Challenge Clamping technology is vital in production when it comes to securely holding workpieces in place. The automotive supplier Webasto previously used pneumatically driven power clamps in the production of soft tops for convertibles. The existing pneumatic power clamps have should be replaced by servo-electric ones.
Solution The servo-electric solution is more energy-efficient and more flexible in use since the power clamps can be used individually as required. The combination of three components results in an intelligent clamping technology solution for the production requirements of the future: precise mechanics by DESTACO, a decentralized power supply with integrated motion controller iSA and the decentralized synchronous servomotors with integrated inverter and hybrid connection ihXT3-05 by AMKmotion.
The synchronous servo motor with the integrated inverter ihXT3 saves installation time. The inverter is directly wired to the servo motor.
The decentralized power supply with integrated motion controller iSA is robust and space-saving. It is easily installed directly in the machine – so the user no longer needs a switch cabinet.
One vital process stage in the manufacture of a convertible soft top is the welding of the so-called roof bows. The holder fitted with the smart clamps fixes the components in place, while the welding head connects them.
Clamping technology is vital in production when it comes to securely holding workpieces in place. The automotive supplier Webasto previously used pneumatically driven power clamps in the production of soft tops for convertibles. Since the beginning of this year, electrically operated smart clamps have been in use – and the company is highly impressed with them across the board. The combination of three components results in an intelligent clamping technology solution for the production requirements of the future: precise mechanics by DESTACO, a decentralized power supply with integrated motion controller iSA and the decentralized synchronous servomotors with integrated inverter and hybrid connection ihXT3-05 by AMKmotion.
That feeling of the wind in your hair and the sun on your face: for some people, driving a convertible is the ultimate thrill in life. Car manufacturers offer various models with folding soft tops that mean they are not only suitable for driving in fine weather. For roof systems such as those used in convertibles, the automotive industry draws on the expertise of specialists like Webasto.
A system partner to the mobility industry, it is one of the 100 largest automotive suppliers in the world with a workforce of nearly 17,000. Its business includes a wide range of roofs, battery systems and heating and cooling solutions for various types of vehicles.
One vital process stage in the manufacture of a convertible soft top is the welding of the so-called roof bows. These are brackets that will later support the soft top tarpaulins. A holder fixes the components and the welding head connects them. “We used to use the tried-and-tested DESTACO pneumatic clamps and we were satisfied with them, too,” says Markus Binder, looking back. He is the manager of the Webasto site in Hengersberg. “But we became aware of the company’s new smart clamps after seeing an advert, so we wanted to find out more.” DESTACO specializes in the development and manufacture of high-performance automation, clamping technology and remote handling solutions.
DESTACO’s new smart clamps are powered and controlled electrically, with sensors already integrated in the modules. “So there were a number of points that led us to take an interest in the clamps,” says Binder. The pneumatic solution used previously required compressed air – a very expensive form of energy. In addition, the old system used external sensors to query the position of the holder – this meant that additional components were used that had to be wired and maintained. “So DESTACO was quickly able to persuade us that the new solution would give us numerous advantages,” explains Binder.
Another argument that persuaded Webasto was the high flexibility of the smart clamps. The opening angle can be variably adjusted – without much effort. In so-called teach mode, i.e. when moving slowly, the system learns where the touchdown points are. AMKmotion’s motion controller iSA stores the data and uses it to control all movement processes. Operation can start.
And there is another argument in favour of the electrically powered solution, too: the speed can be varied, thereby avoiding kickbacks at the touchdown point. “The electric drive allows the user to move at less than 100 per cent of the maximum speed, so you can minimize the speed just before touching down. This means that the movement loses its kinetic energy and the bracket touches down gently,” explains Uwe Lohage. He works in technical sales at DESTACO, specializing in smart technology.
The smart clamps are new on the market and a logical further development. This is because the electric solution is far superior to pneumatics in terms of performance: this not only means that users save on expensive compressed air, but also allows them to control and monitor their processes much more precisely with the built-in intelligence. “Operators also have the option of recording data. This allows feedback to be gained on the speed and quality of production – and it enables preventive maintenance, too,” says Lohage. In addition, the smart clamps can be controlled individually and not just in combination: this increases flexibility in production as required.
Two experts pooled their knowledge to develop the smart clamps: as a global manufacturer of clamping technology, DESTACO contributes its expertise in clamping technology and mechanics, while AMKmotion is responsible for the servo motor and controller. Based in Kirchheim unter Teck in Baden-Württemberg, AMKmotion specializes in electrical drive technology, control technology and industrial automation technology. It has been a market and technology leader for six decades.
The decentralized power supply with integrated iSA motion controller by AMKmotion is located directly on the device and controls the smart clamp. “This saves space in the switch cabinet and ensures short cable runs,” says Jürgen Schnitzler. He’s the key account manager for DESTACO with AMKmotion. The controller, mains supply and charging resistor are integrated in the lightweight aluminium housing. The AMKmotion components are connected on a daisy-chain basis.
The smart clamps are driven by the decentralized synchronous servo motors with integrated inverter and ihXT3-05 hybrid connection. The ihXT connects the inverter and servo motor. “It’s especially suitable for applications that require less power and where space is limited,” explains Schnitzler. Functional safety in the form of Safe Torque Off (STO) is on board as standard. The special feature of the servo motor is a hybrid cable which combines power, STO, 24V supply and communication. The shock- and vibration-resistant drive unit sits in an IP65-protected housing, so it is suitable for direct installation in the machine.
In mid-February this year, Webasto put the smart clamps into operation together with colleagues from DESTACO and AMKmotion. “It all went off like clockwork,” says Binder, clearly delighted with the result. The Webasto technicians had installed flanges and smart clamps in advance. “That was very simple, too: the old clamps were removed and new ones screwed on – the dimensions are identical,” says Binder, looking back. “The system was up and running in less than an hour and has been working smoothly ever since.” Thanks to two adapter plugs, AMKmotion and DESTACO managed to enable alternating use of the previous solution and the new one.
And the cooperation is set to continue: “We already have a number of other projects in mind that could also be realized using this smart solution. This applies not only to clamps but also our turning units,” says Binder. “Converting the small tool was just the beginning. We’re looking to continue along this path.”
