CALYPSO——The total program for standard geometries and more
 
Ø    Many tasks – one tool
CALYPSO is designed for manual and CNC measurements, online and offline programming. CALYPSO is multisensor capable and supports all current sensors and measuring capabilities from Carl Zeiss. Via the I++ DME interface, CALYPSO allows you to control non-ZEISS measuring systems such as 3D measuring machines, articulated arm measuring machines, laser trackers and computer tomographs.
 
Ø    Collision-free – automatically
As soon as you define a part feature and the associated tolerances with a few clicks of the mouse, CALYPSO automatically generates an appropriate measuring strategy that can be modified and applied to other features at any time. CALYPSO quickly moves the stylus around the workpiece without collisions and approaches the part features correctly – you are free to deal with other tasks.
 
Ø    Dynamic mini-plan
CALYPSO’s hierarchical design and feature-oriented programming give you the flexibility to focus your measurement planning on the production process. For example, you can interrupt measuring runs to quickly measure another part. The interrupted measurement can be easily continued afterwards. More intelligent scanning with VAST Navigator CALYPSO supports VAST Navigator – the fifth generation of scanning from Carl Zeiss. Without unnecessary interruptions and with optimal approach and travel paths, VAST Navigator allows you to measure smoothly in one run. A tangential approach is standard. Fully integrated intelligence enables CALYPSO to determine the maximum scanning speed depending on the required accuracy.
 
Optional interfaces: IGES 2D/3D, VDA 2D/3D, STEP 3D, DXF 2D, PMI, and FTA can be directly processed.
Optional direct interfaces: ParaSolid, CATIA V4, CATIA V5, ProEngineer, UniGraphics, Inventor, Solid Works
 
CALYPSO options——Extension: Tools for Special Jobs
 
Ø    CALYPSO curve
Measure and calculate 2D and 3D curves. Inspection features: curve slope, cam throw, curve length, curve form, surface area, etc. Fields of application: crankshafts, cam shafts, turbine blades, powertrains.
 
Ø    CALYPSO freeform surfaces
Measurement of freeform surfaces. Deviations from plan are marked in color. Typical fields of application include medical technology, moldmaking and engine construction in which freeform surfaces have to be inspected along with standard geometries.
 
Ø    CALYPSO preset
Preset erosion electrodes and processing tools. Users are graphically guided through the manual measuring run. The most commonly used measurement plans are saved. CNC extensions are available for square and round basic geometries.
 
Ø    CALYPSO PCM
Menu-guided control of parameter-supported measuring runs. Workpiece variations can be efficiently measured using a measurement plan parameterized with CALYPSO PCM.
 
Ø    myCALYPSO
myCALYPSO turns your measuring machine into a flexible gage. Standard measuring tasks, such as the measurement of the interior diameter or height, are saved as macros and can be loaded with a few clicks of the mouse.
 
Ø    CALYPSO simulation
Virtual collision observation. The part, clamping equipment, stylus, probe, base plate, rotary table, measuring range, or the entire measuring machine, are simulated in the CAD window. In conjunction with CALYPSO planner, measuring runs can be generated and simulated remotely.
 
Ø    CALYPSO/qs-STAT export
Export measuring results in the Q-DAS format for analysis in the qs-STAT statistics program. CALYPSO qs-STAT export converts the CALYPSO result files from a CNC measuring run into Q-DAS description and value files. With qs-STAT, you can then statistically evaluate production processes, for example.
 
Ø    CALYPSO planner
The offline version of CALYPSO. Use CALYPSO planner to write measuring programs offline. Your measuring machine is not blocked by CALYPSO planner and can continue being used for additional measurements. CALYPSO planner saves the finished measuring program. Furthermore, it can be loaded and run at any time with CALYPSO. In conjunction with CALYPSO simulation, measuring runs can be generated and simulated remotely.
 
Ø    FACS automation
FACS (Flexible Automation and Control System) is used to integrate the measurement cells into CIM automation environments. FACS establishes the connection between the measuring cell and the process control computer. This allows you to initiate measuring runs from a customer-specific user interface.

 VAST XXT——Scanning done differently


Ø    VAST XXT——Scanning done differently
There are a large number of measuring applications that can benefit from the flexibility of an articulating probe holder combined with scanning capability. VAST XXT is ideal for such tasks.
Compared to touch-trigger sensors, VAST XXT increases the operational safety and accuracy of the measurements. It also adds scanning functionality, thus providing information on the form of the features.
The compact design of lightweight scanning sensors on the articulating probe holder requires different sensor modules. With only three modules, VAST XXT covers the typical stylus length ranges for this sensor design. This sensor accommodates lateral styli up to 65 millimeters. It is also suitable for fixed installation.

Tons of Precision
——PMT Machines in India inspects high-precision parts for wind turbines twice as fast
 
Despite the impressive dimensions of modern wind turbines, maximum precision in manufacturing is still a must. PMT Machines Limited, the leading manufacturer of machine tools and parts for power and traffic technology in India, therefore relies on measuring machines from Carl Zeiss.
 
The challenge: minimal tolerances
The rotor hub of a 1.5 megawatt wind turbine is two meters in diameter and weighs 7.5 tons. Nonetheless, it must still be manufactured with maximum precision. The maximum error from the perfect round form of the boreholes must be no more than 30 micrometers – not even 0.01 percent of the diameter of the boreholes of 95 and 34 centimeters. If the error exceeds this tolerance, the customer would immediately return the parts – replacing components when a wind turbine fails would be too expensive.
PMT Machines Limited has been manufacturing parts for wind turbines since 2006. In the beginning, the several-ton parts were measured manually in the production machine. However, the tools and machine attachments made the measurements complicated.
 
Solution: automatic measurement with an MMZ G
PMT Machines purchased an MMZ G in 2010. The measuring machine from Carl Zeiss measures the form, size and position of large parts with particularly high demands on precision. With the MMZ G, PMT Machines now relies on one of the most accurate inspection machines of this class in India.
The MMZ G meets the demands of Indian customers for an all-in-one system that completes all their quality inspection jobs in a single go and as close to production as possible, i.e. near the machines used to manufacture the part.
"We have already had very good experiences with another measuring machine from Carl Zeiss IMT," praises Chetan Bhavsar, General Manager at PMT Machines. The company has been using a PRISMO navigator for three years.
 
Benefit: 100 percent accuracy in half the time
Thanks to the MMZ G, PMT is able to fully comply with the quality demands of its customers. Indian wind turbine manufacturers supplied by PMT Machines are very satisfied with the increased quality and precision of the parts.
A key benefit is the considerably higher speed of the quality inspections. "In the past, a complete manual measurement took up to three hours; now it takes less than half as long," states Bhavsar.
 
About the company
PMT Machines Limited is the leading manufacturer of machine tools and parts for power and traffic technology in India. Headquartered in Pune, the company has been manufacturing machine tools for a wide range of industries since 1963, including the automotive sector. In 2006, the company added parts for the rail industry and power generation to its portfolio. Its factories produce components for gas, steam and water turbines, as well as for wind turbines.