISS CALYPSO measuringsoftware," explains Gstafsson, whovalues easy, intuitive operation. ssurdecided on the ZEISS O-INSPECTmultisensor measuring machine toalso cover its optical measuring needs.However, Gstafsson has rarely usedthis option because the contact sensorhas proven so accurate that ssur is stillable to measure workpieces with verytiny geometries by contact.

Benefitting from the amount ofdataBe it contact, optical or manual, ssurdiligently documents all measuringresults. After all, as a manufacturerof medical products, the companymust ensure the traceability of itsmeasurement data in accordance withISO 13485. Up until about six monthsago, Gstafsson and his colleagues

entered this data in Excel sheets: "Atsome point in time, we came to theconclusion that we not only want todocument this enormous amount ofdata, but also use it."

For this reason, ssur introduced ZEISSPiWeb software to analyze, assessand graphically display quality andprocess data in real time. Measurementdata from the coordinate measuringmachines is automatically forwarded

to the software. Even results fromthe remaining manual measurements

"When all Production machines are running, we measure at least 17 different parts every hour,"says CMM

specia list sgeir Pll Gstafsson (r ight)

The software ZEISS CALYPSO was one of the reasons why ssur chose a second ZEISS machine



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Brief profile

ssur

ssur Kristinsson, a young man fromIceland, was dissatisfied with hiscumbersome artificial leg and want-ed a better solution. He opened asmall workshop in Reykjavik in 1971and quickly invented the silicon liner,a new type of connection betweenthe body and prosthetic, that isnow known around the world. Overthe course of two decades, his tinyworkshop grew into a global com-pany now listed on the Copenhagenstock exchange with around 2,300employees. At 18 locations around

the globe, the company manufac-tures and distributes prosthetics foramputees as well as orthopedicproducts for people who suffer fromosteoarthritis or recovering frominjuries. The company is headquar-tered in Reykjavik.

are entered into the central systemby machine operators. Consequently,trends in data sequences can bequickly recognized and visualized.This enables staff members to quicklydraw conclusions about machiningprocesses much faster than in thepast. Gstafsson provides a goodexample: before the introductionof PiWeb, an engineer wrote herthesis at ssur. Her task: using all themeasurement data, find and analyzethe 10 workpieces at ssur that havethe highest defect rate. This took threemonths because she had to review andanalyze every volume product. "WithPiWeb, this is only matter of minutes,"says Gstafsson.

At ssur headquarter in Reyk javik rn IngviJnsson, Director of Management & Operations,and Quality Manager sgeir Pll Gstafsson workfor "a life without limitations"

The results obtained this way forproduction data also improve thequality of the companys products. Thisquality helps people such as LukasKalemba master their everyday activitieson two legs. "Just because you lose aleg, doesnt mean you have to stopliving," says Gstafsson. Sitting in aglass meeting room at ssur, he pointsto a few people walking by: "Out thereis one of the super users, who test ourproducts for everyday activities: HelgiSveinsson, world champion javelinthrower."

Product designer Gulaugur lafsson conductsmeasurements with the ZEISS CONTURA.He is one of the ssur employees wearingan artificial leg himself

Click here for the video:



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When Sebastian Vettel and FernandoAlonso steer their Formula One carsover the track, minute details play akey role in determining the winner.The battle for every second beginslong before they sit behind thewheel it star ts with the manufacturersof engines and drive systems. One ofthem is Pankl Racing Systems AG. Thecompany develops and builds engineand gearing components for variousmotorsport teams in all internationalmotorsport classes, including FormulaOne, the 24 Hours of Le Mans,NASCAR and MotoGP, the pinnacleof motorcycle racing. Pankl Engine

Systems manufactures the enginecomponents at its plant in Bruck an derMur, Austria.

