DMG MORI Introduces Automated probeSET Calibration System
Consistent measurement accuracy is increasingly important as manufacturers push machine tools toward higher levels of automation and increasingly demanding production tolerances. Probing systems play an important role in this process, but their accuracy depends on regular calibration to compensate for changes in the probe, tool holder, spindle and machine environment.
DMG MORI has introduced ‘probeSET’, an automated system designed to calibrate machine-tool probes directly within the machine’s working envelope. The system eliminates the need for manual intervention when setting the probe’s Z-pin to its zero position and can perform the calibration automatically using a dedicated technology cycle.
This approach is intended to make probe calibration faster and more repeatable while reducing the potential for operator error. Because calibration takes place within the enclosed workspace of the machine, the process can also be incorporated more readily into automated manufacturing workflows.
Calibration Without Manual Intervention
Probe calibration may be required following a probe change or adjustments to the tool holder or spindle. Significant changes in machine temperature can also affect measurement performance, making periodic recalibration important where high levels of accuracy are required.
The probeSET is designed to simplify this process. Its calibration sphere is mounted directly on a movable Z-pin, reducing the number of mechanical components compared with conventional arrangements. According to DMG MORI, this simplified design contributes to shorter calibration cycles while helping to achieve a high level of positioning accuracy.
The system automatically determines several parameters required for accurate probing. These include the probe center offset, probe radius and probe length, while additional 3D measurement points can also be determined where required.
The resulting measurement data is provided in a report and retained as part of a continuous calibration history. This provides manufacturers with a record of probe performance that can be used to monitor calibration results over time.
60-Second Calibration Cycle
Speed is a key element of the probeSET system. DMG MORI reports a calibration cycle time of approximately 60 seconds on a DMU 65 monoBLOCK, significantly reducing the time required compared with conventional manual calibration procedures.
The automated sequence also removes a number of manual steps associated with conventional probe setting. DMG MORI says this reduces the opportunity for operator errors and avoids inaccuracies that can arise when probes are manually calibrated, with deviations of more than 8 µm possible with standard procedures under some conditions.
Rather than requiring the operator to manually position and set the probe, the probeSET hardware and associated technology cycle allow the machine to carry out the calibration process automatically.
The system comprises the calibration hardware, including the fixture, together with the software-based technology cycle. DMG MORI is making probeSET available for machining centers in its monoBLOCK, H monoBLOCK, duoBLOCK and Portal series, as well as DMU Gantry machines and the DMU/DMC 55 H TWIN.
Part of Broader Machine Accuracy Strategy
DMG MORI positions probeSET as one element of a broader approach to maintaining machining accuracy. The company offers three complementary calibration technologies covering different aspects of machine and measurement performance.
VCS Complete 2.0 is used to monitor and recalibrate the machine’s volumetric accuracy, while 3D quickSET 2.0 is designed to check and optimize the kinematics of five-axis machines, including their rotary and swivel axes.
ProbeSET addresses the third element by maintaining the accuracy of the machine’s probing system. Used together, the three technologies are intended to provide a more comprehensive approach to maintaining machine-tool accuracy, from the machine’s volumetric performance and five-axis kinematics through to the probe used to measure the workpiece.
For manufacturers using automated probing as part of in-process inspection, the ability to perform probe calibration quickly and automatically is particularly relevant. By reducing calibration time and operator intervention, probeSET is designed to make probe verification a more practical part of the machining process while providing documented calibration results for ongoing monitoring of measurement performance.
For more information: www.dmgmori.com
