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Monitoring Solutions for Multistation Header and Boltmaker

Brankamp monitoring systems detect process failures, protect the machine and tool from overloads, improve the quality of the produced parts and support the operator in quicker machine set-up. In case of production problems (e.g. tool breakage or ejection failures), they stop the machine early in order to prevent or minimize costly consequential damage to the machine and tool. Typical quality defects on formed parts (e.g. head or flange cracks, turned parts), that often occur individually and randomly on formed parts trigger a sorting device without interrupting the production. The failure detection is carried out by a 100% in-process monitoring of all produced parts that are produced on multistation header or boltmaker.

Monitoring systems are an effective way to gain insight into the process and its stability, to detect production faults and quality deviations and, if necessary, to intervene in the machine in a controlling manner (sorting). Deformation failures on work pieces can occur during insertion, forming or ejection. By mounting sensors directly into the force flow of the forming stations, process signals are measured and evaluated using suitable monitoring methods. This prevents machine and tool overloads, detects quality defects, increases the efficiency of the machine and saves a lot of time during setup.

Our goal is to support our customers in achieving the highest productivity and manufacturing quality. Brankamp units provide the key to efficient quality and machine monitoring whenever hundreds of millions of parts are produced Monthly.

Monitoring Solutions for Multistation Header and Boltmaker
  • Precise machine and tool protection to avoid consequential damage and downtimes, reduction of repair costs
  • Detailed monitoring of the manufacturing quality to improve the quality level (0 ppm)
  • Increased productivity through extended runtimes, reduced downtimes and optimized production speed
  • Reduction of tool and scrap costs through early failure detection
  • Insight into the process to reduce set-up times and optimize production
  • Operator support through various counters for piece counting (good and bad parts), recording of shift performance and tool life, counters for quality inspection and maintenance intervals, parts/box and dosing counter.
  • Recording of article-related productivity distributions (production, set-up, stop, rejects) enable precise calculation of part costs
  • Network interface for communication with external programs (MDE/BDE/MES, Teleservice, IoT)
  • Comprehensive documentation of production allows precise runtime analysis and failure tracking

How it works

Force sensors are installed as standard on the ram side behind each forming stage (progressive header) and in setting screws or die block on thread rollers (boltmaker). To protect against machine overloads, calibrated strain sensors record the total machine load. In addition, the wire stop force can be included in the monitoring by a special evaluation channel. With the special Vario Duo Sensor, insertion failures and turned parts can be detected without having to prepare additional sensor hole on the multi station header.

Special features

  • SYSTOMATIC for identification of systematic (permanent) process faults
  • ROTATOR for the detection of turned parts caused by transfer or ejection failures
  • WIRE FEED AID for an optimum setting on the feeding mechanism
  • HD ZOOM for a more detailed monitoring of specific process areas


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