Hainbuch Presents Solutions for Process Optimization

At the AMB 2024 in Stuttgart, Hainbuch, a leading provider of clamping and automation solutions, will demonstrate how targeted measures can significantly boost efficiency and reduce costs in any production operation. Hainbuch’s focus is on reducing setup times, optimizing the entire production process, and increasing machine output.

Dramatically Reduce Setup Times: Efficiency through Quick-Change Systems

Reducing setup times is a crucial factor in enhancing manufacturing efficiency. Hainbuch has set new standards with the centrotex quick-change system for years. This system allows for the change of clamping devices in less than a minute while maintaining high precision. For the centrotex quick-change system, Hainbuch now presents B-Tex, an addition in the area of chuck jaws at AMB. This enables optimal use of the workspace in the Z-direction for mill-turn machines. Alongside the toplus and spanntop chucks for external clamping, the maxxos and mando mandrels, and the compensating 4-jaw chuck, the 3-jaw chuck with a very low profile height completes the range of compatible clamping devices.

The Handling Line, introduced in 2024, supports users of the quick-change interface with setting up, storing, and transporting clamping devices. The setup mobile, an advanced mobile crane, is the heart of the Handling Line. It enables quick clamping device changes in any production hall, even without an overhead crane. The system is complemented by a pallet system with clamping device holders, extension frames, and lids, optimizing pre- and post-processes like storage and transport of clamping devices.

Sustainably Increase Process Stability: Reliability through Advanced Clamping Technology

Increasing process stability is crucial for optimizing manufacturing. Hainbuch offers innovative solutions with the toplus clamping heads and the new maxxos T212 mandrel. The hexagonal shape of the toplus clamping heads prevents dirt accumulation and ensures consistent precision and durability of the clamping devices. This hexagonal geometry has been applied to the maxxos mandrel, achieving even greater stiffness. The maxxos mandrel, with its hexagonal truncated pyramid shape, is designed for the most demanding machining tasks. It achieves 25% higher holding power than the round mando mandrel and up to double the torque transmission and machining rates. Hainbuch will present the maxxos T212 mandrel at AMB. The T212 mandrel, without a pull bolt and with no loss of clamping length, is ideal for workpieces with blind holes or very short clamping lengths.

Avoid Scrap through Precise Measurement: Quality Assurance in the Production Process

Avoiding scrap is a key factor in cost reduction and efficiency improvement. Hainbuch’s IQ clamping devices with integrated measurement intelligence achieve this by measuring and clamping in one. They continuously measure workpiece diameter, workpiece position, and clamping force. Data and energy are transmitted wirelessly to the machine control system, which then performs a target value comparison. If deviations occur, an alert is issued, or immediate correction is initiated. This reduces pre- and post-process measuring tasks, minimizes scrap, and ensures consistent quality. IQ clamping devices can also detect increasing process forces and thus tool wear, allowing for proactive measures to reduce tool costs from regrinding, for instance.

IQ clamping devices can also be used as downstream “post-process” measuring stations, possible even with automated measurement on the station. With intelligent IQ clamping devices – available both as external clamping chucks and internal clamping mandrels – Hainbuch enables manufacturing companies to achieve higher quality and improved process capability.

Future-Proof Production through Innovative Technology

Trouble-free, low-maintenance manufacturing is essential for an unmanned process flow: The clamping device brings the workpiece and machining together. Process reliability is only achieved if the clamping technology is chip-proof and compatible with cooling/lubrication systems. Once the manufacturing process is stable, automation can be implemented in various stages. Hainbuch offers automation in three stages:

For manufacturing workpieces with different clamping diameters, clamping profiles, and single-chuck depths, automated clamping element change, also possible with stop change, is a very practical option.

A higher degree of automation is enabled by quick-change systems like Hainbuch’s centrotex AC, for external and internal clamping. This allows for the unmanned change of an entire clamping device, such as a chuck, mandrel, jaw chuck, or custom clamping fixtures. A groundbreaking automated manufacturing process has been developed by Hainbuch in collaboration with WTO Werkzeug-Einrichtungen GmbH. For every new job, the machines are fully autonomously set up by robots, achieving a grinding accuracy of 3 μm on the workpiece after the change.

Hainbuch’s subsidiary Vischer & Bolli Automation plans and realizes autonomous robot cells with all necessary components and peripherals for automated manufacturing. The starting point for automation is always absolutely process-reliable workpiece clamping. The cell base consists of clamping pallets or zero-point clamping systems in a modular system for direct workpiece loading with automated fixture change. The number of fixtures, workpieces, and tool holders can be freely selected. The robot cells are designed for both single-piece and series production and can be connected to any machine tool.

In any level of automation, a crucial implementation approach – in addition to the machine, robot, and operator – is always the setup and clamping process.

Hainbuch will showcase at AMB 2024, booth 1D10, that every small adjustment in the process counts and that targeted investments in clamping technology can achieve significant efficiency improvements and cost reductions.

For more information, please visit: https://www.hainbuch.com/en/press/