The challenge: precision in series production
Hansgrohe was faced with a complex task for the production of a technical component with an internal thread. The workpiece not only required maximum dimensional accuracy, but also a precisely controlled unscrewing movement. A challenge that pushes classic drive solutions to their limits.
“Such requirements are about far more than just the tool itself,”
explains Deschamps. “It's about process reliability, energy efficiency and
not least the quality of the end product.” Hansgrohe turned to its long-standing
toolmaking partner Polar-Form with this
task.
Three partners, one vision
Thomas Müller, project manager at Polar-Form, remembers the start of the project: “The combination of maximum precision and the necessary unscrewing movement required a special solution. That's why we brought Servomold on board.”
A decision that proved to be groundbreaking. “In the past, core pulls 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.”
The combination of maximum precision and the necessary unscrewing movement required a special solution. That's why we brought Servomold on board.
Project Manager Polar-Form
Innovation in detail
The realized tool, equipped with a four-fold unscrewing unit (SSV) from Servomold, sets new standards in terms of precision and process reliability. The unique design, in which the drive train and thread core are separated, ensures maximum durability and minimum maintenance.
Tobias Schamm, Head of Sampling at Hansgrohe, is delighted with the technical implementation:
“The integrated torque monitoring is a real game changer. The system detects at an early stage if a core seizes up or wear occurs and stops automatically before damage can occur.”
Project overview
Intelligent process control in everyday life
There are further advantages in day-to-day production. “The automatic
reference run has completely eliminated typical set-up errors,” reports Schamm.
“With hydraulic systems, we used to always have to be careful not to mix up
hoses. With the servo-electric solution, such
sources of error are eliminated.”
This process reliability not only means less downtime, but also consistently high product quality. “Every part produced meets our high quality requirements exactly,” confirms Deschamps. “The precision is impressive.”
Looking to the future with servo technology
Sustainability in figures
Opting for a servo-electric solution also pays off in terms of sustainability. Studies by the University of Kassel have shown that servo-electric systems consume up to 90% less energy than pneumatic solutions 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 fit in perfectly with our sustainability strategy,” explains Deschamps. “Ecological and economic advantages come together perfectly here.”
Expertise that convinces
The successful implementation of the project is largely based on the close cooperation of all those involved. Thomas Müller, who has been working with Servomold for over ten years, emphasizes: “Servomold not only impresses with its innovative technology, but also with its deep understanding of customer-specific requirements.”
The Hansgrohe team also shares this opinion. “The support, from technical advice to service, was and is outstanding,” praises Deschamps. “You can feel the years of experience in toolmaking here.”
From theory to practice
In the meantime, the tool has more than proven itself in production. The combination of Hansgrohe's clear quality requirements, Polar-Forms' toolmaking expertise and Servomold's innovative drive technology impressively demonstrates how partnership-based cooperation leads to convincing results.
“The project is a perfect example of how modern technology optimally complements traditional toolmaking expertise,” summarizes Müller. One workpiece, one tool, three partners - united in the pursuit of technical perfection.
Innovation has a future
The successful implementation at Hansgrohe shows that servo-electric unscrewing units are more than just an alternative to conventional systems. They combine precision, process reliability and sustainability in a pioneering solution.