cavity sinking EDM systems handling-systems software-solutions

1. cavity sinking EDM systems handling-systems software-solutions

2. With modern machinery concepts and the latest software we offer our customers economic and highly efficient systems solutions that go well beyond the process of cavity sinking. We do not only offer you single components of highest quality, but we also ensure that the individual parts operate together in an optimum way. We always keep in mind that today’s market demands require you to work with flexible solutions, which will allow you to use existing resources effectively tomorrow.

3. The company • Medium-sized company • Legal form: Ltd. with limited partnership • Managing Shareholder: Klaus Kreim • Managing Director: Armand Bayer • 100 employees • Development, production and marketing of cavity-sinking machines, handling-systems and software solutions • Production location: Germany • Distribution network: Europe-wide, parts of Asia and south America

4. The companybuilding

5. Success also means taking responsibility.

6. Milestones 1985 Foundation of Zimmer & Kreim GmbH. Machine PEC600 becomes synonymous with precision and efficiency within its class. 1987 The dawn of automation: Zimmer & Kreim introduces the first pallet-changer. 1990 From machine construction to software development: Zimmer & Kreim integrates technology into the cavity-sinking process. 1991 Automation for advanced users: the 50fold electrode-changer.

7. Milestones 1998 New and digital: The introduction of an innovative generator technology. Zimmer & Kreim is sold to H.P.I. Holding AG in Munich and operates under the name of Zimmer & Kreim GmbH & Co. KG. 2002 Quantum leap: The cavity-sinking process is revolutionized by the genius-range with its all-new control- and generator-technology. 2004 New dimension: The complete process chain in mold and tool construction enters a new era thanks to the handling-system Chameleon and the cavity-sinking machine genius 700.

8. Milestones 2005New software generation FLOWzukfor integration of multi-machinery-operation. 2006Turn-Key-Solution manufacturing cellProcess reliability ensured by:Technology spanning unit composed of genius 700, Chameleon, an HSC-milling machine, a measuring machine and a loading unit. 2007Transclean wash and cleaning integrated in the automatic work flow. 2013 IPMtec – new Generator • Chameleon Quad – small automation system • Chameleon Mono – automation one by one

9. Solid technology turned into perfect solutions.

10. What you can expect. Groundbreaking machinery concepts, customer oriented distribution network (ongoing expansion in Asia and Eastern Europe), reliable long-term support. Solutions, which include more than just technological improvements. As a systems provider we assume responsibility for the complete process. Practical software solutions, modular, tailor-made units that will optimize your entire production process. After Sales Service,professional and economical support, cooperative customer relationship.

11. What you can expect. Ambitious goals. Continuous growth in Europe and in the expanding markets of Asia and Northern America. Seizable visions. As your reliable partner we will consequently continue on our way to become Germany’s and Europe’s leading company in terms of innovation and quality.

12. Customer oriented sales Stand und Zukunft---flashfilm

13. Passion turned into competence.

14. Our core competences Cavity-sinking machines Precision and efficiency in mold and tool construction Handling-systemsMaximum flexibility for an integrated production process Software-solutions Intelligent systems solutions for efficient operations

15. Integrated readings available Software- solutions CAD-Data Measuring/Presetting Cavity-sinking machines CAM Handling- systems Transfer- and cleaning device HSC-milling Our core competences

16. Amazing results.

17. Cavity sinking machines:Precision and profitablity All machines made by Zimmer & Kreim are equipped with a twist-proof C-axis and a work tank that is continuously adjustable in height. cocoon cavity sinking cell genius 602 genius 700 genius 850 genius 1000 genius 1200

18. Options for EDM – machines.

19. Options for cavity-sinking machines O-Module –Increase in efficiency with surfaces finer than Ra 0,8. C-Module –Improved removal with exotic materials or during cavity-sinking with the rotation head. Rotation head –For fast and precise cavity-sinking of small and deep cavities with tubular electrodes of diameters from 0.6 to 6 mm.

20. Options for cavity-sinking machines Q-Axis –Fully-fledged 5th CNC-Axis, running simultaneously Heavy duty adapter –For attaching heavy electrodes to the sleeve. Measuring-machines – (e.g. Zeiss Mitutoyo)For measuring work pieces and electrodes.

21. Options for cavity-sinking machines genius transfer –Joystick measuring unit for measuring work pieces and electrodes without measuring cycles. Booster –Power amplifier of the genius range’s generator, e.g. from 75A to 150A. Pallet truck –For loading the transfer- and cleaning-unit, machines and measuring machines.

22. Options for cavity-sinking machines Tube guiding – (for high-pressure flushing)Add-on for the rotation head for highly precise and deep drilling. Cooling unit –(no picture available)Pre-cooling the water inside the cooling circuit, supplying the heat exchanger, thus ensuring temperature equalization of the dielectric fluid.

23. Total new and uniqueWash – and Cleaning System.

24. The USPs at a glance • Suitable for all clamping systems • Stand-alone operation • Use in all fully automated cells • Use in mono cells, e.g. milling cell with minimum charge lubrication or eroding cell • Can be used as transfer station • Different washing programmes can be selected • Washing fluid can be regenerated • Economical energy consumption • Plug and play – just set-up and start Transclean – Wash and Cleaning

25. Machine Data Transclean Fan / recirculating air text: • text Filter unit Angled metal plates to prevent drip formation 360° rotator Workpiece, tool Dirt tank for collecting fluids introduced (dielectric) Rotating flushing nozzles

