etro lo g y - Carl Zeiss

Innovation 

The Magazine from Carl Zeiss – Special Edition 

8 

CONTURA 

G2 

METROTOM – ONE like NONE 

Metrology + Computed Tomography = Metrotomography 

Metrology 

SPECIAL 

We make it visible.

Preface 

Quality – 

Making a difference in global competition 

Dr. Rainer Ohnheiser, 

CEO Carl Zeiss Industrielle 

Messtechnik GmbH 

Valued customers and friends of 

Carl Zeiss Industrial Metrology: 

The current discussion in the area of production technology 

and metrology is not about global competition as such, but 

how we handle this challenge and what we do with it. 

In addition to the issue of cost, quality is increasingly 

dominating the discussion: quality inherent in the final 

product, quality in individual components or parts, quality 

from the perspective of the supplier and customer. 

Inadequate quality, as well as inadequate documentation 

and verifiability of quality can lead to costly re-work and 

return of an entire shipment. Quality issues can also lead to 

costly and reputation damaging recalls which, more often 

than not, result in heavy financial losses for the companies 

involved. 

Quality must be measurable. Quality must be reproducible. 

Regardless of location or type of procedure and equipment 

used to measure or inspect, ZEISS measuring technology 

and its systems deliver highly reproducible results that can 

mostly be attributed to the un-matched ZEISS scanning 

technology. ZEISS measuring results are trusted in the 

industrial arena so that both suppliers and end-users can 

rely on them. 

I believe we are starting a new value discussion in the field 

of measuring technology. The customer does not primarily 

decide in favor of a specific product, but the value of the 

decision itself is measured in terms of additional criteria: 

• 

• 

• 

• 

• 

Productivity and proximity to the shop floor and 

manufacturing processes 

The end-user’s acceptance of measuring results and 

protocols 

Error resistant applications through “expert know-how” 

Dependability and availability of the product throughout 

its long life cycle, i.e., potential for expanding product 

capability through retrofits 

Reliable metrology suppliers who deliver cutting edge 

technology 

News 

Quality products 

at Control 2006 

At this year’s CONTROL, the leading show for 

metrology, we present Carl Zeiss as a competent 

business partner and highlight future trends. 

With CONTURA G2, we introduce a platform 

which lends itself to the most varied applications 

and accommodates a broad sensor spectrum thereby 

meeting the current needs of the performance 

class. With this configuration, we appeal to a 

growing market segment of suppliers and mid-sized 

companies. 

We at Carl Zeiss Metrology are focused on delivering “more 

value” than merely delivering a product. Over 30 years of 

experience with CNC measuring machines; 18,000 CNC 

systems worldwide, 1 ,000 of those with scanning capability; 

over 5,000 machine configurations of the VAST and PRISMO 

product line; all these facts send a clear message. Service 

technicians and application engineers with the best training 

in the industry, as well as service and application centers 

with high-end equipment provide a consistent and clearly 

superior support structure worldwide. 

How do our customers benefit? How do we generate 

value for our customers? 

It is because of ZEISS measurement quality and ZEISS 

measurement protocols that your production results receive 

worldwide recognition and are reproducible. 

This technology enables any company to position itself at 

the top of the global market. ZEISS measuring technology 

will give you the advantage if you are purchasing workpieces 

from different suppliers; or are a supplier, i.e. to the 

automotive industry, with local plants and facilities abroad; 

or if you are driving continuous process improvement. 

Quality makes a difference in global competition. By 

relying on ZEISS metrology, you place your trust in a 

product leader and a reputable business partner. As a 

leader in performance and innovation, we help you build 

value for your company by delivering dependable products 

with a long life cycle, as well as a reliable support network 

worldwide. 

We are looking forward to your visit and cordially invite you 

to be our guest at CONTROL 006. 

Dr. Rainer Ohnheiser 

Our leading CALYPSO and HOLOS software 

packages represent the established industry standard 

and even the benchmark for functionality and 

programmability. 

The computed tomography instrument Metrotom 

from Carl Zeiss introduces a new dimension of 

workpiece measurement technology: first rate 

measurement results within computed tomography 

coupled with ZEISS precision. 

With these technology highlights, ZEISS defines 

new frontiers at CONTROL 2006. We show the whole 

spectrum, encompassing both measuring technology 

for everyday use, as well as innovative advances for 

tomorrow’s applications. 

Innovation SPECIAL Metrology 8, 006

Preface 

Quality – Making a difference in global competition 2 

Contents/ Publisher‘s Imprint 3 

Product Report 

CONTURA G2 – The Easy Way to a New Measuring Machine 4 

Bernd Balle 

Metrotomography: Computed Tomography and Metrology 6 

Stephan Klumpp 

3D Scanning Ensures the Quality of Micro-parts 8 

Karl Seitz, Alfons Lindmayer 

Ultimate Performance Classes 10 

Nadine Kimmerle, Dietrich Imkamp 

MZ 2010 – The Latest in Measurement Counters 11 

Michael Knauer 

MMZ Machines Ensure Quality in Vehicle Construction 12 

Berndt Kammleiter 

MMZ Machines Ensure Quality in Energy Technology 13 


New Products for Inline Metrology 14 

Wolfgang Wiedmann, Hannes Daniel 

Accreditation for ISO 10360 16 

Ernst Wiedenmann 

Newsticker 17 

Carl Zeiss Introduces Global Software Licensing 18 

Christina Scheible 

CALYPSO – The Software for Everyone 20 

Otto Boucky 

CAD Offline Programming under CALYPSO 22 

Josef Pfeilmeier, Michael Wieler 

CALYPSO Renews Old Measuring Technology 24 

Lutz Karras, Christoph Grieser 

CALYPSO on non-ZEISS Machines 25 


Operating Data Capture for Coordinate Measuring Machines 26 

Robert R. Roithmeier 

πWeb Small Business – The Solution for Mid-size Companies 28 

Andreas Lotze, Claudia Krönicke, Christina Scheible 

The Application Determines the Sensor – VAST 30 

Dietrich Imkamp, Karl Schepperle 

LineScan – Optical Scanning from Tomorrow Today 34 

Ralf Stecher 

Carl Zeiss Makes It Easier: Switch to Active Scanning 35 

Günter Keck 

Publisher‘s Imprint 

Innovation SPECIAL Metrology Nr. 8, 

the Magazin from Carl Zeiss, Mai 006 

Publisher: Carl Zeiss IMT GmbH, Oberkochen. 

Editor in chief: Alfons Lindmayer (responsible) 

Carl Zeiss, D-73446 Oberkochen, Department I-VM 

Phone (+7364)/ 03539, Telefax (+7364)/ 04657, 

e-mail: lindmayer@zeiss.de (Germany) 

Internet: www.zeiss.de.imt 

Editor and Layout: Nadine Kimmerle 

Carl Zeiss, D-73446 Oberkochen, Department I-VM 

From Users for Users 

CONTURA G2 – Quality Assurance on the Shop Floor 36 

Felix Hoben 

Round-the-Clock CMM Precision Proves 

Essential to Company Success 38 

Annette Smith 

VW Saxony: Coordinate Measuring Systems 

for TSI Engines Ready in Record Time 40 

Matthias Kurth, Heinz-Günter Hoppe 

GageMax – the Flexible Measuring Innovation 

in Differential Bevel Gear Production 44 

Frank Lamberty, Peter Bachem, Theo Sannig, 

Rainer Detzel, Roger Bayer 

OVCMM Enables Efficient Determination 

of Measuring Uncertainty 46 

Björn Blom, Josef Wanner 

DaimlerChrysler Chooses CALYPSO 48 

Kai Gläsner, Günter Keck 

Highly Accurate Gear Tooth Measurements 

in the Production Environment 49 

Roman Groß 

Minutes not Hours 50 

Rolf Bülow 

Pioneering Technology Common-Rail-Systems 52 

Szabolcs Jakob, Jozsef Beke, Christina Riedl, Markus Walcz 

Quality Assurance at BANG & OLUFSEN in Struer 54 

Jens Lynge Petersen, Peder Bay, Wolfgang Schwarz 

About us 

Technology Day in Brazil 56 

Antonio Carlos Coelho, Janaina Iziquiel 

Under the Indian Sun 57 


“IMT Practice Workpiece” 58 

Bernd Georgi 

Product Names and registered trademarks 

from Carl Zeiss IMT GmbH 59 

© 006, Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen 

Permission for the reproduction of individual articles and 

illustrations from ”Innovation” – with due reference to the 

source – will gladly be granted after prior consultations 

with the editors. 

Picture sources: unless otherwise specified, all photographs 

were contributed by the authors or originate in the archives 

of Carl Zeiss. 

Authors: if no information is given to the contrary, the 

authors of the articles are employees of Carl Zeiss and 

can be contacted via the editor. 

Contents 

Innovation SPECIAL Metrology 8, 006 3

Product Report 

CONTURA G2 – The Easy Way to a 

New Measuring Machine from Carl Zeiss 

Bernd Balle 

4 

CONTURA G2 is the next generation 

customized scanning platform for 

small and mid-size companies. 

With CONTURA G2, total scanning 

technology from Carl Zeiss is 

available for the first time in the 

mid-range price class. 

The traditional compromise of having 

to decide between touch-trigger or 

scanning for cost reasons is no longer 

an issue. With CONTURA G , scanning 

as basis of all measuring solutions is 

now available to everyone. 

The measuring task 

determines the 

optimum sensor 

for your solution 

The selection of a sensor should 

not be determined by the available 

CMM options of the manufacturer, 

but rather by the measuring task 

itself. If workpiece features contain 

many angles, sensor equipment with 

an articulating probe holder is often 

recommended. An active central sensor 

is the optimal setup for all traditional 

workpieces that are processed on three 

sides. CONTURA G offers a sensor for 

* Packages and Offerings may differ by Market 

each measuring methodology – without 

compromising the measuring accuracy. 

It offers the identical high measuring 

accuracy both in the version with the 

articulating probe head as well as with 

active scanning technology with the 

central probe. Measuring uncertainty 

and price are no longer determined by 

the type of sensor, but by the machine 

platform. 

At the same time, we offer 

completely new approaches to 

purchasing a machine, including the 

traditional purchase, full-time leasing 

or even pay by use. Return or trade 

in? With this machine, Carl Zeiss is not 

only branching off into new directions 

from a technical standpoint, but also is 

offering several purchasing options. 

Pay by Use* 

The unique program from Carl Zeiss 

for CONTURA G offers maximum 

flexibility. 

Pay by use allows you to get the 

benefits of a CONTURA G without 

having a budget. The most attractive 

point here is the lack of a purchase price. 

With a 1 -month leasing contract, you 

pay only a minimal per-hour usage 

fee for each hour that you use the 

CONTURA G . The only requirement 

is a minimum operation time of for 

example 800 hours per year. After the 

contract expires, you have the option 

of purchasing the measuring machine 

or returning it to Carl Zeiss. 

No-risk purchase* 

The no-risk purchase option makes 

the decision to invest very easy. Carl 

Zeiss guarantees an unlimited right of 

return for the full purchase without a 

reason within the first six months of 

ownership. The no-risk purchase allows 

you to trade in your CONTURA G 

within one year for a similar or higher 

quality Carl Zeiss measuring machine, 

enabling you to adjust to any changes 

in your range of tasks. 

True warranty* 

Where other manufactures only 

provide a partial warranty and simply 

exclude buy-out components, e.g. 

sensors, Carl Zeiss offers a true warranty 

for the entire system. 

Three versions of the 

new CONTURA G2: 

CONTURA G2 RDS 

CONTURA G RDS is designed for 

measuring complex features and parts 

with multiple angles requiring smaller 

styli. With 0,736 angular positions, 

the proven ZEISS RDS articulating 

probe holder reaches every position – 

even with the most complex workpiece 

geometries. VAST XXT can be used 

with styli up to 50mm long, as well 

as very small styli with tip diameters 

of 0.3 mm. The large deflection range 

and the low measuring force make this 

machine a very sturdy scanning sensor. 


CONTURA G2 aktive 

This CMM is ideal for workpieces 

with features in the 6 main planes. 

Thus, the central sensor is the 

general solution for almost any task. 

Measuring deep features, in particular, 

can be optimally completed with long 

extensions. It is available with the 

high-performance DynaTouch sensor 

for active single-point measuring and 

with the VAST XT scanning sensor for 

multi-point measurements of size, form 

and position. VAST XT offers active 

scanning and single-point measuring. 

Its high-speed and high-point density 

capabilities make VAST XT suitable for 

all applications in geometric, curve and 

freeform measuring, as well as reverse 

engineering. It can be equipped with 

extensions up to 500 mm and stylus 

weights up to 500 g. 

CONTURA G2 direkt 

The entry-level machine for 

scanning technology from Carl Zeiss 

– for measuring geometry, form 

AND position — true ZEISS scanning. 

Equipped with the VAST XXT scanning 

sensor, this machine can already 

measure a large number of workpieces. 

For example, applications in which 

small single styli or star probes are 

sufficient. Ideal applications for this 

line include small parts with standard, 

squared geometries without slanted 

geometric features, and production 

progress checks of single processing 

steps. 

CONTURA G models offer X, Y, and 

Z measuring ranges of 700 x 700 x 

600 mm up to 1000 x 100 x 600 mm. 

All versions are equipped with the Ushaped 

granite table that expands the 

effective measuring range of the Z axis 

to 800 mm. 

CALYPSO and scanning 

Measuring runs can be easily 

generated using CALYPSO with Visual 

Metrology. The essential features make 

it the ideal software for your measuring 

requirements: 

• 

• 

• 

• 

• 

Object-oriented programming for 

the easiest generation of measuring 

runs using the same features that 

are also used in the design drawing. 

Easy generation of partial measuring 

runs from entire CNC programs. 

Simple changes, modifications, or 

additions to existing measurement 

programs. 

Software and sensor flexibility: from 

single-point measuring to scanning 

and optical measuring tasks. 

Application-specific display of the 

measurement results. Reports can 

be easily tailored to individual 

requirements. 

Whether for single-point measuring 

or scanning, manual or CNC, on a 

measuring machine or offline, touchtrigger 

or optical, standard geometric 

forms or freeform surfaces – with 

CALYPSO you do not need other 

software. 

True scanning 

ZEISS scanning is unparalleled. 

All relevant elements of a scanning 

system are developed and produced 

in-house: software, controller, sensors 

and calibration procedures. No other 

manufacturer can provide the Carl 

Zeiss IMT scanning experience. 

Finally, the no-risk purchase is a key 

reason to buy a machine from Carl 

Zeiss. 

Bernd Balle 

Marketing/ Business Strategy 


Metrotomography: Computed Tomography 

and Metrology in One 

Stephan Klumpp 

Fig. 1: 

The new ZEISS Metrotom 

instrument 

6 

The term metrotomography is the 

result of combining metrology 

and tomography. The fusion of 

industrial metrology and industrial 

computed tomography (CT) will 

present comprehensive quality 

assurance with even more unknown 

possibilities. 

As a supplement to traditional 

technologies in testing and measuring 

technology, industrial computed 

tomography is conquering new fields 

of application with fascinating and 

very productive solutions. 

The possibility of completely 

capturing a part and thus assessing 

the interior and exterior provides the 

user with all evaluation possibilities 

at a glance – within a short time and 

without destroying the component. 

Carl Zeiss 3D Metrology Services 

GmbH in Aalen, Germany performs a 

fast-growing number of CT services 

for a wide variety of applications 

in industrial testing and measuring 

technology. 

Customers are amazed at the results 

and the simple methodology. 

Metrotomography 

applications 

The main applications are concentrated 

in the following areas: 

• 

• 

• 

• 

Destruction-free testing: 

- Defect checks 

- Porosity analyses 

- Assembly inspection 

- Damage analysis 

- Inspection of materials 

Dimensional metrology 

Reverse engineering 

Comparison of geometries 

Potential 

and challenge 

Technologists for metrology and 

metrotomography at Carl Zeiss, Dr. 

Dietrich Imkamp and Dr. Hubert 

Lettenbauer, summarize the challenges 

of metrotomography as follows: 

“Dimensional measuring is more than 

just quantifying 3D image data. The 

quality of this data, the result of a CT 

scan in this case, largely depends on the 

quality of the entire chain of recording 

and thus from several parameters 

(size of the focal point, stability of the 

tube voltage, quality of the overall 

kinematics, etc.). Mastering this chain, 

as well as suitable calibration methods, 

is the first step in creating high-quality 

image data.” 

The same applies to the subsequent 

evaluation of the data. The orientation 

of the object according to the drawing, 

the inspection of form and position 

and the determination of curve gaps 

or the display of surface forms in 

accordance with DIN are everyday 

tasks in coordinate metrology. 

All these demands apply to CT, the 

same as with traditional measuring 

equipment. However, the deciding 

factor for users is reliable information 

on whether the measured features of 

their part to be measured are within 

specified tolerances nor not. Trusting 

any results without verification of 

measuring system analysis is not only 

negligent regarding the quality of the 

product to be measured. 3D CT would 

also lose acceptance at an early stage 

of its development as specialists usually 

recognize such deficits quickly. 

Only someone able to master the 

entire measuring chain is capable of 

delivering and verifying reliable and 

reproducible results. The benefit to 

the user from the CT data is significant 

and offers enormous potential for the 

future of this technology. 


Fig. 2: 

All-around quality assurance 

Fig. 3: 

An applications technician for over six years, Stephan 

Tomaschko knows the CT system very well 

The future of 

metrotomography 

Having innovative technologies that 

are easily, quickly, productively and 

economically implemented is the most 

important aspect for users. 

An experienced team in testing and 

measuring technology is responsible 

for extensive product development 

and application optimization of 

metrotomography instruments at Carl 

Zeiss IMT GmbH. The CT services team 

at Carl Zeiss 3D Metrology Services 

headed by Stephan Tomaschko has 

the largest wealth of experience in 

industrial CT services. 

