ZEISS Multi Sensor CMMs for Car Body Applications

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ZEISS IQS, Horizontal Arm CMMs

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ZEISS Multi Sensor CMMs for Car Body Applications
More then a Robot – The Hambot

ZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
Trends in Carbody Metrology

Faster to the result.
Surface information (CAD compare)
Digital Twin
Optical sensor on industrial robots

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More than a Robot – The Hambot
Definition Industrial Robot
Industrial robots are defined by ISO 8373:2012:
An automatically controlled, reprogrammable, multipurpose
manipulator programmable in three or more axes, which can beeither fixed in place or mobile for use in industrial automation
applications
Classification by mechanical structure• Linear robots (including cartesian and gantry robots)• SCARA robots - Articulated robots• Parallel robots (delta)• Cylindrical robots• Others•

Horizontal arm CMMs, especially combined with optical sensors are automatically controlled,
programmable in more than 3 axis and are therefore robots based on ISO 8373:2012

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More than a Robot – The Hambot

More than a Robot.
The Hambot.

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More than a Robot – The Hambot
ZEISS CALENO – More than a Robot•

CALENO is a cartesian 6-axis robot•CALENO is a is a robot with an outstanding
optical sensor system – EagleEye•

With CALENO you get proven CMM accuracy, acollaborative system and a multi sensor systemwith automatic sensor change.

This is not possible with an articulating robot.

Therefore, CALENO is more than a robot.

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More than a Robot – The Hambot
ZEISS CALENO – The Hambot••

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ZEISS Multi Sensor CMMs for Car Body Applications
The Hambot - Overview

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Multi-Sensor System
Multi Sensor System

ZEISS EagleEye
Fast laser sensor withintegrated 6th axis

ZEISS IQS, Horizontal Arm CMMs

ZEISS DSC
Highly dynamic, nonindexing sensor
carrier for multisensor applications•With ZEISS EagleEye, geometric elementscan be measured and evaluated in record
time•

Scanning of free-form geometries for CAD
comparison and of geometry elements withthe same sensor•Automatic switch between optical andtactile sensors for features that cannot be
optically measured.

•Thermofit extensions with up to 800mm.

ZEISS RST-P
Tactile reference
sensor with piezo
technology

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Exceptional Technology - CALENO

Trapezoidal Z column and Y-arm for
maximum precision and dynamics

Easy access tomaintenancerelevant parts

Continuous sensor
carrier DSC with hightorque and highdynamics
Optional Indexing
sensor carrier RDS-C6CAA

Collision protection on both sides
for protection of the Y-arm
Avoids downtime of the CMM

Flush-floor access to measuring
range from all sides

ZEISS IQS, Horizontal Arm CMMs

ZEISS optical sensor system
EagleEye for significant
shorter measuring time andCAD compare

Measuring beam with newconcept for thermal
decoupling of the measuring
beam and the foundation

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Exceptional Technology – CALENO T

Full covers made of
EPP for excellent
thermal isolation

Continuous sensor carrier
DSC with high torque andhigh dynamics
Optional Indexing sensor
carrier RDS-C6 CAA

Measuring tables available with
optional T-slots or bore pattern
for the clamping of fixtures

Inherent stiff measuring
plateallows
theinstallation with active
damping system

ZEISS IQS, Horizontal Arm CMMs

Easy access tomaintenance relevant parts

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ZEISS Multi Sensor CMMs for Car Body Applications
Safety for the operator and the Hambot

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More than a Robot – The Hambot
Safety for the Operator•Safety edge at the Y-arm••••ZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
Safety for the sensor system
Collision protection for the sensor•Optional collision protection for theZEISS DSC or RDS-C6•

Protective device on the ZEISS RST-P sensor••
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ZEISS Multi Sensor CMMs for Car Body Applications
CALENO/CALENO T – What is new

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More than a Robot – The Hambot
PRO/ CALENO Improvements•Column turned by 90° for enhanced stiffnessZZZYZYXXXYY

PRO/ CALENOZEISS IQS, Horizontal Arm CMMs

XPRO T/ CALENO T
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More than a Robot – The Hambot
PRO/ CALENO Improvements

PROZEISS IQS, Horizontal Arm CMMs

•PRO/ PRO T wasavailable with standard,or full covers•

CALENO is always withfull coversEnhanced thermalstability

New material EPP withexcellent thermal
isolation

CALENO
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More than a Robot – The Hambot
PRO/ CALENO Improvements•

