news precise to the last micrometer -...

BRANKAMP E:xxacto

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Parts that are too short are the most frequently occurring error during the production of mul-tiple-spindle automatic lathes. Together with Huber Systems, BRANKAMP now offers a solutionfor this typical problem encountered in metal cutting. BRANKAMP E:xxacto will be presentedfor the first time at the EMO 2007.

NewsFACTORY M IN BRAZIL

The production monitoring systemFactoryM is now also being laun-ched in South America. After thesuccessful introduction of themodular works communicationsystem in Europe and China, nowtwo Brazilian manufacturing com-panies have put their trust inBRANKAMP’s FactoryM. The soft-ware solution was recently pres-ented to the South American mar-ket at the FEIMAFE in Sao Paulo.

ARNOLD UMFORMTECHNIKGETS AWARDAs a specialist for intelligent con-nection solutions, Arnold Umform-technik GmbH was honored withthe Bosch Supplier Award in July2007. The Forchtenberg-based com-pany won out over internationalcompetition in the Material andComponents category. Technologygiant Bosch presented a total of 47Supplier Awards to suppliers from14 countries.

BRANKAMP PK 4U NOW WITHBLUETOOTHThe BRANKAMP PK 4U is nowalso available with the innovativeBluetooth function. The wirelessconnection serves as an interfacefor the transmission of importantproduction data. Quantities anddowntimes can be sent via Blue-tooth directly to a cell computer.

QUOTE OF THE MONTH:»Problems are best solved bydetecting them before theybecome a problem.«

Joachim Zahn, Former Head of Daimler-Benz

Digital dimension measurementtechnology measures each partduring the manufacturing pro-cess in the machine. The paten-ted digital measuring sensor ismounted on the central slide ofthe multiple-spindle automaticlathe. The length of the part isthen measured during the pivo-ting process of the materialdrum. BRANKAMP E:xxactodetects even the smallest of devi-ations, accurate to the nearest0.001 millimeter, early on during

Precise to the last micrometer

September 2007 · Edition 3 INTERNATIONAL · Volume 24

A BRANKAMP ET terminal with integrated in-process dimension measurementby Huber Systems on a Tornos Multideco. The multiple-spindle automatic lathefor mass production manufactures turned parts for the automobile industry.

the manufacturing process –without changing the machine’scycle time. As soon as a part that

BRANKAMP E:xxacto: Always the right length.

is too short is detected, thesystem sends a message to the

BRANKAMP at the EMO

All-around genius

All sectors of the metal workingindustry will be represented at theEMO 2007 (September 17-22, 2007).And BRANKAMP can offer everyone of these sectors application-oriented solutions with its indivi-dual ProcessMonitoring systems. InHanover, the Erkrath-based inter-national market leader will presentthe new in-process dimension mea-surement system BRANKAMPE:xxacto for metal cutting for thevery first time. In the punchingarea, the ProcessMonitoring speci-alist will demonstrate its new “high-speed force sensor system” at standF45 in hall 25 (page 4). BRANKAMPwill also be taking the collision pro-tection system CMS (page 2) and themodular production monitoringsystem FactoryM (page 3) to theEMO, for applications in metal cut-ting as well as for the punching andcold forming sectors.

The special issue pages 7

„Hanging up the running shoes“

EMO-SPECIAL

continued on page 2

Dokument 1 10.09.2007 15:45 Uhr Seite 1

NewsBRANKAMP OFFERS UNIQUE TELESERVICE PACKAGEThe successful BRANKAMP tele-service team has put together aspecial offer package, right in timefor the EMO 2007. For only 625euros, BRANKAMP will providethe required hardware and soft-ware for remote maintenance aswell as 10 hours of included onli-ne service. In the event of a systemfailure, the service technician candirectly login to the customer’ssystem. The technician will thenanalyze the problem and, in mostcases, rectify it right then andthere - saving time and money.