Furthermore, Carl Zeiss has stood 

for innovative metrology products, 

superior benefit to the customer and 

leading productivity for years. For 

innovative quality assurers, leading 

opinion makers and trendsetters, the 

near future will be clearly all about 

dealing with the applications as well 

as the influences and limitations of 


CT services 

Carl Zeiss 3D has an applications 

system available for industrial CT 

measurements. The customer receives 

the evaluation of the measuring results 

in the form of a measurement log, 

deviation diagram or images depending 

on the task and the customer’s 

request. Detailed 3D data can be 

processed based on three-dimensional 

models or videos, for example, which 

graphically display the interior of the 

workpiece. For a comparison of a real 

workpiece with available CAD data, 

Carl Zeiss 3D also offers a “false color 

image” that vividly documents the 

deviations between the nominal and 

actual values. Additionally, there is still 

a variety of evaluation possibilities that 

can be easily tailored to the customer. 

MBA Stephan Klumpp 

Head of Product Management Metrotomography 

Metrotomography 

With metrotomography, it is now possible to nondestructively 

measure and make visible features and 

structures from the interior of “materials and parts” 

e.g. material defects (cracks, bubbles, gas porosities 

and inclusions) as well as internal workpiece features 

or geometries that cannot be probed. The preferred 

application of this technology is in the entire 

plastic injection technology, the production of cast 

parts, particularly cast aluminum, and in composite 

materials. 


3D Scanning Ensures 

the Quality of Micro-parts 

Karl Seitz, Alfons Lindmayer 

Fig. 1: 

Scanning sensors to 

measure tiny parts 

8 

Micro-parts are the key elements 

in components for medical devices, 

measuring machines and cars. 

Thanks to their surface qualities and 

exact dimensions, these tiny parts 

ensure smooth operation despite 

often extreme demands. The first 

step is the highly precise production, 

followed by efficient quality 

assurance. Scanning is becoming 

increasingly important. 

More and more applications require 

micro-components. They are essential 

to miniaturized systems such as 

pressure sensors, micro-motors and 

switches, drives, pumps, ball bearings 

and bio reactors, which are used in 

medical and metrology equipment, as 

well as in motor vehicles. For example, 

micro-parts keep the high-speed drill 

at the dentist up and running. They 

ensure the required performance in the 

injection regulator of a turbo diesel. 

The micro-mechanical manufacturing 

process had to be enhanced as fast 

as new application possibilities 

appeared. This is especially valid for 

accuracy, reliability and productivity. 

Micro injection molding and milling, 

micro-bores and eroding enable the 

fully automated production of these 

tiny parts. Their geometric structures 

measure only a few tenths of a 

millimeter. The accuracy with which 

they are manufactured is less than one 

micron. 

Ensuring sustained, problem-free 

operation alone would require the 

quality assurance of micro-parts 

– primarily in medical technology. 

Efficient quality assurance, however, 

is also necessary for economical 

production. Only reliable quantification 

with suitable measuring equipment of 

the geometric product features that 

determine quality, helps to reduce or 

avoid defects or the results of defects 

which endanger success. Technical and 

economical factors determine whether 

or not a measuring system is suitable 

for monitoring the manufacturing 

process. The measuring equipment 

used for quality assurance must be 

able to capture all features of a micropart 

relevant to the function with the 

required measuring uncertainty and 

minimal effort. 

Measuring micro-parts 

with touch sensors 

As with macro-parts, the vertical 

walls of micro-parts can also not be 

captured optically. Tactile coordinate 

metrology is often the only technically 

suitable and economical solution. 

Coordinate measuring machines 

have been used for years as flexible, 

highly efficient measuring systems for 

the geometric quality assurance of 

traditional mechanical components. 

What has proven successful there 

– determining size, form and position 

through single-point measurement and 

Scanning – can also be generally used 

for the quality assurance of micro-parts. 

However, extremely small dimensions 

and different forces exist here; other 

principles apply. Consequently, the 

requirements on a measuring machine 

for micro-system technology are 

completely different than those on its 

“colleagues” in automobile production 

or tool making. 

Positioning and fixing micro-parts 

requires highly precise equipment. At 

the same time, the holding force must 

be very low to ensure that a micro-part 

is not deformed or damaged during 

the measurement. This necessitates 

a sensor system that must work with 

extremely low measuring forces, to guar 

that the micro-part is not deformed 

or moved by the machine when it is 

measured with touch sensors. 

CAD-based software is essential for 

multi-dimensional measuring tasks 

on micro-parts. As the features on 

micro-parts are practically invisible to 

the naked eye, the control data and 

measuring program should be directly 

programmed in the CAD module 

and remotely tested for interfering 

contours and travel paths before the 

measurement. This ensures that all 

features can be reached by the minute 

stylus without a collision. Featureguided 

and object-oriented software 

enables you to select and run any 

number of features from the entire 

measurement program – a decisive 

advantage with detailed measurements 

on micro-parts. 

F25: touch 

measurements with 

7.8 nm resolution 

The F 5 3D coordinate measuring 

machine with CALYPSO measuring 

software offers the above-mentioned 

possibilities. The measuring volume 

of the F 5 is one cubic decimeter. 

This is almost nothing compared to 

its “big brothers” in control and tool 

manufacturing process for example. 

Measuring uncertainty for this 

volume is 50 nm at a resolution of 

7.8 nm. Using minimal probe forces, 

this resolution, along with optimum 

control of the linear drives, enables 

touch measurements even in bores 

less than one millimeter in diameter. 

The basic precision kinematics were 

developed in cooperation with the 

Institute of Metrology and Technology 

(NMI) at the Technical University of 

Eindhoven, Netherlands as part of a 

doctorate project. It is based on the 

Abbe comparator principle. 

The touch, passive scanning sensor 

consists essentially of a scanning solid- 


Fig. 2: 

F25 measuring machine with new award-winning design 

state joint probe based on a silicon chip 

with integrated Piezo resistive elements. 

Developed in a joint effort with the 

Institute for Microsystem technology 

(IMTEK) in Freiburg, Germany, it works 

with resolution of one thousandth of 

a micron and is designed as a flexible 

changer. Single-point measuring and 

scanning are both possible. The sensor 

is designed for stylus diameters of 0 

to 500 microns at a free shaft length 

of up to 4 millimeters. Stylus tips can 

have a diameter between 50 and 700 

microns. A 50 mm long match with 

a 5 mm diameter head is a giant in 

comparison. 

The probe forces were also reduced to 

less than 0.5 millinewtons per micron. As 

a supplement to touch measurements, 

an optical sensor, whose optics have 

been optimized and adjusted based on 

microscope objective, is used for D 

measurements. An additional camera 

aids visualization when probing the 

miniaturized features, thus simplifying 

learn programming. 

The future: inline 

process control 

The F 5 will demonstrate its true 

capabilities in the future. All efforts are 

designed to enhance the measuring 

machine for integrated quality 

assurance in micro-system production 

processes. The F 5 is particularly 

attractive, because it permits the 

measurement of size, form and position 

on micro-system components. 

Karl Seitz 

Director of New Technologies; 

Alfons Lindmayer 

Vice President of Marketing/Business Strategy at IMT 

Award 

C a r l Z e i s s I n d u s t r i a l 

Metrology has been awarded 

one of the most prestigious 

international awards for the 

F25 measuring machine. With 

the “2006 iF product design 

award”, International Forum 

Design GmbH in Hanover 

honored the design of this 

measuring machine for quality 

assurance in micro-system 

technology. The award also 

honors the work of the 

Henssler and Schultheiss 

Fullservice Productdesign 

GmbH in Schwäbisch Gmünd. 

The company was involved in 

the development of the new 

machine and was responsible 

for its attractive design. 


Ultimate Performance Classes 

Nadine Kimmerle, Dietrich Imkamp 

10 

PRISMO navigator from Carl Zeiss: 

Efficient Measuring with High-speed Scanning 

The navigator versions of the PRISMO 

coordinate measuring machine from 

Oberkochen, Germany-based Carl 

Zeiss Industrial Metrology enables 

particularly efficient measurement 

of parts. Navigator is the systematic, 

functional coordination of the VAST 

gold active sensor, VAST navigator 

measuring software, CALYPSO 

scanning software and the Scanning 

Engine as the controller for single point 

measurements and active scanning. It 

increases reliability where speed and 

measuring accuracy are concerned. 

The third generation of PRISMO 

navigator reduces the time needed 

for measurements by up to 65 percent 

depending on the measuring task. 

The specified linear measuring 

tolerance of 0.3µm + L/1000 turns the 

UPMC ultra into an essential reference 

instrument for research, development 

and quality assurance. The patented 

active scanning with the ZEISS sensor 

system permits capture of large point 

densities which serve as the basis for 

all required evaluations. The central 

drive system ensures highly dynamic 

rigidity, which enables short contact 

times and thereby short measuring 

times. CARAT aluminum technology 

for the x-axis and pinole, thermal 

insulation and correction of thermallycaused 

bending of the measuring 

plate ensure the long-term stability of 

guideway behavior. All scales in the 

patented voltage-free and frictionless 

positioning are made of temperaturesensitive 

glass ceramic. As a result of 

Until now, it has been only possible 

to measure quickly or accurately, 

navigator does both. The combination 

of dynamic calibration with Helix 

scanning and tangential approaching 

and scanning allows PRISMO to 

conduct measurements in a very short 

time. PRISMO is ready for measuring 

much faster than with traditional 

scanning technology. Furthermore, the 

measuring strategy for the navigator 

functions is automatically created. 

Equipped with HTG, the optimum 

temperature range expands to 15°C to 

30°C (59°f to 86°F). The S-ACC version 

delivers measuring uncertainties of less 

than 1 micrometer. 

A Class of its Own: 

Universal Precision Measuring Center ultra 

its negligibly low thermal expansion 

coefficient, there are practically no 

influences caused by temperature. 

Computer Aided Accuracy (CAA) is 

used for strict guideway error corrections 

and to correct static and dynamic bending 

errors on the machine mechanics that 

are created by probing forces and 

accelerations. Carl Zeiss IMT offers 

various software packages to make the 

entire performance spectrum of UPMC 

ultra available. This includes CALYPSO, 

Gear Pro, Blade and HOLOS NT. 

Nadine Kimmerle 

Marketing/Business Strategy; 

Dr. Dietrich Imkamp 

Product Management, Bridge Machines 


MZ 2010 – The Latest in 

Measurement Counters 


Measurement counters seem to be 

relicts of the past. But that may 

not be true. Measurement counters 

and their simple, intuitive functions 

are still extremely useful. They are 

indispensable in many development 

areas in which manual horizontalarm 

measuring machines are 

operated. Measurement counters 

are used to calibrate equipment 

and to physically align parts and to 

process the models built on them. 

For example, they support the 

following tasks: network lines are 

scribed, basis points milled and 

models inspected. This occurs again 

and again until the modeler or model 

maker achieves the form envisioned 

for the new object by the designer. 

Cutting sheet metal is specified during 

construction of prototypes in the 

automotive and supplier industries for 

trial runs. 

Nowadays, a measurement counter 

must be self explanatory, enabling the 

operator to reliably guide it to its target 

with just a few mask and key strokes. 

It must allow for numerous possibilities 

and various settings. The features of 

the MZ 010 include: 

• 

• 

• 

• 

• 

• 

• 

• 

• 

• 

• 

Measure of contraction for X, Y, Z 

Axis transposition 

Scale factor 

Entry of stylus constants 

Stylus correction (On/Off) 

Memory preset 

Reference travel 

Dimensions in mm/ inches 

Change decimal places 

Display delay of the probing point 

Counter reset 

The MZ 010 measurement counter 

has one decisive advantage: operators 

are often required to stand very close 

to the measured object – inside large 

objects – in order to be close enough 

to reach the point to be measured 

or processed. They then require the 

display directly near them and not 

fixed to a measuring machine. 

In order to meet this demand, Carl 

Zeiss Industrial Metrology has developed 

a handy solution. It allows operators to 

remove the ergonomically designed 

display of the MZ 010 measurement 

counter from the measuring machine 

and take it to where the action is. 

The system can be directly connected 

to a data station via the integrated 

interface if additional software is 

required beyond “normal” operations. 

This is supplied with data from the 

ZEISS MZ 1060 global format. 

The MZ 010 measurement counter 

is also ideal for those who only utilize 

applications in conjunction with 

software such as HOLOS NT. In such 

cases, the counter box, alone, is 

used as a data supplier for the data 

station. The display is not needed. In 

other cases, it provides – integrated 

into the instrument base – the display 

with information on travel paths, 

measurements or other measuring 

machine information. 

The integrated measurement counter 

solution is designed for all ZEISS 

Stiefelmayer measuring machines. 

Furthermore, almost all manual 

horizontal-arm measuring machines 

from 

Mora 

ZettMess 

Wenzel 

Poli 

or others upon request 

can be retrofitted with the MZ 010 

measurement counter. You will be 

amazed at the resulting flexible 

applications. 

Innovation SPECIAL Metrology 8, 006 11 

• 

• 

• 

• 

• 


Product Manager horizontal-arm machines 

Fig. 1: 

Manual coordinate 

measuring machine with the 

new MZ 2010 measurement 

counter display

MMZ Machines Ensure Quality in Vehicle 

Construction and the Aerospace Industry 


Fig. 1: 

VAST XXT scanning sensor 

on the RDS 

1 

Large gantry-type coordinate 

measuring machines (CMMs) are used 

for quality assurance in the freeform 

segment: MMZ E and MMZ B. 

The VAST XXT and LineScan 

sensors are now available on the RDS 

articulating probe holder. With these 

sensors, bridge-type MMZ machines 

become optimal measuring systems for 

various measuring tasks. 

Vehicle construction 

Here, LineScan enables fast, highpoint 

density capture of freeform 

surfaces on molds. 

However, features with stricter 

requirements on accuracy such as 

trimming edges, slides and inserts 

can also be recorded using the 

available sensors. These sensors 

are ideal tools as the prototype 

must quickly deliver information 

on the connection dimensions. 

Aerospace industry 

New materials and ever narrower 

tolerances require more accurate 

CMMs and more powerful sensors. 

Parts made of composite materials 

often permit only low probing forces; 

inserts must be very accurately 

recorded. LineScan and Vast XXT also 

excel in this area of application with 

fast, reproducible measuring results. 

VAST XXT sensor 

This scanning sensor permits 

highly precise measurements with a 

low probing force. Both automatic 

single-point probing and scanning are 

possible. 

Typical tasks in scanning operations 

include the capture of profile cuts or 

digitizing inserts for the manufacture 

of twin tools. Bores can often be 

captured more quickly and always 

more reliably with scanning than with 

single-point probing. 

However, the inspection of 

connection dimensions of the 

prototypes, for example, is conducted 

using single-point probing. In any case, 

VAST XXT is the optimal system. 

CFK extensions are available for 

deeper insertion depths. They enable 

the sensor to reach deep-laying part 

features without the disadvantages 

of longer styli. Two different, 

corresponding stylus kits can be used. 

The automatic change between several 

styli occurs via a 3x storage rack. 

VAST XXT achieves linear measuring 

tolerances comparable to VAST gold. 

LineScan 

from Wolf & Beck 

LineScan is an innovative sensor 

system with an optical line scanner. 

It can alternate with other sensors. It 

was primarily designed for the highly 

efficient capture of freeform surfaces. 

However, it is also possible to record 

single points during a scan. This often 

occurs faster with LineScan than 

probing single points. 

Measuring weak parts without the 

risk of deformations resulting from 

probing forces is also possible with 

LineScan. 

As a result of the high data rate and 

the large measuring range, LineScan 

permits the capture of large areas in a 

short time. 

The optimum point density can be 

selected before capture when needed. 

The gathered data on the point cloud 

can be transferred to various software 

systems for evaluation or further 

processing. 

Both manual and CNC operation are 

possible. The joystick is often the fastest 

way to digitize a single workpiece or 

parts of it. 

If a CAD model of a workpiece 

is available, the capture can be 

programmed offline and is then 

available as a parts program for 

subsequent repeat measurements. 


Project Manager 

MMZ E, MMZ B 

The bridge-type construction, 

together with RDS, ensures 

the best possible access to the 

measuring points while requiring 

little space. Both models cover 

a large section of the measuring 

range. MMZ E and MMZ B 

offer the best accuracy at high 

throughput. The two new sensors 

now provide optimum equipment 

for vehicle construction, the 

aerospace industry and other 

sectors. 


MMZ Machines Ensure Quality 

in Energy Technology 


Large coordinate measuring 

machines (CMMs) – MMZ G and 

MMZ T – from Carl Zeiss are used 

to ensure very high quality in energy 

generation facilities. 

In times of rising costs and 

declining supplies of fossil fuels, 

power provided by wind, water and 

renewable resources is becoming 

increasingly important. Developing 

industrial countries such as India and 

China require ever more energy. Wind 

turbines and gas engines are becoming 

larger and more effective. Gas turbines 

for energy generation and heat must 

have a long service life with maximum 

effectiveness. As a result, demands 

on the size of the corresponding 

components and modules are growing; 

the tolerances, however, are becoming 

tighter. 

Wind turbines 

In this segment, the large drives and 

all their parts have high demands on 

quality: 

Gear boxes and pinion cages 

with enormous dimensions must be 

measured and documented for form, 

size and position on flange surfaces and 

bearing seats. Measurements are often 

required on features that can only be 

reached with stylus lengths of 800 mm 

and longer. Demands on permissible 

positional tolerance are high. 

Gears with a large diameter ( 000 

mm and more) are used in these 

drives. A highly accurate rotary table 

is necessary for such gear wheels. 