New counter balance system
ZEISS IQS, Horizontal Arm CMMs

Counter weight instead ofbalanceroLess service costsoImproved MTBF

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More than a Robot – The Hambot
PRO/ CALENO Improvements•ZEISS IQS, Horizontal Arm CMMs

New X-carrier

No welded dedicated X-carrier

Reduced complexityStandard with gap covers

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What is new? Summary•

ZEISS IQS, Horizontal Arm CMMs

CALENO is a fully new developed Hambot(horizontal arm CMM)
New designed X-axis as a welded
structure with integrated thermal
decouplingNew Y/Z tower with trapezoid shaped
axis and linear ball bearing in all axis

New counterbalance system for thecolumnNew full covers as standard for
improved thermal isolation,
environmental protection and moderndesignNew non indexing sensor carrier DSC

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ZEISS Multi Sensor CMMs for Car Body Applications
Articulation

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More than a Robot – The Hambot
Indexing sensor carrier RDS-C6 CAAZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
Indexing sensor carrier RDS-C6 CAA - Summary

Sensor carrier RDS-C6 CAA- Indexing articulatingprobe holder• CAA-calibration- For short calibration time
- For maximum uptime of the CMM• Step width of only 2,5°
• Position repeatability ±1”• Maximum extension 400mm- For excellent accessibility even on complex parts• Safety- Spring loaded probe plate with mechanical fallarrester• Sensors- Touch trigger probes:- RST-P, TP6 und TP20
- Optical sensor system FalconEyeZEISS IQS, Horizontal Arm CMMs

05.09.201223

More than a Robot – The Hambot
Non Indexing Swivel Head DSC

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More than a Robot – The Hambot
Non Indexing Swivel Head DSC – Improvements CSC - DSC

Customer benefit•Higher data rates for future optical sensor systems.

•Improved reliability.

•New, attractive designInnovation•New, improved bearings.

•Slip rings for A axis, n X 360°

•B axis ± 137,5°

Replacement for CSC and CSC-U2ZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
Non Indexing Swivel Head DSC – Differences CSC - DSC

DSC – non indexing probe holder• Improved performance compared to indexing
swivel head
 XYZ movement and rotation at the same time

• Improved safety, due to additional collision
protection of the probe plates• If extensions longer than 400mm are required, e.g.

truck cabins• For the optical sensor system EagleEye with6th axis
• Passive probe changer for reduced costs andimproved reliability
 Additional ports can be added• Replaces the CSC
ZEISS IQS, Horizontal Arm CMMs

CSC probe changer
with 4 ports
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ZEISS Multi Sensor CMMs for Car Body Applications
Touch Trigger Probes

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More than a Robot – The Hambot
Touch Trigger Probes Zeiss

RST-P Piezo Probe
Piezo signal

Electr. signal• Dual principle of probing
 first force-free Piezo probe impulse
 then mechanical deflection• Better reproducibility than Renishaw
touch trigger probes• Robust

Mechanical contact
closedMechanical contact
openedProbe force at moment ofcontact <0.01N

 Overtravel 26°
 MTBF more than 5 million trigger• Optimum universal probe due to Stylus weight up to 10g
 Stylus length up to 90mm

• Temperature stabilized invar bodyZEISS IQS, Horizontal Arm CMMs28More than a Robot – The Hambot
Touch Trigger Probes Renishaw

TP6• Universal probe, if
customer requests
Renishaw• More over travel than TP20
• Cheapest touch triggerprobe• Trigger force can be
adjusted

ZEISS IQS, Horizontal Arm CMMs

TP20
• Stylus modules can bechanged• Small diameter• Different probe modules
available• Standard delivery with
one module medium
force and one high force• Due to the risk of false
trigger, low force should
not be used

Electromechanical switch

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More than a Robot – The Hambot
Comparison Trigger Probes

Principle of functionTrigger force in the
moment of data
capture X/Y
Trigger force in the
moment of data
capture Z
Max. possible stylus
lengthMax acceptable stylus
mass
Reproducibility
Stylus length atspecification
Durability/
no. of trigger
Over travel X/YOver travel Z
ZEISS IQS, Horizontal Arm CMMs

RST-P
Piezo
<0,01 N

TP6
Electro mechanical switch

TP20
Electro mechanical switch

0,11 - 0,3 N with stylus L=20mm 0,08N/ 0,25N/ 0,4N with stylus L=10mm<0,01 N??

