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Tool Presetting

SET LINE V9-S

Description
HIGH PRECISION TOOL PRESETTER WITH INTEGRATED INDUCTION COIL FOR AUTOMATIC SHRINKING AND LENGTH ADJUSTMENT
 
The KENOVA Set Line V9-S combines the Set Line V9 tool presetter with the i-Tec XL induction shrink device to create an automatic shrinking and presetting solution. The advanced V9-S machine enables tools to be perfectly measured, preset and simultaneously shrunk on one device.
 
A unique feature of the dynamic shrink fit process is that tools can be very quickly shrunk into holders and adjusted to a nominal length, providing time savings and accuracy benefits over working on separate devices.
 
The KENOVA Set Line V9-S series is supplied with full CNC control in 4 axes, including advanced automatic measuring programming and tool length adjustment. A 5th automatic axis provides movement of the induction coil. The following size options are available:
X axis: 500 mm (Ø)
Z axis: 600 / 800 mm

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Overview

Precise Shrinking and Setting  -  All in One Unit.
 
Shrink cutters in, shrink cutters out, measuring and presetting – the KENOVA Set Line V9-S offers all this and more. A tool presetter combined with an induction shrink fit device and cooling system.

2 Modes for Combined Shrinking/Presetting:

Dynamic Presetting
The tool is automatically set to the desired nominal length using driven length setting pins while the holder is expanded (during the heating phase). This process offers several advantages, including short cycle times and the ability to change cutters in a single cycle. The process is compatible with all standard ISO/DIN type shrink chucks, including those from other reputable manufacturers, ensuring flexibility and compatibility.
 
Static Presetting
If measurements are required that cannot be performed while the holder is expanded, or if maximum accuracy is required for the tool assembly length, then the tool length is determined using special presetting adaptors prior to heating. The tool can then be shrunk to its target length using intelligent calculations and pre-positioning of the length setting pin. This process is mainly designed for complex measuring tasks or for HSS tools.

Revolutionary Structural Design:

Ease of use coupled with maximum precision. This V9-S variant is modern, ergonomically designed and unique in terms of its build quality. With its mineral cast base, cast in one piece from the guideway to the floor, KELCH is setting new benchmarks in the design of tool presetting machines. This structure is incredibly stable and delivers our most accurate and consistent measuring results through reliable KELCH quality.

Features of mineral cast construction:
Environmentally-friendly manufacture thanks to cold casting process
Sustainable recycling of base material is possible
Vibration-damping qualities
Insensitive to temperature fluctuations thanks to thermal inertia
Precise measurement due to robust structure

Unique Performance Features:

  • Combined shrinking and measuring in one machine, with fully automatic and programmable operation

  • Solid measuring device on a single block mineral cast base

  • CNC control in up to 4 axes, also manually operable for quick measuring, even without reference data

  • 5th axis for automatically lowering and raising induction coil during heating cycle

  • Automatic axis movement by powerful servo motors for high-precision positioning

  • Length setting pins for each tool taper type guarantees accurate results

  • Flexible installation of space-optimised peripheral unit, with integrated water cooling system

  • Compact storage of all accessories, such as monitor, keyboard, printer and adaptors

  • The computer and electronics are tidily accommodated and easy to access in the spacious switch cabinet

  • Workshop-compatible and durable with an industrial IPC for measurement control

  • Individually adaptable to all measuring tasks and data flows

  • Drawer for storage of tools and other ancillary materials


Modular Precision Spindle (MPS):
 
The world’s best spindle for Premium Line tool presetters: KENOVA Set Line V9 and V9-S.
KELCH’s own modular precision spindle is the most stable and precise tool holder on the market. Decades of experience coupled with outstanding engineering knowledge and expertise lie behind this ultra-precise spindle. The modular system enables spindle inserts to be swapped within less than five seconds while maintaining excellent precision.
Maximum run-out of 1 μm on the flat surface and < 3 μm at a height of 300 mm and a tool weight of up to 150 kg speak for themselves.
 
 
Inserts for the modular precision spindle
The contact face and the short taper ensure maximum repeatability when changing the insert modules, available for all standard HSK, PSC, VDI, KM and SK tool holders.
Clamping for all tools is similar to the machine tool, with steep taper holders using retention knobs centrally from behind and HSK holders using original clamping units expanded from the inside.
Clamping forces:
SK / BT up to 5 kN
HSK up to 15 kN
PSC up to 25 kN

Operating Convenience - EASY Software:

Users can control their KENOVA Set Line V9-S on a clearly arranged operating screen using the industry proven EASY software: the tool, adapter, measuring function and values measured on the tool are all clearly presented on a single page. When it comes to analysis, the software guides the user in easily understandable steps to the required result. The software offers many additional functions as required. Connection to Industry 4.0 systems is also possible, via RFID chips, QR-code labels or through DNC network connectivity and direct interfacing. As a system supplier with over 80 years experience, KELCH also offers the option of customising the system to your specific workflow.
 