However, it must be possible to conduct 

measurements without a rotary table. 

Gas engines 

Large 16 and 0 cylinder V engines 

are produced for the energy-heat 

coupling. The form and position of 

crankshaft bearings and cylinder bores 

are the most important features. 

Deep-laying features require a 

correspondingly long stylus; however, 

tolerance sacrifices are practically not 

permitted. 

Turbines 

The shafts are the key components 

of turbines. They are known for large 

dimensions with complex connection 

geometries and high demands on 

the operating characteristics. The 

workpiece must be exactly captured 

and documented. Here also, the form, 

size and position of interior and exterior 

cylinders are vital. 

Reliable, 

flexible and safe 

Gears can be measured with or 

without a rotary table. This can be 

best accomplished using GEAR PRO 

software. Highly accurate rotary tables 

with face plate diameters up to 000 

mm and 10,000 kg load capacity are 

available. 

The freely selectable positioning of 

the stylus rack also enables automatic 

changing of large, bulky stylus 

combinations. 

A high safety standard provides 

full collision protection for the shaft 

and probe. Additional safety features 

include light barriers which reduce 

the machine speed when they are 

interrupted. 


Project Manager 

MMZ G, MMZ T 

The high-performance bridgetype 

machines for precision 

parts make it easier to handle 

workpieces. It is also possible to 

load the machine from the side 

using a crane. 

MMZ G and MMZ T offer 

outstanding accuracy with 

high scanning performance. 

The standard setup with VAST 

navigator has further improved 

the performance of these 

systems. This made it possible 

to considerably increase the 

accuracies achieved at higher 

measuring speeds, delivering an 

excellent measuring performance 

primarily for form inspections – 

the decisive feature for the listed 

applications. 


New Products for Inline Metrology: 

More Volume – More Accuracy 


Interlinking capability: 

GageMax with robot loading 

at the Chiron Works booth 

Process capability: 

gage capability and availability are listed on the data sheet 

14 

CenterMax and GageMax, highquality 

products from Carl Zeiss, 

have long proven their value for 

highly accurate measuring directly 

in production. Many customers have 

improved the efficiency and stability 

of their production processes using 

MaxLine machines. Now, enhanced 

specifications and larger measuring 

ranges are expanding the range of 

applications of this line. 

GageMax – efficient, 

accurate and right in 

the middle 

GageMax with the RT1 rotary table 

for the measurement of rotationally 

symmetrical parts, e.g. gear wheels and 

screw compressors, was presented last 

year. Since that time, the percentage 

of rotary tables with GageMax 

has increased by approximately 30 

percent. 

How perfectly suited GageMax is 

for automated production processes 

was on display at the Chiron Works 

booth during the EMO 005 machine 

tool trade fair in Hanover, Germany. 

GageMax was linked to a new 

Quattrocell x double spindle center 

via a loading robot. Loading and 

CNC-start ran automatically without 

user intervention. Unloading of the 

workpieces, evaluation and traceability 

of the measuring results was completely 

automated. 

Electronically locked sliding 

windows provide the necessary 

security, enabling complete process 

checks with GageMax quickly and 

directly on site without specially trained 

personnel – more economical is simply 

not possible. 

GageMax now even 

more accurate 

Carl Zeiss Industrial Metrology 

has taken accuracy to the next level: 

specifications for MPE E of 1.8+L/300 at 

0°C and .8+L/ 00 at 40°C permitted 

an improvement of almost 0 percent. 

The wide range of temperatures 

remained between 15°C and 40°C. 

Without a price increase, GageMax 

should be attractive to customers with 

even more accurate applications. 

The range of applications of GageMax 

has also been expanded. There are 

now two optional, active stylus racks 

for up to 13 magazine positions. The 

magazines are located outside the 

measuring range, leaving the entire 

volume available for measuring. 

GageMax with 

capability verification 

For measurements in production, 

the statement on measuring system 

analysis – the ability of the measuring 

system to measure all tolerances on a 

part with sufficient accuracy reserves 

– is the most important criterion for 

decision making. GageMax is the first 

measuring machine in the world to 

offer customers a clear statement: 

tolerances for two measuring lengths 

(50 and 400mm) and one diameter 

(50mm) which can be reliably 

measured in the production process in 

accordance with generally established 

criteria, are now determined on the 

artifact CMM check. 


CenterMax 11/12/9 

– entering new 

dimensions 

CenterMax, the larger version in the 

line of ZEISS production measuring 

machines, has been expanded once 

again. A longer Z axis combined 

with a new clamping device delivers 

a measuring range of 110 x 1 00 x 

900 mm, resulting in a measuring 

range that is 50 percent larger. This 

measuring range can be fully utilized 

when the new optional three-level 

stylus rack is used, as the magazine is 

completely outside the working range. 

The appropriate level is pneumatically 

moved in only for the actual probe 

change. The magazine can be equipped 

with up to 15 positions. 

The outstanding MPE E accuracy of 

1.4 + L/333 at 0°C and .4 + L/ 33 

at 40°C remains the same. The price 

was also unaffected. Compared with 

a standard coordinate measuring 

machine in the measuring lab or 

traditional single-purpose measuring 

instruments, an investment in an inline 

product from Carl Zeiss usually pays for 

itself in less than two years. 

CenterMax ultra – 

the new class for 

maximum accuracy 

The new CenterMax ultra measuring 

machine launches a new era in 

maximum accuracy. CenterMax ultra 

is designed for use as a reference 

machine in the measuring lab and 

excels with a specification of MPE E = 

0.6 + L/600. 

This is an improvement of 33 percent 

over its predecessor, CenterMax S-ACC 

– all at a price clearly less than other 

comparable machines. 

This also brings ZEISS VAST 

navigator technology to the class of 

V-8 capability: 

the new large CenterMax with active tool changer 

highly accurate coordinate measuring 

machines, leading to reductions in 

measuring times of up to 60 percent 

over existing machines. 

Wolfgang Klaus Wiedmann 

Head of InLine and Projects; 

Hannes Daniel 

Productmanagement InLine 


Accreditation for ISO 10360 

Ernst Wiedenmann 

Fig. 1: 

Calibrating a stepper gage 

block 

16 

Carl Zeiss Industrial Metrology is 

the first company in Germany to be 

accredited for the acceptance and 

confirmation testing of coordinate 

measuring instruments in accordance 

with the DIN EN ISO 10360 Part 2, 

Part 3 and Part 4 standards. The 

Carl Zeiss calibration laboratory was 

extensively evaluated for this by the 

German Calibration Service (DKD) 

corresponding to the DIN EN ISO/ 

IEC 17025 standard. 

The accreditation was realized not 

only for the minimum acceptance 

requirements, but also for all 

measuring properties for which ZEISS 

coordinate measuring machines are 

known, primarily scanning properties. 

The name Carl Zeiss is synonymous 

with scanning using coordinate 

measuring machines. It was therefore 

essential to offer DKD acceptance for 

the THP scanning probing deviation 

and duration of the t scanning 

test parameters. Several defined 

paths must be scanned on a 5 mm 

reference sphere for this calibration. 

The maximum radial difference of the 

individual points and the maximum 

deviation from the calibrated radius 

of the sphere are calculated from 

this. The larger of these two values is 

compared with the specified deviation, 

MPE THP , and incorporates the measuring 

uncertainty. In accordance with DIN EN 

ISO 10360-4, the second parameter 

during scanning is the scanning speed. 

This represents the time required for 

the CNC run when determining the 

THP. Carl Zeiss can now verify the 

conformity of the measuring machines 

with a DKD calibration certificate for 

both parameters. 

Some of the measuring machines 

are equipped with a rotary table as a 

fourth axis. Part 3 in the DIN EN ISO 

10360 series of standards applies 

to the acceptance and confirmation 

testing of rotary tables. In accordance 

with the specifications contained 

therein, a test piece must be measured 

with two spheres at defined positions 

on the rotary table in various angular 

positions. The sphere center points of 

the two spheres are determined from 

a total of 8 angular positions of the 

rotary table. The maximum difference 

of the respective sphere positions yields 

the four-axis deviations. A distinction 

according to radial (FR), tangential (FT) 

and axial deviation (FA) is made for 

the three coordinate axes of the rotary 

table. The individual parameters FR, FT 

and FA for both spheres must be less 

than or equal to the specified limit 

deviations MPE FR , MPE FT and MPE FA for 

conformity. As with the DKD, Carl Zeiss 

Industrial Metrology also indicates 

the measuring uncertainty of the 

process here and considers this in the 

conformity statement. 

The third and final part is the 

acceptance and conformity test for the 

length measuring deviation and touch 

deviation corresponding to Part of 

DIN EN ISO 10360. At the same time, 

the coordinate measuring machine 

is calibrated in seven positions using 

the stepper gage block. A total of 105 

measuring lengths result from this 

whose deviations from the calibrated 

value of the stepper gage block may 

not exceed the limit value of MPE E . 

KobaStep stepper gage blocks up to 

a length of 500 mm are used for 

this calibration. With highly accurate 

coordinate measuring machines for 

the measuring lab and coordinate 

measuring machines for production, it 

is necessary to reduce the measuring 

uncertainty in order to make a 

conformity statement. This can be 

achieved with stepper gage blocks 

whose coefficient of thermal expansion 

is calibrated. The Carl Zeiss Measuring 

and Calibration Center performs this 

calibration. In-house developed stepper 

gage blocks made of glass ceramics 

whose coefficient of expansion is zero 

can be optionally used. A calibration 

sphere which is probed according to 

the sample specified in the standard is 

used to determine probing deviation. 

The expertise in length measuring 

technology and the acceptance of 

coordinate measuring machines is 

accredited based on the requirements 

of ISO/TS 16949. Carl Zeiss thus 

enables its customers to have their 

coordinate measuring instruments 

calibrated in such a way that they can 

pass every audit. This emphasizes that 

the acceptance has a firm basis with a 

100% reliable result which is ensured 

by the DKD calibration of all acceptance 

standards and by established experts 

“who are used to splitting the µm”. 

See for the new opportunities in the 

Measuring and Calibration Center at 

Carl Zeiss Industrial Metrology. 

Dr. Ernst Wiedenmann 

Head of Measuring and Calibration Center 

Phone: (+7364)/ 0-3731 

kalibrieren@zeiss.de 


Newsticker 

Measuring houses bring us closer to the customer 

Our network of measuring houses is growing, with new locations opening in recent months: Volders, Austria; 

Budaörs, Hungary and Dubica, Slovakia. We are now able to ensure additional support for our customers there. 

FORD U.K. turns to inline metrology 

Within the scope of a new engine line, FORD U.K. has opted for the CenterMax inline coordinate measuring 

machine from Carl Zeiss. These measuring machines enable random testing of engine components such as cylinder 

blocks, cylinder heads and crankshafts. Equipped with a loading system and the corresponding software, these 

machines can be ideally operated by employees in production. 

Hyundai/ Kia opts for metrology from Carl Zeiss 

Approximately 300,000 cars will roll off the assembly line at the new plant in Zilina, Slovakia. Hyundai/ Kia place 

their complete trust in Carl Zeiss for quality assurance: several PRISMO navigator machines are used in engine 

production to monitor quality. The new PRO horizontal-arm line from Carl Zeiss is used in car body construction. 

I++/DME interoperability: 

standard interfaces let you select 

I++/DME is an initiative from Audi, BMW, DaimlerChrysler, Volkswagen and Volvo. It pursues the goal of 

increasing efficiency, and reducing production times and costs through the standardization and exchangeability of 

software. The I++/DME interface allows you to use a measuring program on coordinate measuring machines from 

other manufacturers. 

New ScanWare pro version for ScanMax 

The new ScanWare pro version 2.8.2 will be available in May 2006. New functions such as a configurable 

selection list for protocol variables, expanded ISO 1101, adjustments in stylus calibration and expansions in borepattern 

best fit simplify your daily activities. The new version now offers the XML protocol which can be used for 

special database applications. Furthermore, ScanMax will be available with the Windows XP operating system in 

May 2006. 

50 th DKD meeting at Carl Zeiss 

The 50th meeting of the Length Technical Committee of the German Calibration Service (DKD) took place at 

the end of February in Oberkochen, Germany. The main topic was offering economical high-quality services which 

comply with all standards. 

Carl Zeiss IMT Newsletter 

With the Carl Zeiss IMT Newsletter, we provide all our customers or prospective customers with information 

covering all aspects of dimensional metrology, including all services. It contains news on new products, qualification 

strategies for users, innovations from our hardware and software development, measures to keep your measuring 

machine up and running and our ideas on how we can help you with your measuring tasks. 

Sign up at: http://www.zeiss.com/imt-newsletter 


Carl Zeiss Introduces 

Global Software Licensing 


18 

= 

Fig. 1: 

The software package contains CALYPSO software 

with licenses on CD-ROM and certificates for 

each software option 

At Control 2006, Carl Zeiss 

Industrial Metrology will introduce 

global software licensing to 

provide its customers with a more 

comprehensive support system. The 

new licensing procedure will take 

effect with CALYPSO 4.4 and CMM- 

OS 3.4. It will also be gradually 

introduced with other software 

packages worldwide. 

The main benefit for customers 

and users of ZEISS software: 

Carl Zeiss can provide even more 

targeted support and react more quickly 

and efficiently to problems on site or 

via telephone hotline. Furthermore, 

the new procedure permits temporary 

demo licenses, enabling potential 

buyers to test software options for 

a limited period of time prior to 

purchase. 

+ 

What does this mean 

to software users? 

Carl Zeiss recently initiated the 

“Safe Software” project, setting the 

course for a new software protection 

technique. The objective is to make 

software licensing as easy as possible 

for customers. This means that Carl 

Zeiss Industrial Metrology will now 

issue licenses to all of its customers. 

For new coordinate measuring 

machine (CMM) purchases, licenses for 

ordered software will be installed and 

activated on the computer. Users can 

begin measuring and evaluating results 

as soon as the CMM is set up. 

All customers with a software 

maintenance contract or an upgrade 

to CALYPSO 4.4 or CMM-OS 3.4 will 

receive a CD-ROM and certificates for 

all ordered program options. 

SAN 

Another new feature of the new 

licensing procedure is the software 

workstation number (SAN). Each 

customer will receive a label with the 

SAN that serves as a reference number 

each time a user contacts our hotline. 

The SAN enables hotline staff to 

obtain the customer’s current software 

configuration from the database 

within seconds and therefore provide 

efficient, customized support. 


License Manager 

All licenses are available as files 

on the accompanying license CD. 

The ZEISS License Manager (ZLM), a 

program specifically developed by Carl 

Zeiss Industrial Metrology, makes it 

very easy to import these files. 

The ZLM, which is used to install the 

licenses on the evaluation computer, 

can be activated via a desktop icon. 

The latest version as well as all 

relevant information on software 

licensing is available at: 

http://www.zeiss.com/imt-softwarelicensing 


Project Manager software licensing 

SAN Nr: CZ1_4711 

Fig. 2: 

SAN – software workstation number on computer 

Terms 

License 

Certificate 

SAN 

HW-ID 

• Refers to certificate and hardware 

• The right to use software with defined hardware 

• Activation code for software 

• Verification of the legal use of a software option 

• Globally unique 

• Required to obtain a license 

• Software workstation number 

• Serial number of the software workstation 

• Each workstation computer receives a SAN. It remains 

the same even if the associated computer is replaced. 

32-digit ID number of a computer (hard disk, MAC 

address or Dongle ID) 


• 

Fig. 3: 

Easy installation of 

licenses with the 

ZEISS License Manager

CALYPSO – The Software for Everyone 

Otto Boucky 

Fig. 1: 

Metal part in CALYPSO 

0 

CALYPSO, the software for everyone 

– Carl Zeiss Industrial Metrology took 

the Control 2005 motto seriously. 

One example is the enhancement of 

the applications. What began with 

the introduction of the freeform 

surface module was systematically 

enhanced with the addition of 

functions for sheet metal metrology 

such as the relative measurement of 

features. Users can now also utilize 

the benefits of feature-oriented 

measurement and the performance 

of CALYPSO with prismatic parts in 

the freeform or sheet metal area. 

It is also now possible to connect 

CALYPSO to older coordinate 

measuring machines (CMMs) without 

having to retrofit the controller. This 

includes, of course, most of the older 

ZEISS CMMs as well as many non- 

ZEISS models. Nowadays, they can 

be easily and directly connected to 

Fig. 2: 

Upgraded coordinate measuring machine 

CALYPSO and its options. Because 

the existing controller does not need 

to be replaced, users can continue to 

run all their parts programs on existing 

data systems. With CALYPSO, you 

are using a state-of-the-art software 

platform that permits unparalleled, 

fast generation of test plans for new 

parts using the learn mode or the CAD 

model. This allows you to dramatically 

increase the productivity of older 

measuring machines, thus extending 

the value of past investments for years 

to come. Older CMMs from Carl Zeiss 

or non-ZEISS CMMs can be calibrated 

directly on site by the Carl Zeiss Service 

Organization using precise laser 

interferometers. 

Even measuring instruments that 

are not CMMs in the traditional 

sense can be connected to CALYPSO 

today: articulated arms, laser trackers, 

form testers and, in the future, also 

computed tomography systems 

for Metrotomography. Particularly 

noteworthy is that CALYPSO makes 

the previously tedious task of manual 

extraction of geometric elements 

unnecessary. The user simply selects the 

geometric element to be measured in 

the CAD model. CALYPSO automatically 

extracts the associated measuring 

points from the point or voxel cloud. 

Fig. 3: 

CALYPSO simulation 


As a result, a solely manual process in 

the past can now be automated. 