0,75N/ 1,9N/ 3,2N

90 mm

50 mm

50 mm (high force)

10 g

5g

5 g (high force)

0,3 µm0,35 µm

0,35 µm

20 mm

20 mm

10 mm

> 5 Mio> 1 Mio> 1 Mio

± 26°
8 mm

± 22°
5,5 mm± 14°
4 mm/ 3,7 mm/ 2,4 mm
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ZEISS Multi Sensor CMMs for Car Body Applications
Optical Sensor System EagleEyeZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
Productivity improvement with the EagleEye system

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More than a Robot – The Hambot
Ease of useZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The HambotAccuracy

µµSphere Centre Test EagleEye
7060504030201003D/µm05101520251 The accuracy of the sensor is defined as the maximum deviation of the X or Y center point of a sphere, measured in the measuring area of the sensor
2 Sphere center test on PRO premium 16/25. 29 angular positions of A-/ B- and C-axis

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Robustness•••ZEISS IQS, Horizontal Arm CMMs

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Description of the Application/ differentiation

Feature Analysis

Feature Serial
Measurement

Individual features are measured
in order to detect and correct
problems.
Feature measurement during
product startup.

Process control based on test
features and functional
dimensions. Statistical evaluationof the results. Samples from thecurrent series.

ZEISS IQS, Horizontal Arm CMMs

CAD Compare outer shell

CAD Compare problem
analysisComplete Scan for virtual
Meisterbock

Essentially, the visible surfaces inthe area of the outer skin aredetected. There is no requirement
to detect the inside of thecomponents, or the structuralareas.

A typical problem analysis with
optical metrology is shown in thepicture above. It is e.g. for leaktests in the area of the doors. For
this purpose, only the informationin this subarea is needed.

All components are recorded
completely, ie inside and outside,in order to carry out virtual
analyzes and simulations of thecomponents to each other. For
this, the deformations must be
simulated by the dead weight ofthe components for the virtual
masterbuck.

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ZEISS Multi Sensor CMMs for Car Body Applications
SoftwareZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
ZEISS CALIGO - The software for freeform surfaces and features

02 Benefits // Highlights• Easy to use software• Path-in/Path-out• Efficient software architecture for processing large data quantity• Efficient change management• Integrated simulation functions for off-line programming• Collision protection by using automatic travel paths• Including ZEISS PiWeb reporting (professional report creation)

01 Main application // description

03 Installation locations // facilities•Facilities of automotive manufactures and suppliers:••••

Efficient tool for testing and inspection freeform surfaces
and standard geometries in car body construction
Allow meaningful conclusions of car body reports
Sectional view and 3D intersection curves
Statistic analyses for processes and production means
Management dashboards

ZEISS IQS, Horizontal Arm CMMs•

Individual parts, assembly (geometries, features, surfaces)•Body construction (geometries, features, surfaces)•

Client/server installation is embedded in existing IT infrastructure38More than a Robot – The Hambot
ZEISS PiWeb - Quality data management

02 Benefits // Highlights• Central data store with global data availability• Tools for in-line data, fast creation of reports with large data
• User specific reports for QA and in-line(e.g. tool manufacturing, assembly, final assembly, management)• Fast and intuitive handling and creation reports with drag and drop

01 Main application // description

03 Installation locations // facilities

••
•
•
•

Facilities of automotive manufactures and suppliers:

Interactive reports for complex data
Allow meaningful conclusions of car body reports
Sectional view and 3D intersection curves
Statistic analyses for processes and production means
Management dashboards

ZEISS IQS, Horizontal Arm CMMs••

Individual parts, assembly (geometries, features, surfaces)
Body construction (geometries, features, surfaces)•Paint shop (gap-and-flush measurement after painting)•Final assembly (gap-and-flush measurements for fully assembled vehicles)•Client/server installation is embedded in existing IT infrastructure

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ZEISS Multi Sensor CMMs for Car Body Applications
Applications

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Analysis of press parts, assemblies and BIW

In which phase is being measured?

How will be measured?

•Part qualification for start up phase of production•Fast, tactile and optical feature measurement•Fast analysis in the series•

CAD compare for problem analysis.

What will be measured?

•Digitization•

How to create the measuring programs?

Press parts, hanging parts, up to the complete body-in-white.

