Opening Stations

Opening stations can be realized both for new systems and as part of modernization projects. Existing production layouts are analyzed to define suitable positions for transferring out and processing tools. Depending on available space and safety requirements, compact solutions close to the press or standalone stations may be considered. Thanks to the modular design, an opening station can later be expanded or combined with additional functions, such as additional cleaning or layup units, when production grows or changes.

Opening stations are especially suitable for industries in which Langzauner supplies press and automation solutions: aviation, automotive, caravan, sports, and aerospace industries, as well as metal, defense, and wood industries. Wherever complex tools are used and manual intervention on internal tool surfaces is required, these stations provide advantages. Typical applications include composite layup processes, tool cleaning, visual inspection of critical contours, or insertion of inserts and inlays before the tool is returned to the automated process.

At the beginning, Langzauner analyzes processes, tool concepts, and the specific need for manual intervention. Based on this, an opening station is designed on a project-specific basis, from the pure tool opening function through combinations with cleaning or layup stations. Design, manufacturing, and integration into the overall system are carried out by the in-house engineering department. During commissioning and the ramp-up phase, workflows are optimized together and operating personnel are trained. This creates a solution that takes ergonomic requirements, cycle times, and quality objectives into account.

Clearly structured workplaces at opened tools allow cleaning and layup processes to be standardized. Tools can be checked, cleaned, and prepared at defined intervals before being returned to the automated process. This lowers the risk of contamination, layup errors, or undetected tool damage. Random quality checks are easier to integrate because opening stations form fixed points in the process sequence. They therefore make a significant contribution to higher process stability and reproducible product quality.

Opening stations are designed to provide operators with ergonomic working conditions. Both inner tool surfaces are made accessible so that cleaning and layup work can be performed in an optimal body posture. Heavy tool halves are mechanically supported, and swivel and lifting movements are performed in a controlled way through the station. This reduces strain from heavy lifting or unnatural working positions and, at the same time, lowers the risk of crushing and accidents in the immediate press area. Ergonomics and safety are thus combined in a coordinated overall system.