BERG Spanntechnik - the name stands for custom clamping systems of the highest quality. To manufacture these reliably, the production managers rely on state-of-the-art equipment - from tools to machines. Tool presetting plays an important role, which is why BERG recently invested in the HAIMER high-end device Microset VIO linear. It not only delivers μm-accurate, reproducible measurement results but also paves the way for comprehensive digitalization with its interface to the tool and data management system.
BERG Spanntechnik produces modular clamping systems for cutting and forming machine tools. The company distinguishes between four application areas: tool and workpiece clamping, special applications, and forming technology. Sales Manager Christian Wenge explains: "We are the specialist for demanding clamping technology that cannot be bought off the shelf. We produce almost exclusively custom-made products that are specifically tailored to the customer's application purpose."
Accordingly, there are BERG clamping systems from small to large - for medical to energy technology, for the automotive industry, general mechanical engineering, and many other sectors.
The Bielefeld company has more than 100 years of experience in the design, manufacture, and assembly of demanding clamping technology. "It is crucial for us to always deliver the best quality so that our customers can also produce high-quality products," says Christian Wenge. "For this, we have a consistently modern machine park, which we are increasingly automating and digitalizing - down to the last detail."
An important part is the tool management, which BERG brought up to date in 2021 with the COSCOM ECO system. Since then, all tools and holders have been stored as digital twins in the system. However, in recent years, direct data exchange with the tool presetting device was still missing for digital continuity.
Tool presetting - an important element of cutting manufacturing
CAM programmer Oliver Oberkoch points out that BERG has been utilizing the advantages of tool presetting since the 1980s: "Back then, we still had manual devices to set and measure our tools before the process. About 20 years ago, we then invested in a semi-automated presetting device Microset UNO, which already allowed some data transfer. But our current highlight is the fully automatic HAIMER Microset presetting device VIO linear, which also manages bidirectional data exchange with our tool and data management system."
Oliver Oberkoch, who is also responsible for digital tool management and coordination of tool presetting at BERG, mentions the fundamental advantages of tool presetting: "Since the exact tool data is available when changing the tool in the machine, we reduce machine downtime, increase precision, and decrease rework and scrap. We achieve consistent and repeatable processes." And he adds: "It is ideal when the presetting device receives the target data directly from the tool management or CAM system and can also transfer the measured actual data digitally to the machine. That is exactly what we achieve with our new HAIMER Microset presetting device VIO linear."
Decision for the high-end solution
That an investment would be made in a HAIMER Microset device was clear very quickly. Until now, the production team at BERG has been very satisfied with the Microset devices. "HAIMER shares the same quality philosophy as we do," says Oliver Oberkoch. "Thus, the offered technology in the highest quality was decisive for the purchase."
The Microset VIO linear is designed as a complete solution in the field of fully automatic high-end presetting devices. At BERG, the standard device 20/50 is used, which perfectly matches the requirements. According to Oberkoch, the 400 mm height of a new Microset UNO - which was also in consideration - would not have been sufficient. The VIO 20/50, on the other hand, allows measuring tools up to 500 mm in length, which BERG needs, among other things, for deep hole drilling.
Thorsten Böker, the responsible technical sales representative from HAIMER, mentions some technical details that are crucial for quality: "The device features a FEM-optimized and thermally stable gray cast construction, which impresses with high rigidity. This results in virtually no twisting even under maximum permissible load. The linear drive is unique. It ensures fast, quiet, and highly accurate positioning. With a repeat accuracy of ±2 μm and a roundness accuracy at the spindle of also 2 μm, the VIO linear meets the highest precision requirements."
An important element is the ISS-Ultra-precision spindle. It works with the same clamping system as the production machine, allowing for highly accurate, practical measurement results.
Open for data exchange with various tool management systems
Another decisive advantage of the HAIMER Microset system is its openness for communication with third-party systems. HAIMER Microset offers over 50 interfaces to systems from various providers, thus emphasizing its flexibility and customer orientation. "It was a decisive criterion for us that our new presetting device can exchange data with the COSCOM software," emphasizes Oliver Oberkoch. "HAIMER was able to provide us with a perfectly functioning interface and was also a great help with newly programmed post-processors for our machining centers."
To make working with the HAIMER Microset VIO linear as easy as possible, the responsible parties had two monitors installed instead of one. The employees in tool presetting can view the assembly on one screen while the measurement software runs on the other screen. This ensures optimal workflows, and the machine operator has everything in view.
Consistent digital workflow
Sales manager Wenge confirms: "With the HAIMER Microset VIO linear and the connection to the COSCOM software, we have taken a big step towards Industry 4.0 and simplified our system landscape to these two elements." The improved digital connection significantly reduces the likelihood of errors. "Previously, it was still possible to accidentally read in the wrong tool data. That is almost excluded today," adds Oliver Oberkoch.
"The NC program, as well as all manufacturing-related information and tool data, are transmitted through a unified interface, resulting in very high process reliability."
And this is what the fully digital process looks like: When a new manufacturing order arrives, the component is programmed in the CAD/CAM system. For this purpose, the tool data or the digital twins of the tools can be read in via the tool management system. Once the programming is complete, the tool data is transferred to the tool presetting. The responsible employee retrieves this data and then knows exactly how the tools need to be assembled for the program to work.
Subsequently, he measures the tools using the Microset software and saves the actual data of the tools on the server via a HAIMER post-processor. The machine operator can then access the data sheet of the component to be manufactured at an IPC terminal located close to the machine and load the program. Through the same interface, he finally sends the tool data to the machine control and starts the machining process. Oliver Oberkoch points out that the fundamental advantages of tool presetting still apply:
"We also record a time gain during setup, which cannot be precisely quantified, but varies depending on the manufacturing case."
Valuable Partnership
Oberkoch accompanied the introduction of the new Microset device VIO linear from A to Z and has praise for the partner HAIMER: "The support was perfect, whether in terms of the interface to our existing tool management or the programming of the post-processors. Just as we are used to from HAIMER in other areas."
Finally, at BERG Spanntechnik, many other HAIMER products are in use, for example, the entire range of shrink technology – from the Power Clamp shrink device to various shrink holders and extensions. Additionally, BERG uses other tool holders, modular milling arbors, and is currently testing tools with a Duo-Lock interface for reaming in hard materials. Oliver Oberkoch summarizes: "It is a great advantage for us that HAIMER is a system provider for the entire tool area around the machine tool."
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