Thus, CALYPSO is the software 

package in metrology that makes it 

possible to unite the most measuring 

equipment under one software 

platform. The advantages are obvious: 

personnel only require training for 

one software program and can be 

flexibly deployed. CALYPSO combines 

the different measuring instruments 

with a single protocol. Feature results 

can be displayed in the same manner, 

regardless of how the raw data was 

generated. 

However, the common measurement 

plan is even more important than the 

single protocol. CALYPSO is the only 

software in the world that permits the 

generation of a common measurement 

plan from a CAD model even with 

different measuring instruments. 

Because of the powerful CAD core, 

this can easily be done at an offline 

programming station without wasting 

valuable machine uptime. The use 

of intelligent simulation tools which 

incorporate the measuring machine, 

the sensor, the workpiece and the 

clamping device considerably shortens 

and simplifies the start-up of the 

generated parts program. 

Otto Boucky 

Manager Business Unit Modules IMT 

Fig. 4: 

Lego block 


CAD Offline Programming under 

CALYPSO Increases Measuring Capacity 

Josef Pfeilmeier, Michael Wieler 

As product lifecycles become 

ever shorter, enhancements and 

innovations face increasing time 

and cost pressures. CAD offline 

programming under CALYPSO 

increases the efficiency of product 

development: the measurement 

program can be created and tested 

before the first real workpiece 

exists. 

Until now, measurement plans 

were usually generated directly on the 

machine, i.e. online. During this time, 

the machine was occupied, thus making 

it unavailable for measurements. 

Valuable measuring capacity was lost. 

CALYPSO makes it possible to create 

complete CNC measurement plans at a 

remote computer CAD offline station. 

Testing the run via stylus simulations at 

the CAD offline station is also possible. 

Performing all these tasks offline frees 

up valuable measuring capacity. 

A further upgrade is the use of an 

INSPECT module on the CAD side for 

automatic stamping and generation 

of feature lists. The “Characteristic” 

interface from Carl Zeiss is available on 

the CALYPSO side, making it possible 

to import features and tolerances 

directly from CAD and thus generate a 

measurement plan shell automatically 

at the push of a button. Transferring 

to an offline station creates more 

measuring capacity and more efficiency 

resulting from the automation of 

the measurement process chain – 

regardless of the version used. 

Fig. 1: During the simulation, CALYPSO includes the coordinate measuring machine, stylus, equipment and workpiece 

Increased measuring 

capacity 

Measurement plans can be generated 

offline, i.e. away from the machine, 

with a CALYPSO CAD offline package, 

resulting in the following advantages: 

• 

• 

• 

• 

• 

The entire machine capacity is 

available while the measurement 

plan is being created 

Unproductive approach times are 

reduced considerably 

The focus is on efficient programming 

away from the machine and 

measuring lab 

It is possible to generate and 

optimize a measurement plan on the 

CAD model before the finished part 

is available 

Higher machine utilization reduces 

part costs. 

Increased efficiency 

through stylus 

simulation 

Stylus systems can be easily assembled 

using the virtual CALYPSO CAD offline 

stylus kit. These configurations are then 

used to check the accessibility of the 

measuring location. Equipment can be 

loaded and included in the simulation 

which not only tests if the measuring 

location is accessible, but also reliably 

recognizes and saves any collisions 

resulting from a faulty measurement 

plan. Furthermore, they are quickly 

and easily corrected before the real 

measuring run takes place. These 

possibilities considerably reduce the 

approach times on the coordinate 

measuring machine. 


Revolution in the 

measurement process 

chain 

Today, information for measurement 

planning is usually still transferred 

to paper from design drawings and 

measurement plans. 

Features must be located and 

stamped in the drawing, and the 

feature lists derived from it must be 

manually created. This process is 

expensive, and until now, faulty and 

inefficient. All steps must be repeated 

when changes are made. 

INSPECT modules from Pro E, UG 

or CATIA automatically complete 

feature lists and stamp the features in 

the drawing at the push of a button. 

Features are assigned a distinct number 

that is linked to the corresponding 

element in the CAD model. As a result, 

all information on the features is 

derived directly from the CAD model. 

The relevant features with tolerances 

in the QDAS ASCII format, and geometric 

data in the STEP format, are exported 

from the INSPECT module at the push of 

a button. CALYPSO automatically links 

the tolerances, reference elements and 

geometric data to inspection features 

in the “Characteristic In” interface. 

The result is a measurement plan shell 

that is subsequently completed and 

simulated. 

Significant savings 

The advantages of automatic 

generation of a measurement plan 

shell are obvious: 

The elimination of manual stamping 

and generation of feature lists results 

in enormous time and cost savings. 

Considerable time savings of up to 

60% with automatic generation of a 

measurement plan shell through the 

import of features and tolerances 

from the CAD system. 

Easy to change – CAD modifications 

are also recognized and added to 

the measurement plan during the 

CAD model comparison. 

Simplification – characteristics 

automatically contain the correct 

designation as a result of electronic 

stamping. 

Avoid errors – all features 

automatically have the correct 

tolerances from the CAD model. 


• 

• 

• 

• 

• 

Josef Pfeilmeier 

Head of Sales Support IMT; 

Michael Wieler 

Product Management bridge-type machines 

Fig. 2: 

Functional diagram of the “Characteristic In” 

interface in CALYPSO: 

Up to 60% time savings resulting from the import 

of features and tolerances at the push of a button

CALYPSO Renews Old Measuring Technology 


4 

It does not always have to be 

the latest measuring machine. 

Upgrading the hardware and 

software is often enough. CALYPSO 

offers an easy option for extending 

the life of existing coordinate 

measuring machines (CMMs) using 

state-of-the-art software. 

CALYPSO provides several benefits 

for ZEISS CMMS with old controllers and 

GPIB communications. Additionally, this 

software can replace various software 

versions. CALYPSO permits a common 

interface, delivering numerous 

advantages in workflows, flexibility 

and, finally, in your productivity. Thus, 

users of these older machines are able 

to access the advantages of modern 

measuring software. 

CALYPSO is currently productively 

utilized on C 400, C 700 and ECLIPSE 

measuring machines with the C 90 

controller, and measuring machines 

with touch-trigger probes – MC, PMC 

and WMM – with the ST 87 and ST 9 

8-bit controllers. 

Fig. 1: 

C 400 with 

C 90 controller 

Customers and pilot customers have 

chosen CALYPSO for various reasons. 

The most important, as emphasized 

by several customers, is that they find 

CALYPSO‘s basic design unmatched. 

Commercial aspects are increasingly 

influencing the decision to purchase 

CALYPSO: if different measuring 

machines are in use, capacity shortages 

can only be quickly and efficiently 

compensated with a uniform software 

environment. For example, measuring 

runs generated with CALYPSO Offline 

can be used with a PRISMO as well as 

other measuring machines. 

Fig. 2: 

Old WMM with touch-trigger probe 

When upgrading to CALYPSO, 

customers value the following 

benefits: 

• 

• 

• 

Uniform operation of the measuring 

machine – from qualification of 

the styli to integration into existing 

processes, 

Learn programming and 

Identical output protocols. 

Lutz Karras 

Product Management Software; 

MBA Christoph Grieser 

Services Carl Zeiss IMT 


CALYPSO on non-ZEISS Machines 


Fig. 1: 

CALYPSO – The software for all, even non-ZEISS machines 

Whether you use a measuring 

machine or a measuring system 

from Carl Zeiss or from another 

manufacturer, you do not have to 

do without CALYPSO. Carl Zeiss 

Industrial Metrology (IMT) has 

several options available that allow 

you to use CALYPSO with non-ZEISS 

measuring systems. 

DME and customer-specific-interfaces 

open the door to CALYPSO 

In the future, non-ZEISS measuring 

systems can be operated with the 

CALYPSO software DME client, if they 

are equipped with a corresponding 

DME server as a machine interface. 

Carl Zeiss IMT has also developed 

a variety of direct interfaces that 

make it possible to connect CALYPSO 

directly to existing hardware. This is 

not limited to 3D measuring machines 

in the traditional sense. There are 

also interfaces for articulated-arm 

measuring machines, laser trackers 

and computed tomography systems. 

Furthermore, it is also possible to 

retrofit older measuring machines 

with a new controller unit and a new 

sensor system. Carl Zeiss IMT offers 

upgrades with proven proprietary 

components as well as with other 

standard components, allowing users 

to benefit from CALYPSO by selecting 

the solution best suited to their needs. 

Lutz Karras 

Product Management Software; 

MBA Christoph Grieser 

Services Carl Zeiss IMT 

Info 

CALYPSO is not only ideal for 

ZEISS measuring machines. It 

can also be used on non-ZEISS 

CNC measuring machines, 

on articulated arms and laser 

trackers. 


Fig. 1: 

Utilization and status displays on several measuring machines 

Operating Data Capture for 

Coordinate Measuring Machines 

Robert R. Roithmeier 

6 

The amount of data required today 

to efficiently control a production 

process grows with the demands 

on reliability and quality. What has 

long been standard for production 

machines, is also now possible for 

coordinate measuring machines 

(CMMs) – complete capture of 

operating and machine data (BDE/ 

MDE) for measuring machines. 

Machine status, stops and 

downtimes are displayed in the same 

way as measuring runs and results. 

Reports can be freely configured 

regarding time intervals, measuring 

machines, CNC runs and types of 

events. As a result, the distribution 

of measuring tasks on various CMMs 

can now be optimized, enabling more 

flexible use of available measuring 

capabilities which leads to a clear 

increase in efficiency in professional 

coordinate metrology. Flexible data 

capture tools deliver the current 

machine and operating data. Data is 

captured on software computers that 

run on CALYPSO or UMESS systems; 

data transport via TCP/ IP. As a result, 

it is now possible to capture detailed 

operating data on CMMs – regardless 

of location. With this move, Carl Zeiss 

takes another step towards complete 

integration of the measuring machine 

into production. 

CMM 

Master Control Center 

This new method of comprehensive 

operating data capture was developed 

within the scope of control room 

technology for coordinate measuring 

machines from Carl Zeiss. The Carl 

Zeiss product line in this area now 

ranges from measurement log 

management to version management 

of CNC programs that complies 

with standards, measuring lab and 

knowledge management, and onboard 

diagnostics on the CMM for proactive 

disruption management to BDE/MDE 

(operating and machine data capture). 

These components are all part of 

the CMM Master Control Center: an 

access-secured solution for company 

intranets. It is a server-based software 

solution installed at the company. As 

it can be intuitively operated and is 

easy to manage, users do not require 

training or special courses. The CMM 

Master Control Center provides clearly 

arranged user and access management, 

as well as easy, customized 

enhancement possibilities for any new 

content. The index-based, extremely 

fast full text search is particularly 


Fig. 2+3: 

Product range of control center technology 

sophisticated and scans through all 

types of documents (including PDF, 

Word, Excel, PowerPoint, Shockwave 

Flash, Text, PostScript) according to 

key words, authors, categories and 

other criteria. 

Dr. Robert Roithmeier 

Project Manager User Support 

Operating data capture 

Operating data capture on 

CMMs is a powerful, state-ofthe-art, 

flexible control tool to 

monitor order costs, cost centers 

and machines. User-specific 

adjustments can be made very 

precisely in order to meet the 

needs of each operation. 

Operating data capture for 

ZEISS CMMs contains run, idle, 

upgrade and malfunction times, 

as well as product-relevant data. 

Operating times can be optimized 

and sources of malfunction 

accurately eliminated based on 

the knowledge gained from this 

data. 

O p e ra t i n g d a t a c a p t u re 

contains: 

• Display of the CMM utilization 

according to machine and/or 

single measuring tasks 

• List of machine statuses in a 

table 

• T r a n s p a r e n t r e a l - t i m e 

monitoring provides current 

information at any time on 

measuring machines, orders 

and test results (OK/ not OK) 

• Complete output of cumulative 

operating data as a graphic 

• Can be exported as an Excel 

table 

• Remaining time display for 

measuring runs in volume 

production 

• Optional connection of the 

databases to ERP and PDM/ 

PLM systems 


Small Business – 

The Solution for Mid-size Companies 

Andreas Lotze, Claudia Krönicke, Christina Scheible 

8 

The Innovation Center for Metrology 

IZfM in Dresden developed the 

πWeb Small Business solution for 

mid-size companies just in time for 

Control 2006. πWeb Small Business 

is designed as an intuitive quality 

data management system that 

is available as an out-of-the-box 

installation. 

The Innovation Center for Metrology 

caused a quite a stir at Control 005 

when it presented πWeb – the modular 

system for the analysis and evaluation of 

production and quality data. However, 

a year ago, the focus was on large 

customers in the automotive industry. 

Today, the developers of πWeb can 

offer a new solution tailored to midsize 

companies: πWeb Small Business. 

The highlight of the Small Business 

solution is that it is based on standard 

components and databases, making 

it very easy to install. The idea behind 

the out-of-the-box installation: πWeb 

installs automatically once the CD is 

inserted into the drive, nothing else 

is required. Development partner 

eXXcellent solutions used standard 

technology (e.g. MSDB) for the 

corresponding database. Global access 

is possible via modern web service 

interfaces. For on-the-fly calculations, 

quick access to any data area is required 

– a procedure that requires powerful 

structures and intelligent services. 

What exactly is behind 

Small Business? 

π – the Greek letter P – stands for 

process and refers to the complex 

algorithms and intelligent data 

structures used to develop web-based 

πWeb. 

πWeb – the extremely powerful 

quality data management system from 

Carl Zeiss is not only suitable for large 

customers in the automotive industry, 

it is also ideal for small companies or 

suppliers. Because of its scalability in 

the Small Business version, location is 

also no longer an issue. State-of-theart 

communication protocols enable 

easy global access and networking of 

the various locations. 

The power of the real-time process 

control provided by πWeb can be seen 

whenever the time between measured 

data capture and process evaluation 

must be reduced, and therefore control 

mechanisms accelerated. In a best case 

scenario, this leads to full utilization of 

production tolerances. 

Conclusion 

πWeb Small Business is 

designed for small and midsize 

companies. The experience 

gained from large customers in 

the automotive industry benefits 

midsize companies which are able 

to fully utilize the implementation 

p o t e n t i a l a n d p ro d u c t i o n 

tolerances of their production 

processes as a result of online 

monitoring. 

With πWeb Small Business, Carl 

Zeiss offers an attractive, webbased 

quality data management 

system, i.e. the web technology 

alone, enables more users to 

participate in quality assurance 

– in real time. 

In the future, networked 

quality assurance will become 

increasingly important as a result 

of the growth in global production 

and the ever more urgent demand 

for transparent quality data 

alone. Carl Zeiss has recognized 

this trend and can now offer 

both large customers (Enterprise 

version), and smaller companies 

and suppliers (Small Business 

version), an adequate quality data 

management system. 


π Components: 

πWeb Reporter 

Quality data is quickly and clearly 

merged into reports and displayed. 

The Report Designer enables 

customers to design their own layout 

to display their process data. For 

this, special emphasis was placed on 

intuitive operation. Anyone capable of 

creating PowerPoint presentations can 

also generate these reports via drag 

& drop with only a few clicks of the 

mouse. 

With the πWeb Reporter, Carl Zeiss 

offers its customers an innovation 

with time and cost benefits: the report 

is automatically updated from the 

database when changes are made 

and, as a result, eliminates costly data 

management. 

πWeb Monitor 

The module is designed for 

process monitoring. It is used 

exclusively to display the process 

and quality data, on monitors 

directly in production, for example. 

πWeb Planner 

Inspection planning, and the 

creation and management of 

inspection characteristics are easily 

performed with the Planner. Version 

control can also be optionally used, i.e. 

when changes are made to a feature, a 

new version of the feature is created in 

addition to the date of change without 

overwriting the previous version. This 

provides seamless documentation of 

all changes to inspection planning 

that can be easily monitored, similar to 

appointments in a calendar. 

New at Control 2006: 

πWeb Mobile 

This module permits mobile access 

to quality data using a PDA. If certain 

access limits are exceeded, πWeb 

Mobile offers the option of sending 

alerts via SMS or email. 

Quality Status Map 

As it only contains the most 

important information, the new plot 

enables an overview of the quality of a 

feature or an entire part. 

Green: everything is OK 

Yellow: values outside of warning 

limit 

Red: values outside of tolerances 


• 

• 

• 

The specific reports are then available 

for error analysis. 

Andreas Lotze 

Vice President & General Manager Carl Zeiss IZfM; 

Claudia Krönicke 

Software Developer Carl Zeiss IZfM; 


Product Manager Carl Zeiss IMT

The Application Determines the Sensor: 

VAST Scanning Probe Systems 

Dietrich Imkamp, Karl Schepperle 

VAST line: 

30 

Single point 

Passive scanning 

Active scanning 

Rotatable/ tiltable 

Carl Zeiss offers various scanning 

probe systems. The VAST (Variable 

Accurate Scanning Technology) 

line consists of the VAST XXT 

passive scanning system for the 

RDS articulating probe holder and 

the VAST XT gold and VAST gold 

active scanning systems, which 

are integrated into the shaft of 

a coordinate measuring machine 

(CMM). Both VAST systems have 

special features and, thus, areas of 

application. 

Touch trigger and 

scanning systems 

The DIN EN ISO 10360-1 standard 

describes probes as touch probe 

systems. The standard differentiates 

between “touch trigger” and 

“scanning” systems depending on the 

type of measuring point acquisition. 

VAST XXT 

on RDS 

Touch-trigger systems record the 

measuring point at the moment of 

contact through a mechanical switch or 

through an electrical pulse transformer 

element, e.g. a Piezo sensor or wire 

strain gages. The scanning system 

captures the deflection of the probe 

system when contact is made with 

the workpiece surface utilizing the 

integrated measuring system, and 

determines the deflection. It is used to 

correct the measuring point coordinates 

delivered by the measuring system of 

the axes of motion [1, ]. 

