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 provides 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 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, manufacturing, and assembly of demanding clamping technology. 'What is crucial for us is that we always deliver the best quality so that our customers can also produce high quality,' says Christian Wenge. 'For this, we have a consistently modern machine park that we are increasingly automating and digitalizing - down to the detail.'
An important part is 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, there was still a lack of direct data exchange with the tool presetting device 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. Almost 20 years ago, we then invested in a semi-automated presetting device Microset UNO, which already allowed for some data transmission. But our current highlight is the fully automatic HAIMER Microset presetting device VIO linear, which also masters 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 meets 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 that impresses with high rigidity. This results in almost no distortion 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, thereby 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 thus 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
Satış Müdürü Wenge onayladı: "HAIMER Microset VIO linear ve COSCOM yazılımı ile bağlantı sayesinde Endüstri 4.0'a doğru büyük bir adım attık ve sistem yapımızı bu iki unsur etrafında sadeleştirdik." Geliştirilmiş dijital bağlantı hata olasılığını önemli ölçüde azaltıyor. "Önceden yanlış alet verilerini okumak mümkündü. Bugün bu neredeyse imkansız," diye ekliyor Oliver Oberkoch.
"NC programı ve tüm üretimle ilgili bilgiler ve alet verileri tek bir arayüz üzerinden aktarılıyor, bu da çok yüksek bir süreç güvenliği sağlıyor."
Ve işte sürekli dijital sürecin görünümü: Yeni bir üretim siparişi geldiğinde, parça CAD/CAM sisteminde programlanıyor. Bunun için alet verileri veya aletlerin dijital ikizleri alet yönetim sistemi üzerinden okunabiliyor. Programlama tamamlandığında, alet verileri alet ön ayarına aktarılıyor. İlgili çalışan bu verileri çağırıyor ve aletlerin nasıl birleştirilmesi gerektiğini tam olarak biliyor, böylece program çalışıyor.
Sonrasında aletleri Microset yazılımı üzerinden ölçüyor ve aletlerin mevcut verilerini bir HAIMER post işlemci ile sunucuda saklıyor. Makine operatörü, makinenin yakınındaki bir IPC terminalinde üreteceği parçanın veri sayfasını çağırabilir ve programı okuyabilir. Aynı arayüz üzerinden nihayetinde alet verilerini makine kontrolüne gönderiyor ve talaş kaldırma sürecini başlatıyor. Oliver Oberkoch, alet ön ayarının temel avantajlarının hala geçerli olduğunu belirtiyor:
"Ayrıca, alet değiştirme süresinde bir kazanç kaydediyoruz, ancak bu tam olarak nicelendirilemez ve üretim durumuna göre farklılık gösterir."
Değerli Ortaklık
Oberkoch, yeni Microset VIO linear cihazının tanıtımını A'dan Z'ye takip etti ve HAIMER için övgü dolu sözler buluyor: "Destek mükemmeldi, mevcut alet yönetim sistemimize arayüz açısından veya post işlemcilerin programlanması açısından. HAIMER'den diğer alanlarda alıştığımız gibi."
Son olarak, BERG Spanntechnik'te birçok başka HAIMER ürünü de kullanılmakta, örneğin Power Clamp sıkıştırma cihazından çeşitli sıkıştırma tutucularına ve uzantılarına kadar tüm sıkıştırma teknolojisi yelpazesi. Ayrıca, BERG başka alet tutucuları, takma freze mandrelleri kullanıyor ve şu anda sert malzemelerde delme için Duo-Lock arayüzüne sahip aletleri test ediyor. Oliver Oberkoch özetliyor: "HAIMER'in alet makinesi etrafındaki tüm alet alanı için bir sistem sağlayıcısı olması bizim için büyük bir avantaj."
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