Further information about our EASY measuring software can be found here:

Maximum Measuring Envelope:

Length: 600 / 800 mm
Diameter: 530 mm

Video

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SET LINE V9-S Overview Image

Technical

Construction:
> Mineral cast body for stability, vibration absorption and     reduced thermal deviation
 
Measuring ranges:
> X = -50 mm to 530 mm (ø) *
   * 420 mm (ø) rotational
> Z = 600 / 800 mm
 
Positioning:
> CNC driven positioning of the axes with electro-pneumatic      brake and ergonomic handle
> The single block body of the V9-S is extremely vibration-     resistant and less sensitive to temperature fluctuations
> Automatic 4th & 5th axes for length setting and shrink coil
> Infinite micrometer fine adjustment in 1 micron increments via     electronic impulse to appropriate motor
 
 Tool holder:
> Modular Precision Spindle (MPS) to accommodate diverse SK,     HSK, PSC (Capto), VDI etc. adaptors
> Mechanical tool clamping up to 25 kN
> Positional fixing:
    a) Manual: by mechanical clamp and brake
    b) Autofocus / CNC: by a coupling
> Maximum tool weight: 150 KG
 
Cutting edge scanning:
> Hi-res CMOS camera with telecentric lens and top light for
   ± 1 μm repeatability
> Optional: optical turning centre measuring equipment
   S-camera for tool grinders
   Probe for cutting edges difficult to access
 
Electronic measurement equipment:
> PC electronics with intelligent image processing
> 24" TFT monitor
> 10" monitor on camera carrier (optional)
 
 
Dimensions:
> LxDxH (mm): 3050 x 1350 x 1924 (for V9-S with Z = 600mm)  
> LxDxH (mm):
3050 x 1350 x 2124 (for V9-S with Z = 800mm)  
 
Shrinking:
> Automatic induction coil for HSS and carbide
> Automatic length setting with spindle pins
> Optional: Vacuum filter for smoke removal
 
Cooling:
> Separate cooling station with simultaneous cooling of 3 shrink chucks
> Contact cooling with sealed water system
> Cooling time approx. 60 seconds

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SET LINE V9-S Technical Image

DATA TRANSFER

Optional Integration Solutions - Fit for Industry 4.0! 
 
The industry-proven KELCH EASY measuring software ensures that you can always save tool-based data and transmit it to the right place. It does not matter whether the data comes from machine controls, tool management programs, CAD/CAM systems or other manufacturing systems. With EASY we have dozens of "off-the-shelf" interface solutions ready and available to connect with your external system. Due to the flexible design of the software, it is also possible to develop a customised integration or special process which is tailored to your specific requirements.
 
Interfaces are available using the following technologies and systems:

RFID Chip Systems
(Balluff, Euchner, Pepperl & Fuchs...)
Store tool ID, measured values and other machine-specific data on an RFID chip mounted to the tool holder

QR-Code, Data Matrix or Barcode Systems
Store tool ID, or complete set of measurement and machine-specific data on a 2D QR-code

DNC File Transfer
(Tool offsets to Heidenhain, Siemens, Fanuc...)
Package up your tool measurement data along with machine-specific data into a formatted text file or tool table and transfer directly to the machine via network, or through a separate DNC system

Third Party System Interfaces
(TDM System, Fastems, Mazak Smooth/CPC, Fastems, CosCom...)
Standard interfaces are available to a range of common tool management and manufacturing execution system which provide a secure 2-way process for transferring your data
 
Errors caused by incorrect input can be ruled out by sending the measured results directly to the machine control by post-processor via the network. This greatly enhances the process reliability and production efficiency. Along with the inclusion of tool identification this makes a significant contribution to process security when providing digital data exchange within your smart factory.
 
Using RFID or QR-code technologies greatly improves process reliability by having your tool and measurement data stored on the physical tool. Tools can easily be identified with the click of a button, and data can be transferred directly into the machine controller each time the tool is loaded into the magazine. RFID data chips have the additional benefit of being able to retain residual tool life once a tool is removed from the magazine, therefore improving tool utilisation.
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