Due to their direct proximity to the tool and workpiece, tool clamping systems are ideally suited to capture process-relevant parameters and generate meaningful data. Continuous process monitoring – combined with targeted evaluation and clear visualization of the data – can stabilize production and improve its predictability. Now, a retrofitting solution developed by Fraunhofer IWU together with a manufacturer of clamping systems is market-ready: Users benefit from a more efficient production process with consistently high workpiece quality and minimal downtime.
Tool clamps are the mechanical interface between the forming machine and the tool. The newly presented tool clamps integrate a smart sensor module that detects the smallest elastic deformations on the pressing ram during the forming process. The module can also be retrofitted to existing tool clamping systems. Once installed, the software operates completely autonomously.
It requires no parameterization and does not impose special qualification requirements on the operating personnel. The effort for retrofitting the clamping technology with sensors is also low. The system works directly at the point of action and captures important process data inline. Whether for small quantities or large series, very compact or large-format components – 'BERGtronic' also makes older presses fit for production in the digital age. The latest evolutionary stage of the software continues to monitor the tool clamp but now focuses on analyzing the forming process.
Identify errors faster and address them specifically with anomaly detection
Sensor data – such as the pressing force profile or the distribution of process forces – can be evaluated during production. Should deviations occur, these form the basis for targeted root cause analysis. The data captured at multiple points can be evaluated individually or correlated. A envelope curve monitoring system, where an upper and lower tolerance limit (the 'envelope') is automatically set, reliably detects process irregularities during production. This allows for a quick response, if necessary from stroke to stroke. The software develops a 'memory' for error types, logs detected deviations against the target in a logbook, and compares a detected error with previously occurred events. The evaluated data and information can be made available to higher-level systems such as databases and plant controls.
The anomaly detection also specifically identifies errors in tools. It is based on automatic detection of the working cycle and thus provides the basis for a tool-specific root cause analysis. Specialized knowledge for applying the analysis algorithms is not required.
Manufacturer-independent retrofitting, quick check, and evaluation
Project manager Mohaned Alaluss emphasizes: 'The sensorized clamping technology can be integrated into presses independently of the control concept. Whether a machine is suitable for retrofitting and whether the solution fits the planned monitoring task can be checked with little effort.' An example: Since March 2026, the intelligent clamps and the software developed at Fraunhofer IWU have been in use as a high-tech retrofitting solution at Magna Body & Chassis Germany GmbH under the harsh production conditions of press hardening.
EuroBlech: Joint appearance with Berg & Co. GmbH Spanntechnik
Fraunhofer IWU will demonstrate the newly developed software for process monitoring live at the EuroBlech from October 20 to 23 at the stand of Berg & Co. GmbH Spanntechnik (27-F51) – directly at a forming press. The researchers look forward to welcoming guests who want to be convinced of the advantages of efficient anomaly detection in forming processes.
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