Every gram counts"Lighter, more reliable and better quality,"says Mario Pichler, Head of QualityAssurance at Pankl Engine Systems,describing the constantly growingdemands. Engine components formotorsports repeatedly demand theutmost of manufacturers. In general, it

all starts with a specification sheet onwhich designers note how much stressan engine part is subjected to during

a race how many RPMs, how muchignition pressure and maximum torque,as well as the values for the boreholediameters and idle stroke. The engineersat Pankl are then tasked with designingsuch parts be it a titanium connectingrod or an aluminum piston so thatthey are as light as possible, yet able towithstand extreme forces on the track:

"Our engineers try to get the most outof the part, often a thin line betweenweight and sustainability," says Pichler.

Measure, measure, measureMotorsport demands the utmost notonly from design and production, but

also the measuring technology. First,precision down to a few micrometersis essential to pushing the limits of thetechnologically feasible. Second, anenormous amount of measurementshave to be taken. Low quantities of80 or even 30, as well as constantlychanging requirements on parts arecommonplace in motorsport. Therefore,the engineers in Bruck often face 15initial sample approvals for new partsin a single day. Pankl measures each

of these samples several times beforedownstream production can start. Thisis supplemented by random samples

and 100 percent measurements duringrunning production. 10-15 machineprocesses cover the production of aconnecting rod for motorsports, forexample and measurements are madefollowing every single step.

Until a few years ago, Pankl reliedprimarily on manual measuringequipment for these in-processmeasurements from slide gauges,quick tests and height gauges tomicrometers and contour measuringsystems. "This took a lot of time andwas largely dependent on the skills of

the employees," remembers Pichler. Theresults obtained with manual measuringequipment fluctuate from colleague tocolleague due to minimal differencesin how it is used. Management andQuality Assurance considered the useof an automatic measuring machinewith the primary goal of automatingin-process measurements to acceleratethem and make them reproducible.

Plug & play

Pankl decided to test the DuraMax 3Dcoordinate measuring machine fromZEISS. The compact measuring machine

Mario Pichlers goal was to automate in-process measurements



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is specially designed to replace manual

measuring equipment in a productionsetting. It is also obliv ious to mechanicalvibrations and temperature fluctuationsbetween 18-30 degrees Celsius, andhas a footprint of just one square meter.With accuracy down to 2.4 m, it is alsoconsiderably more precise than manualmeasurements even if it is not quiteas accurate as the ZEISS PRISMO SACCcoordinate measuring machines thatPankl uses in its measuring lab. TheDuraMax can also be operated with

ZEISS CALYPSO measuring software,which eight measuring technicians inBruck are already familiar with thanks

to their experience with the other ZEISS

machines. "DuraMax was simply aplug & play option for us," says Pichler.The measuring technicians transferredexisting measuring programs to themachine, measured the first workpiecesand began test operations. Manyproduction employees, of course, hadto be convinced that it was time toreplace their trusted manual equipmentwith an automatic measuring machine.

"However, within two weeks, theyno longer wanted to do without the

measuring machine. The decisionhad been made: we were keeping it,"reports Pichler.

80 percent reduction in measuring

timeDuraMax enabled Pankl to reach its goalof automating in-process measurements:

"All measurements that we did byhand in the past can now be madeon the DuraMax," states Pichler. Thisallows Pankl to reduce its measuringtime by 80 percent for certain tasks.According to the measurement plan,for example, around 80 characteristicsmust be measured following the millingof contours on a connecting rod. As

Pichler says, "Before DuraMax, weneeded six different gauges and analtimeter with five different fixtures to

"All the measurements that we did by hand in the past can now be made on DuraMax,"says Mario Pichler, Head of Quality Assurance at Pankl Engine Systems



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reach everything." This process tookone hour and twenty minutes. Now, anemployee can clamp the workpiece ona single measuring machine, the ZEISSDuraMax. At the press of a button, thestylus automatically measures the part,thus recording all necessary values.According to Pichler, this takes just 15minutes. Projected on to the numerousprocess steps and initial sampleinspections in motorsport, this results inconsiderable savings at the productionlevel for Pankl.

