Röhm is adding a retrofit solution to its iJaw product range.
The iJaw measuring clamping system is equipped with sensor technology and wireless data transmission to measure clamping force in real time during machining. The latest version means it can now be retrofitted to all existing turning machines.
Users can now retrofit Röhm's iJaw smart clamping jaw without having to integrate the technology into the machine's control system and existing turning machines can be easily upgraded and benefit from smart clamping jaw advances.
“With iJaw, we are effectively revolutionising the manufacturing process in machining,” explains Gerhard Glanz, CEO of Röhm. “This is because real-time measurement of the clamping force during the machining process provides the user with a whole range of benefits. This starts with higher machine availability because setup times can be reduced, and machining processes accelerated. This reduces part costs on the one hand, while part quality increases on the other.”
He adds: “It is pure process optimisation and a real milestone in the digitalisation of manufacturing. Overall, sensor-controlled workpiece machining is, of course, much safer than conventional manual clamping by feel. The system means users don’t have to set a higher clamping force than necessary in order to be sure safe clamping has taken place.
“Particularly with thin-walled components or sensitive surfaces, this can be counterproductive because having too high a clamping force quickly leads to deformation or even crushing of the workpiece. With exact knowledge of the applied clamping forces, you can significantly reduce rejected parts,” Mr Glanz says.
The forces introduced into the jaw are detected by an integrated sensor and the data is processed accordingly. The iJaw measures not only the actual applied forces of the internal and external clamping but also its own temperature, and in addition, the charging status of the battery is constantly displayed.
The iJaw measures in real-time during machining. For this purpose, it has a suitably robust hardened steel design, and the internal transmitting antenna has a cover made of high-temperature plastic to protect against hot chips.
The system transmits the measured data wirelessly to a gateway via the robust input/output (IO) link wireless protocol with a high sampling rate of 100Hz. The gateway consists of an industrial PC for data processing and interfaces, an IO link wireless master and a router. The ‘iJaw Connect’ gateway communicates with the iJaw via IO wireless technology. The data is transmitted via ethernet to a computer for further processing via the integrated LAN interface.
The gateway processes the data in real-time and displays it on a tablet or PC. For ease of use the universal iJaw Gateway from Röhm uses only standard protocols and interfaces.
In addition to the sensored clamping jaws, users only need the iJaw Connect gateway and a medium for visualising the measured data. This can be a local PC or a mobile tablet. The system is then controlled by the iJaw Mobile web app that establishes a connection between the iJaw and the gateway.
“Through iJaw Mobile, users can then create jobs, manage their jaws, create evaluations and, of course, receive warning messages, for example, if the minimum or maximum clamping force is undercut or exceeded,” Mr Glanz explains.
The iJaw enables process or productivity analysis and the documentation of measurement data. With the iJaw Mobile app, users can therefore access the data on the industrial PC installed in the gateway and evaluate machining parameters.
“Especially in the production of components requiring documentation, such as the aerospace industry, this is a valuable feature. The iJaw virtually archives the digital fingerprint of the machining process as proof of the quality of the manufacturing process,” notes Mr Glanz.
The iJaw can be mounted and used on lathe chucks with a matching jaw interface like any other clamping jaw. For the market launch, the iJaw is available as a single-stage jaw, two-stage jaw, and through-hole jaw for lathe chucks with straight gearing in sizes 215, 260, 315, and 400 as well as a special jaw for independent chucks.
A suitable lathe chuck from Röhm is the power chuck with the quick jaw change system Duro-A RC. Various interchangeable hard and soft clamping inserts are locked onto the jaw with screws to adapt the jaws to different workpiece geometries.