ZEISS IQS, Horizontal Arm CMMs•

Offline, with simulation for the start up phase•

Direct at the CMM for problem analysis

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Meisterbock analysis and finished car analysis

In which phase is being measured?

How will be measured?

•Part qualification for start up phase of production••

Fast analysis in the series

design issues can be discussed on theMeisterbock with parts, data and reports

What will be measured?
••If necessary, tolerances, construction andVerification of the dimension of theHow to create the measuring programs?

individual components.

•Direct at the CMM for problem analysis

Verification and analysis of quality, flush&gap,optics, haptics, function and assemblies capability.

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More than a Robot – The Hambot

Serial measurement BIW

In which phase is being measured?

How will be measured?

••

Fast process control in serial production

Direct measurement of geometrical featureswith optical or tactile sensor.

What will be measured?

How to create the measuring programs?

••

Body-in-white and hanging parts

Central creation of measuring programs,
or at offline stations in the measuring room.

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Serial measurement BIW – Correlation for Inline Measurement

In which phase is being measured?
•Correlation for inline measurement

What will be measured?
•Body-in-white and hanging parts

How will be measured?
•Direct measurement of geometrical featureswith optical or tactile sensor .

How to create the measuring programs?
•Central creation of measuring programs,or at offline stations in the measuring room.

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ZEISS Multi Sensor CMMs for Car Body Applications
Portfolio Overview

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More than a Robot – The Hambot
Portfolio Overview
Premium CMMs

Performance CMMs
Flush to floor

CALENO DSC
with optical sensor system EagleEye,
Option HA and HP

CALENO RDS C6-CAA
Table version

CALENO DSCCALENO T DSCCALENO T DSC
with optical sensor system
EagleEye,
Option HA and HP

CALENO T RDS C6-CAA

Application

Upgrade concept of CALENO T and CALENO up to highest specification

ZEISS IQS, Horizontal Arm CMMs

Speed, better accuracy sensor carrier, optical sensor

Performance46

More than a Robot – The Hambot
The platform strategy

EagleEyeDSC

RDS-C6 CAA

Trigger probes

Options

Collision protection
Temperature compensation

Accuracy (HA)
Performance (HP)

CALENOZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The Hambot
The platform strategy

ZEISS IQS, Horizontal Arm CMMs

Accuracy for 16/25
Option High accuracy
Measuring range X
Measuring range Y
Measuring range ZMax acceleration
Option performance
Max. Travel speed without light barrier
Max. Travel speed with light barrier
Sensor Carrier

CALENO / CALENO T
27+L/80≤7018+L/125≤50
3.000 - 25.000
121200 , 1600, 1800
22100, 2500, 3000
1000mm/s²
1500mm/s²
260mm/s
3866mm/s
RDS-C6, indexing 2,5°/
DSC, continuous

Max. probe extension RDS (indexing)
Max. probe extension CSC (continuous)
Tactile probes
Optical sensor CSCCovers

400mm
800mm
TP6/ TP20/ RST-P
EagleEye
Full covers

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ZEISS Multi Sensor CMMs for Car Body Applications
Summary

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More than a Robot – The Hambot
Summary•Modular platform concept of the CALENO / CALENO For an optimized
adaption of the CMM to the customer needs
The CMM can be upgraded with modules like high speed andhigh accuracy•Flexible installation

Flush to floor with CALENOSide mounted table version CALENO T•

Highest precision and highest productivity•Robust and service-friendly•

RDS C6 – CAA, DSC
the benchmark for indexing andcontinuous articulating heads•

Machine and operator safety•

Maximum flexibility of the measuring range•

Technology from one source: ZEISSZEISS IQS, Horizontal Arm CMMs

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More than a Robot – The HambotSolutions

CALENO RDS-C6 CAA Duplex
Typical for OEMs with small and medium
quantities or pure analysis systems

CALENO T Single/ Duplex

CALENO DSC Duplex

Typical for 1st Tier

Typical for big OEMs•••••••Analysis
Process control series and correlation –low and mid volume
Meisterbock CMMs
Finished car analysis

ZEISS IQS, Horizontal Arm CMMs

•Analysis of press parts and hangingparts
Serial measurement, e.g., battery
trays in production environment••Analysis
Process control series and correlation –high volume
Meisterbock CMMs
Finished car analysis

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Hambot und Scanbox: Differentiation of the two measuring systems Inline/Atline/Offline

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