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September 2007

Herausgeber: Dr.-Ing. K. Brankamp SystemProzessautomation GmbH,Max-Planck-Straße 9, D-40699 Erkrath

V.i.S.d.P.: Tom Brankamp,Michael Tobias (enterpress)

IMPRESSUM

machine, which in turn separa-tes the part out or stops produc-tion. The data can be viewed bythe worker at any time. The wor-ker can follow the digital dimen-sion measurement on the BRAN-

KAMP monitoring terminal.And BRANKAMP E:xxacto of-fers a double layer of protection,because the digital measuringsensors by Huber Systems usethe same interface as the BRAN-

KAMP ProcessMonitoring sys-tem. The digital dimension mea-surement as well as the provenBRANKAMP process monitoringcan thus be used in parallel viaa single monitor.

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Precise to the last micrometer

With 18 percent, China is clearlythe favorite production locationin the world. Germany is insecond place with 11 percent, fol-lowed by the US/Canada withnine percent.

FIGURE OF THE MONTH:The five top locations world-wide for the establishment ofproduction facilities:

Sour

ce: E

rnst

& Y

oung

USA/CANADA

POLAND

INDIA

CHINA 18 PERCENT

GERMANY 11 PERCENT

9 PERCENT

7 PERCENT

4 PERCENT

BRANKAMP CMS

Time is money

have had many successfulresults with over 50 machineswhere a collision without amonitoring system would havelead to a lot of machine dama-ge,” says Marvin Schlieker fromtransmissions manufacturer ZF.Thanks to the System SecurityChecker function SSC, the relia-bility of the BRANKAMP CMSwas increased even more. Assoon as the machine operatorpresses the SSC button, themachine automatically switchesto the check mode and tests thefunctionality of the machinewhile it is running. Thanks tothis safety test, permanent moni-toring of machines and tools isguaranteed.

A high degree of machine availability, optimal parts quality and machine breakdowns reducedto a minimum – these three important factors are crucial for keeping a manufacturing companycompetitive in today’s tough world of competition. BRANKAMP’s CMS systems reduce machinedowntimes to a minimum, thus helping increase profitability.

monitoring system for about twoand a half years. Up to now we

You can’t miss hearing a machi-ne crash. A loud bang and youknow instantly that a collisionhas occurred. It can take up to 10seconds for the machine opera-tor to react to the noise and pressthe emergency OFF button –which translates into 10,000milliseconds. The innovativeBRANKAMP CMS machine pro-tection system executes the OFFcommand 100 times faster. Thissignificantly minimizes the timeto final machine shutdown.

Limiting Damage by Decrea-sing Reaction Time

The result: damage to machinesand tools is clearly decreased.This saves valuable time andsimultaneously reduces repaircosts. “We have been usingBRANKAMP’s CMS100 collision


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Y E A R S30

1988: World pre-miere: absoluteforce monitoring

Fit for the Future

BRANKAMP’s succession hasbeen settled. The Erkrath-basedcompany and its 50 employeeswill remain in the family. Thenew Managing Director is long-time Executive Director Hans-Peter Schneider. BRANKAMP’snew management crew has been

New management in place at BRANKAMP

a well-synchronized team formany years. Managing DirectorDipl.-Ing. Hans-Peter Schneider,54, has been with BRANKAMPsince 1988, most recently as Exe-cutive Director and Manager ofthe Punching Division and Tech-nology Manager. The executive

management also includes twolongtime BRANKAMP employ-ees: Dipl.-Ing. Franz Saliger, 54,will continue to head the cold for-ming business area. Werner Ebe-ling, 62, will continue to beresponsible for the metal cuttingarea. Continuity is also insured

on the shareholder side. BRAN-KAMP will remain a family busi-ness. Anna, Jochen and TomBrankamp will take over the cor-porate shares of their father, Pro-fessor Dr.-Ing. Klaus Brankamp,who founded the company in1977.