The VAST scanning systems from Carl 

Zeiss use the “sliding determination of 

mean values” procedure in conjunction 

with the ZEISS Intelligent Scanning 

Controller (ISC) during measuring point 

acquisition. During this process, the 

measuring machine is stopped after 

it registers a probe pulse due to the 

deflection of the probe. The system then 

VAST XT gold VAST gold 

checks whether the sum signal from 

the probe deflection and positional 

data of the measuring machine axes 

remain constant. A probing point is 

only accepted if the signal remains 

constant within a short interval. 

The mean value from the deflection 

signals recorded during this period is 

used to correct the probe deflection. 

Sliding determination of mean values 

automatically dampens noise pulses 

caused by vibrations, for example. As 

a result, the probes of the VAST line 

are less affected by electromagnetic 

interferences than a touch-trigger 

probe, which have an effect the 

moment contact is made with the 

workpiece. This technology permits the 

reliable use of VAST probes also under 

difficult environmental conditions 

and reduces sensitivity to outliers. 

Passive and active 

scanning systems 

Scanning systems are distinguished 

by the type of measuring force 

generation. With a passive system, 

the measuring force is generated by 

a mechanical spring. An active system 

consists of a linear drive that generates 

the probing force electrically. This is 

also known as an „electrical spring“. 

The use of electrical springs enables 

the operator to set the measuring 

force over a large force range, largely 

independent of the deflection, thus 

permitting a larger measuring range 

which is required for a high scanning 

speed [1]. 

The measuring range of a passive 

system is limited by the linearity range 

of the mechanical springs in which 

the deflection and the force are 

proportional. It is two to four times 

smaller on a passive system than an 

active system. It is important not to 

confuse the measuring range with the 

deflection range which represents the 

mechanical range of motion of the 


Passive and active scanning 

Measuring force 

Linearity range of 

the mechanical springs 

probe and is usually larger than the 

measuring range. It is necessary to 

ensure that the probe does not move 

directly against its mechanical stop and 

trigger an emergency stop following a 

slight collision, for example. 

Active scanning and 

self-centering probing 

As already shown, active systems 

allow significantly higher scanning 

speeds. Scanning speeds of up to 300 

mm/s with the VAST gold probe are 

possible together with procedures to 

correct the dynamic bending of the 

device structure and the compensation 

for centrifugal force – Navigator 

technologies [3]. Navigator achieves the 

parameters for scanning performance 

in accordance with DIN EN ISO 

10360-4 [4] in less than 30 seconds. 

An essential feature: this Navigator 

scanning performance can be utilized 

for all stylus configurations used in 

Measuring force 

Deflection Deflection 

Passive system Active system 

Measuring force proportional 

to the deflection 

Fig. 1: 

Active and passive systems according to [1] 

Measuring force can be 

selected depending on the 

deflection and almost constant 

everyday measuring operations (see 

example in Fig. 4). Other manufacturers 

specify scanning speeds higher than 

300 mm/s, but these are only available 

for certain applications and only for 

one stylus in the axis direction of the 

sensor. The actual existing flexibility 

of a CMM (Fig. 4) is thus not always 

available. 

The large measuring range and 

the better probe force regulation of 

active systems have also proven to 

Fig. 2: 

Self-centering probing with active probe 

be advantageous with self-centering 

probing. Self-centering probing is a 

procedure in which the stylus is placed 

in a largely spherical or cylindrical bore 

which is smaller than the diameter of 

the stylus tip. Probing occurs in the 

direction of the axis and perpendicular 

to this direction at the same time. In 

doing so, the stylus centers itself in a 

way that the position of this bore can 

be determined. To begin the centering 

process, the stylus must be positioned 

so exactly that it is located within its 

measuring range during probing. 

Therefore, active systems can use their 

larger measuring range to compensate 

for deviations during positioning of the 

stylus in front of the bore. During the 

centering process, the better probe 

force regulation of the active system 

leads to exact centering of the stylus at 

the lowest point. With passive systems, 

the centering process can be halted as 

a result of friction before the lowest 

point is reached. In such cases, this 

point is not reached and the measuring 

result is inaccurate. The effect also 

applies to self-centering scanning. 

Beneficial: articulating 

probe holder 

There are numerous applications in 

which many features must be measured 

at very different angles (e.g. metal 

parts). In such cases, it is advantageous 

to mount the probe to an articulating 

Fig. 3: 

Application for articulating probe holders 


3 

probe holder, allowing you to avoid 

a variety of stylus configurations. The 

overall size of an active probe that is 

required to generate the probe force 

prevents the use of an articulating 

probe holder. A passive probe system 

that utilizes only one mechanical 

spring, however, can be so small and 

lightweight that it can be mounted to 

an articulating probe holder. 

Characteristic of a small passive 

probe system intended for attachment 

to an articulating probe holder is the 

lacking stylus counterweight. Thus, 

these systems are only suitable for very 

light and, compared to active systems, 

short styli. The mounted stylus deflects 

the measuring force spring with its 

own weight, thus further reducing the 

small measuring range of a passive 

sensor. This effect can be somewhat 

minimized with modules of varying 

spring stiffness for different stylus 

lengths. With active systems from Carl 

Zeiss, the counterweight is achieved 

via the corresponding control of the 

electrical spring. 

Limitations of the 

articulating probe 

holder 

Even if the use of an articulating 

probe holder enables you to avoid the 

many different stylus configurations, it 

should not be overestimated. There are 

several features that cannot be reached 

by an articulating probe holder. Suitable 

stylus configurations on an active 

probe enable the operator to reach 

almost any feature as illustrated in the 

“all-sides“ measuring task in Fig. 4. 

Fig. 4: 

All-side measurement with special stylus configuration on active probe 

Effective measuring 

range with fixed probe 

Effective measuring 

range with articulating 

probe holder 

This also once again illustrates 

how the use of an active fixed probe 

and a probe on an articulating probe 

holder affects the available measuring 

range (Fig. 5). Because it is possible to 

approach the workpiece directly with 

a properly designed stylus, the active 

fixed probe requires a considerably 

smaller measuring range. 

Fig. 5: Utilization of measuring range with active fixed probe compared to articulating probe holder 


Furthermore, you must consider that 

the highly precise determination of 

positional deviation with the use of an 

articulating probe holder often requires 

a rotating or swiveling motion as the 

workpiece must be measured from 

different sides. This motion generates 

additional measuring uncertainty as 

a result of the limited reproducibility 

of the articulating probe holder. This 

effect does not exist with an active 

probe with a T stylus configuration. 

The effects on the error of dimension 

in determining the positional deviation 

is illustrated in the comparison in Fig. 6. 

Dr. Dietrich Imkamp 

Head of Product Management Bridge-type Machines; 

Karl Schepperle 

Head of Sensor Development 

Advantages 

From CONTURA G2 to ACCURA to PRISMO navigator, Carl Zeiss offers 

instruments that are able to work with both systems, providing users 

with a selection of sensors for their specific measuring tasks. 

VAST (XT) gold 

• High scanning speed 

• Function-oriented measurements 

through self-centering probing 

• Long and complex stylus 

configurations reach every 

feature 

• Precise determination of the 

position with the T stylus 

VAST XXT on RDS 

• Use on an articulating probe 

holder reduces the number of 

stylus configurations with many 

features in angular positions 

• Suitable for small and sensitive 

components as a result of the 

lower moving masses 

Range of results: 0.7 µm -> capable for tolerance of 0.01 mm 

Range of results: 6.3 µm -> not capable for tolerance of 0.01 mm 

Fig. 6: 

Inspection of the capability to determine positional deviation (simulation of the measurement of a part from two sides with a ring gage) 

Bibliography 

[1] Neumann, H. J.: Taktile Sensorik an Koordinaten- 

messgeräten, in: Neumann, H. J. (Hrsg.): Präzisionsmess- 

technik in der Fertigung mit Koordinatenmessgeräten, 

Expert Verlag, Renningen, . edition 005. 

[ ] Pfeifer, T.: Fertigungsmesstechnik, Oldenbourg 

Verlag 001. 

[3] Bernhardt, R., Imkamp, D., Müller, H.: Der VAST 

Navigator für mehr Produktivität auf Koordinatenmess- 

geräten, in: Innovation Messtechnik Spezial Nr. 6, Carl 

Zeiss Industrielle Messtechnik GmbH, Oberkochen 004. 

[4] Imkamp, D., Wanner, J.: Die Spezifikation für 

Produktivität: Scanningleitung: MPETHP und MPEt nach 

DIN ISO 10360-4, in: Innovation Messtechnik Spezial Nr. 6, 

Carl Zeiss Industrielle Messtechnik GmbH, Oberkochen 

004. 


LineScan – Optical Scanning 

from Tomorrow Today 

Ralf Stecher 

Fig. 1: 

Optical scanning with LineScan 

34 

Today, fast optical sensors are the 

only alternative to touch sensors. 

They are the tool of choice, 

particularly in mold making, 

modeling and design, as well as for 

touch-sensitive surfaces or surfaces 

with tiny structures. 

Using optical sensor technology 

together with traditional solutions has 

not been possible until now due to 

incompatible mechanical, electrical and 

software interfaces. Optical scanners 

for coordinate measuring machines 

were usually an exclusive add-on 

and only available as separate special 

solutions. With LineScan, Carl Zeiss 

already offers the “Optical scanning 

of tomorrow” today. LineScan evolved 

from the proven WBRetro designed to 

retrofit manual and CNC-controlled 

ZEISS measuring machines. 

Fig. 2: 

Measuring compared to a CAD data set in HOLOS 

LineScan is available as an option for 

almost all new ZEISS bridge-type and 

horizontal-arm measuring machines 

with RDS. LineScan is an optical 

scanning solution with an ultra-fast 

laser-line sensor. The sensors optically 

scan freeform surfaces to record and 

transmit up to 50,000 points per 

second. Definable dot matrices and 

consolidation possibilities reduce the 

output on the desired format and also 

increase accuracy. Using point clouds 

to capture the entire surface of forms 

is becoming increasingly important 

– whether for a comparison with 

available nominal CAD data sets or 

to create a new CAD model or milling 

data. 

The LineScan solution can easily 

be integrated into the existing ZEISS 

measuring machine and software 

environment without limiting other 

applications on the measuring 

machine. 

All necessary functions are available 

in a clear and reliable manner from an 

online interface to HOLOS application 

software. This extends from path 

programming to stylus calibration and 

measurement acquisition in measured 

workpiece coordinate systems up to 

online comparison to CAD data during 

the measuring process. It goes without 

saying that the use of touch probes 

is supported – i.e. real multi-sensor 

technology. Many existing machines 

– manual or CNC-controlled – can 

also be upgraded to LineScan with the 

WBRetro retrofit package. 

Dr. Ralf Stecher 

Sales Support Manager 


Carl Zeiss Makes It Easier than Ever: 

Switch to Active Scanning 

Günter Keck 

Upgrade, retrofit, modernization 

– they all mean the same thing: 

bringing the components of a 

coordinate measuring machine 

(CMM) up to date, thus making future 

measurements more economical. 

The “XT modernization package” 

turns even older touch-trigger ZEISS 

measuring machines such as WMM, 

MC and PMC into state-of-the-art 

scanning measuring machines. 

A current controller is often required 

in order to use the power of the latest 

software on CMMs. The investment 

is based on various factors such as 

economic feasibility and necessity. 

The following questions must be 

answered before making the decision 

to upgrade: 

• 

• 

• 

• 

Is the existing measuring range 

sufficient? 

Is the existing measuring accuracy 

still enough? 

Are the measuring methods and 

speeds still adequate? 

Is the investment meaningful over 

the mid-term or is a new machine 

more economical? 

For a long time, considerations on 

the measuring method and speed 

prevented a necessary upgrade, as it 

was too time consuming and expensive 

to exchange the sensor system. Carl 

Zeiss Industrial Metrology today offers 

the professional solution to upgrade 

WMM, MC and PMC machines: replace 

the ST touch-trigger probe with the 

VAST XT active scanning probe. The 

affordable package contains the 

necessary components – the latest 

C 99 controller, control console, 

cables, computer and monitor, as well 

as CALYPSO object-oriented measuring 

software. 

The metrology 

advantages 

The benefits are obvious: scanning 

instead of single-point measuring, thus 

the capture of hundreds of measured 

points in a short time. The measuring 

results are not only more reliable, but 

also permit form measurements. The 

VAST XT probe also permits extensions 

of up to 500 mm and 500 g with 

a minimally permissible stylus tip 

Fig. 1: 

Asymmetrical stylus configuration up to a weight of 500 g and extensions up to 500 mm are possible following 

an upgrade. 

diameter of 0.6 mm, thus expanding 

the range of use of the measuring 

machine. 

One example is self-centering probing. 

This function is already possible with 

the DT (DynaTouch) probe, which is a 

very economical intermediate solution 

on the way to scanning technology. 

DynaTouch has the same performance 

data as a single-point probe – except 

the scanning functionality. It can be 

easily replaced with a VAST XT probe. 

The stylus adapter on DT and VAST XT 

are identical. Thus, it is easily possible 

to take over the existing stylus 

combinations. 

Customers have confirmed that the 

possibility of upgrading their proven 

measuring machine from a touchtrigger 

to a scanning probe was the 

decisive factor in their decision to 

upgrade. In many cases, modernization 

is the best possible solution which pays 

for itself within a short time as a result 

of the expanded range of use and the 

reliable measuring results. Also Carl 

Zeiss Industrial Metrology offers the 

possibility of trading in an old machine 

for a new or refurbished machine that 

is already equipped with the latest 


Günter Keck 

Head of Retrofits and Pre-owned machines 

Fig. 2: 

Identical stylus adapter on 

the DT intermediate 

scanning solution and the 

VAST XT scanning probe 


From Users for Users 

CONTURA G2 – 

Quality Assurance on the Shop Floor 

Felix Hoben 

Fig. 1: 

CONTURA G2 and 

software CALYPSO 

36 

More than 400 employees in 

Hainichen develop and manufacture 

hinges for cars and commercial 

vehicles. They also produce engine 

parts for the controller in the cylinder 

head, oil pumps and CNC precision 

parts, as well as models and 

prototypes. Reliable and efficient 

quality assurance is necessary as 

these parts must fulfill stability and 

protection functions. Two CONTURA 

G2 coordinate measuring machines 

(CMMs) from Carl Zeiss are the latest 

measuring equipment to make the 

inspection process more efficient. 

ISE in Hainichen generally uses 

tolerance ranges of 10 µm for its 

production processes. With hinges 

for automobiles, for example, the 

tolerances of important parts are 

± 0.5 mm, depending on the assembly. 

In this case, all single tolerances, 

including form and position, must be 

met. It is therefore understandable that 

quality assurance be performed close 

to the shop floor. This is accomplished 

primarily using 3D measuring machines 

– two ZEISS CONTURA G systems. 

Test gages are used in isolated cases 

for fast inspection of single features at 

the processing centers. 

Prototypes and models, in 

particular, were previously sent to 

the measuring lab; now they are 

measured on CONTURA G CMMs 

near the shop floor. This enables ISE to 

process customer orders quickly, thus 

eliminating time-consuming stationto-station 

travel times. Furthermore, 

carefully planned routines that specify 

exactly which measurement will be 

made at a defined interval, when a 

tool must be changed and the times 

when a measurement has to take place 

contribute to an effective inspection 

process. 

Fig. 2+3: 

Short measuring times with the VAST probe 

including Scanning function 

A versatile machine 

Dietmar Schönfelder and Ramona 

Steiner, head of quality assurance and 

metrology coordinator respectively, 

as well as the quality staff, value the 

user-friendly features of CONTURA G 

and its CAD-based CALYPSO software. 

If a measuring run is programmed 

from a 3D CAD model, operators 

need only to clamp the workpiece and 

start the measurement. CONTURA G 

automatically runs the program. 

The main advantage that comes with 

the CONTURA G is the significantly 

shorter measuring times. According 

to Steiner, the scanning function is a 

major contributor to the high stability 

and very easy operation. Until now, 

there have been no failures. If problems 

occur, operators can help themselves 

with self-explanatory, easy-to-use, 


Fig. 4: 

Metrology coordinator , Ramona Steiner and head of quality assurance, Dietmar Schönfelder, appriciate the accuracy and stability of the CONTURA G2, that is for the 

precise pieces from ISE Industries absolutely necessary. 

graphic-supported software. When all 

else fails, says Steiner, online help is 

always available. In extreme cases, Carl 

Zeiss Service reacts within 4 hours. 

Schönfelder and Steiner both 

emphasize that a CONTURA G delivers 

the measuring accuracy and reliability 

required for the quality assurance of 

precision parts. ISE was so impressed 

with its CONTURA G machines that 

two additional systems have already 

been ordered after only six months. 

Review 

3D coordinate metrology has 

been used at ISE since 1996 when 

the company replaced its expensive 

SPC measuring stations, which 

were tailored to the parts, with 

flexible measuring methods. The first 

coordinate measuring machine – which 

is still in use – is a ZEISS MC 550 that 

entered service in 1989. ISE also uses 

an ECLIPSE and a PRISMO. 

Dietmar Schönfelder explains: “We 

closely monitor what our customers 

might require from us and how we can 

best meet their needs. This involves 

investments in production technology 

and probably also the corresponding 

measuring technology. To us, precision 

manufacturing and precision metrology 

go hand-in-hand.” 

Felix Hoben 

Head of bridge type machines 

ISE 

The ISE plant in the German 

town of Hainichen near Dresden 

is a subsidiary of automotive 

supplier ISE Industries GmbH 

in Bergneustadt. The factory 

provides the parent company 

with parts, but also delivers 

directly to customers. These 

include renowned firms such as 

DaimlerChrysler, Audi, BMW, 

VW and Opel, as well as Saab, 

Bentley and Lamborghini. 


