March 2014 · Edition 1 · Volume 31 News & TreNds iN

iNdusTrial ProducTioN

Distinctive Feature: International well situatedMarket concentration and globalization are two trends which will define the deve-lopment of the automotive industry and mechanical engineering over the coming years. They also hold great challenges for their suppliers – particularly for medium-sized companies in the for-ging industry.

The German forging industry enjoys a reputation as technology leader. In Europe it is the clear market leader; globally, it is number two after China. Last year, around 250 companies pro-duced almost two billion components

with a total weight of around 2.9 milli-on tons and a value of 8.5 billion euros. It was primarily small and medium-sized companies which contributed to this success – more than every third company in the industry only has up to 49 employees. “Having to expand in distant countries abroad involves con-siderable effort for such companies,”

says industry expert Franz Saliger, who has been responsible for the area of for-ging at process monitoring specialist, BRANKAMP, for almost 25 years. “No matter whether it is in Eastern Europe, India or China, the same unconditio-nal quality requirements are valid at all locations. Everywhere customers place the highest demands on process effici-

ency and productivity. One of the key elements in mastering this challenge – even as a small company – are modern process monitoring technologies.” These technologies enable optimized quality and improved degrees of utili-zation. At the same time, they prevent process errors or shut down machines promptly in the event of malfunction. At the same time, the systems used form the basis for a production net-work, referred to as FactoryNet. This allows production locations across the world to be controlled centrally, for example. Yet the technology is only one side of the coin: “For our customers, availability worldwide, local service and investment security are also deci-sive factors,” says Franz Saliger. These requirements have now led to the for-mation of a new provider in the area of process monitoring. Under the umbrel-

ECO 600The system sets new standards in its class. Page 4

Gripper MonitoringBRANKAMP can recognize transfer failures by measuring gripper move-ment. Page 3

X3 High-tech tightly arranged. Page 5

Imprint Published by: BRANKAMP GmbH, Max-Planck-Straße 9, D-40699 Erkrath Responsible for content under the German press law: Hans-Peter Schneider Editorial work and design: Enterpress

www.brankamp.com

la of the Italian MARPOSS Group, the world’s largest enterprise in the indu-stry has been generated. This combines the advantages of strong medium-sized brands such as ARTIS, BRANKAMP, SANTec or DITTEL with those of an integrated Group. Since March 2012, BRANKAMP has also been part of the MARPOSS Group. “BRANKAMP can now draw on a close-knit network of 80 locations in 23 countries. We are particularly strong in Germany, the US, Japan and China. We have a potential of around 300 service techni-cians worldwide who are in close pro-ximity to our customers and who speak their language. That represents a real advantage for our customers,” says Franz Saliger.

BRANKAMP at the wire trade fair:

Hall 15, Booth 15H35

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The MARPOSS Group is one of the ten largest patent applicants in the European Union in the segment for modern production engi-neering. BRANKAMP customers profit from direct access to new types of tech-nology from this strong group of companies. Here are two examples, among others, which will be shown at the wire trade fair.

Innovative MARPOSS-Solutions for the Forging Industry

Thread Testing with ARTIS DDUARTIS, headquartered in Lunenburg Heath, Lower Saxony, will demonstrate the contact-free DDU sensor system, which enables torque and axial forces to be measured equally. The system is used in an industrial context in thread drilling and testing, for example.

Eddy Current Test by MARPOSSBRANKAMP will exhibit a material test using eddy currents. This technology is a non-destructive test used for characterization of materials. It is based on measuring the amplitude and phase of eddy currents. MARPOSS customers have successfully used this technology to produce camshafts or fastening elements, for example.

HALL 15BOOTH 15H35

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On automated multi-stage presses, BRANKAMP can recognize whether transfer failures are occurring bet-ween the individual stages by measuring gripper move-ment. Together with deve-lopment partner Volkswagen AG in Kassel, the innovative technology has been develo-ped to market maturity.

“The goal of this new method is to measure the gripper movement on automated multi-stage presses when a part is inserted into the transport gripper,” explains Dr.-Ing. Thomas Terzyk, CEO of Prokos GmbH, a company of the BRANKAMP Group. The new monitoring method was developed together with Dipl. Ing. Björn Hesse, Process Opti-mization Forge, Volkswagen AG Kassel. “With the aid of the new sensor, it is possible to check at an early stage whether and how a part is ejected and transported. The monitoring system recognizes pre-cisely if a part is inserted into the gripper incorrectly. In cases where a

“Through this new measurement method, we can measure gripper movement to ensure reliable reco-

gnition of transfer errors between the individual stages,” adds Dr. Thomas Terzyk. “Transfer errors are often an indication of ejector or tool fai-lure. Now we can detect this at such

Gripper Monitoring on Hot Forging Presses

part should not be present, such as during bar transfer when billets are dropped, the existing material can

nevertheless be recognized reliably. This is also the case if a part remains stuck to the punch or if a part cannot be ejected from the die and is thus not transported,” says Mr. Hesse.