August 1977: BRANKAMP Pro-cess Automation isfounded, andscrew manufactu-rer ABC is its firstmajor customer

January 1987: Moveto the new admini-strative building

October 1987:BRANKAMP Italy is founded

January 1988: BRANKAMPAmerica and UKare founded

1988: Takeover ofWidatronic fromKrupp

June 1988: Initialsuccess on the Japa-nese market

September 1989:Trade show booth atthe EMO with a new,open design

October 1989: Productionof the first punched parts

launched in ghost shifts atWolf Geräte, Wendel

1977 1989

From left to right: Executive Director Werner Ebeling, Tom Brankamp, Jochen Brankamp, Anna Brankamp, Managing Director Hans-Peter Schneider and Executive Director Franz Saliger.

1977: Processa 0101 1981: Processa 0102 1985: Processa 3040 1985: Processa 2050 1985: Processa 4051 1987: Processa 8100

March 1982: The500th BRANKAMPsystem Processa 0101is rolled out

1986: BRANKAMPdevelops the data-collection system DC 5000


Y E A R S


30

May1990: Move to the newproduction hall

October 1990:In-house exhibi-tion in the GDR

September 1992:Exclusive con-tract with Prokos

April 1993:ProcessMonitoring forcan production

November 2000:DIN ISO 9001 certification

September 1998:New motto: Forward Thinking

December 1998:Double dynamic

envelope curve

October 2001:Ford ”Q1 Award“

Forward ThinkingForward Thinking

1990

”Thanks to the use of pressing forcemonitoring, unplanned failures, suchas bearing shell collapses, for exam-ple, can now be almost entirely pre-vented. In addition, we were able toincrease the tool operating life byaround 25 percent.“

Klaus Rothammer, Production Manager at SEISSENSCHMIDT (2007)

”Our employees tested various systems for many months. Theresults were heavily in favor of the BRANKAMP PK 508.Naturally, a big advantage from the user’s perspective is user-friendliness, and this aspect also contributed in large part towinning my team over.“

Rolf Burghauser, Master Craftsman in the area of cold forming at Peiner Umformtechnik (2002)

”Thanks to ProcessMonitoring wewere able to decrease our reaction andsetup times and significantly increasethe service life of tools. The resultswere convincing. Our failure ratedecreased from eight percent to zeropercent.“

Manfred Nußer, Technical Specialist at the DriveLine Product Center at the MTUFriedrichshafen (2006)

”Our experiences have been verypositive. Before we started usingBRANKAMP ProcessMonitoringwe did not have any exactly repro-ducible configurations and nopossibility of an unmanned shift.This changed abruptly with Pro-cessMonitoring.“

Iris König, Economist andOwner of J.C. König Stiftung& Co. KG (2007)

”BRANKAMP and ABC have been working together for decades. We particularly value the flexibilityand support that we always get from BRANKAMP.“

Michael Belasus, Technical Manager Production at ABC Umformtechnik GmbH & Co. KG (2007)

1990: Widatronic 8030 1991: Processa 3060 1992: PK 732 1992: PK 508 1994: CMS 1997: GT 90 1998: PK 400 1999: C 9

”I can’t imagine modern coldforming without Process-Monitoring. The devices arean important part of ourquality strategy!“

Martin Schneider, PlantManager Metals atEmhart Teknologies inGießen (2007)

”Thanks to the systems, we havebecome significantly more flexi-ble. Even to the extent that laborcosts now play a smaller role incertain processes due to multiplemachine operation – for exam-ple, in the manufacturing ofcomponents for electronic par-king brakes.“

Hans Zirwes, Plant Managerat Textron FasteningSystems in Neuss (2005)

1997: Modular con-cept with fanlesstouchscreen PC

2000: Moni-toring insemiconduc-tor produc-tion 2002:

Develop-ment of

Ultra-Emission



Y E A R S30

February 2002:Single-buttonoperation(eDrive)

