Etalon offers systemic solutions for accurate and complete geometric analysis, monitoring and improving the accuracy of machines, industrial robots and measuring machines. Innovative and high-quality technologies make Etalon products efficient and easy to use.
The company is active around the world, operates in high-tech markets and works with highly qualified local partners to optimally support our customers.
The company’s customers include companies in the fields of mechanical engineering, industrial equipment, the automotive and aerospace industries, as well as the research sector.
The solutions we offer for geometric problems and more:
6 possible geometric deviations in the machines
For each axis of the machine there are 6 possible deviations, which in addition to them, there are also vertical and parallel deviations between the axes. Although production technology has advanced greatly in recent years, even in new and expensive machines there are still geometric problems.
The causes of problems can be many – manufacturing inaccuracy, hasty and inaccurate installation, mechanical abrasion, sinking of the surface on which the machine stands and more. Even a new machine has deviations as a result of moving from place to place, installation and more. In total, a 3-axis machine has 6 possible deviations per axis, and 3 deviations stand between the axes themselves. The more axes the machine has, the more deviations there are options, which ultimately causes an accumulation of inaccuracies.
Each deviation causes accuracy problems, and the more axles there are or the larger the machine, the small problems can turn into to big problems that will affect the accuracy of the machine and more.
Solutions to the inaccuracy of the machines
In the past, dealing with deviations was done only at a mechanical level, but today there are computer-based and computer-assisted solutions that allow for maximum accuracy, even when it comes to mechanical problems.
For many years the possibility of compensation for deviations (PITCH ERROR and CROSS ERROR) has existed in the computer system of the machines, and for over 20 years some of the computers even support volumetric compensation.
Accuracy correction using this method was not common in Israel, for various and varied reasons, some of which were due to the fact that for measuring the deviations, expensive equipment is needed that works with the help of laser systems, a skilled team that will operate it, a software that is able to calculate deviations and construction of compensation tables. The whole process took a long time, was complicated and cost a relatively large amount of money.
ETALON Company and the solutions for testing and calibrating machines
ETALON was founded as a subsidiary of the German Institute of Metrology:
“Physikalisch Technische Bundesanstalt” (PTB, the National Metrology Institute of Germany) In Braunschweig, in 2004.
In 2008, the company became a partner of “SIEMENS SOLUTION”.
In 2009, the company became a partner of “ZEUSS SOLUTION”.
In 2019 she joined HEXAGON MANUFACTURING INTELEGENCE.
The company’s measurement systems are installed in projects such as telescopes with a radius of 6 meters of CCAT PRIME, and the BORNWINN GAMMA platform.
"TIM Machinery for Industry Ltd." performs geometric tests and computerized precision correction of machines using ETALON laser systems.
The services we offer are as follows:
- Checking the accuracy of the machine according to the requirements of ISO 230-2, 230-6 standard.
- BALLBAR test based on the ISO 230-4 standard.
- Build PITCH ERROR and CROSS ERROR compensation tables for the controls of: SIEMENS, HEIDENHAIN, FANUC, MITSUBISHI, MAZAK.
- Complete inspection of rotary axes, including construction of a compensation table.
- Mapping the working volume of the machine and building tables (VOLUMETRIC COMPENSATION) for supportive controls.
- Measuring up to 20 meters.
Testing and calibration options
Machine accuracy test according to ISO 230 standard and BALL BAR test using the ETALON laser system
Machine accuracy test according to ISO 230 standard and BALL BAR test using the ETALON laser system. This test allows for quick and accurate identification of geometry problems that may be critical. Periodic and thorough monitoring of the condition of the production machinery can prevent prolonged downtime, unnecessary expensive repairs and improper parts. All of these can save a lot of time and money for the factory.
The time and duration of the test depend on the size of the machine and the number of axes it has. The average time for checking the accuracy of a medium-sized machine is between two and four hours. The test is helping to see the condition of the machine throughout the working space, according to the requirements of the ISO 230 standard.
A BALL BAR test which is done by a laser, is not limited in a radius of rotation and gives a more accurate picture than the competitors’ devices.
Testing accuracy and calibration of machines with the help of ETALON's laser system.
The ETALON laser system, combined with the TRACK CALC software, is able to check the entire working space of the machine, and compensate for all the geometric deviations of all the axes, including rotating axes.
The test is performed in several stages.
First, the system maps the working space of the machine and receives a “fingerprint” of the machine.
The software prepares a work plan and the system monitors the actual execution.
After running the content from four places, the software TRAC CALC produces compensation tables that are adapted to the controls of: SIEMENS, FANUC, HEIDENHAIN, MITSUBUSHI & MAZAK.
After installing the tables in the controller, the system does a re-check to make sure and be accurate again.
Calibration of a machine with the help of ETALON’s system, can significantly improve its accuracy and compensate for some of the mechanical problems that may arise in the future.
Machine inspection before purchase
Today, when buying a machine, or when getting a new machine, it is not customary to do thorough tests for those machines. As mentioned, there is no need to explain how important the accuracy of the machine is.