The special issue

we initially worked on comprehensi-ve fundamental analyses for gripper monitoring. To do this, we carried out precise measurements under rea-listic conditions for various applica-tions. The new system was used on different Hatebur machines,” says Dr. Terzyk. “Now, at every stage, we can precisely record the movement of the transport grippers when parts are inserted and ejected as well as during transport, thereby further increasing process reliability.”

an early stage that we can intervene even before the next stroke, thereby preventing massive tool damage.”

The innovative sensor technolo-gy can be retrofitted easily. The measuring signals of the new type of distance sensors on the gripper can be assessed problem-free by

all current BRANKAMP Process-Monitoring systems. Volkswagen AG in Kassel inspired the development of the new measurement technology. “Together with the Volkswagen team,

Phot

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press force

gripper movement

„Simply Clever“: The new StandardBRANKAMP exhibits the newly developed ECO 600-sy-stem at wire trade fair in Düsseldorf.

The BRANKAMP ECO 600 is opti-mized for use in the forming industry. The operator can even select con-figuration for the relevant machine type from the menu of this innovative system. Irrespective of whether it is a multi-stage press or a thread roller, operation of the ProcessMonitoring system is the same across the entire production line thanks to the universal

BRANKAMP ECO 600. “The BRAN-KAMP ECO 600 is a robust Process-Monitoring system which can be used to solve virtually all standard applica-tions in a hassle-free way,” says Franz Saliger from BRANKAMP. “Further-more, thanks to a new type of system architecture, the BRANKAMP ECO 600 is available at a highly competitive price.”

HALL 15BOOTH 15H35

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All with one click: further information about the new BRANKAMP ECO 600.

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Come and experience the innovative BRAN-KAMP ECO 200-system at the wire 2014

Die Vorteile des BRANKAMP ECO 600-Systems auf einen Blick:

monitoring and visualisation of six parallel sensor signals

compact system with 9“ touch screen

eeasy-to-use and very little training effort

Duomatic: double envelope curve technology to ensure the quality of the parts

quick Installation for rapid and easy installation on all metal forming presses

and thread rolling machines

Process Quality factor - a reliable indicator for the quality of the entire process

Stop & Go Diagram records the running and down-times over the last 7 days

and creates the „fever chart“ of the plant

multi-channel display of the stage-related maximum force with its preset limits

numerous counters: order counter, tool counter, total counter, sorting and

dose function

Powerful programs to monitor maximum force, envelope curves, trend etc.

for all forming processes

A Step Ahead due Tech-nology: BRANKAMP X3High-tech tightly arranged: BRANKAMP shows the inno-vative X3-system at the wire trade fair.

The innovative X3 system from BRAN-KAMP can handle much more than just standard applications. It is equip-ped with a patented algorithm for crack detection as well as with innovative Quattromatic envelope curve signal

processing for detecting and sorting micro chipping during running pro-duction. Thus, the BRANKAMP X3 fits seamlessly into the high-quality X Series, which is characterized in parti-cular by its technological lead.

Here you‘ll find further information about the innovative BRANKAMP X3-system.

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Come and experience the whole X-series at the wire 2014

The advantages of the BRANKAMP X3 at a glance:

attractive device design with integrated warning lamps (Superlux)

9 inch display

touch screen

multi-curve display (up to six)

tool memory for up to ten different tools

tool safety device for up to 16 inputs with one query per channel

up to 16 cam outputs

Special monitoring program for thread rollers

(optional with line up aide)

FactoryNet

LAN compatible as a standard, W-LAN optional

HALL 15BOOTH 15H35

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BRANKAMP GmbHMax-Planck-Str. 940699 ErkrathGermany

Phone +49/ 211/ 25 07 60 Fax +49/ 211/ 20 84 02 E-mail bpd@brankamp.com Web www.brankamp.com

BRANKAMP is directly present worldwide in 27 countries by the sales and service network from the MARPOSS Group and also represented in other countries via authorized dealers.

The innovative TrifleX measuring sensor from BRANKAMP provides enhanced in-process control for detecting material cracks on parts produced with multi-stage presses.

Due to the complexity of formed parts on the one hand and the qua-lity requirements of the automotive industry on the other, the demands placed on modern ProcessMonitoring systems have grown enormously over the past few years. Brankamp is mee-ting these demands with the innovati-ve development of new sensors, signal processing methods and ProcessMo-nitoring systems. The measurement

signal is considerably more precise and is not influenced by neighbo-ring production stages or the travel of the adjustment wedge. Specially developed performance hardware and software in the systems of the X-series analyze the input signals and react even to the slightest changes in amplitude. This ensures that material cracks and microchipping are reco-gnized reliably.

Crack Detection thanks to Innovative TrifleX Measuring Technology

Come and experience the comprehensive range of sensors at the wire 2014