Peripheral Systems and Energy Efficiency

© Fraunhofer IPA
High-precision clamping technology for band saw tools

For both precise and productive as well as cost-effective and safe sawing processes, the tool itself is only part of the equation. Peripheral systems also play a crucial role. These include clamping systems, chip removal, cooling and lubrication systems, extraction technology, and more. Even simple monitoring systems can be considered part of the process periphery—especially when integrated into comprehensive process monitoring, such as energy monitoring on legacy equipment without OPC-UA interfaces.

We support you in developing, optimizing, selecting, integrating, and validating peripheral systems tailored to your cutting process.

 

Case Study: Adaptive Clamping System for Thin-Walled Tubes

For high-throughput processes, it can be beneficial to clamp and process multiple tubes in a disordered (chaotic) arrangement. Conventional systems for this purpose are often complex, customized, and expensive. To overcome this, we developed a flexible tube clamping system using air cushions, allowing for the chaotic positioning and simultaneous cutting of tubes—without the need for rigid clamping mechanisms.

 

Case Study: Extraction Technology

Many materials release hazardous or even explosive dusts during processing. This is not limited to composites like CFRP and GFRP but also includes certain wood types. The health and safety risks posed by such dusts are often underestimated. In several research projects, we are continuously improving dust extraction systems through experimental validation and simulation—ensuring both safety and performance.

 

Case Study: Energy and Productivity Monitoring

In many SMEs, productivity and energy use are not sufficiently tracked—not due to a lack of awareness, but because older machinery lacks built-in monitoring capabilities. In several projects, we have developed retrofittable sensor solutions that allow for the monitoring, evaluation, and visualization of energy and productivity data, regardless of the machine’s age. This creates new opportunities to identify and realize process improvements.

© Fraunhofer IPA
Flexible clamping technology for pipes with air cushions
© Fraunhofer IPA
Integrated energy consumption in existing systems without conversion
© Fraunhofer IPA
Extraction technology

What we offer

Workshops and Consulting

Do you think your peripheral systems could be optimized in terms of energy consumption or process efficiency? With tailored consulting sessions, we evaluate the potential with you.

Energy Optimization

To optimize your energy consumption, we record all relevant resource flows within your processes, visualize them, and identify opportunities for savings and improvements.

Productivity Monitoring

With real-time analysis of PLC data and additional sensors, we can evaluate machine metrics like number of cuts, cycle time, and setup time in real time. This creates production transparency and reveals optimization potential on the shop floor.

Extraction Systems

You need a customized extraction system for dust, fumes, or vapors in your production process? We assess the on-site situation, measure airflow, and design a system tailored to your specific needs.

Clamping Technology

You need a new clamping solution for your tool or workpiece? Or want to improve your existing clamping setup? We’re happy to support you with your specific requirements.