Published 4/18/2018

How Intelligent Clamping Technology Can Contribute to Process-Flow Optimization

Germany’s Metav 2018 trade fair presented various hands-on solutions in regard to Industry 4.0, automation, digitalization and data-driven manufacturing. One topic that stood out was intelligent clamping technology with integrated measurement capabilities to generate data to optimize machining processes.

Barbara Schulz

European Correspondent, Gardner Business Media

Metav 2018, which took place February 20-24 in Dusseldorf, Germany, was about hands-on solutions in regard to Industry 4.0, automation, digitalization and data-driven manufacturing.

Konrad Keck, head of sales for DACH region at Benz Werkzeugsysteme in Haslach, Germany, explained how angle heads can give users a competitive advantage in milling, drilling, counterboring, threading and reaming applications.

The Benz i.com Industry 4.0 app enables the continuous monitoring of production processes and minimizes machine downtime.

Josef Dechant from Maschinenfabrik Reinhausen (Regensburg, Germany) explained how the medium-size company has developed an in-house assistance system that enables the intelligent networking of all plants, systems and people involved in the production process. Called ValueFacturing, the system eliminates manual data entry and offers bidirectional online communication in real time with all machines, plants, systems and people involved in the manufacturing process and the ability to smartly enrich information.

A special theme park, "Industry 4.0," was dedicated to the digital transformation of the metalworking industry.

Hainbuch’s Toplus IQ, an intelligent clamping chuck with integrated measurement technology, is able to constantly measure the electronic clamping force and any changes during rotation. The TESTit clamping-force gage measures the effective clamping force in real time. By using the optimum clamping force, workpiece deformations and uncontrolled workpiece scrap can be prevented. To network clamping technology with the machine, Hainbuch cooperates with DMG MORI, for example, where all data generated by Toplus IQ is visualized with the Condition-Analyzer in the CELOS CNC. According to Hainbuch, there will be a similar solution for Siemens CNCs by the end of the year.

From Spring 2018, DMG MORI’s focus will be on integrated digital workflows with CELOS version 5.0, from production planning to monitoring. “Digital Tooling” is one workflow package. All of the tool information necessary for the production process can be managed centrally with this CELOS app.

The EWS-Varia VX quick-change system features a sensor that works with Bluetooth Low Energy (BLE) technology, which constantly collects data such as operating time, revolutions per minute, temperature, sealing condition, battery life, maintenance data and so on via Bluetooth. It does this without directly connecting to other systems, saving energy. The user decides when to read-out the data. Called “CyberCon4,” the sensor connects virtual data with tool-presetting parameters, the machine control and data management in a cloud. According to EWS, algorithms derive maintenance intervals, which previously has not been possible.

Schunk showcased fully automatic chuck jaw change via a FANUC robot. The robot loads the PEK 20 interchangeable inserts and locks them in the the TRP 200-1 supporting jaw. The robot loads machines and unloads the workpiece. The PEK 20 inserts are unlocked again, removed from the chuck and returned to their storage rack.

Roemheld showcased bore clamps for five-sided machining and optimum workpiece accessibility. The bore clamps are particularly well suited for clamping workpieces with smooth bore holes with diameters ranging from 7.8 to 17.7 mm in the support surface. The size of the possible machining forces is certainly limited using this type of clamping, especially crosswise to the clamping surface, Roemheld says. Except for the static-friction force between the workpiece and the support, the bore clamp cannot compensate any side loads.

VDW, the German Machine Tool Builders' Association, Executive Director Dr. Wilfried Schäfer presented the first interim results of VDW's project "Connectivity for Industry 4.0" at the Metav 2018 opening press conference. The aim is to develop a standard for linking a range of disparate machine control systems to a shared interface (a connector) and to create the necessary software to do so. After a core team had been involved in the first phase of the project with companies DMG MORI, Emag, Grob, Heller, Liebherr-Verzahntechnik, United Grinding and Trumpf since 2017, VDW now announced that CNC suppliers including Beckhoff, Bosch Rexroth, FANUC, Heidenhain and Siemens look forward to collaborating with VDW in this project.

“Meat or cheese?” is a commonly asked question in short-haul flights when snacks are offered. Messe Stuttgart invited media representatives, colleagues and friends to their booth to promote upcoming trade shows such as Lasys, AMB and Moulding-Expo. Manager of Messe Stuttgart’s industrial events, Gunnar Mey served drinks and food.

Metav, the Düsseldorf, Germany-based show that takes place biennially in February, faces the burden of occurring only a few months after the world's biggest metalworking show, EMO Hannover, and a few months before world events such as AMB, the International Manufacturing Technology Show (IMTS) and the Japan International Machine Tool Fair (JIMTOF). As a result, exhibitors use the show to connect with customers from Northern Germany and don't necessarily present world-introduction solutions.

Therefore, for my coverage of the event, I focused on what is new in clamping technology, toolholding and workholding—areas in which customers are increasingly benefiting from solutions designed for the age of Industry 4.0. Exhibitors had a number of intelligent workholding and toolholding solutions for automation and networked manufacturing up their sleeves. Digital-workflow data collected from these “smart” devices can be used to manage process flows, and productivity can be increased by performing the appropriate analysis and data processing. Similarly, some new clamping technology generates data that can contribute to process-flow optimization. For example, tooling and maintenance times can be reduced in advance and the machine time can be used for production instead.

Click through the slideshow above to see a sampling of some of those technologies I spotted at the show.