This technology uses sensors to detect and correct anomalies and faults. EMO Hannover is a companion on the road to zero-defect production. Exhibitors such as Hainbuch from Marbach and H.D. Schunk. Spanntechnik KG from Mengen (near Sigmaringen) will be showcasing exciting solutions in which digital transformation plays an important role at the world's leading trade fair for production technology from September 18 to 23, 2023.

"The future is cyber-physical": With these words, the VDMA Precision Tools Association and the Mechanical Engineering Institute from Frankfurt am Main hosted a clamping device forum in Düsseldorf in 2020. At the well-attended forum, production experts from industry and research discussed the advantages of clamping devices that are evolving into cyber-physical equipment thanks to digitalization.

Starting signal for a digital world

But what happened to this mega-trend at the time, was it just a short-term hype topic? It proved to be the starting signal for a new, digital production world for the manufacturer Schunk, which presented a sensitive tool holder with integrated sensor technology at the clamping device forum in Düsseldorf in March 2020, which can even be retrofitted into existing machines. Markus Michelberger, Head of Sales Clamping Technology at Schunk, believes there is a lot to be said for this form of digital transformation. For example, integrated sensors in various clamping devices allow process parameters to be permanently monitored and corrected in the event of deviations.

"Inline monitoring and adjustment ensures a reliable process and consistent product quality for the user," explains Michelberger. "Automated inspection of the clamping devices or tool holders in real time during production is the basis for predictive maintenance or correction. Last but not least, it also serves to document measurement and test values in the production process." Reasons enough for Schunk to continue on its digital path. The South German company attaches particular importance to simple plug-and-play solutions that users can quickly integrate into their systems.

Clamping module sends real-time data

The highlights at EMO Hannover 2023 will include a new electromechanical clamping module with fully integrated sensors and a smart hydraulic expansion toolholder that provides real-time data directly from the tool and detects wear at an early stage. This intelligent tool holder enables process-reliable machining, extends tool life and reduces rejects. "With the itendo² intelligent tool holder, digitalization has arrived in the machine tool - it literally brings inline control straight to the point," says Michelberger. "It demonstrates its advantages in all industries where the quality of the surfaces to be machined is paramount - for example in precision drilling and when high surface quality is required."

© Grove book

The sales manager describes the electric zero-point clamping module, which is controlled via IO-Link, as unique because it can generate identical forces to comparable pneumatic clamping systems without increasing the installation space. Schunk has also fully integrated the sensors. No external sensor is required, so there is no interference contour. Michelberger: "The NSE3-PH 138 zero-point clamping module generates the same pull-in forces as the conventional system with the same dimensions. This technology is absolutely new on the market and can rightly be described as 'disruptive'."

Hainbuch approaches zero-defect production in different ways. Stefan Nitsche, Head of Main Products, describes the basic requirement as dirt-resistant and virtually low-maintenance clamping devices that are characterized by very high rigidity and holding forces, high concentricity with deviations of no more than five micrometres and minimal centrifugal force losses.

Fast and precise: external clamping with clamping head chuck

Secondly, Nitsche recommends that users always work with the ideal clamping device for the workpiece, even if this increases the set-up effort. For example, internal clamping is ideal when machining from five sides. However, if the workpiece does not have the necessary clamping bore, the division manager considers external clamping with a clamping head chuck to be the ideal solution. Nitsche: "To keep the manual set-up time to a minimum - less than a minute with our system instead of the usual 30 minutes - and the changeover repeatability to a maximum of three micrometres, we rely on our Centrotex quick-change system and the Docklock zero-point clamping system."

Hainbuch describes its measuring intelligence, which enables in-line process control, as the third "zero defect" component that has been tried and tested in use for over 15 years. With its help, the clamping diameter from pre-machining is checked in the micrometer range and the workpiece system is detected. "In addition, the actual clamping force is continuously measured on the workpiece, which is an important factor in process stability with increasingly difficult components," explains Nitsche. "We will be demonstrating all three technologies and products live at EMO Hannover. Anyone can easily change our clamping devices with Centrotex or Docklock with µm precision in seconds on site or clamp with high precision using our IQ clamping devices and carry out the various measuring operations at the same time."