The introduction of DuraMax broughtanother benefit to Pankl: the results

obtained in the measuring lab, as wellas production, are now reproducible.Until now, Pankl only made in-processmeasurements on coordinate measuringmachines in the measuring lab forcertain critical dimensions. The restwere manually documented and thussubject to numerous factors such as theindividual methods of the productionworker. In extreme cases, thedeviations from the ideal dimensionswere only discovered in the final checks

after a lot of time and money hadalready been invested in downstreamproduction. Today, DuraMax provides

Pankl with a high amount of securityregarding the quality of its products atan early stage. This was only possiblebecause the coordinate measuringmachine, like the gauges, was ideal foruse in a production environment.

Directly on the production line"This is not an earthquake, but ratherour demagnetization system for theconnecting rod," Pichler tells visitorsto Bruck when the building shakes a

bit. A measuring machine designedto withstand mechanical vibrationswas therefore required to replacemanual measuring equipment: "It wasabsolutely necessary for the in-processmeasurements to take place in theproduction hall," explains Pichler. Priorto this, waiting times in the measuringlab were on the agenda because manualmeasuring equipment was not accurateenough for some random samplemeasurements. Now, there are very few

Connecting rods in motorsport

As part of the crank drive in anengine, a connecting rod transfersthe linear motion of the piston intothe torque of the crankshaft.It is usually made of twocomponents screwed together.It may sound simple, but inmotorsport it is highly complex:the production process at Panklinvolves 10-15 steps. And theworkpiece is measured after everysingle one.

In-process measurements with DuraMax are made on site in the production hall



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Brief profile

Pankl Racing Systems

Pankl Racing Systems AGheadquartered in Kapfenburg,Austria, specializes in lightweightcomponents designed to withstandextreme mechanical stress.The company has around 1150employees around the world who

develop, produce and distributeengine and drive systems, as wellas chassis parts for motorsport,luxury cars and helicopters. Panklmanufactured its first connectingrods for motorsport back in 1985.Today, the companys racing divisionis the market-leading supplier ofengine and drive systems. The enginesystems are built in Bruck an der Mur,Austria, and Irvine, California, whilethe drive systems are put together

in Kapfenburg, Austria, and Bicester,UK.

in-process measurements that have tobe made in the measuring lab. Today,we use DuraMax to measure everythingwe can. As a result, we have much lesstraffic in Quality Assurance and thewaiting times have been eliminated.This also necessitated a few preparationsand a clear distribution of responsibilitiesamongst measuring techniciansand machine operators. Today, themeasuring technicians prepare thefixtures to clamp the workpieces sothat the machine operators knowexactly how they have to position theirworkpieces on the coordinate measuringmachine. The measuring technicians

generate the measuring programs usingoffline measuring stations. On thisbasis, production employees can makemany of the in-process measurementsthemselves they simply have to selectthe program and press start.

The good experiences with ZEISSDuraMax led Pankl to buy four of thesecompact measuring machines. Twoof them are used for connecting rodproduction alone. In addition to small

batches for motorsport, Pankl recentlybegan manufacturing an increasingnumber of connecting rods and other

components in large quantities forluxury cars such as Ferrari, Porsche,McLaren and Mercedes. They alsoplace considerable demands on design,production and measuring technology even if the drivers wont be facing offagainst Vettel and Alonso.

The coordinate measuring machine allows Pankl to reduce its measuringtimes by up to 80 percent. Photo: Mario Pichler and Ren Hautz



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Quality for

Your EyesContact lenses are around 0.12 mm thick, which is not much thickerthan a piece of paper. From the beginning to the end of their production,precision in the micrometer range is vital. Jun He Technology in Taiwanuses the CONTURA bridge-type measuring machine, the O-INSPECTmultisensor measuring machine and the METROTOM computertomograph from ZEISS to ensure that the stringent standards are met.