26. Machine DataTransclean

27. Unique selling points –Distinctive features compared to competitors.

28. Differences for the competition Ingersoll: • machine frame is a weldment => bad vibrational properties, difficult to keep thermal stability • design concept as gantry with one central drive and measurementsystem • neither own control or generator (Mitsubishi) nor development • needs a lot of space • small opening + low tank height => less dielectric fluide above table • centralized lubrication • all guide ways are completly open=> washout of the grease by dielectric steams • cooling of the frame with current of air => thermal instable weldment

29. Differences for the competition Ingersoll: • Z-axis has problems by warming from Z-drive • neyboard / control is placed 1.70 m above bottom! Ergonomics! • additional PC at the side (also for electrode-changer) • bad accessibility, cleaning aggravated

30. Differences for the competition Exeron: • coordinatesystem can only be lined up at the X-axis • glass scales only as an option • expensive programming • automatisation and handling neither modular nor expandable • design concept as gantry with one central drive and measurementsystem • well balanced space-drive relation • at present, the genius is superior in EDM • problems with the dataflow • even the adaption of a CMM is circumstantial • No mirror finishing possible

31. Differences for the competition AGIE: • needs a lot of space • work tank is not sinkable • relation between tables size and pathways suboptimal • cross table (a high weight has to be moved) • different product lines (low-cost machine) • C-axis only optional • bad accessibility (completely encapsulated) • Hyperspark, despite 50 % improved performance to the pre-control, at present, the genius is superior in EDM • no own handling-system • basically there are two PCs neccessary, if it should be worked with a handling-system • performance problems by OS/2 operating system in the controlprimarily at connection to systems • Bad resulte in graphite

32. Differences for the competition Charmilles: • EDM with the C-axis almost not possible, because it is weakly designed(at stuck C-axis one can turn the axis by hand) • shaft encoder has only 360 increments and will be interpulated up to 0.001° (only a distorsion bigger than 1° will be recognized!) • different product lines (low-cost machine) • the new control hasn't ripened yet, it isn´t supported by Zwicker Systems yet! => adaption problems to other handling-systems! • touch screen12“ • no hand wheel => operation only with buttons • max. axes speed: 3,6 m/min with 5 mm spindle lead

33. Differences for the competition Charmilles: • centralized lubrication with oil => strong pollution • work tank is not sinkable - filling time is more than twice as long as ours (filling CT 60sec, genius700 25sec, draining CT 45sec, genius700 20sec) • RF550 needs 1000 l dielectric fluid => 8 filters, high cooling performance • ISOPULSE generator: material removal copper/steel: 400 mm3/min genius: 400 mm3 /min material removal graphite/steel: 480 mm3/min genius: 580 mm3 /min • generator power 10 kVA => twice so high as genius (5 kVA) • generator current (std.) 64A • general data for accuracy at stabilised temperature for only 20° +/- 1° • cooling temperture has to be < 10°! => risk of condensed water! • NC-kernel is Fanuc

34. Differences for the competition ONA: • no contact, not present in our market yet Makino: • work tank has to be filled • machines are expensive • bad accessibility • problems with automatisation

35. Differences for the competition Sodick: • in case of linear Motor he have to cool the machine body • Difficult programming • No ful trop tank • Need big space • No special generator technology • complex and expensive control circuit • produces much heat • axis has to be braked pneumatically(pneumatic because of the needed reaction speed) • High dependence of the complete system availability(cooling, lubrication, pneumatic, ...)

36. Advantages of ZK genius • mechanical accuracy • everything from one hand; machine, handling and software(interface solution = system support und responsibility) • single options and modules are upgradeable at everytime • very good accessibility to the machine • low floor space needed • open PC-control • strong C-axis • own development department • high performance generator, even so with special technologies • it’s possible to combine older machine generations with new systems(downward compatibility!)

37. Advantages of ZK genius • Max. Flexibility in automationPersons Independent repeatable quality levelCross-Process ManufacturingMax. Machine utilization through ext. Set upProcesses can be fully automated with full accessibility for manual editsFull data throughput in a data baseEach process is updateable for themselvesNo room for error through automated data flowMinimized waiting times by parallel processing of individual processesProcess integration from raw material to final measured productWorking with original 3D model dataOpen to integration with other machine manufacturer

38. Competitive edges consideringcavity-sinking tests as examples.

39. automatic process control The gap supervision adapts the work parameters automatically, depending to the changing conditions at crosscuts during the work • the current will be adapted • the pause time will be changed • the timer will change • the feed forward will be adapted

40. advantages of automatic process control • the user has not to manipulate the generator settings • even if there are graded electrodes or premilled workpieces • one can be sure to reach a good quality result, even with a view simple settings

41. Connecting systems for more growth

42. Handling-systemsQuality assurance and process reliability Our handling-systems are the guarantors for quality assurance within your production chain.16fold(electrode changer) 24fold(electrode changer) Chameleon(handling-system)

43. 24fold plate changer: efficient, practical, reliable • Electrode changer • Suitable for all current clamping systems • Electrode identification via RFID-chip • Stand-alone solution • Overload- and collision-protection

44. Chameleon: modular, linear, fully automated • Works system spanning, e.g. integrating milling-, wire-cutting- or measuring-machines • All-purpose handling-system, suitable for work pieces, electrodes and milling tools. • Stand-alone solution with integrated control unit and open interfaces • Infinitely expandable thanks to modular design

45. Chameleon: modular, linear, fully automated • Fully automated identification system – production reliability thanks to faultless access • Significantly lower changing duration, especially while in continuous operation • Works with all tool construction machines that demand a handling system • Flexible mounting of machines and magazines horizontally and vertically

46. All units networked

47. Software solutions Software is the key to create new potentials within your company. This is why we develop tailor-made solutions for which we also assume systems responsibility. Our software module are the guarantor of your process reliability.

48. Forward developmentForward thinking

49. Software solutions for technology spanning operations

50. We are there. Wherever you are.