September 2002:Siemens certifiesBRANKAMP iMSoft

October 2002:Over 40,000 systems inoperation worldwide

January 2003:Bruderer certi-fies BRAN-KAMP

January 2003:Rotator detectstransfer error

June 2003:Takeover ofHelpro

December 2003:Factory Net: Networked production

April 2004:Absolute force measure-ment for thread rollers

June 2004:Yamazaki Mazak choo-ses BRANKAMP

October 2004:ZF Friedrichs-hafen: Testseries for theintroduction ofthe CMS

2004

”For us, the introduction of ProcessMoni-toring was definitely the right thing to do.Our investments have completely paid forthemselves in just one year.“

Christian Grzegorzek, MaintenanceManager at Siemens AG in Mühlheim(2003)

”We have been using the BRANKAMP CMS 100collision monitoring system for about two and ahalf years. During this time we have had muchsuccess with over 50 equipped machines where acollision without a monitoring system wouldhave resulted in a lot of damage to the machi-nes.”

Marvin Schlieker, Condition-Based Maintenance at ZF (2007)

”We have had good experiences with the BRANKAMP PK 4000 systemin wheel manufacturing. This is how we got to know the company.“

Hans Josef Richner, Electrical Engineer at Ford in Cologne (2007)

”Within a very short time frame, we have minimized tool mainte-nance of stamping steps and reduced waste. With the help ofBRANKAMP systems we can now not only detect stamped slugs butare also able to prevent them from occurring to a large degree. Inaddition to decreased tool maintenance and minimized waste, weare also able to increase the manufacturing speed.”

Bernd Schäfer, Team Leader Toolmaking at ElringKlinger AG (2006)

999: C 90 1999: B 400 1999: C 100 1999: PK 550 2001: PK 5000 2001: PK 6000 2002: PK 4000 2004: HELPRO MP

”We were very skeptical due toprevious experiences with othermonitoring systems. BRAN-KAMP was able to convince usthat we are on the right pathand that we still have manyoptions for improvement opento us.“

Ralf Bohlander, Pre-Fabrication Foreman atKeiper GmbH & Co. KG inRockenhausen (2007)

”Processes take place at all levels of a company. ProcessMonito-ring systems help our employees master the very demandinginterface between the physical/technical and the production/organizational world. The BRANKAMP philosophy, ”Focus onthe Employee,” fits in very well with the process-related testphilosophy of SFS Intec.“

Jörg Holthöfer,Project Manager Process Development at SFS intec AG (2007)

”Thanks to BRANKAMP’s machine monitoring, the consequential costs of a collisionwere kept to a minimum“

Steven Tröger, Project Manager in the Technology + Manufacturing Depart-ment at Uhlmann (2007)


Y E A R S


30

March 2005:CMS on robotand handlingunits

April 2005:BRANKAMPrepresentationin China

November 2005:Emails on theproductionmachine

January 2006:Together with E.W.Menn, development ofa new process for moni-toring thread rolling

April 2006:RFID technology

August 2006:Factory M

September 2006:Initiative per location Germany

January 2007:BRANKAMP: the Slugbusters

Professor Dr.-Ing. Klaus Brankamp

Increased quality, decreased costs – this is the main objective ofevery state-of-the-art manufacturing process. ProcessMonito-ring plays a central role in achieving this objective. Thirty yearsago, Professor Dr.-Ing. Klaus Brankamp introduced the innova-tive technology, which above all enables optimized quality andan improved level of utilization in the industrial manufacturingsector.

”One can compare our Process-Monitoring systems to a car’stachometer,” Professor Dr. KlausBrankamp said last year. ”Somedrivers watch the tachometer tomake sure they don’t reach thered zone and overrev the engine.Others use it so they know toshift in time, thereby savingfuel.” The modern BRANKAMPsystems prevent process errorsor switch machines off in time,for example, in the event of mal-functions, thus preventing orlimiting the occurrence of expen-sive damage.