49

// From Users for UsersJun He Technology / Taiwan



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Daniel Lin, ZEISS dealer on Taiwan, and Peter Chen, measuring technician at Jun He, di scuss the measuringresults from ZEISS METROTOM

A stee l form... ...is used to manufacture inject ion mo lds...

far more informative results thanconventional measurements on a cutline through the mold. (Scan the QRcode for a short video on the use ofMETROTOM at Jun He.) Jun He was thefirst company in Taiwan to purchasea METROTOM, which is capable ofcompleting such measurements in 40minutes. Its employees were trained bya 3D engineer flown in specially fromGermany.Jun He now operates six ZEISS machines.Daniel Lin, who has been a ZEISS dealer

in Taiwan for 20 years, remembersthe interaction: "In the beginning,production employees did not wantto believe that our measurement datawas correct; after all, they work withprecision machines. But our results werereproducible, every time. In the end,this is what created the trust in ZEISS."This trust is also shared by customersas described by Lin Zhensheng, SalesManager at Jun He: "Another benefit ofthe ZEISS machines is the data report.Our customers know that you cannot

describing his initial contact to ZEISStwo years ago. Back then, he waslooking for a machine that he could useto precisely measure the gap betweenthe two halves of the assembled plasticinjection mold before entering massproduction. The METROTOM 800was just what he was looking for: thecomputer tomograph generates a highlyprecise, three-dimensional image ofthe contact lens shape including thelens, which enables measurementsat any location. It therefore delivers

...for the production of contact lenses



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manipulate ZEISS measurements. Theyreceive their products together with thedata sheet and can see everything inblack and white."

From the steel mold to the plastic

injection moldThe development of a nickel-platedsteel mold provides the foundation forthe production of contact lenses. Theirindividual components are milled onhighly precise machines and checked foraccuracy prior to assembly. The finishedsteel mold is also measured twice beforeit is used to manufacture the plasticinjection molds. In the past, a measuringtechnician had to manually measuresingle points along the curves; the ZEISSCONTURA G2 bridge-type measuringmachine now scans eight steel moldsin an hour. Because the CAD data of

the mold is entered into the machinebefore the measurement, the machineknows exactly where to measure. "Weoperate very precise lathes and millingmachines, meaning that our measuringmachines also have to be very accurate.

In the past, our measuring uncertaintywas only five micrometers. Nonetheless,it was too high. With the CONTURA, wenow measure with accuracy of just onemicrometer," says Wang.

30 times fasterThe next step of production is moredemanding because plastic is a verytricky material. It has the habit ofshrinking after it is injected hot intothe mold. Different humidity levels,temperatures and injection speeds,different materials, even differentbatches of the same material can lead

to varying results with the same mold.This is where measurements are a mustand adjustments made in a correctionloop. After all, with the high productionspeed in plastic injection molding, toomuch would be lost very quickly if the

accuracy were not given. Jun He uses anO-INSPECT with a white light distancesensor to capture the very small edges,such as those for the outer edge ofa lens. It can be used to measure 3Dstructures optically and efficiently. Theproduction of the injection molds ischecked every four hours. Finishedmolds are measured to ensure that theprocess is stable. "In the past, I had fiveor six people measuring non-stop; nowthere is only one," explains Wang. AnO-INSPECT 322 has now replaced themanual measurements from variousolder machines and is 30 times faster.

A measuring technician at Jun He prepares the nex t measuring process for in jection molds for contact lenses with a ZEISS O-INSPECT



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Within 15 minutes, it scans the curvesof eight molds and transmits the dataautomatically to statistical processcontrol via CALYPSO software. Thetemperature or injection speed can thusbe modified immediately, if necessary.

Thanks to the precision and speed, thereject rate for the injection molds hasbeen reduced to around three percent.The speed and immediate adjustmentpossibilities during the process alsoenable Jun He to deliver finished plasticinjection molds in only two weeksfollowing receipt of the order. This is akey factor in the fast-paced market forcontact lenses.