With the help of ETALON’s laser systems, “TIM Machinery for Industry Ltd.” performs machine tests before purchase, or a new machine test. By a short and accurate test it is possible to see whether the machine is accurate and whether the accuracy levels meets the ISO standard.
Products
ETALON LASERTRACER-NG
The LaserTRACER-NG was developed for calibration, monitoring and accuracy enhancement of measuring machines and machine tools. It is a self-tracking laser interferometer that automatically tracks a reflector, and hence allows for the identification of geometrical deviations with highest precision.
Unrivaled accuracy
In contrast to conventional measurement devices, the LaserTracer features an unprecedented accuracy of the center of rotation thanks to a patented measurement technique: A sphere with a form deviation of just 50 nanometers is used as an optical reference for the interferometer. As a consequence, the mechanical errors of the rotation and swivel axes are fully compensated.
The measurement process: fast and effective
For measurement execution, the LaserTracer is stationary placed at several different positions inside the working volume of the machine. Then, the reflector is mounted to the tool or probe. In the following automated measuring process, the LaserTracer tracks the actual path of the machine in its entire working volume. Meanwhile, the system acquires highly precise measurement values that are processed by our software packages TRAC-CAL and TRAC-CHECK for calculating and analyzing the machine errors with sub-micron accuracy.
TRAC-CAL: Calibration of CMMs and machine tools
The user-friendly software TRAC-CAL guides the operator through the measurement process. Combined with the LaserTracer, the software determines all systematic geometrical deviations of coordinate measurement machines and machine tools. This includes position deviations, straightness deviations, rotational deviations (pitch, yaw, roll), and the squareness of axes to one another.
TRAC-CHECK: Testing of CMMS and machine tools according to standards
By using the LaserTracer in combination with the Software TRAC-CHECK, it is possible to determine within 30 minutes if a machine is still within the specification or if it needs maintenance or error compensation. The patented method allowing for automatic alignment of the laser beam reduces measurement time significantly.
MULTITRACE: Real-time multilateration for highest precision and dynamic resolution
For applications requiring highest spatial precision and dynamic resolution, four electronically coupled LaserTracers are used, forming a real-time multilateration system with a short-term data rate of up to 50 kHz (1000 Hz continuous) and sub-micron-accuracies.
ETALON X-AX LASERBAR
The X-AX LASERBAR is the solution to calibrate 3-5 axis machine tools completely with minimal measuring equipment expenditure.
Calibration technology rethought: new techniques and patented developments combined with proven methods have created the X-AX LASERBAR. A measuring system for determining volumetric machine deviations has never been so compact, light and inexpensive.
Determination of deviation values for the linear and rotation axes
As with the LASERTRACER, purely interferometric measurements are used to determine the geometric condition of the machine. With the X-AX LASERBAR, the laser is guided from the machine via the multi-stage telescopic tube. The two ends are supported by precision spheres in sphere nests. This makes it possible to calibrate smaller and medium-sized machine tools with 3, 4, 5 or more axes with manageable hardware.
With the competitors measuring equipment, the total geometric deviations of a 5-axis machine can only be determined with extremely high effort – the entire process can take several days. Etalon’s X-AX LASERBAR, on the other hand, requires no more than two to four hours to fully capture all geometrical deviations of a 5-axis machine.
Software package TRAC-CAL
Combined with the sophisticated TRAC-CAL software, the measuring system analyzes the entire working area of the machine tool. It provides an accuracy of 1 µm and determines position deviations, straightness deviations, rotational deviations (pitch, yaw, roll) and the perpendicularity of the axes to each other. The angular positioning deviations, the axial and radial movements and the wobbling of rotary axes are also fully recorded. At the push of a button, a corresponding measurement report is generated for documentation purposes.
To increase the accuracy of the machine, correction data can then be automatically generated for the control system. The result: a maximum reduction of all geometrical errors, a process stable production from the first component and thus hardly .any rejects or reworking effort
ETALON ABSOLUTE MULTILINE TECHNOLOGY
The ABSOLUTE MULTILINE TECHNOLOGY is a pioneering solution to the precision measurement of lengths up to 20 m with a measurement uncertainty of 0.5 µm per meter, on up to 124 channels simultaneously. Unlike conventional interferometers, the laser beam of the ABSOLUTE MULTILINE TECHNOLOGY can be interrupted at any time without causing precision loss. In fractions of a second the absolute distance is recovered. Thanks to these worldwide unique system properties, the patented ABSOLUTE MULTILINE TECHNOLOGY takes metrology automation in production to a new level.
Traceability and accuracy
The metrological traceability of the ABSOLUTE MULTILINE TECHNOLOGY is ensured by the reference to fundamental physical constants: In every measurement, the molecular absorption spectrum of a gas cell that stays constant over decades is scanned and the system is thus automatically recalibrated during every measurement. Comparison measurements using a conventional interferometer at the National Physical Laboratory in England confirmed a measurement uncertainty of 0.5 ppm (equivalent to 0.5 μm per meter) for distances between 0.02 m and 30 m.
