{"id":63900,"date":"2024-11-27T08:09:26","date_gmt":"2024-11-27T07:09:26","guid":{"rendered":"https:\/\/www.gressel.ch\/blog\/5-axis-centric-clamp-systematically-rolled-out\/"},"modified":"2025-02-24T11:37:25","modified_gmt":"2025-02-24T10:37:25","slug":"5-axis-centric-clamp-systematically-rolled-out","status":"publish","type":"blog","link":"https:\/\/www.gressel.ch\/en\/blog\/5-axis-centric-clamp-systematically-rolled-out\/","title":{"rendered":"5-axis centric clamp"},"content":{"rendered":"\n

5-axis centric clamp – Systematically rolled out<\/h1>\n\n

Kurt Betz GmbH<\/a> from Leingarten near Heilbronn is a family business with almost 100 employees that has been active in toolmaking and mechanical engineering since it was founded in 1980. Core competence: crimping technology. Customized products are supplied to customers primarily from the electronics and automotive industries. In the machining department, the parts are clamped using Gressel clamping technology. <\/p>\n\n

Rolling out a successfully introduced technology to other machines or production areas is often the goal of the next step in machining. After all, the effects achieved at the outset can be multiplied in this way. Especially when this goes hand in hand with higher-level approaches such as automation. This is what happened at Kurt Betz: After centric clamps from Gressel had been used on a “DMG CMX 50 U”, they were first used on a “DMG DMU 50”, then on a “DMG DMU 75” and finally on a “DMG M1”. Safe, flexible, efficient. Automated working with pallets formed the framework. <\/p>\n\n

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For 5-axis machining with a “DMG CMX 50 U”, Kurt Betz uses “C2 125 L-160” centric clamps from Gressel on a “gredoc” console.<\/figcaption><\/figure>\n\n
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Systems for complete connectors<\/strong><\/p>\n\n

Like automation, testing and tool technology, crimping technology is one of Betz’s main fields of activity. In addition, the company offers production according to customer specifications right down to the individual part, covering all manufacturing steps from sawing, turning, milling, grinding, die-sinking and wire erosion to laser marking. Customized and task-specific control systems are also designed and manufactured. While Betz carries out automation orders for assembly automation, cable processing, assembly, test automation, packaging and special feeders, the production engineering department handles tool technology and contract manufacturing tasks. In close cooperation with the customer, the Leingarten-based company also develops measuring devices and gauges for quality assurance, including devices for manual measurement as well as multiple devices for automatic, series-accompanying measurement. “Of course, our core competence is crimping technology, where our machines process solid and stranded wires with and without insulation and ensure automatic bare wire detection via crimp force monitoring,” explains Ralf Schutzbier from Production Process Technology. “The customer usually comes to us with a cable and wants a matching connector. We then build the machine that insulates the cable, inserts the pin onto it and into the connector and checks the whole thing with a camera.” Customers for such machines are often suppliers to the international automotive industry. <\/p>\n\n

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A “Deckel Maho DMU 50” works in Leingarten with a “PH 150” pallet handling system. The components are prepared for milling on “C2 80-IP-ITS 148” centric clamps. <\/figcaption><\/figure>\n\n

One, two, …<\/strong><\/p>\n\n

Betz uses systems for workpiece handling in two basic areas: on the one hand in the crimping machines, where they make up the complete gripper technology for the robots and handling systems, and on the other hand as workpiece clamping systems in mechanical production. “While Schunk technology is primarily used in the first case,” explains Joachim Sch\u00f6nberger, Technical Consultant at Schunk, “Gressel systems are used in the second. The starting signal was given in 2016 after Betz purchased a CMX 50 U with swivel axis. This made it clear that repeatable clamping devices were needed that would allow easy access to five sides of the component. “After looking at several systems in detail, we ended up with Gressel,” recalls Schutzbier. “Since then, we have been working on the CMX with a ‘gredoc’ console as an elevation for 5-axis machining and a ‘C2 125 L-160’ centric clamp with different system jaws.” The decisive factors for Betz in 5-axis machining are the good accessibility of the clamp, its high stability, clamping forces of up to 35 kN and clamping ranges of up to 160 mm, as well as the low cleaning and maintenance requirements thanks to the encapsulated spindle. Schutzbier: “Today, we manufacture the five sides reliably in a single clamping operation.” <\/p>\n\n

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Prepared on centric clamps of type “C2 80-IP-ITS 148”, the 5-axis machine is supplied with components via pallets.<\/figcaption><\/figure>\n\n
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Tailwind, with which a first 5-axis simultaneous milling machine including pallet handling “PH 150” came into the house in 2019. This required 24 vices. “So we looked at various manufacturers again, but once again came to the conclusion that Gressel offered the optimum solution.” Today, the parts are prepared for machining on “C2 80-IP-ITS 148” centric vices before being transported on pallets for handling and finally supplied to the machine. In addition to various system jaws, an integrated clamping solution is also used: “The basic body of the C2 centric clamp and the interchangeable pallet with the “Erowa ITS148″ zero-point clamping system are a monoblock variant,” explains sales engineer Frank Scheurer from Gressel. “In this combination, the C2 80-IP-ITS 148 offers high stability with clamping forces of up to 25 kN and a clamping range of up to 120 mm. The fully encapsulated spindle also ensures long cleaning and maintenance intervals.” The system jaws used for clamping the blanks are “grip 3 mm” reversible jaws with a width of 40 or 80 mm and “carbide-grip 3 mm” reversible jaws for high-strength and hardened materials up to a hardness of HRC 58. <\/p>\n\n

