Scholarly record

SENSOR-GUARDED AUTOMATED PNEUMATIC CLAMPING FOR INDUSTRIAL VISES: EFFECTS ON SAFETY, ERGONOMICS, AND OPERATIONAL EFFICIENCY

Alexandru MINA, Dennis Frentiu, Titus Frentiu, Florin Alexandru Santa, Dragos Vasilescu

Abstract

Clamping and fixture operations are frequent sources of injuries and productivity losses in small and medium industrial workshops. Traditional manual vise tightening can create pinch points, repetitive strain, inconsistent clamping force, and longer cycle times, especially when parts are handled in batches. This paper presents a simple, invention-driven concept: an automated pneumatic clamping system that retrofits to a standard industrial vise and uses sensors and safety logic to improve occupational safety (SSM) while increasing throughput. The proposed system replaces manual torque application with a pneumatic actuator controlled by a compact valve block. The operator initiates clamping via a two-step input (for example, a guarded button and a confirmation switch) to reduce accidental activation. A pressure sensor and a position sensor confirm that the workpiece is present and that the jaw travel is within safe limits. If abnormal conditions occur (unexpected pressure spike, incomplete travel, or obstruction), the controller stops motion and vents pressure to a safe state. This sensor-guarded approach aims to reduce crush and pinch risks without adding complex maintenance burdens. To evaluate impact, the paper outlines a practical comparison between manual and automated clamping in terms of ergonomics, noise, vibration, and incident risk. Key indicators include: cycle time per part, operator posture and hand force, repeatability of clamping pressure, and the frequency of near-miss events. The system design also considers secondary risks such as compressed-air hazards, hose routing, and unintended release. Simple mitigation measures are proposed: pressure regulators, mechanical stops, protective covers, and periodic inspection steps that can be embedded into standard workshop routines. From an inventor's perspective, the main novelty is a claimable combination of retrofit geometry, sensor-based confirmation, and a safety interlock that links pressure thresholds to jaw position. The concept is suitable for patent protection as a modular kit that can be installed on existing equipment, with optional add-ons for data logging and predictive maintenance (tracking cycles, leaks, and pressure drift). Future work includes prototype testing across different vise sizes, integration with machine-tool start signals to prevent machining without confirmed clamping, and optimization of air consumption for energy-efficient operation.

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