| Carl Zeiss IMT Corp. Press Release |  |
Around-the-clock Measuring Precision
KERN utilizes the F25 coordinate measuring machine from ZEISS to ensure the quality of precision parts for Swiss watches
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| Thomas Wicknig from Kern operating the ZEISS F25 coordinate measuring machine for the quality assurance of microsystem parts. |
Oberkochen/Muranu, Germany – June 12, 2007 — Murnau-based KERN Micro- und Feinwerktechnik GmbH & Co. KG performs contract production of micro-mechanical parts for various industries. In addition to the manufacture of maximum precision CNC micro-milling centers and CNC micro-boring centers, for which KERN is well-known beyond the borders of Germany, contract manufacturing is also an important pillar for the company. Many well-known watchmakers place their trust in the quality of KERN products. KERN has used a ZEISS F25 coordinate measuring machine (CMM) for quality assurance in production monitoring and control since September 2005. The F25 is utilized for both the generation of initial sampling reports and the ongoing monitoring of production processes.
Shift operations, various product lines and quantities between 20 and 10,000 machined parts require not only the most accurate planning, but also reliable inspection technology. For Oliver Fischer, Plant Manager at KERN, the constant availability of accurate data is vital to ensuring continuous production processes and the manufacture of quality products. Until recently, it was not even possible to inspect several of the parts produced on order with a contact CMM. There simply were no systems suitable for inspecting the small dimensions and tolerance ranges of the workpieces. They had to be measured using different – also manual – measuring equipment. An image-processing measuring machine only provided information on the position of the features. Obtaining information on the diameter of bores required additional test probes; an accurate statement was only vaguely possible. A final statement on bore depths was only possible using a time-consuming measuring method. This was practically impossible for workpieces with up to 200 inspection features.
Manual "trial and error" inspection processes using the widest variety of test probes took up to five hours per workpiece and were not uncommon. Measurement logs cannot be generated in this manner. The influence of the operator on these manual measurements must also not be disregarded. Constantly changing workpieces in partially small batches required increased manpower. Drawn-out start-up processes and the generation of initial sample reports delayed the processes.
Measurement of micro-system parts with the F25
Statements about size, form and position on micro-system components can now be delivered in a single measuring run on the F25. The measuring volume of the 3D coordinate measuring machine is one cubic decimeter. Measuring uncertainty for this volume is 250 nm at a resolution of the measuring system of 0.25 nm. Using minimal probe forces, this resolution, along with optimum control of the linear drives, enables contact measurements even in bores with diameters of less than one millimeter. The 3D microprobe is designed for stylus diameters of 50-500 micrometers and stylus tip diameters of 120-700 micrometers with a free shaft length of up to four millimeters. The probe forces have also been minimized to less than 0.5 mN/µm. In addition to contact measuring, an optical sensor, whose optics were taken from ZEISS microscopes and specially optimized for the F25, is utilized for 2D measurements.
Time savings thanks to CAD-based CALYPSO® measuring software
The F25 immediately impressed KERN employees. The measuring time for the bottom plate of a watch with 200 inspection features was reduced by 93 percent from five hours to 21 minutes. In-depth and graphic measuring logs convinced customers and verified the consistently high quality. The use of Calypso planner also drastically reduced the start-up time: the complete measuring program is created and simulated offline on a computer before the first workpiece undergoes a quality assurance check. The initial sampling reports are available a few minutes after the first workpieces of a new series are produced. Waiting times, in which production had to wait for the results, are a thing of the past.
With CALYPSO, as many features as needed can be selected from the entire measurement program – without additional work – and subsequently implemented – a decisive advantage for detailed measurements. Thomas Wicknig, metrologist at KERN, is particularly impressed with the user friendliness of CALYPSO. The program's automation interface allows him to store auto-run measuring programs for his colleagues on the late shift, which also enables inexperienced employees to reliably inspect their workpieces. The easy-to-read measurement log also offers fast statements on necessary changes to the production process. Additionally, since the deployment of the F25 to monitor production at KERN, the company has taken a significant step towards its goal of zero-error deliveries to its watch component customers.
For more information, please contact:
Carl Zeiss Industrielle Messtechnik GmbH
Marketing
Alfons Lindmayer
73446 Oberkochen
Germany
Phone: +49 (0) 7364/20-3539
Fax: +49 7364 20-4657
Email: lindmayer@zeiss.de
Contact for the press (USA):
Annette Smith
Maple Grove, Minnesota
Phone: (763) 744-2409
Fax: (763) 533-0219
Email: asmith@zeiss.com
Headquartered in Oberkochen, Germany, Carl Zeiss Industrielle Messtechnik GmbH is a member of the Carl Zeiss Group. It is the global leader in CNC coordinate measuring machines and complete, multi-dimensional metrology solutions for a wide variety of industrial sectors. Approximately 1300 employees at three manufacturing locations and more than 100 sales and service centers serve customers around the world.
Carl Zeiss is a globally leading international group of companies in the optical and opto-electronic industry. In fiscal year 2005/06 (ended 30 September), the Carl Zeiss Group, which is wholly owned by the Carl Zeiss Foundation, generated sales totaling EUR 2,433 million. The Carl Zeiss Group has approximately 11,250 employees, including about 3,400 outside Germany. Further information is available at www.zeiss.com and www.zeiss.com/imt.
KERN Micro- und Feinwerktechnik GmbH & Co. KG, a mid-sized company with more than 120 employees, has decades of experience and tradition. The micro and precision engineering company known throughout the world has been producing its proven CNC maximum precision micro-milling and boring centers for almost 20 years. Highly trained staff, dedicated management personnel and state-of-the-art machinery provide the foundation for the company's international success in the field of micro-system technology. KERN's long-term business philosophy, maximum precision = KERN expertise, ensures controlled growth and a high degree of customer satisfaction.