"Finally," says Wang, "manufacturingcontact lenses requires a machine thatprovides maximum accuracy to delivera highly finished product. You can onlycheck the work if you have access to

the most accurate measurements. Andthis is the only way to achieve a level ofquality good enough for your eyes.

BRIEF PROFILE

Jun He Technology

Jun He Technology is a manufactur-er of precision injection molds andproducts for the optical industry.In Taichung, Taiwans third largestcity, the company manufacturesflash and camera lenses for smart-phones, components and molds forcamera lenses and LED lenses forTVs, and is thus the primary supplier

to brands such as Canon and HTC.The companys story began in 2005with the design of a mold for themanufacture of contact lenses. JunHe soon became a key supplier tothe contact lens industry in Taiwan.Today, the company offers totalsolutions in this industry from theinitial steel molds to plastic injectionmolds to the cases.

A finished lens must not deviate from the idealform by more than 2 .5micrometers. For the steelmolds at Jun He, this means a tolerance of just onemicrometer, or 80 times thinner than a human hair

The finished steel form is measured twice before it is used in production. The ZEISS CONTURA G2 measureswith one micrometer accuracy



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In 2002 BYD Precision Plastic Injection Tooling Factory purchased itsfirst ZEISS CMM. Today, a total of 19 ZEISS CMMs are running withthe utmost accuracy, efficiency and reliability. They have proven to bea technological backbone for technological innovation at the plant.

Pursuing Excellence,Shaping the Future

// From Users for UsersBYD Precision Plastic Injection Tooling Factory / Shanghai / China



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BYD ranks among the worldsleading manufacturers of mobilecomponents and providers ofassembly services. It is one of themost influential national brands inChina. With its 11 large industrialparks across the country, BYDsteadily pursues its developmentconcept of being technology-based and innovation-oriented.

Founded in 2002, BYD PrecisionPlastic Injection Tooling Factorycovers an area of more than 30,000square meters and has a staff of 1500workers. Specializing in the design,manufacture and maintenance ofprecision plastic tools, the plants mainfocus is on consumer electronics suchas mobile phones and notebooks, aswell as precision parts for automobileinteriors and precision mechanical parts

for the automotive industry. Whenchoosing new equipment or upgradingtechnology, reliability, precision,accuracy and superior quality are alwayskey factors. To this day, the factoryhas developed more than 20,000 setsof precision plastic tools and broughtthem to the international market.Making the right investments, valuinginnovation, demanding excellence intechnology and implementing openmanagement concepts has allowed

BYD to continuously stay ahead of thecurve. For its measurement activities,the factory relies on 19 ZEISS measuring

machines, which operate at high speedday in, day out. The ZEISS measuringmachines have enabled the factory toactively innovate and independentlydevelop an automated programmingand measuring platform, which hasbeen well reviewed by the industry.

Reliable equipment, solid choiceWhy did BYD choose ZEISS? Reliability!When BYD Precision Plastic InjectionTooling Factory initially looked formeasuring equipment, the companywas surprised to see that the ZEISSequipment used by its clients wasoperating reliably even in the open air.Therefore, it was an obvious choicefor ZEISS and the start of a lastingcooperation.

The very first CMM purchased by BYDPrecision Plastic Injection Tooling Factory

when the factory opened in 2002 wasmade by ZEISS. When the company setout to purchase the second round ofequipment in 2007, the first machinewas still performing well. Now, all 19CMMs owned by the factory are madeby ZEISS, underlining the factoryscontinued trust in ZEISS. Because thefactory produces its precision plasticinjection tools under great timeconstraints, it has adopted a two-shiftsystem. This allows operators to run

the equipment for almost 20 hoursnon-stop every day. Keeping the unitsoperating reliably for long stretches at

such a high capacity is therefore vital.The superior quality and exceptionallyhigh reliability of ZEISS products havecompletely satisfied the productionrequirements of the factory and its long-term performance has deepened thefactorys trust in ZEISS.

