Tool clamping systems form the mechanical interface between the forming machine and the tool. The newly developed clamping device incorporates an intelligent sensor module that accurately captures minute elastic deformations of the press ram during forming. The module can also be retrofitted to existing tool clamping systems. Once installed, the software operates entirely autonomously. It requires no parameterization and places no qualification requirements on operating personnel. Retrofitting the clamping technology with sensors involves only minimal effort. The system operates directly at the point of action and acquires critical process data inline. Whether for small production batches or high-volume manufacturing, compact components or large-format parts, BERGtronic enables even older presses to meet the demands of digital manufacturing. The software has now evolved beyond clamping system monitoring to deliver in-depth analysis of the forming process.

Faster Error Identification and Targeted Troubleshooting Through Anomaly Detection

Selected sensor data, such as anomalies in the press force curve or in the distribution of process forces, can be analyzed directly during production and used for more targeted root-cause analysis. Data captured at multiple measurement points can be evaluated individually or in correlation. Envelope monitoring with automatically generated tolerance limits reliably detects process irregularities during production. This enables rapid intervention, if necessary, from one stroke to the next.

The software establishes a continuously growing knowledge base of defect patterns. The resulting data and insights can be selectively transferred to higher-level systems such as databases and machine control platforms.

The anomaly detection functionality also identifies tool-specific defects. Automatic detection of the forming cycle enables tool-specific root-cause analysis, while the software’s intuitive analytical functions require no specialized expertise.

Manufacturer-Independent Retrofitting, Quick Checks, and Evaluation

Project manager Mohaned Alaluss emphasizes: “The sensor-equipped clamping technology can be integrated into presses regardless of the control system concept. It takes very little effort to determine whether a machine is suitable for retrofitting and whether the solution meets the intended monitoring requirements.” Since March 2026, the intelligent clamps and the software developed at Fraunhofer IWU have been in use as a high-tech retrofit solution at Magna Body & Chassis Germany GmbH, operating under the demanding production conditions of press hardening.

EuroBLECH: Joint Presentation with Berg & Co. GmbH Spanntechnik

From October 20 to 23, Fraunhofer IWU will present its newly developed process monitoring software live at the Berg & Co. GmbH Spanntechnik booth (Hall 27, Booth F51) at EuroBLECH. Integrated directly into a forming press, the system demonstrates how intelligent anomaly detection can support reliable, data-driven forming operations. The research team looks forward to discussing the technology and its benefits with industry professionals and other interested visitors.