Precision Tension & Automation: Driving Production Efficiency

Schunk Revolutionizes Metalworking with Flexible Automation and Precision Clamping at EMO Hannover 2025

In an era marked by global uncertainties,intense competitive pressures,and a growing shortage of skilled labor,the path to efficient and future-proof manufacturing processes is more critical than ever. At the upcoming EMO Hannover 2025, the world’s leading trade fair for production technology, Schunk is poised to provide concrete answers, demonstrating how its innovative solutions in flexible clamping, modular automation, and global engineering expertise empower companies to navigate these complex challenges.

Driving Efficiency Through Automated Machine Tools

The automation of loading and unloading operations stands as a paramount strategy for boosting productivity and enhancing overall efficiency within manufacturing. Schunk is offering clear guidance and a comprehensive array of automation solutions, meticulously designed to cater to diverse requirements related to batch sizes, workpiece characteristics, and specific manufacturing processes. These solutions are crafted to simplify and optimize part handling and in-machine processing, making them more flexible and resource-efficient.

Pioneering Clamping Solutions for Diverse Applications

Beyond automation, Schunk provides essential components for versatile and streamlined workpiece clamping within the machine. For tasks involving the processing of intricate workpieces or the management of small batch sizes, the company is unveiling new clamping solutions specifically engineered for the demands of flexible manufacturing environments.

Introducing the Kontec KSC-5X: The Next Generation of 5-Axis Tensioning

Schunk is expanding its highly successful family of 5-axis tensioners with the introduction of the Kontec KSC-5X, a powerful central tensioner developed for demanding processing applications. Its robust base jaws offer the unique capability to securely clamp complex workpieces in conjunction with a selection of system and top jaws,a combination that is unrivaled in the market for optimal accessibility. The Kontec KSC-5X is designed for rapid and straightforward adaptation to new clamping tasks, seamlessly integrating into Schunk’s extensive clamping technology portfolio. This allows for versatile combinations, ensuring highly efficient workpiece clamping.

Tailored Solutions Through Schunk Engineering

Schunk champions a structured approach to developing bespoke solutions,guiding users through a comprehensive process. From the meticulous definition of requirements to design,manufacturing,and integration,Schunk partners with its clients to create individualized solutions precisely matched to their production needs across a spectrum of industries. A prime example is the progress of ultra-precise hydraulic clamping devices for turbine rotors in the aerospace sector, which are rigorously validated and optimized using advanced digital simulation tools.

Standardized Complete Solutions for Immediate Impact

While custom-engineered developments are indispensable for complex requirements, small and medium-sized enterprises (SMEs) frequently enough seek practical, rapidly implementable concepts. Schunk addresses this need with its new modular grow automation cells. These turnkey, CE-certified complete solutions are characterized by their intuitive design, flexible customizability, and specific focus on enabling the swift and efficient automation of manufacturing processes.

Real-Time, Data-Driven Process Control

Schunk’s electrical and sensory clamping systems provide real-time monitoring of clamping states, workpiece conditions, and tool vibration behavior – all critical process-relevant parameters. This not only enhances security and provides consistent transparency but also simplifies integration, offering a sophisticated level of process control previously unattainable.

how does implementing a closed-loop tension control system impact material waste and production speed in the packaging industry?

Understanding the Core of Precision Tension Control

in modern manufacturing, achieving consistent product quality and maximizing throughput hinges on precise control of tension. Whether it’s web handling – think films, foils, paper, textiles, and nonwovens – or wire and cable production, maintaining optimal tension is paramount.But what does “precision” really mean in this context? It’s not simply about applying a set force; it’s about consistently applying the right force, accounting for variations in material properties, speed, and process conditions. This is where the distinction between “precision” and “precise” becomes crucial,mirroring the nuance highlighted in discussions around engineering tools – it’s about repeatable accuracy,not just a single,exact measurement.

The Impact of Incorrect tension

Incorrect tension levels can manifest in a multitude of production problems:

Web Breaks: Excessive tension leads too material tearing, causing costly downtime.

Wrinkling & Creasing: Insufficient tension results in uneven material flow and surface defects.

Dimensional Instability: Inconsistent tension affects the final product’s dimensions and shape.

Reduced Throughput: Frequent adjustments and repairs due to tension-related issues slow down production.

Wasted Material: Defects necessitate scrap, increasing material costs.

These issues aren’t isolated; they ripple through the entire production process, impacting profitability and customer satisfaction.

Automation: The Key to Consistent Precision

Manual tension control, relying on operator skill and judgment, is inherently prone to inconsistencies. Automation offers a solution by providing real-time monitoring and adjustment capabilities. Modern automated tension control systems utilize a variety of technologies:

Load Cells: These sensors accurately measure the tension force.

Programmable logic Controllers (plcs): PLCs process sensor data and control tension-regulating devices.

Variable Frequency Drives (VFDs): VFDs adjust motor speed to maintain desired tension levels.

Brakes & Clutches: These mechanisms apply and release tension as needed.

Closed-Loop Control Systems: These systems continuously monitor tension and make adjustments to maintain the setpoint.

Types of Automated Tension Control Systems

Different applications require different levels of automation. Here’s a breakdown of common system types:

1. Open-Loop Control: Simple systems that apply a pre-defined tension based on speed and material properties. Less accurate but cost-effective for less demanding applications.
2. Closed-Loop Control (Basic): Uses a single load cell and PLC to maintain tension. suitable for applications with relatively stable conditions.
3. Closed-Loop Control (Advanced): Employs multiple load cells, sophisticated algorithms, and predictive control to handle complex variations. Ideal for high-speed, high-precision applications.
4. Centerline Control: Focuses on maintaining tension around a target “centerline” value, accommodating natural variations in material and process conditions.

Benefits of Implementing Precision Tension & Automation

Investing in precision tension and automation delivers a meaningful return on investment:

Increased production Efficiency: Reduced downtime and faster cycle times translate to higher output.

Improved product Quality: Consistent tension leads to fewer defects and more uniform products.

Reduced Material Waste: Minimizing breaks, wrinkles, and dimensional errors lowers scrap rates.

Lower Labor Costs: Automation reduces the need for manual intervention and operator adjustments.

Enhanced Process Control: Real-time data and analytics provide valuable insights into process performance.

Greater Repeatability: Automated systems ensure consistent results, batch after batch.

Real-World Applications & Case Studies

The benefits of precision tension control are evident across numerous industries.

Packaging: Maintaining consistent tension in film unwinding and rewinding is critical for accurate label submission and package integrity. A leading flexible packaging manufacturer implemented a closed-loop tension control system, resulting in a 15% reduction in material waste and a 10% increase in production speed.

Textile Manufacturing: Precise tension control is essential for weaving, knitting, and finishing processes. automated systems ensure uniform fabric quality and prevent yarn breakage.

Wire & Cable Production: Maintaining consistent tension during extrusion and winding is crucial for achieving the desired cable diameter and preventing defects.

Paper & Converting: