Develops sensor screws, force and acceleration sensors, and measurement and edge systems for the digitalization of presses and forming machines
ConSenses GmbH
RoßdorfNew on Amplifa
About ConSenses
ConSenses GmbH, headquartered in Roßdorf near Darmstadt, is a technology-driven company in the field of industrial measurement technology. The company develops and manufactures sensors such as the patented force-measuring screw PiezoBolt (PB12/PB16/PB20), MEMS-based acceleration sensors (BAxA), and reference sensors including draw-wire sensors, magnetostrictive linear encoders and rotary encoders. In addition, ConSenses offers measurement and analysis systems (ProductionSenses), mobile measurement cases (DeveloperSenses), the EdgeSenses edge technology, and software such as the Manufacturing Data Suite, ProcessScope and SmartEvaluator. The services include the Machine Fingerprint as a standardized mechanical characterization of forming machines, servo curve optimization, measurement projects, system rental, exclusive developments, maintenance, remote support and training. The interdisciplinary team covers the entire measurement chain, from application consulting and sensor manufacturing to signal conditioning and data analysis. Key areas of application are press shops, forging, bulk forming, sheet metal processing and rolling mills.
- Site
- Roßdorf
- Processes
- Force and vibration measurement with sensor screws (PiezoBolt PB12/PB16/PB20) in serial production, Acceleration measurement (acceleration sensors BAxA, MEMS-based, measurement ranges -50...+50 to, Machine Fingerprint – standardized mechanical characterization of forming machines, Servo curve optimization for servo presses (reduction of mechanical loads in the double-digit, Process monitoring and digitalization of presses (force, pressure, acceleration,, Measurement projects / rental of measurement systems for short-term measurements, Exclusive development and custom sensor development, Sensor manufacturing (force-measuring screws, acceleration sensors) incl. application consulting,
- Materials
- Sheet metal (solid sheets in forming processes, structural elements), Force-measuring screw PiezoBolt (PB12/PB16/PB20), MEMS acceleration sensors, Magnetostrictive linear encoders, Draw-wire sensors, Rotary encoders
- Industries
- Press shops, Forming technology/bulk forming, Forging shops, Sheet metal processing, Rolling mills/strip lines, Industry 4.0/IoT
- 01
Application consulting and design analysis
- 02
Sensor manufacturing (force-measuring screws, acceleration sensors)
- 03
Signal routing and signal conditioning
- 04
Installation on machines and systems
- 05
Real-time data acquisition and edge processing
- 06
Data analysis, visualization and IT integration
- 07
Maintenance, remote support and training
Sensor Technologies and Measurement Methods
Force-measuring screw PiezoBolt (PB12/PB16/PB20)
Patented sensor screw that resolves force signals down to the single-digit newton range and captures dynamic loads in real time.
MEMS acceleration sensors
Capacitive MEMS elementary sensor technology, shock-resistant up to 10,000 g, for measurement ranges from -50/+50 to -500/+500 g.
Magnetostrictive linear encoders
Contactless position encoders for long-term, low-wear integration on press rams.
Draw-wire sensors
Flexible reference sensors with switchable magnetic mounts, e.g. for tilt measurement on press rams.
Rotary encoders
Reference sensors for continuously or start-stop operated rolling mills and strip lines.
Location
Roßdorf
DEDevelopment, sensor manufacturing and system integration (Headquarters)
- EdgeSenses Gen. C (edge device)
- ProductionSenses (measurement and analysis system)
- DeveloperSenses (mobile measurement system)
- PiezoBolt PB12/PB16/PB20 sensor screws
- BAxA acceleration sensors
Sensors and Systems
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Force and vibration measurement with sensor screws (PiezoBolt PB12/PB16/PB20) in serial productionInspection | – | – | – | – | – |
| Acceleration measurement (acceleration sensors BAxA, MEMS-based, measurement ranges -50...+50 toInspection | – | – | – | – | – |
| Machine Fingerprint – standardized mechanical characterization of forming machinesInspection | – | – | – | – | – |
| Servo curve optimization for servo presses (reduction of mechanical loads in the double-digitEngineering | – | – | – | – | – |
| Process monitoring and digitalization of presses (force, pressure, acceleration,Inspection | – | – | – | – | – |
| Measurement projects / rental of measurement systems for short-term measurementsInspection | – | – | – | – | – |
| Exclusive development and custom sensor developmentEngineering | – | – | – | – | – |
| Sensor manufacturing (force-measuring screws, acceleration sensors) incl. application consulting,Engineering | – | – | – | – | – |
| Measurement of preload forces in bolted joints during tightening/loosening (tensioning tool)Inspection | – | – | – | – | – |
| Tilt/eccentricity measurement on press rams (draw-wire sensors, position measurement)Inspection | – | – | – | – | – |
| Design analysis (technical drawings, STEP models) for process improvementEngineering | – | – | – | – | – |
7 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Edge device for mechanical process data acquisition | ConSenses EdgeSenses Gen. C | – | – | – | Roßdorf |
| Measurement and analysis system with touch panel | ConSenses ProductionSenses | – | – | – | Roßdorf |
| Mobile measurement system in a plastic case | ConSenses DeveloperSenses | – | – | – | Roßdorf |
| Sensor screw (force-measuring screw) | ConSenses PiezoBolt PB12 / PB16 / PB20 | – | – | – | Roßdorf |
| Acceleration sensor (MEMS) | ConSenses BAxA | – | – | – | Roßdorf |
| Reference sensors (draw-wire sensors, magnetostrictive linear encoders, rotary encoders) | ConSenses | – | – | – | Roßdorf |
| Force measuring rings / load cells (third-party integration) | Third-party | – | – | – | Roßdorf |
Additional services
Reference customers
History
- 2013
Funded by the BMWi in the eXist Research Transfer program as an outstanding research-based startup project; rooted at TU Darmstadt.
- 2018
Hardware standardization of the DS systems with other system families
- 2024
Introduction of EdgeSenses as edge technology; more than 10 years of 24/7 operational experience