Round-the-Clock CMM Precision Proves 

Essential to Company Success 

Annette Smith 

38 

Running five shifts, supporting 

four different product lines and 

processing more than 20,000 parts 

per month requires not only detailed 

planning, but also reliable inspection 

technology. For Dietmar Ingensiep, 

Group Leader of the Common Rail 

Division at Robert Bosch Corporation, 

consistent output of accurate data is 

essential for ensuring uninterrupted 

manufacturing processes and 

producing high-quality products. 

In 001, when Ingensiep took over 

the department, one of the major 

bottlenecks he noticed was the 

extensive time needed to develop new 

coordinate measuring machine (CMM) 

programs. Now, four years later, 

with the help of dependable CMM 

technology and user-friendly software, 

this is no longer a concern. 

Bosch purchased a UC 550 and 

an ECLIPSE CMM from Carl Zeiss in 

1989 to support the ABS production. 

Over the years, as more product lines 

were added, they also increased their 

inspection capacity by adding two 

CONTURA and four PRISMO CMMs – 

equipped with VAST sensor technology 

and CALYPSO CAD-based software. 

VAST sensor technology allows highspeed 

multi-point measurement of size, 

form, and position; an important factor 

when inspecting a wide range of parts. 

The key benefits of CALYPSO include 

its off-line programming capability and 

easy creation of measuring programs. 

Almost 7,000 to 9,000 jobs are 

processed per month in two metrology 

labs. With a standard job consisting 

of three components, Bosch inspects 

about 1,000 to 7,000 parts. That 

kind of volume requires not only quick 

Fig 1: 

The flange, a common rail component, is part if the high pressure pump, supplying the common rail system with pressurized diesel fuel 

turn around time, but also machine 

reliability. “The CMMs are essential to 

our success,” says Ingensiep. “Certain 

production areas rely on CMM data 

to adjust their machines. If the data is 

incorrect, it would not be noticed until 

it hits the assembly line, which would 

be too late and could cause production 

to shut down. So for me, reliability and 

speed are a must.“ 

Bosch is dedicated to meeting 

customer requirements one hundred 

percent. But when it comes to 

metrology, the customer is not the 

driving force. “There is nobody that 

has more influence than our internal 

customers,” says Ingensiep. “We are 

constantly challenged, for example, by 

our product development department. 

It is not only the accuracy, it is the fact 

that the parts are getting smaller and 

smaller. We are always pushing the 

envelope in all aspects of product design 

and therefore each of the CMMs. Our 

customers expect a product that works 

flawlessly and it is our job to design, 

measure and produce it.” For Bosch, 

this also implies investing in the latest 

technologies. 

With several product lines 

manufacturing the same products 

at different locations world wide, 

accurate and correlating part quality is 

a priority. Bosch solved this problem by 

establishing compatible manufacturing 

conditions in each facility. This means 

that not only the same measuring 

equipment has to be purchased, but 

also the same production machines. 

Before installing CALYPSO CADbased 

software from Carl Zeiss, Bosch’s 

in-house programming resources were 

limited due to the lengthy process of 

learning the programming language. 

They had to mostly depend on external 

companies to write programs. Because 

of their lack of product knowledge, 

several iterations were necessary 

before programs were ready. This was 

not only time consuming, but it also 


Fig. 2: 

For Dietmar Ingensiep, Group Leader of the common rail division, reliability and speed are essential to ensure 

an uninterrupted manufacturing process 

resulted in high costs driven by an 

ever-changing environment requiring 

frequent program modifications. 

With CALYPSO, programs can now 

be written off-line, while the CMMs 

continue measuring production parts. 

The short learning curve of the software 

also allowed Bosch to train several of 

their quality personnel within just a 

couple of months. By increasing their 

on-site knowledge pool, Bosch is now 

able to implement software program 

modifications immediately, making 

parts inspection a more efficient 

process. 

Annette Smith, 

Marketing Carl Zeiss Minneapolis, USA 

BOSCH 

Robert Bosch Corporation, 

part of the Bosch Group 

automotive technology business, 

manufactures OEM components 

for customers such as Ford, GM 

and DaimlerChrysler. This includes 

anti-lock breaking systems, fuel 

injection and diesel injection 

systems such as common rail 

and unit injector. At their plant 

in Charleston, South Carolina, 

eight CMMs from Carl Zeiss work 

non-stop to keep the production 

running. 


VW Saxony: Coordinate Measuring Systems 

for TSI Engines Ready in Record Time 

Matthias Kurth, Heinz-Günter Hoppe 

40 

Two GageMax and three CenterMax 

machines with manual and fully 

automatic loading systems ensure 

the quality of parts for TSI and TDI 

engines. The new systems for quality 

assurance took up operation at the 

end of 2004 after only 16 weeks of 

project time. 

Ever shorter development times 

require ever more flexibility in 

production. This necessitates metrology 

which meets the demands of large 

volumes in a special way – as at the 

Volkswagen Saxony GmbH engine 

manufacturing plant in Chemnitz, 

where ZEISS measuring machines have 

been in operation since the end of 

004 as SPC measuring equipment. 

In addition to the measuring 

technology, the goal was to transfer 

a portion of the traditional measuring 

tasks to production personnel. In doing 

so, value was placed on well-defined 

operation, clear visualization of the 

statistics and an ergonomic design. 

Anyone can monitor and control their 

processes for the first time largely 

without any additional help. However, 

metrologists are available to provide 

support for the measuring process. 

This avoided investments in special 

testing equipment, measuring 

lab infrastructure and personnel 

requirements. At the same time, 

the measuring machines deliver a 

denser information base for process 

monitoring than earlier strategies. 

Furthermore, their flexibility permits 

fast, problem-free process conversions, 

process optimization and new setups. 

The complete switch from UMESS 

to CALYPSO also made the extensive 

system integration possible. The 

object-oriented approach of CALYPSO 

soon had a very positive effect on the 

process modifications and the short 

programs adjusted to the processes. 

It quickly became evident that 

the capacities of existing measuring 

machines had to be increased in 

addition to the production equipment 

and measuring systems with special 

loading systems for cylinder crankcases, 

cylinder heads, cylinder head covers 

and balancer shaft housing. Metrology 

services were also required. Entire 

measurement plans had to be 

generated during the 16 weeks of 

the project – from planning to the 

first measurement. This also included 

stylus calibration and test programs, 

coordination of the measurement 

strategy with VW Saxony and the 

suppliers of the processing centers and 

much more. 

The entire parts spectrum requires 

two measuring systems: balancer 

shaft housing and cylinder head 

covers are suitable for measuring with 

GageMax with a measuring range of 

500 x 700 x 500 mm. With its large 

measuring range of 900 x 1 00 x 700 

mm, CenterMax is ideal for cylinder 

crankcases and cylinder heads. The 

measuring systems can take over for 

each other in an emergency. 

Special production 

measuring technology 

for special parts 

The workpiece storage positions 

for the balancer shaft housing and 

cylinder head covers was optimized 

on GageMax. The long shaft of 

the balancer shaft housing requires 

measurements from one side with a 

long stylus. Furthermore, styli in the 

stylus rack restrict each other in the 

X axis. Therefore, the housing had 

to be placed very close to the edge 

of the measuring range of the Y axis 

and moved forward in the X axis 

asymmetrically. 

Since many people load the system 

during volume measuring operations, 

Fig. 1: 

Measuring run on a cylinder head cover on GageMax 

the decision was made for special 

equipment as a workpiece-specific 

receptacle. This equipment is faster, 

compact, highly robust, unaffected 

by loose clamps and can be retooled 

reliably. 

Versions and number 

of devices optimized 

The number of devices with the 

balancer shaft housing is limited to 

a total of three devices for all five 

housing versions: one each for the 

upper and lower parts and one for 

the finished housing. A total of two 

devices are used. 

Only one device is required for 

all eight cylinder head covers. The 

essential fast sensor to capture the 

Fig. 2: 

CAD model of a balancer shaft housing for a 

2.0 l TDI engine with mounting fixture 


workpiece temperature was integrated 

into all devices for both GageMax 

machines. It is spring-mounted near or 

directly on a workpiece tray. When the 

pallet is lowered into the measuring 

position, the contact to the standard 

workpiece temperature interface on the 

measuring machine is established and 

read in the CNC measurement plan. As 

a result, the measurement results are 

compensated to 0 °C according to 

the actual workpiece temperature and 

the workpiece expansion coefficients. 

Optimized stylus 

configurations 

The stylus configurations to measure 

the workpieces consist of standard and 

special elements. All length-relevant 

elements are made of thermally stable 

Thermofit. After starting the program, 

all screw holes are set and cemented. 

Only the actual stylus is screwed 

together. Four configurations are used 

for the balancer shaft housing; only 

three for the cylinder head covers. 

Manual loading system 

on GageMax 

Parts are introduced to the GageMax 

production measuring machine using 

a manual loading system. Pallets are 

used for transport and are brought 

to the measuring position from pallet 

storage on a roller. The pallet storage 

in front of the measuring machine can 

hold a total of five pallets. 

If the shaft is in the safety position, 

the operator can roll the pallet into 

the storage position and remove it 

following the measurement. The roller 

is pneumatically raised and lowered 

in the storage position where the 

workpiece on the pallet reproducibly 

sits on a 3-point sphere receptacle. The 

worker starts the measurement plan 

via the auto run interface on CALYPSO; 

the workpiece position complies with 

CNC. 

Fully automatic 

loading of CenterMax 

Cylinder crankcases and cylinder 

heads require a larger measuring 

machine due to their size, more 

complex processing and measuring 

tasks. As with GageMax, an essential 

advantage of CenterMax is the 

temperature range of 15-40 °C. 

However, the larger measuring range 

and the larger number of stylus rack 

positions are decisive. They are located 

outside the measuring range. 

For cylinder crankcases, variable 

special equipment can be used for all 

parts, including those from production 

segments. Due to the measuring task, 

the cylinder heads require an adapter 

plate for the first sequence. Only the 

cylinder heads are clamped during 

the final sequence. This involves two 

special devices. 

Eight stylus configurations are used 

to probe each of the adaptations of 

the parts. They contain a temperature 

sensor which records the temperature 

of the workpiece via the VAST gold 

probe, thus sparing sensors in the 

equipment as on GageMax. 

Fig. 3: 

GageMax total system for 

measuring cylinder head 

covers 


Fig. 4: 

Fully loaded, automatic 

loading system for 

measuring cylinder 

crankcases on CenterMax 

4 

An analysis has shown that the 

measuring systems would run 

continuously. Regardless of the 

measuring cycle, employees must be 

able to change the parts at any time 

for all versions. This requires a fully 

automatic system with a number of 

set-up locations corresponding to the 

equipment versions. The versions with 

the cylinder head require at least four 

set-up locations for each of the two 

systems. It has also been shown that 

two measuring machines in continuous 

operation are sufficient to measure the 

cylinder crankcases. Therefore, three 

fully automatic measuring cells were 

installed – two for cylinder crankcases 

and one for cylinder heads. 

Fig. 5: 

CenterMax complete system with automatic loading system for cylinder crankcases 

Safe, automatic 

measuring operation 

through FACS and SPS 

Personnel load one of the workpiece 

receptacle devices located at the setup 

locations in order to load the fully 

automatic measuring system. They then 

select the equipped set-up location in 

the FACS (Flexible Automatic Control 

System) customer-specific automatic 

user interface. The workpieces hold 

an electronic data carrier. A chip 

reader records all measurement plan, 

processing and part-specific data. 

The data for the automatic start 

of the correct sequence, protocol 

header format, subsequent extensive 

statistic classification and evaluation 

is allocated to the FACS software 

option. Any number of free set-up 

locations can be loaded parallel to 


measuring operations. They will be 

fully automatically processed one 

after another or according to specified 

priorities. 

The shaft moves to the loading 

position as soon as CALYPSO informs 

FACS of the end of the measurement 

plan. The storage programmable 

controller (SPC) on the loading 

system is tasked with unloading and 

reloading the measuring machine. The 

SPC then executes the part change 

independently. The system removes the 

part from the measuring position and 

transports it to the shuttle. From there 

it is transferred to a set-up location. It 

is now time for the next part on the 

list. 

The SPC is also responsible for 

safety. It monitors all movements 

relevant to machine safety – and also 

the safety of people. A light grid which 

can shut down the loading system 

monitors intrusions into the setup area. 

Measuring operations are not affected 

by this due to the intrinsic safety of 

CenterMax. The emergency off circuits 

on CenterMax and the loading system 

are coupled. They affect the entire 

system. Access via the maintenance 

door, however, is only granted if there 

are no travel movements. 

Measuring lab with 

the same possibilities 

as production 

In addition to the five new systems, 

the machines in the measuring labs 

received the same workpiece-specific 

equipment. This makes them capable 

of conducting analytical or capacityrelated 

measurements on a comparable 

basis. An additional set of mounting 

equipment and stylus configurations 

was also delivered. 

As a result of the weight and 

dimensions, two additional PRISMO 

VAST measuring lab machines were 

equipped with an identical manual 

pallet loading system. The pallet 

storage is a pallet transport carriage 

with a rotary changer in front of the 

two PRISMO VAST machines. It can be 

removed if it is not needed, enabling 

free access to the measuring machine. 

Matthias Kurth, responsible 

for measurement planning, says: 

“Implementing such a complex project 

in only 16 weeks is visible proof of 

the professional cooperation of the 

specialists at Carl Zeiss Industrial 

Metrology and our employees in engine 

production.“ Michael Emmer, head of 

quality inspection in production, added: 

„After a good year of operations, I 

can say that the measuring machines 

have been positively accepted by the 

employees in production. However, for 

quality assurance, reliable results are 

the deciding factor. These measuring 

machines are reliable.” 

Matthias Kurth 

Production planning Volkswagen Saxony; 

Heinz-Günter Hoppe 

System engineering Carl Zeiss 3D Metrology Services 

Fig. 6: 

PRISMO VAST in the 

measuring lab at the VW 

factory in Chemnitz 


GageMax – the Flexible Measuring Innovation 

in Differential Bevel Gear Production 

Frank Lamberty, Peter Bachem, Theo Sannig, Rainer Detzel, Roger Bayer 

Fig. 1: 

GageMax in Visteon colors 

From left to right: Ralf Stocki, 

Frank Lamberty, Peter Bachem 

and Dieter Finner 

44 

Pinions and drive wheels for 

differential gears typically go 

unnoticed, but are still required to 

do amazing things. They ensure 

that each driving wheel optimally 

transfers engine power to the street. 

During production of bevel gears 

in the hundredths of a millimeter 

range, maximum value is placed 

on high-quality production and 

measuring procedures. 

Centrally located between Aachen 

and Cologne, the Visteon factory 

in Düren, Germany manufactures 

several thousand pinions and drive 

wheels per day. The requirements from 

the automotive industry on quality, 

flexibility and delivery reliability are still 

the benchmark for efficient, customeroriented 

production. 

In addition to flexible production, 

a correspondingly flexible measuring 

strategy is required to satisfy customers’ 

increasingly shorter development 

times. Standard electronic gages that 

are primarily used in the automobile 

supplier industry are simply not enough. 

Electronic gages can only occasionally 

be used after a product group has 

been discontinued. Conversions 

are often technically impossible or 

uneconomical. 

GageMax – the flexible 

measuring strategy 

The Visteon factory has utilized a 

3D measuring machine from Carl Zeiss 

Industrial Metrology for over a year. The 

main feature of GageMax is that it can 

be used directly in production without 

an enclosure for climate control. 

The quality inspection of finished 

bevel gears occurs at specified 

intervals under the responsibility of the 

respective machine operator. 

“When we decided on the GageMax 

strategy,” explains Frank Lamberty, head 

of production planning & production 

of differential gears, “it was important 

to us that we could also efficiently use 

this 3D measuring machine beyond the 

product cycle for bevel gears and other 

products, particularly prototypes.” 

Looking back, Lamberty emphasizes 

that the measurement strategy with 

GageMax has achieved the required 

flexibility. 

The acceptance and response of the 

machine operators also underscores the 


GageMax strategy. This is mainly due 

to the very good user interface with a 

touch screen that was implemented in 

close cooperation between Visteon and 

Carl Zeiss. The measurement results are 

displayed via CMM reporting, providing 

the operator with an easy and clear 

interpretation of the measurement 

results. The measurement plan is 

designed in a way that corrected values 

can be immediately transferred to 

the production machine. Storing and 

evaluating the measurement data with 

qsSTAT and the extremely user-friendly 

CALYPSO software, make the GageMax 

concept a complete success. 

GageMax designed for 

production 

With GageMax, Visteon is armed 

with measuring equipment that 

combines the advantages of gages 

with the flexibility of a 3D measuring 

machine. 

“As a result of the sturdy design, 

insensitivity to temperature, vibrations 

and dirt, the measuring machine 

is ideal for the rough production 

environment,” explains production 

planner Peter Bachem. “The high 

level of safety, the robustness and the 

reliability of the GageMax measuring 

machine make standard gages 

practically unnecessary.“ 

Frank Lamberty (Visteon) 

Head of production planning & production 

of differential gears; 

Peter Bachem (Visteon) 

Process planner in production; 

Theo Sannig 

Regional sales manager Carl Zeiss IMT; 

Rainer Detzel 

Application technology manager Carl Zeiss 3D; 

Roger Bayer 

Key account manager Carl Zeiss IMT 


Fig. 2: 

Pinions 

Fig. 3: 

CALYPSO user interface 

with touch screen; programmed 

by Pascal Klein, Carl 

Zeiss 3D 

Fig. 4: 

Measurement result with 

color coding from qs-STAT 

in the CMM reporter; 

programmed by Robert 

Disser, Carl Zeiss 3D

OVCMM Enables Efficient Determination 

of Measuring Uncertainty 

Björn Blom, Josef Wanner 

Fig. 1: 

UPMC 850 CARAT 

in the calibration lab 

46 

29,000 calibrations per year – from 

one important customer alone – 

an impressive bit of work by the 

accredited calibration lab at Swedish 

company, Coor Service Management. 