1,500 to 2,000 workpieces need to bemeasured throughout the plant everyday. Thanks to its excellent reliability,extremely low failure rate, rapidmeasuring speed and perfect measuringaccuracy, ZEISS equipment is able to notonly deliver high quality and efficiency,but also largely reduce costs for BYD.

Accurate measurement, efficientand flexible technologyZEISS has accompanied the entire11-year development of BYD PrecisionPlastic Injection Tooling Factory: from

the plants opening, to the markedachievements of the present. So far, thefactory has successfully delivered morethan 20,000 sets of precision plastictools to many global clients. ZEISSCMMs have witnessed the developmentof the factory and contributedsignificantly to this success.The factory mainly produces precisionplastic tools and small workpieces withhigh accuracy requirements that areusually in the 0.005 mm range. Also,

each part is unique. According to theproduction pattern of BYD, exporteddata from the CMMs is used to make

e factory owns 19 ZEISS CMM units, with each ofe manual measuring units running for 20 hours

ontinuously each day



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corrections to the workpiece in themanufacturing department. Minorinaccuracies in the data can result in therejection of workpieces. Larger errors

could even cause machine tools tocollide with machines. Thus, measuringequipment must be very accurate andprovide flexible measuring capabilities toreduce the rate of rejected products to aminimum, while guaranteeing productsof highest quality.

For example, the most popular machinein the factory is the CONTURA G2bridge-type CMM. It can easily satisfythe demands of production of BYD. Itsscanning technology can rapidly deliverhigh-quality measuring results, quicklydetect any changes in the product andthereby reduce the rejection rate to aminimum. The modular design enableseasy maintenance and facilitates futureupgrades. Therefore, it provided ashortcut for BYDs effort to automate.

Outstanding performanceFollowing the companys principleof technology-based and innovation-oriented, BYD always adheres to

innovative development concepts.With excellent reliability, outstandingtechnological performance andflexibility, ZEISS equipment has providedsubstantial support to BYDs technicalinnovation.The automated programming andmeasuring platform independentlydeveloped by the factory is basedentirely on ZEISS equipment. Thisplatform has completely eliminated theneed for manpower in this process and

has made the smart and automatedcompletion of measuring tasks a reality.

Robotic arms and computers workingtogether have replaced the manual workof loading and unloading workpieces.Computers can read data, write the

programs and issue instructions on theirown. Linked up with the productionplans and cooperating with robots, theycan measure all workpieces. Furthermore,when one robotic arm cooperates withtwo CMMs to measure four parts, it notonly frees up manpower, but also greatlyimproves production efficiency, whilealso allowing longer working hours.Completed over a period of three years,the automation platform has undergoneseveral technological upgrades. The highreliability and flexible technology of ZEISSequipment played a crucial role whenthe company transitioned from a setupwithout robots to the current systemof one robot paired with two fast andefficient CMMs.

Such an automated measuring platformputs high demands on the reliability ofmeasuring equipment. First, they must beable to operate reliably and continuouslyfor long periods. This was the biggestconcern of BYD when the company

first introduced the automated system.However, once the platform had beenin operation for nearly one year, theZEISS equipment had proven to be fullycapable of very reliably tackling such aheavy work load.Meanwhile, the modular design andcomprehensive aftersales serviceof ZEISS provided a premise for theresearch and development of theautomation platform at BYD. Themodular design of ZEISS equipment not

only provides for easy maintenance, butalso enables easy upgrading to satisfy

the demands of future development,thus allowing BYD to effortlesslyupgrade equipment throughout theproducts lifecycle.

