Fraunhofer IWU Develops Smart Retrofit Solution for Forming Presses
Sensor-Equipped Tool Clamping System Developed for Metal Forming Presses
A new retrofittable tool clamping system developed to capture elastic deformations at the press ram during metal forming operations has reached market maturity, myfactory-magazin.de reported. Developed jointly by the Fraunhofer IWU and a manufacturer of clamping systems, the technology integrates smart sensor modules into the mechanical interface between the press and the tool to stabilize manufacturing processes and reduce downtime.
The Tech TL;DR:
- The “BERGtronic” sensorized clamping system retrofits onto existing metal forming presses without requiring complex parameterization or specialized operator training.
- An integrated smart sensor module measures microscopic elastic deformations at the press ram, capturing inline process data for both small batch runs and high-volume serial production.
- Built-in anomaly detection automatically logs deviations from the work cycle, enabling envelope curve monitoring and rapid fault identification from stroke to stroke.
Retrofitting Legacy Presses With Inline Process Monitoring
Tool clamping systems serve as the critical mechanical junction where forming machines transfer energy to workpieces. By positioning sensors at this exact workstation, the newly commercialized hardware captures high-resolution force profiles and deformation metrics that traditional controller setups often miss. According to the reported details, the accompanying software operates entirely autonomously once installed. It requires no complex configuration parameters and places minimal qualification demands on floor operators, lowering the technical barriers typically associated with factory floor retrofitting.
The system, branded as “BERGtronic,” is engineered to bring older stamping and forming presses into modern digital manufacturing workflows. Whether deployed on compact presses or large-scale machinery handling heavy sheet metal components, the inline data acquisition monitors real-time variations in pressing force. If anomalies occur, the software records the deviation against established baseline tolerances. This continuous envelope curve monitoring allows engineers to detect tool wear and mechanical irregularities early, protecting expensive tooling from catastrophic failures.
Intelligent Clamping Units Undergo Trials at Magna Body & Chassis
Implementation trials are already underway in heavy industrial environments. Since March 2026, the intelligent clamping units and the Fraunhofer IWU monitoring software have been deployed at Magna Body & Chassis Germany GmbH, operating under the demanding conditions of industrial press hardening. Project lead Mohaned Alaluss noted that the sensorized clamping technology integrates independently of specific press control concepts, allowing operators to evaluate machine compatibility with minimal effort.
Public demonstrations of the live process monitoring software are scheduled to run from October 20 to October 23, 2026, at the EuroBlech trade fair. The Fraunhofer IWU will exhibit the technology directly on an active forming press at the booth of Berg & Co. GmbH Spanntechnik (Hall 27, Stand F51), showcasing how real-time anomaly detection translates into documented logbooks and actionable plant data.