The data on measuring uncertainty 

required for calibration is obtained 

using OVCMM (Offline Virtual 

Coordinate Measuring Machine) 

running on CALYPSO measuring 

software. 

The lab’s range of services includes 

the calibration of gages, thread gages, 

dial gages and setting ring gages. The 

service offering also includes measuring 

and calibrating parts. The company 

uses a ZEISS UPMC 850 CARAT ultra 

precision measuring center, an SIP 30 

and various other linear measuring 

instruments. 

The calibration lab sees the 

utilization of a coordinate measuring 

machine and the OVCMM option from 

CALYPSO software as a cost efficient 

means of receiving approval for various 

measuring tasks from the National 

Office for Technical Accreditation in 

Sweden. The calibration of measuring 

machines and workpieces using the 

UPMC CARAT from Carl Zeiss is one 

of the methods in the „Flexible Scope“ 

program. The company uses CALYPSO 

with the OVCMM option to determine 

measuring uncertainty. 

Calibration with 

OVCMM 

CALYPSO OVCMM enables the 

input of feature-specific measuring 

uncertainties in the measurement log. 

According to ISO 9001, the measuring 

uncertainty of a measurement must be 

known and be within suitable relation 

to the required tolerance. 

ZEISS UPMC CARAT and CALYPSO 

software with the OVCMM option 

provide an ideal process, enabling the 

calibration lab to offer its customers 

part-specific gages (reference parts) 

and a suitable calibration method. 

Furthermore, this highly accurate 

measuring machine permits traceable 

measurements on customer. Traceability 

was achieved with the support of Carl 

Zeiss 3D Metrology Services in Aalen 

which is accredited for the installation 

of OVCMM. Coor Service Management 

metrologists also received their training 

in Aalen. 

Another benefit with OVCMM 

is that measuring uncertainty is 

determined largely automatically 

with minimal user input. Specialists 

install and start-up the system on 

coordinate measuring machines, 

ensuring the correct determination of 

the influencing variables. The complex 

interactions of these uncertainty values 

are mathematically stored in OVCMM. 

Users perform the following additional 

procedures: 

• 

• 

• 

The user executes a measurement 

plan using CALYPSO and receives 

actual values for the workpiece. 

OVCMM virtually varies – without 

a new measurement – the probing 

points within the known uncertainty 

ranges. CALYPSO then calculates 

additional possible measuring results 

for the individual tested features. 

OVCMM determines the measuring 

uncertainty from the range of values 

of the simulated results. 


• 

In the measurement protocol, 

CALYPSO provides all characteristics 

with the complete measuring results 

consisting of actual values and 

associated measuring uncertainty. 

Users do not need in-depth 

knowledge for this process. Timeconsuming 

repeat measurements are 

no longer required. Determination of 

measuring uncertainty with OVCMM 

complies with standards, and is fast, 

automatic and objective. Above all, it 

is adjusted to the flexible measurement 

possibilities of the respective coordinate 

measuring machine. 

OVCMM for CALYPSO is the most 

cost-efficient method of determining 

the measuring uncertainty of a 

measuring machine. Other possible 

methods require numerous tests and 

calculations for every characteristic 

to be measured. The ability to check 

the quality of measurement plans is 

an additional advantage of OVCMM 

which allows users to determine how 

the measuring uncertainty varies 

with changes to the measurement 

strategy, the stylus geometry and 

the measurement location before 

measuring tasks are completed. Thus, 

OVCMM can also be used as a type of 

quality assurance. 

Accredited by Swedac 

The Coor Service Management 

calibration lab has been accredited 

(registration no. 0018) by the National 

Office for Technical Accreditation 

in Sweden, Swedac, for a series of 

calibration methods in accordance 

with ISO 170 5. Implementation of 

the ISO 1001 : 003 standard and the 

ISO/TS 16949 technical specification 

requires a simple method of calculating 

measuring uncertainty. The standards 

demand that either an external lab 

be certified for ISO 170 5 or that the 

Fig. 2: 

Calibrating a workpiece 

customer check the lab for compliance 

with this standard. 

The accreditation also covers the 

“flexible scope“ program for several 

methods. This means that the lab 

is allowed to modify methods it 

developed. The lab can also use 

current versions of standard methods 

and standards that are available for 

accreditation. It is possible to introduce 

new, comparable methods without 

having to inform the accreditation 

office ahead of time. The requirement: 

changes, updates or new methods 

must not contain new measuring 

principles that were not intended in 

Coor Service 

Management 

the original scope. Coor Service Management, 

a company in the international 

3i private equity company, is 

the leader in integrated service 

Björn Blom 

management in Scandinavia. 

Senior Quality Engineer, Coor Service Management; It specializes in management, 

Josef Wanner 

development and optimization 

Bridge CMM Division 

of internal services required 

to manage offices, production 

facilities and public service 

organizations. The company 

has 3000 employees in Sweden, 

Denmark, Norway, Finland 

and Belgium. The lab for linear 

calibration is located in Trollhättan, 

70 km north of Gothenburg, 

Sweden. 


DaimlerChrysler Chooses CALYPSO 

Kai Gläsner, Günter Keck 

48 

For the quality assurance of 

mechanically manufacturerd parts, 

DaimlerChrysler AG is increasingly 

turning to CALYPSO software from 

Carl Zeiss. This measuring software 

will become standard in the power 

train area throughout the company. 

Cooperation between the Stuttgartbased, 

Germany, automotive company 

and Carl Zeiss Industrial Metrology in 

prismatic coordinate metrology was 

finalized in a general agreement. 

The agreement on the future 

cooperation was signed on Jan. 1 , 

006. It covers DaimlerChrysler and 

its subsidiaries. The entire plant in 

Hamburg, Germany is the first to be 

upgraded. Its factory in Gaggenau, 

Germany and other locations will 

follow in the coming months. 

It was particularly important that 

CALYPSO cover a wide range of 

applications in coordinate metrology at 

DaimlerChrysler. Furthermore, because 

it supports the I++ DME measuring 

machine interface, CALYPSO is also ideal 

for non-ZEISS measuring machines, 

thus enabling synergy effects. The 

automaker is currently upgrading its 

Hamburg, Germany, facility to 

CALYPSO licenses with more than 30 

interfaces and additional software 

for bridge-type and horizontal-arm 

measuring machines and measuring 

arms from four manufacturers. 

Günter Keck, head of modernization 

and used instruments at Carl Zeiss 

Industrial Metrology sees the 

agreement as a mutual benefit: „I am 

well aware of our responsibility to our 

customers. I also see the advantages 

for us when we learn from the 

experiences in coordinate metrology at 

DaimlerChrysler.“ This can only help us 

enhance and improve CALYPSO. 

Metrologists at both companies 

believe that the general agreement is 

a guarantee for mutual success and a 

good, close cooperation. At the same 

time, the agreement is seen as a new 

milestone in the history of coordinate 

metrology. 

Increased efficiency 

through uniform 

software 

DaimlerChrysler has used HOLOS 

NT from Carl Zeiss for years for car 

body measurements based on a 

corresponding general agreement 

and is the largest single user of 

this freeform measuring software 

with more than 400 licenses. The 

decision to go with ZEISS CALYPSO to 

standardize the power train measuring 

software and have closer cooperation 

was only logical. This is also due to the 

fact that Carl Zeiss Industrial Metrology 

also provides a complete service 

offering for metrology in addition to 

manufacturing coordinate measuring 

machines and software. 

Stephan Ivanuakas, Product 

Manager in Quality Planning at 

DaimlerChrysler in Hamburg, and Kai 

Gläsner, responsible for the corporatewide 

use of metrology software at 

DaimlerChrysler, have recognized 

current trends: “The software packages 

currently being used in prismatic 

coordinate metrology can no longer 

fulfill the various requirements over 

the long run. Furthermore, an analysis 

indicated that the systems are hitting 

a type of dead end regarding the 

availability of hardware and further 

development.” This led to a project 

to analyze the software situation on 

measuring machines. 

A comprehensive examination and 

numerous tests led DaimlerChrysler to 

the result that CALYPSO is the most 

innovative power train measuring 

software on the market. It enables 

effective programming of coordinate 

measuring machines and the clear 

display of the measurement results 

which can be easily interpreted. 

Kai Gläsner 

Responsible for car-body measurement and software 

at DaimlerChrysler; 

Günter Keck 

Head of Retrofits and Pre-owned machines 


Highly Accurate Gear Tooth Measurements 

in the Production Environment 

Roman Groß 

Magna Powertrain in Lannach, 

Austria approached Carl Zeiss 

Industrial Metrology with a 

requirement for flexible and highly 

accurate measuring equipment for 

gear tooth measurements directly 

in production. Magna is one of the 

world’s largest suppliers of highquality 

automobile gears whose 

precision-manufactured bevel 

gears are used in engines from 

leading automobile manufacturers. 

Therefore, maximum precision is 

also demanded in quality inspection 

and assurance at Magna as a poorly 

produced gear would cause it to fail 

or wear prematurely. 

The basic conditions in the project 

with Carl Zeiss included simple and 

intuitive operation of the measuring 

software as well as the entire 

measuring system. The evaluation of 

the measurement results should be 

available quickly for corrections on the 

shop floor near the Gleason bevel gear 

production machines. The cycle time 

specifications for parts measurement 

are therefore under five minutes. At 

the same time, the solution should be 

suitable for use as close to production 

as possible. 

GageMax 

The inline solution for measurement 

on the shop floor – GageMax – was 

practically created for the demands and 

the environment at Magna Powertrain. 

GageMax from Carl Zeiss is a thermally 

stable measuring system with high travel 

speeds, a fast rotary table and maximum 

precision. The use of GageMax allowed 

Magna Powertrain to meet its cycle time 

specification of five minutes to measure 

the pinions and ring gears. 

Gear tooth measurements 

with software 

GEAR PRO 

With the CALYPSO autorun 

interface and GEAR PRO bevel gear 

wheel measuring software for bevel 

gears, Carl Zeiss was able to fulfill the 

requirement for “easiest operation 

by an employee.”. Combined with 

a touch screen monitor, CALYPSO 

autorun offers the possibility of starting 

a measurement directly by selecting 

from the touch screen monitor. 

Fig. 1: Autorun interface 

Here, the workpiece alignment is 

automatically measured with CALYPSO 

and the measuring tasks specific to gear 

wheels are then performed using GEAR 

PRO bevel. 

Fig. 2: GEAR PRO bevel 

Magna has already requested an 

additional system – the best evidence 

of customer satisfaction with the total 

solution from Carl Zeiss. 

GEAR PRO 

bevel 

GAGE 

Enterprise 

CALYPSO 

GEAR PRO 

bevel 

Correction data for 

the production machine 

Automatic determination of the 

correction data from the measurement 

results for the Gleason bevel gear 

production machines was another 

requirement mastered by Carl Zeiss. 

This task was completed with the 

direct interface to the Gleason GAGE 

Enterprise Database. The measurement 

process forms a closed loop and is 

illustrated in the above diagram. 

During the measuring process, the 

nominal bevel gear data is transferred 

from GAGE Enterprise to GEAR PRO 

bevel. The actual measurement then 

begins with the determination of the 

workpiece alignment in CALYPSO. 

Measuring tasks specific to gear wheels 

are performed on GageMax using 

GEAR PRO bevel. The measurement 

results are displayed in a customerspecific 

protocol and simultaneously 

sent to GAGE Enterprise. Following a 

measurement in closed-loop operation, 

GAGE Enterprise delivers the machine 

correction data for the corresponding 

Gleason bevel gear production machine. 

Furthermore, the measurement results 

are transferred from GEAR PRO bevel to 

Q-DAS qs-STAT via a specially designed 

interface for statistical evaluation. 

Roman Groß 

Application Technician 

Fig. 3: 

Automatic determination of 

the correction data for the 

production machine 


Minutes not Hours 


Fig. 1: 

KLU technician Jürgen Roth 

using the PRO T select 

50 

KLU GmbH measures car body parts 

with a PRO T select horizontalarm 

measuring machine from Carl 

Zeiss. Metrology from Carl Zeiss is 

also beneficial to small companies. 

Kleiner-Lang-Umformtechnik GmbH 

(KLU) in Möckmühl, Germany is 

a perfect example. The company 

delivers car body parts to customers 

such as Audi, BMW and EvoBus. 

An automated measurement 

procedure should meet the increasing 

demands on quality while reducing 

measurement and personnel costs. 

Following a presentation, CEO Thomas 

Kleiner decided against a purely 

optical measurement process. “The 

range of parts manufactured at KLU 

requires a solution using primarily 

tactile measurements,” says Kleiner. 

“However, we wanted to keep the 

option of optical measurement open.” 

PRO T with HOLOS NT: 

a productive team 

The PRO T select horizontal-arm 

measuring machine and HOLOS NT 

freeform surface and analysis software 

from Carl Zeiss Industrial Metrology 

was the best solution for KLU. KLU 

Measuring Technician Jürgen Roth 

emphasizes that this is true primarily 

for measuring speed and accuracy. 

Furthermore, unlike in the past, higher 

part throughput, positioning of the 

measuring equipment and clamping 

of several parts occurs at the same 

time. The accuracy of PRO T select 

is 5 + L/100 ≤ 60 µm. In repeat 

measurements of a metal sheet, the 

difference between measured values 

is 10µm at most, says Roth. Thus, the 

machine measures very reliably within 

the tolerance specifications. 

The question of whether an increase 

in productivity can be seen after a half 

year of measuring operations was 

affirmed by Kleiner. Roth provided 

several examples: “If I program a part 

Fig. 2: 

CEO Thomas Kleiner is extremly happy about the 

increased productivity at KLU 

with HOLOS NT, I need an hour to 

measure it completely. I would have 

needed half a day doing it manually.” 

In the past, he measured the 900 

measuring points of the floor for a new 

Karmann Sprinter over two days; now 

he needs five hours. Roth explains: “It 

is ideal that everything can be saved, 

even windows and part positions that 

were selected once. The “deviation 

flags” also have fixed positions. HOLOS 

NT delivers decisive advantages over 

our previous system.” 

KLU 

KLU produces tools for volume 

production, structural parts 

and exterior panels, and for 

the manufacture of steel and 

aluminum parts. Up to 2500 parts 

per month are churned out using 

a laser system and hydraulic and 

mechanical presses. Furthermore, 

K LU d e l i v e r s c o m p o n e n t s 

cemented and welded from several 

parts, as well as prototype parts 

and volume parts manufactured 

using a laser for one-off and 

serial production. KLU‘s 55 

employees produce metal parts 

not only for renowned German 

car manufacturers, but also wellknown 

non-German brands such 

as Lamborghini and Seat. 


PRO T: economical 

even in the future 

Looking towards the future, Kleiner 

emphasizes that being able to use 

optical sensors in addition to the 

variety of touch sensors made the 

difference. Two points are important 

from an economical standpoint: 

“It was important to install PRO T 

select on the first floor without any 

additional measures. More important, 

however, was that the measuring 

machine worked reliably during the 

test run. Until now, there have been 

no downtimes.” Kleiner explains that 

this is particularly important as KLU 

does not have several measuring 

machines that can replace each other. 

High reliability helps to ensure that the 

often tight deadlines from customers 

are kept. 


Product Manager horizontal-arm machines 

Fig. 3: 

Horizontal-arm measuring 

machine PRO T select 


Pioneering Technology Common-Rail-Systems 

Successful Cooperation between Denso und Carl Zeiss – Accretech 

Szabolcs Jakab, Jozsef Beke, Christina Riedl, Markus Walcz 

Fig. 1: 

3D coordinate metrology 

from Carl Zeiss with 

software CALYPSO 

5 

The global company has set its 

sights high. In doing so, it has also 

increased the demands on a potential 

partner. The partnership with Carl 

Zeiss – Accretech is now a tradition: 

more than thirty measuring systems 

for 3D metrology – primarily form, 

surface and contour – ensure the 

high standard of quality directly 

in production at Székesfehérvár, 

Hungary. 

Fig. 2: 

DENSO‘s worldwide locations 

Technology from Carl Zeiss 

and Accretech is used for highly 

accurate form, contour and surface 

measurements, as well as 3D 

coordinate metrology, to check 

injection pump casings, for example. 

This requires measuring the bore and 

thread positions, as well as flatness 

and parallelism. On the injector pump 

itself, the surface parameters of the 

cylinder contact surface and the 

piston opening are captured using the 

surface measuring system. In the diesel 

injector valve area, contour measuring 

systems analyze features such as 

chips, excursion and thread profile. 

Furthermore, the roundness and 

cylindrical form of the piston opening 

is checked on these parts. 

Powerful bridge-type 

measuring machines 

and CALYPSO 

On the machines used: measurements 

in 3D coordinate metrology are 

performed primarily with a CONTURA 

measuring machine from Carl Zeiss. 

A highly accurate UPMC reference 

machine is also in operation at DMHU. 

Most systems are now equipped with 

trendsetting CALYPSO measuring 

software from Carl Zeiss. 

Surface measurement 

For surface checks, DMHU currently 

uses several Surfcom 1400 machines 

and the highly accurate Surfcom 3000 

reference machine which is known for 

its extremely high performance data. 

Equipped with a laser in the measuring 

unit, Surfcom 3000 is able to determine 

both roughness and contour very 

accurately in the same measuring run. 