Comprehensive service,professional attitudeApart from the outstanding reliabilityand technological flexibility of theZEISS equipment, ZEISS comprehensiveaftersales service also greatly facilitatedtechnological innovations achieved with

Founded in 2002, BYD Precision Plastic Injection Tooling Factory covers an area of more than 30,000 m2and has a staff of 1500

The high-level measuring technology of ZEISS can

completely satisfy the measuring demands of BYDfor precision too ls



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the ZEISS equipment. According to BYD,ZEISS aftersales service was the mostsystematic and professional provided bymultiple measuring equipment suppliers

interviewed by BYD Precision PlasticInjection Tooling Factory. ZEISS servicedoes not merely deliver training on howto operate equipment, but is also morethan willing to teach additional basicknowledge.

The BYD factory focuses on one-offproduction. Each part is unique andneeds its own measuring program,which requires a large amount ofwork. Because of this, to increaseefficiency the factory needed to conductadditional development activities onparts of ZEISS equipment and simplifysome programming procedures, forexample a modular development basedon ZEISS CALYPSO. Although this wasinitially completed with the help ofZEISS, BYDs demand for additionaldevelopment also rose as its fleet ofequipment increased. ZEISS has helped

to conduct systematic training on thistechnology in accordance with BYDsspecial demands. It has helped totrain the factorys technicians on the

required developments and has helpedthe company establish its own technicalteams.

A reference book titled GeometricCoordinate Measuring Technologyand Applicationwas published byZEISS in association with ShanghaiUniversity in 2012. This book filleda gap in this field of knowledge inChina and provided the factory withprofessional, comprehensive andsystematic theoretical support in termsof technological innovation. This pointillustrates the professionalism of ZEISSand its efforts in providing service. Theprofessional technical training servicesof ZEISS were a crucial factor in theresearch and development activities ofBYD Precision Plastic Injection ToolingFactorys automated programming andmeasuring platform.

The automated programming and measuring

platform independently developed by BYD re lies onZEISS measur ing un its and has made automatedmeasuring tasks a reality



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MicrometerPrecisionA single tool can make all the difference in the quality of millionsof products. Toolmaker KWS Klle is therefore a true proponentof maximum precision. The company covers all productionsteps in-house and measures all components with a coordinatemeasuring machine from ZEISS.

Innovation Metrology Speci al 17, 2013 59

// From Users for UsersKWS Klle / Mauerstetten / Germany



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by my hand." Until a few years ago,KWS relied on external measuring labsto ensure the high precision. This led todelays in production and also meant thatsome errors were not detected until thenext manufacturing step. This resulted inadditional costs. Furthermore, it contra-dicted the company's slogan of doingeverything itself. Therefore, KWS decidedin 2011 to purchase a new measuringmachine.

Ease of useTo find the right system, the companycompared the sample measurementstaken on machines from various provid-ers. In addition to high precision, thetest came down to whether or not themachine could be used at temperaturesabove 21 degrees Celsius. After all, itwouldn't be used in a separate mea-suring lab, but in an air conditionedproduction hall. KWS wanted to access

the measuring machine directly fromproduction without having to wait forthe workpieces to acclimate.

demands on precision have increasedsignificantly in recent years: "In the past,the dimensions of the tools usually hadto be accurate down to five micrometers;now two micrometers is not a rare occur-rence," says Hbner. He holds up a toolto give you an example of how minutethis is: "Just holding this workpiece in myhand causes its shape to change severalmicrometers due to the heat generated

KWS works with a wide range of raw materials

As a p ilot customer of ZEISS, KWS Klle used a measuring machine with the new XTR sensor for the firs t time the photo shows KWS President Helmut Hbner (left) talking with Bernd Balle from ZEISS

One other criterion played a key role:"We looked at ease of use and this iswhere we ran into considerable dif-ferences among the providers," statesHbner. Because the quantities at KWSare very small with between one and tenitems for each product, the work neededto create the measuring programs wasanything but negligible. After extensiveconsiderations, KWS opted for theACCURA bridge-type measuring machine

from ZEISS with a measuring range of1200x901x900 mm.

