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Carl Zeiss IQS Deutschland GmbH

Carl Zeiss IQS Deutschland GmbH

Carl Zeiss IQS Deutschland GmbH

05.03.2024 01:03

ZEISS PRISMO CMM of the new generation shortens the duration of the measurement program by 74 percent

ZEISS and Starrag enter a new era of quality assurance in the aerospace industry

ZEISS is demonstrating the performance of the new ZEISS PRISMO 7/12/7 fortis as part of a pilot project carried out at Starrag: Equipped with the ZEISS CMM Acceleration Mode for Aerospace Applications package, the CMM scores with its high measuring accuracy and high productivity. The significantly reduced definition time of the rotary table axis by 80 % and the optimum interaction with the ZEISS CALYPSO software are just some of the numerous advantages.

The Starrag Group, headquartered in Rorschacherberg, Switzerland, manufactures machining centers for production solutions that work with turbine blades, blisks and other components. Applications in the aerospace industry are a major focus. Precision is crucial in this industry and the requirements for measuring accuracy have become much stricter in recent years. The growing and very diverse needs of customers worldwide require Starrag to perform highly efficient measurements that deliver very fast, highly accurate and easily reproducible results.

In this pilot project, the ZEISS PRISMO 7/12/7 fortis was used in the test laboratory to perform crucial and demanding measurements. Starrag was very impressed with the measurement results. Roland Ziltener, Head of Quality Management at Starrag, puts it in a nutshell: "Traditionally, accuracy is slow in measurement technology. But with the ZEISS PRISMO 7/12/7 fortis with ZEISS CMM Acceleration Mode for Aerospace Applications, the exact opposite is the case." Ziltener explains with a smile: "His customers always react with "fascination and slight shock" when they see how accurately and quickly this new generation CMM works.

Roland Ziltener Head of Quality Management, Starrag Group Speed and accuracy used to be somewhat contradictory until we installed the new generation of ZEISS PRISMO fortis.
A new approach for rotary table applications
The ZEISS PRISMO 7/12/7 fortis is equipped with a highly dynamic rotary table that significantly reduces measuring times. The ZEISS Acceleration Mode for Aerospace Applications package also combines the two rotary table measurement options ZEISS VAST Rotary Table (ZVR) and ZEISS VAST Rotary Table Axis (ZVRA). By improving the positioning speed of the rotary table and the speed of axis definition, they offer a new approach to rotary table applications. ZVRA reduces the axis definition time from 60 to 12 seconds. This represents a remarkable time saving of 80% in a process that Starrag performs for every workpiece. The higher positioning speed also means that fewer probes are required. This means that measurements are not only faster, but also more flexible. In terms of mutual support, ZEISS and Starrag exchanged geometry data and worked together to develop effective contour monitoring solutions that can process difficult geometries even better. ZEISS also assisted Starrag in practice with training and support.

The implementation of the new solution on site went smoothly. In this context, Starrag was also able to refer to its many years of experience with the ZEISS CALYPSO software. For example, simple teach-in programming of contours has already been ensured and, according to Ziltener, familiarizing the team with the latest software version and the various upgrades of the new ZEISS PRISMO 7/12/7 fortis was "not difficult at all". Starrag not only relies on simple pass/fail evaluations of the workpieces, but also relies on high quality feedback to determine machine performance: ZEISS CALYPSO meets these requirements by providing highly accurate and repeatable results, while also providing the data and graphics required for further development. By making it easy to analyze the results, the software facilitates communication between Starrag and the suppliers by providing a "very good basis for discussion" regarding deviations and solutions.

Measurements now 74% faster with sufficient accuracy
Above all, the pilot project has shown a clear increase in productivity. Ziltener notes that Starrag can measure more components in less time, and "with the same accuracy as we had before". The most obvious example of the increase in production is that Starrag takes 74% less time to complete its standard turbine blade measurement program. The program used to take 4 minutes and 30 seconds, with the emphasis on repeatability. Today, it only takes 70 seconds to deliver accurate and reproducible results. This gives the company greater flexibility in the selection of parameters and workpieces to be measured. With the large number of turbine blades and profiles to be measured, the benefits increase significantly. Ziltener explains that the new generation ZEISS PRISMO 7/12/7 fortis with its high measuring accuracy at high speed "amazes all end customers on site", as these two features were previously always considered contradictory.

According to Ziltener, the new ZEISS PowerSaver feature "makes a massive contribution to our ability to save energy" - a sustainability benefit that is all the more important in view of the current energy crisis. ZEISS PowerSaver is easy to operate and only needs to be programmed once. This feature reduces consumption to zero during user-defined downtimes and runs automatically in the background. With the new laser-based system, speeds can be automatically reduced in the event of danger and then increased again.
This combination of safety and performance ensures a high level of operational safety, which is of course a key priority at Starrag. Loading and operation are therefore not only safe, but also uncomplicated and convenient for the operating personnel. Last but not least, the new generation ZEISS PRISMO family impresses with numerous ergonomic innovations, such as a slimmer control panel with a special holder for better workpiece handling and overall improved accessibility.

With the ZEISS PRISMO 7/12/7 fortis with ZEISS CMM Acceleration Mode for Aerospace Applications, Starrag is focusing on further long-term success in quality assurance. For the company, it is not just a matter of achieving certain results for a specific workpiece. "We need to be able to interpret these results and data" and then "discuss them with our internal and external partners," says Ziltener. With the ZEISS CALYPSO software, the pilot project supports the simple documentation and visualization of the results, even by non-experts. The multi-layer concept of the ZEISS CALYPSO software makes these functions accessible to a wide range of people. At the same time, the software also offers more detailed options for expert users. Conclusion: Starrag has already set new standards in quality assurance with this pilot project. The close cooperation with ZEISS, which is based on mutual exchange, offers a great deal of development potential for the future.

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