The deflection range in Z is ±6 mm. 

Contour measurement 

The Contourecord 600 is the 

measuring machine of choice for 

contour measurements at DMHU. Its 

measuring unit with glass scales in 

X and Z deliver maximum accuracy. 

DMHU has now received its second 

machine from the new Contourecord 

1700 line introduced last year. Equipped 

with patented linear motor technology 

in the tracer driver, Contourecord 1700 

provides outstanding performance 

data at significantly higher measuring 

speeds. The globally patented linear 

motor technology also eliminates 


Fig. 3: 

Highly accurate form testing with Rondcom 65 

background noise and wear. This, and 

the modularity and upgradeability of 

the systems underscore the uniqueness 

of this machine. 

Form measurement 

Last but not least for highly accurate 

form measurements: DMHU primarily 

uses systems from the Rondcom 65 line. 

These extremely accurate machines 

enable DMHU to verify and meet the 

extremely high demands the company 

places on the quality of its products. 

Rondcom 65 features roundness 

tolerance of 0.01µm as well as a rotary 

table that aligns fully automatically. 

All Rondcom, Contourecord and 

Surfcom machines use pioneering 

TIMS software which offers maximum 

flexibility, a high level of automation 

and a software base for all abovementioned 

operations. 

In addition to hardware, DMHU and 

Carl Zeiss also work closely together 

on the customer service front, for 

maintenance, application support and 

user training, for example. This type of 

cooperation covers the entire range for 

quality assureance at DMHU and is the 

basis for collective success. 

DENSO 

Technology and experience 

make Denso one of the world’s 

largest and most successful 

suppliers to the automotive 

industry. With diesel injection, 

air conditioning and navigation 

systems, the Japanese global 

group is also a key supplier to the 

automotive industry in Europe. 

Denso focuses on development 

and quality. It opened a new 

development center in Wegberg, 

Germany in April 2005 where the 

company is diligently working on 

adapting Japanese innovations to 

European engines. 

Denso has also had a plant in 

Székesfehérvár, Hungary since 

1997, which today has more 

than 2500 employees. Denso 

Manufacturing Hungary Kft. 

(DMHU), along with Siam Denso 

Manufacturing in Thailand and 

the two Japanese factories, 

Nishio and Zenmyo, form the 

CRS network. CRS stands for 

the environmentally friendly 

Szabolcs Jakab 

QI-Manager DMHU; 

Jozsef Beke 

Audit Laboratory Team Leader DMHU; 

Christina Riedl 

Customer Relationship Manager; 

Markus Walcz 

Key Account Manager 

Common Rail System: 1800 bar 

pressure and up to 5x injection 

process during each combustion 

phase reduce both diesel fuel 

consumption and discharge of 

pollutants. Denso has produced 

the CRS with solenoid valves since 

2002. Since then, the technology 

has been enhanced with a faster 

switching Piezo actuator. 

The success of the Hungarian 

factory is reflected in rapid 

growth: set up as a facility for 

diesel injection systems, the plant 

now also produces a variety of 

engine components for gasolinepowered 

motors. 

However, the core competency 

remains the diesel business where 

the next development is on 

the horizon: Denso is currently 

working on increasing the CRS 

injection pressure to 2000 bar. 

The solenoid version of this 

development will be launched 

in Japan in 2007; a year later a 

version with Piezo actuators. 


Quality Assurance at BANG & OLUFSEN 

in Struer, Denmark 

Jens Lynge Petersen, Peder Bay, Wolfgang Schwarz 

Fig. 1: 

The reference lab: WMM 

with software CALYPSO 

54 

For more than 20 years BANG & 

OLUFSEN has kept track at the 

quality of the products produced 

and delivered from Struer. The first 

coordinate measuring machine, a 

perfectly maintained WMM 550, 

still enables the intense analysis on 

the production processes to ensure 

the highest quality levels. 

New requirements 

With the growth strategy to extend 

from consumer electronics into other 

business areas, the technology setup 

had to be adapted accordingly. Together 

with new high-end car models, such 

as the AUDI A8 and the BMW M5, 

components are now delivered with 

high volume from Struer. AUDI offers 

a high-end audio sound system from 

BANG & OLUFSEN, BMW assembles 

in their higher-level cars aluminium 

components from BANG & OLUFSEN 

for the door frame covers or the I-Drive 

control button. 

This extended program required 

a re-structured metrology concept. 

Instead of using the gages and fixtures 

as before, a more flexible solution was 

required. 

Mr. Jens Lynge Petersen: “Before we 

scrapped our own parts, now we have 

parts from AUDI and BMW and have 

to monitor and control quality much 

better”. 

The established quality of the existing 

tools was no longer sufficient any 

longer for delivering these automotive 

products. 

The number of MSA’s (Measuring 

System Analysis) is increasing: “The 

automotive industry demands a Cpk 

value better than 1.67 – Statistical 

Process Control (SPC) is the only way 

to prove it..” according Mr. Jens Lynge 

Fig. 2: 

Controlpanel of BeoCenter 2 

Fig. 3: 

Automotive components 

Petersen statistics is a must to maintain 

the quality level of the total process. 

But also the costs for maintaining 

and calibrating these inspection tools 

were too high, since automotive model 

changes could not guarantee a long 

use of fixed arrangements. Therefore 

the total equipment cost could not 

exceed the cost of the fixed equipment 

of the previous three years. 


Fig. 4: 

The Mechanical Metrology Competence Center and its specialists 

Metrology at 

BANG & OLUFSEN 

This goal has been achieved with 

the SPECTRUM 10/10/6 – all fixtures 

of the actual production can be 

easily installed within seconds by 

the production people for a fast and 

reliable measuring result. 

In three shifts the employees are 

performing the measurements by 

themselves. “Measuring the process 

capability must be done by those who 

can react to the data – therefore it 

has to be done on the shopfloor”, the 

production manager says. 

After specialized training, the 30 

production people knew how to run 

the Metrology equipment, which they 

quickly adopted as their preferred tool 

located in a separate metrology room. 

The comment by the engineer 

describes this best: “To improve the 

process capability, we must have 

the correct data to work with. This 

demands an accurate measurement.” 

The central metrology lab, with all 

their experienced specialists, supports 

the use of CALYPSO on part subprograms. 

Programs are now also 

done based on CAD-files. The “old” 

environment based on UNIX was 

upgraded with a retrofit to the WMM 

with new PC-hardware and the latest 

CALYPSO Software package. 

The new structure run of by 

Mr. Petersen with his department 

“Mechanical Metrology Competence 

Center” has worked out perfectly. 

Bang & Olufsen 

Although in global terms Bang 

& Olufsen’s size is modest, the 

company has achieved world wide 

recognition for its spectacular 

TVs, audio systems, loudspeakers 

and telephones. 

Bang & Olufsen also develops 

high performance, highly compact 

digital amplifier units as well 

as medical compliant devices, 

stethoscopes etc. for the medical 

technology industry. Development 

and product maturation is located 

at the Group’s head quarter 

in Struer in Denmark. Bang & 

Olufsen’s vision is expressed 

in the sentence “Courage to 

constantly question the ordinary 

in search of surprising, long 

lasting experiences” – a sentence 

with which Bang & Olufsen’s 

2,300 employees across the world 

identify with pride. 

Because of the positive experience, 

the group plans to add more flexible 

coordinate measuring machines close 

to the shopfloor – according the Bang 

& Olufsen vision: questioning the 

ordinary way… 

Jens Lynge Petersen 

Manager Plastic Competence; 

Dipl.-Ing. (FH) Peder Bay 

Brock & Michelsen, Zeiss Business Partner; 

Dipl.-Ing. (FH) Wolfgang Schwarz 

Sales Europe 


About us 

Technology Day in Brazil: Expertise and 

Technical Support – the path to success 

Antonio Carlos Coelho, Janaina Iziquiel 

Fig. 1: 

Workshop at INA 

Sorocaba – Brazil 

56 

Carl Zeiss Brazil is staying with the 

Carl Zeiss 3D concept of taking our 

technical knowledge in the area of 

industrial metrology and showing 

the Carl Zeiss expertise to our 

customers. Carl Zeiss Brazil together 

with Carl Zeiss IMT Germany has 

organized a series of technology 

workshops in several cities in Brazil, 

close to their key customers. 

The Brazilian workshop series began 

in Sorocaba, where Carl Zeiss received 

help from the Schaeffler Group (INA). 

They assisted Carl Zeiss with the use of 

their facilities and in the organization 

of the event. The city of Joinville, in 

the center of southern Brazil, was 

the location of the second workshop. 

The third and last workshop was in 

Porto Alegre, in Southern Brazil. This 

workshop was attended by many new 

customers interested in information on 

ZEISS products and technologies. 

This event took place at the beginning 

of December 005 and more than 

150 participants from varying areas 

of interest were present including 

Volkswagen, Daimler-Chrysler, Bosch, 

INA, LUK, Ford, FAG, EMBRACO, Tupy, 

WEG, Delphi, GKN and Parker among 

others. 

During the workshops, German and 

Brazilian specialist presented general 

topics from Industrial Metrology in 

the areas of hardware, software and 

services and specific themes like Active 

Scanning, Navigator technology, 

EagleEye navigator, retrofit of 

ZEISS and non-ZEISS CMMs, CMM- 

Check, etc. The subject that was 

mostly discussed, however, was the 

technological differentiation between 

ZEISS products and their competitors. 

All of the presentations translated 

into Portuguese, in order to reach 

all the participants of this event. 

Application Report 

ScanMax 

The company INA presented their 

work with the use of a ScanMax in the 

tool and mold making department. 

The process engineer Ms. Neusa Silva 

explained the use of ScanMax for 

the “Electric Discharge Machining” 

(EDM) area. The data collected from 

ScanMax with corrected values are 

transformed for the EDM process. 

This completely new process helps 

greatly increase the productivity in this 

sector. The use of ScanMax for this 

application helped reduced the EDM 

set-up process for every piece to 5 

minutes. Ms. Neusa Silva concluded 

her contribution to this workshop, 

explaining the indispensable need of 

this type of equipment in the modern 

tool making department: “Without 

ScanMax, the tool making department 

could simply not work effectively.” 

Positive Reaction 

Our business partner, Mr. Ronaldo 

Stivalli, was impressed with the high 

level of the Brazilian customers‘ 

attendance: 65% of all the Carl Zeiss 

customers in Brazil were present and 

4 new customers were there to 

receive more information regarding 

Carl Zeiss technology. Mr. Stivalli 

hopes that this kind of event will 

continue in the future in Brazil. 

Up-to-Date Expertise 

2006 – Brazil 

This event in Brazil encouraged 

customers to discuss current topics, 

exchange information and receive 

news concerning technologies 

developed for the world market. 

Due to the great response of this 

event, Carl Zeiss Brazil has already 

scheduled a series of workshops for 

the beginning of November, 006 in 

the same Brazilian regions. Brazil is a 

very large country and each potential 

customer wants to participate in these 

events, only however if they take place 

close to their production facilities. This 

is why the events will take place in São 

Bernardo do Campo (Volkswagen and 

DaimlerChrysler Operation Center in 

Brazil), in Campinas (Bosch, Siemens 

VDO Operation Center in Brazil), 

Curitiba (Audi, Volvo) and probably in 

Caxias do Sul (center of tool making 

producers in Brazil). 

Antonio Carlos Coelho 

Sales manager Carl Zeiss do Brasil; 

Janaina Iziquiel 

Marketing Carl Zeiss do Brasil 


Under the Indian Sun 


The GageMax coordinate measuring machine displayed 

its open-air capability at the February 2006 Tooltech 

in New Delhi. India. Set-up in a parking lot, it braved 

the harsh Indian climate. Nonetheless, the dispersion 

of the measuring results on a bevel gear was only two 

microns. 

The GageMax spent a week in the parking lot. The 

measuring machine isolated the vibrations of passing cars. 

It defied the Indian sun that beat down on the temporary 

enclosures, whose interiors became saunas at midday. Even 

heavy dust was no match for this ZEISS machine. 

As a result of delays caused by customs formalities and 

transport problems, the GageMax was delivered at 10:00 pm 

the night before the show opened. Too late, according to 

show organizers, who would not allow Carl Zeiss employees 

to set-up the measuring machine in the exhibition center. 

A new challenge presented itself for the Indian colleagues 

of Industrial Metrology, one they solved with a bit of Indian 

ingenuity: they built a temporary enclosure around the 

GageMax. The team had decided earlier that a measuring 

machine for a rough production environment must also 

withstand the Indian climate. 

Since the GageMax was located directly next to the 

entrance of the exhibition center, the booth became the 

main attraction. Visitor after visitor pointed out that „it was 

worth coming to the show, just to see GageMax alone.“ 

Competitors were less than thrilled as they had nothing to 

show that was that original. 

Wolfgang Klaus Wiedmann 

Head of InLine and Projects; 

Hannes Daniel 

Productmanagement InLine 

Open-air capable: 

GageMax at the Indian Tooltech trade fair 


“IMT Practice Workpiece” 

Bernd Georgi 

Development of the real practice cube to CAD models up to point clouds 

A few IMT milestones 

1973: 

The first 3D coordinate 

measuring machine with a 

measuring stylus 

1995: 

Start of the InLine series 

1995: 

PRISMO VAST 

2006: 

Metrotom 

58 

The IMT “practice workpiece” has been a standard 

element of measuring exercises on coordinate 

measuring machines (CMM) for 33 years. Many readers 

wonder what an ancient idea from 1973 is doing in 

Innovation in 2006. 

The story is quickly told, ensuring that there is enough 

space to throw in a short anecdote. 

The practice workpiece was designed for the market 

launch of the UMM 500. Carl Zeiss established a milestone 

in industrial metrology with this first real 3D measuring 

instrument. It quickly became clear that a real 3D practice 

part was required for training purposes in order for 

metrologists to become familiar with the possibilities of 

the probe head and the software, as well as for hands-on 

exercises. 

The requirements were clear: 

• 

• 

• 

• 

• 

• 

Complete 3D part 

Scannable from all sides using the star probe 

General validity 

Easy to clamp 

With all typical geometric elements 

Good for all typically connected features. 

While the “ZEISS cube” was a part of the U1 operating 

manual in the beginning, it has now been used by several 

thousand metrologists worldwide as the first step in 3D 

coordinate metrology (UMESS 36, UMESS 300, UMESS 

1000, UMESS-UX and CALYPSO). CALYPSO enabled the 

cube to also enter the CAD world and repeatedly appear 

in trade publications. This year, it helped – x-rayed – to 

understand the principle of computed tomography. 

The real reason for its longevity rests with the Swabian 

mentality. If it isn’t broke and isn’t criticized, don’t fix it. 

Furthermore, Swabians are known for spending their 

money wisely on important things. The left column shows 

a portion of this successful IMT-strategy. On this note, the 

cube can „still put in a few more years of service” – with a 

new paint job, of course. 

Bernd Georgi 

Development CT 

Historical moments 

1974: 

Germany wins World Cup 

in soccer 

1974: 

VW Golf 

1977: 

CD 

1978: 

ABS 

1979: 

Walkman 

1985: 

Cellular phone for the 

C network 

1989: 

100 years of the Carl Zeiss Stiftung 

Photo: Ernst Abbe, Carl Zeiss 

1989: 

Fall of the Berlin Wall 

1989: 

German reunification: 

Carl Zeiss in East and West Germany 

1990: 

Germany wins World Cup 

in soccer 

1995: 

GPS fully operational 

1998: 

Memory stick 

2004: 

Missions to mars 


Product Names and registered trademarks 

from Carl Zeiss IMT GmbH 

In the text of the Innovation 8, the product names are correctly written, but the ® registered trademark and the 

accentuation will not be included in order to facilitate reading. On this page you can see the proper spelling of ZEISS 

products that can be found in the pages of this publication. They are grouped together by product lines: 

Hardware 

ACCURA ® 

CenterMax ® 

CenterMax ® ultra 

Contourecord 

CONTURA ® G 

CT 

F25 

GageMax ® 

MC 

Metrotom 

MMZ B 

MMZ E 

MMZ G 

MMZ T 

PMC 

PRISMO ® navigator 

PRO ® T 

PRO ® T compact 

PRO ® T select 

PRO ® T premium 

Rondcom 

ScanMax ® 

ScanMobil 

Surfcom 

UPMC S-ACC 

UPMC ultra 

WMM 

Software 

CALYPSO 

CALYPSO curve 

CALYPSO PCM 

CALYPSO planner 

CALYPSO simulation 

CMM-OS 

DME ® 

GEAR ® PRO 

GEAR ® PRO bevel 

HOLOS ® 

ScanWare pro 

TIMS 

UMESS ® 

Sensor systems 

DT DynaTouch 

EagleEye navigator 

LineScan 

MT 

RDS 

RST P 

ST 

VAST ® gold 

VAST ® navigator 

VAST ® XT 

VAST ® XT gold 

VAST ® XXT 

ViScan 

Miscellaneous 

AUKOM 

CAA 

Carl Zeiss (as company) 

CMM Master Control Center 

Messpro DB 

Metrotomografie 

OVCMM 

πWeb 

qsSTAT ® from Q-DAS ® 

ZEISS (as brand name) 


60-25-086-e Printed in Germany. IV/ 006 Too 

Subject to technical modification and to changes in scope and design. 

Printed on chlorine-free paper. 

© Carl Zeiss © Text and design by: Carl Zeiss. 

„ “The accuracies and repeatability are better with CONTURA 

G2 than with touch-trigger systems. We can see things better and 

more clearly with scanning than we were able to in the past.” 

Dietmar Schönfelder, 

head of quality assurance at ISE in Hainichen 

„

etro lo g y - Carl Zeiss

Create successful ePaper yourself

Delete template?

Save as template?