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Kurt Betz uses various profiled reversible jaws when clamping the raw parts.<\/figcaption><\/figure>\n\n

… three …<\/strong><\/p>\n\n

Last year, another 5-axis simultaneous system came to Leingarten – a DMG DMU 75 – again with a PH 150 handling system and 24 stations. “It was clear from the outset that what worked perfectly the first time would work again,” emphasizes Schutzbier. The decision in favor of Gressel was therefore clear. In any case, the collaboration had become increasingly close as the range of products grew. “At the same time, we increasingly exploited the possibilities of the tensioners. For example, we also used them on a machine for HSC machining of aluminum.” Previously, the C2 80-IP-ITS 148 centric clamps were installed on the DMU 75. Smoothly, after all it was the same setup as the DMU 50. <\/p>\n\n

The long slide guides, which prevent the jaws from rearing up at clamping forces of up to 3.5 t, also contribute to the reliable use of the modular and compact 5-axis clamps in the C2 series in Leingarten. At the same time, the vibration-optimized systems work with a quick adjustment in the clamping area. “The basic clamping stroke is up to 130 mm without spindle conversion,” says Scheurer. “In the case of Betz, the machining process is also stabilized by the fact that one less mechanical interface is used: Unlike products from market competitors, the C2 80-IP-ITS 148 centric clamp is integrated directly into the exchangeable pallet without an additional intermediate plate.” The pallet and the base body of the centric clamp thus form a compact unit. Thanks to the greater stability and compact height, higher workpieces can be clamped and machined. <\/p>\n\n

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C-series centric clamps offer a clamping force of up to 3.5 t.<\/figcaption><\/figure>\n\n

… and four<\/strong><\/p>\n\n

Betz and Gressel’s last project for the time being came this year with the purchase of a new 3-axis milling machine. The background to the investment: the two 5-axis machines with handling system create a high output. A DMG M1 was purchased so as not to block the expensive machines with the machining of the sixth side, but to use them even more intensively. “Because this machine was also to be used for production with as few people as possible, we investigated whether pallet handling was worthwhile. But it doesn’t. The decision was therefore made in favor of two “M1” multiple clamping systems. System jaws with a smooth clamping surface are used because they are used to clamp parts that have already been machined. The machine is loaded by an employee who then returns to his main workstation. <\/p>\n\n

With the multiple clamping system, Betz now achieves the intended long machine running times. Among other things, the fact that the machine can be operated with a minimum of manpower makes it possible to fix workpieces with pinpoint accuracy. As an alternative to multiple clamping of small parts, it is possible to switch to holding large workpieces. “You only have to remove the centerpiece to produce a panel, for example, with minimal set-up effort,” reports Scheurer. “The machine is therefore not used for small parts. As with the centric clamps, flexibility is key.” <\/p>\n\n

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Centric clamps of type “C2 80-IP-ITS 148” are also used on the “DMU 75”: safe, flexible, efficient.<\/p>\n\n

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Good reasons for rolling out<\/strong><\/p>\n\n

So what are the effects with which Betz has now rolled out the clamping technology from Aadorf across the entire range of materials and parts? Not only are many types of steel up to 1.2379 reliably clamped, the systems also make no distinction between roughing, finishing or HSC machining. “We machine many parts that protrude high,” continues Schutzbier. “Safe clamping is just as guaranteed as accessibility. The interfering contours are relatively low down so that they are not a problem during milling. In addition, there are no chip nests and the clamp does not have to be rinsed after each part. Because we safely remove the chips via the internal cooling, we have no problems, for example in automation. This means that gripping is not hindered when changing pallets.” The wear on the jaws is very low. The ones from the first order in 2019 are still in use. The longevity of the entire system is also evident in another area: the spindles, which continue to generate constant clamping forces to this day. “Above all, the system is characterized by high repeat accuracy.” <\/p>\n\n

That leaves the service: “We appreciated the communication and support from Gressel from the very first installation: Here, a company thinks about how best to solve problems. If I ask an expert from Gressel a question, I get an answer from an expert. The sales force also knows our parts. If there is something new that suits us, they contact us. He is the contact person for the entire clamping technology. That makes working for us simply efficient.”<\/p>\n\n

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Joachim Sch\u00f6nberger, Ralf Schutzbier and Frank Scheurer (from left) have rolled out the workpiece clamping technology in Leingarten together.<\/figcaption><\/figure>\n","protected":false},"excerpt":{"rendered":"

The company started with centric clamps on a DMG CMX 50 U and systematically transferred the concept to other machines. The clamps score particularly well in 5-axis machining thanks to their stability, accessibility and low maintenance. <\/p>\n","protected":false},"featured_media":63882,"parent":0,"template":"","meta":{"_acf_changed":false,"content-type":"","footnotes":""},"blog_kategorien":[546],"blog_tags":[545],"class_list":["post-63900","blog","type-blog","status-publish","has-post-thumbnail","hentry","blog_kategorien-clamping-technology","blog_tags-clamping-technology"],"acf":[],"yoast_head":"\n5-axis centric clamp | GRESSEL clamping technology<\/title>\n<meta name=\"description\" content=\"The company began with centric clamps on a DMG CMX 50 U, expanding the concept to other machines. 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