Handling customer projects always presents unique challenges – especially when designing fixtures and connecting tools. This is precisely where our approach comes in: We develop smart fixtures and smart press tools, which seamlessly integrate into our worker assistance system ELAM .
The result is a seamless connection of hardware and software: Intelligent fixtures and digital work instructions work together to ensure quality, ergonomics, and efficiency.
For many of our tools, we already use software controllers that can be directly connected to our worker assistance system ELAM . However, we frequently encounter new tools without a standardized device interface. Our task then is to make them ELAM-compatible .
Example: Pressing Operations for Pipe Connections
During pressing, the workpiece (e.g., 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 pressing pliers and the target parameters are met.
To monitor this, an interface is required.
We developed such an interface for a manufacturer of pressing pliers. This allows closing force and closing path to be recorded and reported to ELAM . The system automatically monitors these values, so the worker can only proceed if the target values have been precisely achieved.
In this way, we safeguard the process and ensure quality at all times.
With this, we have added another cost-effective, secure, and process-stable work step to our portfolio – fully integrated into the digital worker guidance of ELAM.
Once tool monitoring is clarified in a project, the focus shifts to the fixtures used to hold the workpieces. Because only if these are ergonomic and process-reliable designed, can efficient workflows be achieved.
Depending on requirements, workpieces must be held, clamped, lifted, lowered, rotated, turned, or tilted. Our intelligent fixtures enable:
The design is particularly challenging when multiple workpiece types need to be processed on a single fixture. If an identifier is also captured, the fixture can automatically adapt – an important step towards flexible and secure manufacturing.
What Makes a Fixture "Intelligent"?
Thus, intelligent fixtures play an active role in quality assurance and process control.
For the use of intelligent fixtures, clamping and motion elements are required that can be directly controlled by the worker assistance system ELAM . We have also broken new ground in this area: The rotary and lifting modules were made controllable and simultaneously monitorable .
As initial units, we equipped a rotary unit and two lifting units with analog interfaces. These are connected to the sensor/actuator box , which in turn is 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 goes directly into the ELAM system, where it is processed.
No programming knowledge is required: Complex PLC programming is eliminated – and thus, additional effort and costs.
The Smart Work Assistant 5 Client has 10 inputs and 10 outputs "on board". The analog signals are captured by the sensor/actuator box and transmitted via the SWA to ELAM .
The interplay of software and adapted hardware simplifies processes and enables the simple, secure design of intelligent fixtures.
The individual work steps are visualized in digital work instructions , so they can be supplemented or adjusted at any time.
Another advantage lies in mobility: Clamped workpieces can also be used in remote locations – data is transmitted conveniently via Wi-Fi.
It is advantageous if – as in our case – the axes of motion have self-locking mechanismsthat remain effective even in the event of a power interruption.
Key features in combination with intelligent fixtures:
Comprehensive tool monitoring is an indispensable component of modern process reliability.
Armbruster Engineering continuously develops new connection options so that tools and fixtures can be optimally integrated into the worker assistance system ELAM .
An overview of all available interfaces can be found on our controller list.
The combination of smart tools and intelligent assembly fixtures creates a forward-looking solution for digitized production.
Thanks to direct connection without an additional PLC, processes are not only simplified but also made more efficient and secure.
For our customers, this means:
This makes it clear: Worker assistance and intelligent fixtures are not just a technological advancement, but a real added value for quality, efficiency, and competitiveness in manufacturing.
