CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Presented by
Dieter Marschall
Ametek GmbH, BU Precitech
At Precision Fair 2013 Conference
CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Who’s Precitech
Who are our customers
Typical tasks in UP‐machining
Machine design improvements
Novel technologies
Application example
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CLEAR VISION
SOUND STRATEGIES
Precitech is located in Keene,
New Hampshire USA
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¾
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SOLID PERFORMANCE
Who’s Precitech?
Approximately $30 million in yearly revenue
Precitech has over 100 employees
The only vertically integrated manufacturer of ultra precision tools:
• oil hydrostatic bearing slideways
• purpose built CNC motion control system
• motorized air bearing spindles
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1300 machines installed in 22 countries
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Who’s Precitech?
Optoform® 40
Nanoform®
Optoform® 80
Drum Roll Lathe
Optomill 363
Optoload® 1000
Freeform®
Planoform®
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CLEAR VISION
Diffractive
Diamond Turning
Zinc Selenide ZnSe
Nanoform® 250 Ultra
Scanner Mirrors
Planoform® 650
Fog Lamp
Plastic Molded Part
Molded w/Copper/Nickel
Freeform Surface
Air Bearing Journal
Bore Outer Diameter
2-axis Diamond Turning X,Z
Nanoform® 250 Ultra
SOUND STRATEGIES
Hybrid Element
Diamond Milling &
Turning Copper
Collimating Mirror
Square Spherical
Lenslet Array
Fast Tool Servo
SOLID PERFORMANCE
Military Grade
Flashlight Reflector
2-axis Diamond Turning
X, Z Nanoform® 250 Ultra
Hip Joint
Hard Turning
Tool Normal X,Z,B
Nanoform® 700 SuperTurn
Lens let Array
Generated by FastTool-Servo technology
on a 2-axes lathe
Lens Mold
3-axis X, Y, Z Milling
Freeform Surface
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Who are our customers?
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Typical tasks in UP-machining
Frequent
Ones only
Insert blank
Part programming
CAD/CAM
CNC‐Code
Remove part
Rough
Tool exchange
Making part fixtures
Engineering
Manufacturing
Correct
Finish
Process setup
Prepare machine
Initial tooling
Measure
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CLEAR VISION
SOUND STRATEGIES
Initial task: Part programming
SOLID PERFORMANCE
Typical tasks in UP-machining
Data points
Optical Design Software
Data points
CAD/CAM
Software
Data points
Proprietary Software
Text format
minor
manipulation
Data point cloud
DiffSys® Software
• 2D Aspheres, Zones, Corrections
• 3D Freeform turning, Corrections
• Adds TTC based on tool information
CNC
Control
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Typical tasks in UP-machining
Frequent task: Part mounting and referencing
Common method:
• Manual, mounting of blank
• Manual centering on vacuum chuck
Improved method:
• Manual, mounting of blank
• Automatic centering on vacuum chuck
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CLEAR VISION
SOUND STRATEGIES
Frequent task: Material removal (rough & finish)
SOLID PERFORMANCE
Typical tasks in UP-machining
Less cuts
Shorter
cycles
Higher
speed
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CLEAR VISION
SOUND STRATEGIES
Frequent task: Measure and correct
Machine part
Re‐reference part
SOLID PERFORMANCE
Typical tasks in UP-machining
Machine part
Remove part
Integrated Metrology
External Metrology
Compensate
Measure & qualify
Compensate
Measure & qualify
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Frequent task: Tool exchange
Typical tasks in UP-machining
CCD-Camera looks at setup stud surface
1
Initial tool set (OTS)
1
7
2
Insert back setup stud
Cutting setup stud
OK
6
Correct for height and X‐center
Initial tool set (OTS)
Improvement
3
Remove setup stud
5
4
Offline inspection X‐center
Offline inspection height
4
2
Correct for height & X‐
center
OK
Cutting setup stud
3
Online inspection
Height & X‐
center
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CLEAR VISION
SOUND STRATEGIES
Frequent task: Tool exchange
SOLID PERFORMANCE
Typical tasks in UP-machining
Prolonging tool live when machining heavy abrasive materials like Silicon Required tool sweep
depends on surface slope
Distributing tool wear over
entire available tool sweep
by means of B-axis
Virtual Center Technology
Technologies facilitating use of B‐axis
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CLEAR VISION
Frequent task: Tool exchange
SOUND STRATEGIES
SOLID PERFORMANCE
Typical tasks in UP-machining
Overcoming limited tool sweep by applying “Virtual Center Technology”
Complicated surface structure
1.
2.
3.
Define tool angle by 6 points (1-6)
Measure 3 points on tool edge (7-9)
Define tool radius center as
B-axis virtual center for this tool
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Machine design improvements
Nanoform® Series
1992
1998
2006
2013
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Machine design improvements
1998
Nanoform
200
First linear motor driven slide ways in our industry
2004
UPx Control
Real Time
Operating System offers unique capabilities
2006
Nanoform
250 Ultra
With 16pm feedback resolution
2008
Adaptive Control Technology
Boosting freeform turning operations
2010
Virtual Center Technology
Outstanding feature for using Hydroround
rotary B‐axis.
Hydroround
with patented bearing design offering unprecedented
tilt stiffness
2013
HS150 air bearing spindle
Higher speed (10K rpm), improved thermal stability for greater productivity.
2013
Nanoform X
Complete re‐
design of previous model.
Changes also addressing productivity aspects
Robust for industry use.
3 years warranty
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CLEAR VISION
Conventional PID
Servo Control
SOUND STRATEGIES
SOLID PERFORMANCE
Novel technologies
Eliminates periodic error
motion within 2 seconds
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Novel technologies
High Performance CNC
Unique process monitoring and
diagnostic features possible by
using control software based on
“Real Time Operating System”
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CLEAR VISION
SOUND STRATEGIES
Control Architecture
SOLID PERFORMANCE
Novel technologies
• Machine log file
refreshed every
second
• Content configurable
• Remote access
possible via intranet
Machine status display on Windows console
IP-Address
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CLEAR VISION
SOUND STRATEGIES
Control Software
SOLID PERFORMANCE
Novel technologies
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CLEAR VISION
SOUND STRATEGIES
Integrated metrology for high volume production
SOLID PERFORMANCE
Application examples
Customer Problem:
Precitech solution:
Due to material properties residual form error after finish cut fluctuated unpredictable.
Enabling integrated metrology device (contacting probe) to measure and export data points in fully automated mode.
To minimize scrape rate all parts required to be measured and final error compensated.
Current technology allowed to do that, but in a semi automated and operator guided dialogue, requiring machine attendance and operator skill.
Import data points in Taylor Hobson AAU off‐line software and generate a set of correction data, stored in a file.
CNC‐control reading correction data in P‐table for running error compensated tool path.
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
Integrated metrology for high volume production
Application examples
Load and execute part program
If accepted activate new correction for part program
Operator choice ACCEPT, FINSHED or ABORT
SCRAPE
Load and execute measurement program
FINISHED
Detect new correction data and prompt operator
Send measurement data to network share and wait
Detect and load new data into analysis software
Process new data and store new correction data
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CLEAR VISION
SOUND STRATEGIES
SOLID PERFORMANCE
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