Professor Dr.-Ing. Klaus Bran-kamp was born on August 29,1939 in Düsseldorf. He studiedmechanical engineering at theRWTH Aachen University andobtained his doctorate there in1967. After his postdoctoral lec-ture qualification in 1970, hetaught ”Planning and New Pro-duct Development” at ”his” uni-versity. At the same time, Dr.Brankamp founded a consultingfirm, the nucleus of today’sBRANKAMP Group.

The company founder

Seven years later, a project spon-sored by the state of NorthRhine-Westphalia was the pointof departure for the inventionthat today is known the worldover: ProcessMonitoring techno-logy. The objective of that projectwas to sound out the opportuni-ties and possibilities of ”ghostshift production”.

”The active support of the pro-duction team by electronic mea-surement systems, multiplemachine operation or productionduring breaks were still onlyideas at that time whose imple-mentation was regarded asimpossible,” Professor Bran-kamp stated in retrospect.

Today, the technology he develo-ped is well-known everywhere inthe world. Over 50,000 BRAN-KAMP applications are in useworldwide. Buzzwords such as”ghost shift”, ”productivity in-crease“, ”automation“ and ”qua-lity“ are inextricably linked withthe name Brankamp in the indu-stry.

Professor Dr.-Ing. Klaus Bran-kamp was an active member ofthe VDI and the IHK. He belon-ged to several managementboards and advisory boards andauthored numerous textbooks.Characteristic of Klaus Bran-kamp were his open, people-oriented nature, his engaging

manner, his extraordinary senseof obligation and responsibilityand his immense expert know-ledge.

Professor Dr.-Ing. Klaus Bran-kamp passed away after a shortbut serious illness on February27, 2007.

2005 2007

June 2007:New managementin Place at BRANKAMP

2005: PK 4U 2005: ECO 500 2006: HELPRO UP 2007: ECO 100 2007: PK 900


September 2007T H E S P E C I A L I S S U E


BRANKAMP FactoryM

How is an order progressing? Can the agreed delivery date bemet? These customer questions are part of everyday businessfor department managers and production managers. But theanswers are found in the production hall rather than in the offi-ce. Each query therefore means a walk down to the productionfacility. This costs valuable work time and hinders the reliableflow of information. With the works communication system Fac-toryM from BRANKAMP, production managers can retire theirrunning shoes.

Hanging up the running shoes

Unlike the usual productiondata acquisition systems, withFactoryM the productionmanager can decide whichfunctions are really needed andwhich ones can be donewithout. Expensive overallsolutions that can only be par-tially used are now a thing ofthe past. “FactoryM is a trulymodular system that everycompany can adjust andexpand according to its speci-fic needs,” says BRANKAMPManaging Director Hans-PeterSchneider.

Everything at a Glance

As the pioneer in process moni-toring systems, BRANKAMPhas been developing indepen-dent production data acquisi-tion solutions since 1985. “Fac-toryM is comparable to a navi-gation system. It guides theoperator through the produc-tion process in a simple andconcise manner,” says Schnei-

Saving shoe wear-and-tear: FactoryM saves production managers and workers muchlegwork.

der. The most important pro-duction data can be viewed ata glance on the operator’s PC.The relevant impulses frombetween six and eight machi-nes are recorded with a BRAN-KAMP IMC Box and saved. Thedata is transmitted directly tothe in-house servers and auto-matically stored in the Facto-ryM database. They can thenbe accessed at every authorizedPC with just a touch of a but-ton. The production data is notlost even when there are net-work disruptions, because it isstored temporarily in the IMCBox. If a company uses BRAN-KAMP ProcessMonitoring

able data even at 3,000 strokesper minute.”

