Retrofit Solution for Forming Presses Clamping Technology Provides Data for Efficient Forming Processes

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Fraunhofer IWU has developed a plug-and-play solution in collaboration with a clamping system manufacturer: Sensors in the tool clamping device monitor the forming process.

Due to their close proximity to the tool and workpiece, tool clamping systems are ideally suited for capturing process-relevant parameters and generating meaningful data. Continuous process monitoring—combined with targeted analysis and clear visualization of the data—can stabilize production and improve its predictability. Now, a retrofit solution developed by the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in collaboration with a manufacturer of clamping systems is ready for the market: Users benefit from a more efficient production process with consistently high workpiece quality and minimal downtime.

Analysis of the Forming Process

Tool clamps serve as the mechanical interface between the forming machine and the tool. The tool clamps presented here feature an integrated smart sensor module that detects even the slightest elastic deformations in the press 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, nor does it impose any special qualification requirements on operating personnel. The effort required to retrofit the clamping technology with sensors is also minimal. The system operates directly at the point of action and captures key process data inline. Whether for small batch sizes or large production runs, very compact or large-format components—“BERGtronic” makes even older presses ready for production in the digital age. The latest version of the software continues to monitor the die clamping mechanism but now focuses on analyzing the forming process.

Identify Errors More Quickly and Resolve them Effectively

Sensor data—such as data on the press force curve or the distribution of process forces—can be analyzed in real time during production. Should deviations occur, they serve as the basis for a targeted root-cause analysis. The data collected at multiple points can be analyzed individually or in correlation with one another. Envelope curve monitoring, in which upper and lower tolerance limits (the “envelope”) are automatically set, reliably detects process irregularities during production. This enables a rapid response, stroke by stroke if necessary. The software develops a “memory” for error types, records detected deviations from the target in a logbook, and compares a detected error with previously occurred events. The analyzed data and information can be specifically made available to higher-level systems such as databases and plant control systems.

Anomaly detection also specifically identifies errors in tools. It is based on automatic detection of the work cycle and thus provides the basis for a tool-specific root cause analysis. No specialized knowledge is required to apply the analysis algorithms.

Vendor-Neutral Retrofitting, Quick Check, and Evaluation

Project Manager Mohaned Alaluss emphasizes: “Sensor-based clamping technology can be integrated into presses regardless of the control system. It takes very little effort to determine whether a machine is suitable for retrofitting and whether the solution is appropriate for the planned monitoring task.” Here’s an example: Since March 2026, the smart clamps and the software developed at Fraunhofer IWU have been in use as a high-tech retrofit solution at Magna Body & Chassis Germany GmbH under the harsh production conditions of press hardening.

At Euroblech 2026, Fraunhofer IWU will be demonstrating its newly developed process monitoring software live at a forming press at the Berg & Co. GmbH Spanntechnik booth (Hall 27, Booth F51).