Handling customer projects often brings unique challenges — especially when it comes to designing fixtures and integrating tools. This is precisely where our approach comes in: we develop intelligent fixtures and smart press tools that integrate seamlessly with our Operator Guidance System, ELAM.
The result is a perfect fusion of hardware and software: intelligent fixtures and digital work instructions interlock smoothly, ensuring quality, ergonomics, and efficiency throughout the production process.
For many of our tools, we already use software controllers that can be directly connected to our Operator Guidance System, ELAM. However, we regularly encounter new tools that lack a standardized device interface. In these cases, our task is to make them ELAM-compatible.
Example: Pressing Processes for Pipe Connections
When pressing, the workpiece — such as a pipe or fitting — is permanently deformed under high pressure. The result is a tight and stable connection, provided the process is carried out with the approved press jaw and the target parameters are met. To monitor this, an interface is required.
For a manufacturer of press jaws, we developed such an interface. It records the closing force and stroke and transmits the data to ELAM. Within the system, these values are automatically monitored, ensuring that the operator can only proceed once the defined parameters have been precisely achieved. This safeguards the process and guarantees consistent quality.
With this solution, we have added another cost-efficient, safe, and process-stable work step to our portfolio — fully integrated into ELAM’s digital operator guidance.
Once tool monitoring has been defined within the project, the focus shifts to the fixtures used to hold the workpieces. Only when these are designed to be ergonomic and process-safe can efficient workflows be achieved.
Depending on the requirements, workpieces may need to be held, clamped, lifted, lowered, rotated, flipped, or tilted. Our intelligent fixtures enable:
Designing fixtures becomes particularly challenging when multiple types of workpieces must be processed on a single fixture. If an identification code is captured, the fixture can automatically adapt itself — an important step toward flexible and reliable manufacturing.
What Makes a Fixture “Intelligent”?
With these capabilities, intelligent fixtures take an active role in quality assurance and process control.
The use of intelligent fixtures requires clamping and motion elements that can be controlled directly by the ELAM Operator Guidance System. In this area, we have also broken new ground: the rotary and lifting modules have been equipped with electrical interfaces, making them both controllable and monitorable at the same time.
As the first units, we equipped one rotary unit and two lifting units with analog interfaces. These are connected to the sensor/actuator box, which is in turn monitored by the SWA — Smart Work Assistant.
All movements are monitored by sensors, and their activation is reported to the SWA. From there, the data is transmitted directly to the ELAM system, where it is processed. No programming knowledge is required — complex PLC programming is eliminated, saving both time and cost.
The Smart Work Assistant 5 Client comes with 10 inputs and 10 outputs on board. The analog signals are captured by the sensor/actuator box and transmitted to ELAM via the SWA.
The interaction between software and customized hardware simplifies workflows and enables the easy and safe design of intelligent fixtures. Each individual work step is visualized in digital work instructions, allowing updates or adjustments at any time.
Another advantage lies in mobility: clamped workpieces can also be used at remote locations, with data conveniently transmitted via WLAN. It is particularly beneficial when, as in our case, the motion axes feature self-locking mechanisms that remain effective even in the event of a power failure.
Key features in combination with intelligent fixtures:
Comprehensive tool monitoring is an essential part of modern process reliability.
Armbruster Engineering continuously develops new integration options to ensure that tools and fixtures can be optimally connected to the ELAM Operator Guidance System.
An overview of all available interfaces can be found in our controller list.
The combination of smart tools and intelligent assembly fixtures creates a forward-looking solution for digitalized production. Thanks to direct integration without additional PLCs, processes become not only simpler but also more efficient and secure.
For our customers, this means:
This makes it clear: operator guidance and intelligent fixtures are not just technological progress — they represent a genuine added value for quality, efficiency, and competitiveness in manufacturing.