Flexible and Modular

In addition to informationabout the quantity producedand a digital workshop over-view, FactoryM also offersnumerous analysis options,such as a machine control cen-ter and flexible administrationof shift times. Companies canput together their individualpackage from a total of 10 dif-ferent modules. This cost-effec-tive solution enables the hig-hest degree of flexibility.

systems or other commonmonitoring systems, the impul-ses are directly transferredfrom there. Even high-speedpunches pose no problems forFactoryM. Hans-Peter Schnei-der: “The system provides reli-


I N N OVAT I O N I S T H E F U T U R E

The BRANKAMP “High-Speed Force Sensor System”


September 2007I N N OVAT I O N I S T H E F U T U R E

Reliable, fast, cost-effective!

BRANKAMP GMBH, DEUTSCHLANDPhone +49/ 211/ 25 07 60Fax +49/ 211/ 20 84 02eMail [email protected]

BRANKAMP S.R.L., ITALIAPhone +39/ 039/ 60 81 917Fax +39/ 039/ 60 85 207eMail [email protected]

BRANKAMP INC., USAPhone +1/ 617/ 492 16 92Fax +1/ 617/ 497 56 75eMail [email protected]

Greater reliabi-lity in punchingManufacturing is a complexprocess during which break-downs occur time and again.But no punching operation canafford long production down-times. Reliable process moni-toring is therefore crucial.With its multi-sensor PK 900measuring device, BRAN-KAMP is setting new standardsin production safety.

Continual monitoring of the cur-rent machine status is essentialfor optimal management of pro-duction processes. The data fromup to 20 independent punchingprocesses can be viewed with acombination of the PK 900 andthe GT industrial terminal.Equipment is easily selected viaa touch screen on the left side ofthe screen.

The data and information from allmonitored punching operationsis brought together in the BRAN-KAMP GT industrial terminal. Inthis way the machine operatorhas an optimal overview of pro-duction. Using the touch screen,he can easily access the data foreach individually monitored pun-ching operation and display themon the color monitor. Standardfunctions include, amongstothers, envelope curve monito-ring, zoom and trend display. Andthe screen withstands raw pro-duction conditions, because thetouch screen of the BRANKAMPGT is up to four times more shat-ter-proof than conventional touchscreen monitors.

Dr.-Ing. K. Brankamp System Prozessautomation GmbH, Max-Planck-Str. 9, D-40699 Erkrath

One-hundred percent error-free parts are an absolute must in the connector and contact indu-stry. In automobile electronic engineering, in particular, nothing may go wrong. Nevertheless,typical punching problems such as stamped slugs, surface markings and male die fractures con-tinue to occur. Time-consuming and cost-intensive final inspections are the result. The new “high-speed force sensor system” by BRANKAMP is here to help. The system enables seamless moni-toring - even at speeds up to 3,000 strokes per minute.

Previously, measurements ofthe pressing forces of high-speed punches always faileddue to the vibration of themachine. The vibrations wereso great that they superimpo-sed the determination of theforming capacity and thereforedistorted it. Exact measure-ments were almost impossible.BRANKAMP’s new “high-speedforce sensor system” measuresand assesses the pressing for-ces, even at extremely high stro-ke rates. The sensors are moun-ted appropriate to the particu-lar tool.

BRANKAMP’s two other sen-sors, UltraEmission and Acou-sticEmission, complete the in-process control in the punchingshop. While the high-speedforce sensor system” determi-nes the pressing forces, Acou-sticEmission detects male diefractures in the machine andinforms the worker immedia-tely. UltraEmission makes surethat even the smallest punchingwaste is spotted in the tools.With the all-inclusive packagefrom BRANKAMP, punches areoptimally protected and partsquality is ensured. All the infor-

mation gathered is transferredto a clearly arranged colordisplay by the BRANKAMPProcessMonitoring system.Using envelope curves, themachine operator can see ifany defective parts were rejec-ted or if there are any tool ormachine errors. The advantageof this is that final inspectionby additional personnel issuperfluous. Productivity isalso increased thanks to thepossibility of multiple-machi-ne operation. Costs for tool andmachine repairs are reduced toa minimum.


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