Projectstory
Precision in three-part harmony: When innovation meets expertise
"Plastic parts often appear simple at first glance - a round component with a few holes. But when tolerances of 0.02 mm are required, things become challenging." Dominique Deschamps, Head of Toolmaking at Hansgrohe Group, leans back in his chair and smiles. As a trained toolmaker, he knows that in apparent simplicity often lies the greatest complexity."
:quality(85) "Insights HansGrohe")
For the production of a technical component with an internal thread, Hansgrohe faced a complex task. The workpiece not only required the highest level of dimensional accuracy, but also a precisely controlled unscrewing movement. A challenge that pushes traditional drive solutions to their limits.
"When it comes to such requirements, it's about much more than just the tool itself," explains Deschamps. "It's about process reliability, energy efficiency, and last but not least, the quality of the end product." With this task, Hansgrohe turned to their long-standing toolmaking partner Polar-Form.
:quality(85) "Insights HansGrohe")
Thomas Müller, project manager at Polar-Form, remembers the beginning of the project: "The combination of highest precision and the necessary unscrewing movement required a special solution. That's why we brought Servomold on board."
A decision that would prove to be groundbreaking. "In the past, core features were implemented using racks and gears, which was very cumbersome.", explains Müller. "The servo-electric unscrewing units from Servomold open up completely new possibilities here."
:quality(85) "SSV")
The realized tool, equipped with a fourfold unscrewing unit (SSV) from Servomold, sets new standards in terms of precision and process reliability. The unique design, in which the drive train and the threaded core are separated, ensures maximum durability and minimal maintenance effort.
Tobias Schamm, Head of Sampling at Hansgrohe, is excited about the technical implementation. "The integrated torque monitoring is a real game changer. The system detects early on when a core gets stuck or wear occurs and stops automatically before damage can occur."
Project Overview
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Customer
Hansgrohe AG / Polar-Form Werkzeugbau GmbH
Application
4-fold spindle housing (PSU-GF20)
Unscrewing units
Threaded core systems
Temperature control systems
Torques
44 Nm available for thread core
Drilling time
1.7 seconds
Servo control
:quality(85) "Insights HansGrohe")
In everyday production, further advantages become apparent. "The automatic reference run has completely eliminated typical setup errors.", reports Schamm. "In the past, we always had to be careful not to mix up hoses in hydraulic systems. With the servo-electric solution, such sources of error are eliminated."
This process reliability not only means less downtime, but also a consistently high product quality. "Each produced part meets exactly our high quality standards," confirms Deschamps. "The precision is impressive."
:quality(85) "Insights HansGrohe")
The decision for a servo-electric solution also pays off in terms of sustainability. Studies from the University of Kassel show: Servo-electric systems consume up to 90% less energy than pneumatic and 75% less than hydraulic solutions. This also means a corresponding reduction in CO2 emissions.
"The elimination of hydraulic fluids and the significantly lower energy consumption align perfectly with our sustainability strategy.", Deschamps explains. "Here, ecological and economic benefits come together optimally."
The successful implementation of the project is largely based on the close collaboration of all parties involved. Thomas Müller, who has been working with Servomold for over ten years, emphasizes: "Servomold impresses not only with innovative technology, but also with a deep understanding of customer-specific requirements."
This assessment is also shared by the team at Hansgrohe. "The support from technical advice to service was and is excellent.", praises Deschamps. "Here you can feel the years of experience in toolmaking."
:quality(85) "Insights HansGrohe")
:quality(85) "Insights HansGrohe")
Meanwhile, the tool has proven itself more than successful in production. The combination of Hansgrohe's clear quality requirements, Polar-Form's toolmaking expertise, and Servomold's innovative drive technology impressively demonstrates how collaborative partnership leads to convincing results.
"The project is a perfect example of how modern technology optimally complements traditional toolmaking expertise.", Müller summarizes. One workpiece, one tool, three partners - united in the pursuit of technical perfection.
Innovation has a future
The successful implementation at Hansgrohe shows: Servo-electric screwdriving units are more than just an alternative to conventional systems. They combine precision, process reliability, and sustainability in a forward-looking solution.
:quality(85) "Team Richard Gane")