How the ZEPO-v clamping system streamlined production at Bosal

For our customer Bosal, we addressed the issue of changing welding fixtures at an automated workstation. The original process took approximately 30 minutes. By implementing our solution using the NES-T 135 and NES-T-F 135 pneumatic clamping sockets, we were able to reduce this time to about 1 minute. This case study demonstrates that a quick-change clamping system is not only beneficial for CNC machines but can also significantly streamline welding operations.

Time-consuming fixture change slowed down the workstation

At the customer’s site, changing the welding fixture on the automated workstation was unnecessarily slow. The original mounting required more operator intervention, longer downtime, and precise re-alignment after each change. The change itself took approximately 30 minutes, which in welding operations meant unnecessary downtime and lower production efficiency. In mass production, setup time has a direct impact on workstation performance, operational flexibility, and overall productivity.
It was therefore necessary to find a solution that would speed up fixture changes, reduce downtime, and ensure precise and repeatable clamping.

Solution Using NES-T 135 and NES-T-F 135 Clamping Sockets

Although the NES-T series of pneumatic clamping sockets is typically used for precise and rigid clamping on CNC machines, in this case it was applied in a welding shop. The entire system was built using a combination of two types of modules:

NES-T 135 Pneumatic Quick-Change Clamp

The NES-T 135 model is a pneumatic quick-change clamp designed for installation in a robust clamping base. It is suitable where a compact and rigid solution, high positioning accuracy, reliable self-locking clamping, and quick change of fixtures or pallets are required. This module features a body made of heat-treated stainless steel, a self-locking mechanism, a clamping force of 24 kN, and a height of 36 mm. It also includes alignment grooves for 90° indexing.

NES-T-F 135 Pneumatic Quick-Change Clamp

The NES-T-F 135 model is based on the design of the NES-T 135 series but additionally allows for 1 mm of center offset. This is important in applications where expansion or thermal expansion during the process must be accounted for. In this project, this feature was important due to thermal loads during welding. The socket also includes a centering ring that returns the center to its original position. This facilitates the initial setup of the fixture and helps precisely define the spacing between sockets.

Summary of the Benefits of System Implementation

The implementation of the ZEPO-v system at Bosal confirmed that significant time savings can be achieved even outside the realm of CNC machining. In this case, the fixture changeover time was reduced from 30 minutes to approximately 1 minute—a 97% reduction. The solution also provided high rigidity and stability thanks to its self-locking mechanism. Another important benefit was the reduction of issues related to thermal expansion of the material during welding.

Do you need to streamline your operations as well?

Did this case study catch your attention, and would you like to achieve similar results in your facility? Whether you’re addressing clamping on CNC machines or in automated welding shops, our ZEPO-v system will help you minimize downtime. Contact us, and together we’ll find the ideal configuration of NES-T clamping sockets for your needs.