Optimization in the automotive industry: Webasto relies on smart clamps

Servomotor Intelligent Clamping Technology: Continue the Path

2024-11-13 Source: Ute Drescher AMKmotion | Translated by AI 4 min Reading Time

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In the manufacturing of convertible tops, automotive supplier Webasto previously used pneumatically driven power clamps. Now electrically operated smart clamps are being used. It is the combination of three components that results in an intelligent clamping technology solution.

A central process step in the manufacturing of a convertible top is the welding of the so-called bows. The fixture equipped with smart clamps holds the components in place, while the welding head connects the parts.(Image: Webasto) — A central process step in the manufacturing of a convertible top is the welding of the so-called bows. The fixture equipped with smart clamps holds the components in place, while the welding head connects the parts.
(Image: Webasto)

Feeling the wind in your hair. Enjoying the sun. For some people, driving a convertible is the epitome of joie de vivre. Car manufacturers offer different models that, thanks to foldable roofs, are suitable not only for sunny days. For roof systems in convertibles, the automotive industry relies on the expertise of specialists like Webasto.

The system partner of the mobility industry is among the 100 largest automotive suppliers worldwide and employs nearly 17,000 people. The business includes a wide range of roofs, battery systems, and heating and cooling solutions for various types of vehicles. The Hengersberg site is an important production and development location for Webasto.

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The synchronous servomotor with integrated inverter ihXT3 saves time during installation. The inverter is directly wired onto the servomotor here.(Image: AMKmotion GmbH + Co KG)

The opening angle can be adjusted variably without much effort. In the so-called teach mode, during slow operation, the system learns where the contact points are.(Image: Webasto)

A central process step in the production of a convertible top is the welding of the so-called bows. These frames later support the cover fabrics. For this, a bracket secures the components, and the welding head connects the parts. "In the past, we used the proven pneumatic clamps from Destaco and were satisfied with them," recalls Markus Binder. He is the head of the Webasto site in Hengersberg. "However, through an advertisement, we became aware of the company's new Smart Clamps and wanted to know more." Destaco specializes in the development and manufacture of high-performance automation, clamping technology, and remote handling solutions.

Save costs, use data

Drive and control of Destaco's new Smart Clamps are electric, and sensors are already integrated into the modules. "There were thus several points that made the clamps interesting for us," says Binder. The previously used pneumatic solution required compressed air—and thus a very expensive form of energy. Furthermore, the old system used external sensors to query the position of the bracket—this meant additional components were in use, which had to be wired and maintained. "Destaco was therefore able to quickly convince us that the new solution brings us numerous advantages," explains Binder.

Another argument for Webasto was the high flexibility of the smart clamps. The opening angle can be adjusted variably without much effort. In the so-called teach mode, during slow operation, the system learns where the contact points are. The Motion Controller ISA from AMK-Motion stores the data and controls all movement processes. The operation can begin.

Due to the electric drive, the fixture sets down gently.

Uwe Lohage, Technical Sales, Destaco

And there is another point in favor of the electrically operated solution: the speed can be varied, which avoids backlash at the contact point. "The electric drive allows the user to operate at less than 100 percent of the maximum speed. The pace can be reduced slightly just before contact. This way, the movement loses its kinetic energy, and the bracket gently lands," explains Uwe Lohage. He works in technical sales with a focus on smart technology at Destaco.

Concentrated expertise

The Smart Clamps are new to the market and a logical advancement. The electric solution far surpasses pneumatics in terms of performance. Users not only save on expensive compressed air but can also control and monitor their processes much more precisely with the built-in intelligence. "Operators also have the option to record data. This allows conclusions to be drawn about the speed and quality of production—and it enables preventive maintenance," adds Uwe Lohage. Additionally, the Smart Clamps can be controlled individually and not just as a group, increasing production flexibility as needed.

In the development of the Smart Clamps, two experts combined their knowledge: As a global clamping technology manufacturer, Destaco contributes its expertise in clamping technology and mechanics, while AMK-Motion is responsible for the servo motor and control. AMK-Motion from Kirchheim (Germany) unter Teck in Baden-Württemberg specializes in electrical drive technology, control technology, and industrial automation technology. For six decades, the company has been among the market and technology leaders.

The decentralized power supply with the integrated motion controller ISA from AMK-Motion regulates the Smart Clamp and is located directly on the device. "This saves space in the control cabinet and ensures short cable paths," emphasizes Jürgen Schnitzler. He supports Destaco as a key account manager for AMK-Motion. Control, power supply, and braking resistor are integrated into the lightweight aluminum housing. The motion components are connected in a daisy chain.

The decentrally controlled synchronous servo motors with integrated inverter and hybrid connection IHXT3-05 drive the Smart Clamps. The IHXT combines inverter and servo motor. "It is particularly suitable for applications that require lower power and where space is limited," explains Schnitzler. Functional safety in the form of Safe Torque Off (STO) is included as standard. The special feature of this servo motor is the hybrid cable, which combines power, STO, 24-volt supply, and communication. The shock- and vibration-resistant drive unit is housed in an IP65-protected enclosure, making it suitable for direct installation in the machine.

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It started in no time

In mid-February of this year, Webasto, together with colleagues from Destaco and AMK-Motion, commissioned the Smart Clamps. "It went like clockwork," says Binder happily. The technicians from Webasto had previously mounted flanges and Smart Clamps. "That was also very easy: unscrew the old clamps and bolt on the new ones, the dimensions are identical," Binder recalls. "The system was up and running in less than an hour and has been functioning smoothly ever since." Through two adapter plugs, the engineers from AMK-Motion and Destaco succeeded in allowing both the previous and the new solutions to be used alternately.

The cooperation is to be continued in the future as well. "We already have several other projects in mind that should also be implementable with this smart solution. This applies not only to clamps but also to our turn units," summarizes the head of the Webasto site in Hengersberg. "The conversion of the small tool was the beginning. We want to continue down this path," Markus Binder affirms.