New scanning probe for complexgeometriesThe ZEISS ACCURA coordinate measur-ing machine measures with accuracyof 1.6+L/333 m at room temperaturesbetween 20-26 degrees Celsius as longas the temperature remains constant. Themeasuring range also provides room forlarger tools. A special feature: as a pilot

customer, KWS selected a new scanningprobe for the measuring machine. ZEISSACCURA measuring machines are usually



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equipped with a scanning probe that canmeasure the features and contours notonly point-by-point, but also continu-ously. However, the XTR sensor featuresan integrated rotary axis. It enables thestylus system to turn as far as possible in15 degree increments and thus always bepositioned at the right angle to the part.It reaches practically every location evenwith complex workpiece geometries without sacrificing accuracy.

One machine has it allThe bridge-type measuring machineequipped with the XTR sensor providesKWS with numerous benefits: thecompany was able to achieve the desiredaccuracy of one micrometer. The newsensor also enables the measurement ofalmost all components of the differenttools with just a few stylus configurationsand an occasional change-out. The small-est stylus features a diameter of just 0.2

millimeters: "We were amazed at howaccurate we can measure with this stylus.I mean it is so small that you can hardly

see it," says Hbner enthusiastically.It is more than just all the workpieces

from complex small parts up to 500kilogram tool designs that the twomeasuring technicians at KWS can nowmeasure on a single machine.The ZEISS ACCURA can capture all

required dimensions even radii, whichrequired a contourograph in the past.This further increased accuracy becausethe results from a single measuringmachine can more easily be comparedthan those from two or more differentsystems.

The XTR sensor features an integrated rotary axis. It enables the stylus system to also be positioned at the right angle to the part and reach practically every locationwithout sacrificing accuracy even on complex geometries. Martin Degelmann, measuring technician at KWS Klle



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Taking responsibilityEver since KWS switched to ZEISS,there have been fewer questions anddiscussions with customers about themeasured values because many of them

use ZEISS measuring machines them-selves and trust the results. Accordingto Hbner, the company "now has evenmore responsibility because customersoften no longer check our work and, ofcourse, we do not want their productionlines to shut down because one of ourtools is not precise enough." Anotherchange at KWS: the measurements in anexternal lab are now a thing of the past:

"We now do everything here, just as itsays in our philosophy."

Ease of use was a key factor in the selection of themeasuring machine

Brief profile

KWS Klle

KWS Klle has been manufacturingtools for more than 30 years,including compound, punching,bending and forming tools, as wellas injection molding, zinc die-cast and glass molds. Its productportfolio also includes highlyprecise one-off parts and smallseries, prototypes, assemblies,fixtures and gauges made ofvarious materials. KWS employs50 specialists and trainees whocover every processing step onsite. The majority of the company'scustomers can be found in theautomotive industry, as well as themedical technology, mechanicalengineering, electronics, cosmeticsand other segments.

Innovation The Magazine from Carl Zeiss

Industrielle Messtechnik GmbHIssue 17, May 2014

Published by:Carl Zeiss Industrielle Messtechnik GmbH,OberkochenManagement Board: Dr. Rainer Ohnheiser,Harald Klaiber, Felix Hoben

Editors:Bernd BalleCarl Zeiss Industrielle Messtechnik GmbH,OberkochenCarl-Zeiss-Str. 2273446 [email protected]: +49 (0) 7364/ 20-8148Fax: +49 (0) 7364/ 20-4657

Graphics & Design:Agentur BeckerMarcus Mantel | Bro fr Gestaltung

Contributors to this issue:Judith Schwarz, storymakerChristoph Robisch, agentur becker

Translation: Clive Poole, Paul Soos, HollyO'Reilly, Carl Zeiss

Printing: C. Maurer Druck und Verlag,Geislingen an der Steige

The contents of the articles do not alwaysreflect the opinion of the publisher.Reprint only with the express wr ittenpermission.



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