TOX -ElectricDrive. Electro-mechanical Servo-Systems 0,5 400 kn Press force line-q line-x

Transcription

1 TOX -ElectricDrive Electro-mechanical Servo-Systems 0,5 400 kn Press force line-q line-x 1

2 TOX -ElectricDrive When work processes require high flexibility and precision, then conventional drives are often no longer sufficient. This calls for the use of electromechanical servo drives. Tailored drives from 0,5 400 kn. From the standard drive up to the complex special machine. Advantages TOX -ElectricDrive: High life expectancy and robustness due to the compact planetary roller screw spindle Future-oriented project planning and very good retooling capability due to its universal applicability Maximum energy efficiency, i.e. significantly reduced operating costs compared to conventional drives Special executions can be easily realized due to the modular design High-dynamic performance by force and distance regulation and the possibility of transition speed High precision due to adaptable, regulated deflection compensation Simple and comprehensive parameter setting, control, service, via TOX software Can be run on most commonly used operating systems Utmost safety up to and including category 4 as per EN 954-1, Performance level e as per EN ISO and SIL3 as per EN/IEC is possible Stand-alone operation without PC/PLC is possible The system is pre-configured and calibrated, thus, ready for service plug and play Applications for TOX -Servo-System: 1234 Forming Assembling Fastener insertion Edging Bending Drawing Flaring Pressing Squeezing Testing Peening Clinching Riveting Marking Scope of delivery: The set: TOX -Electric Power Module or TOX -Electric Power Curver TOX SoftWare Axis-Controller (line-x shown) Cable set consisting of motor cable, resolver cable and force sensor cable Ballast resistor Mechanical Housing with planetary roller spindle (EPMS 10 with ball screw), working rod, bearing, resolver, motor with reducer, DMS force transducers Controller Complete control unit, incl. ballast resistor and Ethernet cable. Cable set Applicable for use with cable tracks (pay attention to the minimum bending radius). 1x Motor cable, 1x resolver cable, 1x force sensor cable, (standard length 5 m, additional lengths up to 25 m in steps of 5 m are available). Cables for robotic applications available also on request. TOX SoftWare on CD-Rom no licence fee can be updated Independent of operating system free unlimited use without additional cost

3 Network for modern production Process monitoring, operating, programming and diagnostics directly over your network. Quality data Production monitoring Ethernet Production data Zone controller Statistics TOX sofware Logfile PC/Laptop or IPC for servicing, parameter setting and visualization PLC controller Ethernet Fieldbus e.g. Profibus DP TOX -Service: The decisive advantage Dependable service worldwide (see brochure backside) Remote service possible over modem generally installed in each complete machine delivered or via company network (VPN) Wide experience in various applications (general industry, automobile, medical technology, ) TOX is your active partner during the entire project duration, from the planning to the operation stages Installation and process optimization assistance Training at the customer or in-house at TOX Calibration and repair service Hotline service +49 (0) 160 / Maintenance: The electro-mechanical servo systems are designed such that only minimal maintenance work is required. Maintenance-free servo motors Maintenance-free gears Maintenance-free belt drive (for EPMK-/EPMR-Series) Long lubrication intervals for the spindle From single components to complete machines System solutions from one source. See page for application examples

4 The electromechanical servo spindle Design (example: EPMK 55) Anti-rotation for spindle 2 greasing points (plugged) Housing with planetary roller spindle Housing with belt drive Eyebolt provision (both sides) Working rod Mounting pilot Bolt circle for mounting screws Force sensors Resolver (for distance measurement) Electrical interfaces Servomotor Gearbox (not with EPMK 10) Mounting instructions: The working rod should be guided externally in order to avoid any potential side loads. You will find corresponding examples in the TOX - Presses catalog. The connection to the external guidance or ram guide plate must be done using a flexible coupling. For more information on our couplings, please see data sheet for TOX -Powerpackage accessories. Referencing: Generally, referencing is done using the internal positive stop of the servo drive. Alternatively, referencing can be done using an external limit switch. For CAD files, please visit us at Planetary Roller Screw Advantages: Compact design High life expectancy High static capacity due to large bearing area Highest transmission speed Highest efficiency Highest rigidity High revolutions Planetary roller screws are designed for high loads over millions of cycles making them the best choice. We will be glad to provide a calculation of the expected life expectancy if you provide us with your cycle load requirements. The data required or the calculation can be found in your offer or at. The calculated life expectancy is a theoretical value with a 90% probability. Construction of a Planetary Roller Spindle Spindle Planetary roller Spindle nut

5 Model Overview Press force from 0,5 400 kn can be mounted in all TOX press frames (see TOX -Presses catalog) can be mounted in any orientation Electromechanical servo drive with planetary roller screw: High speed Highly dynamic Precise Long lifetime Modular design Precise force measuring Integrated anti-rotation The slim standard drive TOX -Electric Power Module EPMS 10*, 25, 55, 100, 200 kn Standard design Minimum space requirement Applications: Joining machines Assembly machines Special machines The compact drive TOX -Electric Power Module EPMK 10*, 25, 55, 100, 200, 400 kn Compact design Optional brake (see option) Applications: Joining machines Assembly machines Special machines Press drive for presses with the highest safety requirements (see page 2) The robotic tongs drive TOX -Electric Power Module EPMR 55, 100 kn Super compact Super light With special flanging system Application: Minimum space requirement TOX robot mounted clinch units type TZ *EPMS/EPMK 10 with ball screw and without gear reducer. Option: Holding brake/redundant safety brake The EPMK drive can be additionally equipped with brakes: either with a holding brake to avoid a drifting of the working piston in case of heavy tool loads or with a redundant safety brake to fulfill highest safety requirements (see page 2). How to order: EPMS The maximum holding force of the brake is at least 5% of the corresponding nominal force. Technical data and dimensions incl. models with stronger brakes on request. Stroke [mm] Variant number Rated force kn Design: S = standard/k = compact/ R = robotic tongs drive Electric Power Module

6 Data sheet TOX -Electric Power Module EPMS 10, 25, 55, 100, 200 kn For CAD files, please visit us at C I J B U T R M*** K*** G W ØD ØV L ØH ØF A N A2 A1 Dimensions Order no. Type Nominal force Stroke [kn] A A1 A2 B C D Ff7 G H I J K L M N R T U Vg6 Weight approx. W kg EPMS xM8x M12x1, EPMS xM8x ,5 M22x2 48, EPMS , xM10x M30x EPMS xM12x M30x EPMS xM16x M39x Specifications EPMS EPMS EPMS EPMS EPMS Mechanical Rated force* push 10 kn 25 kn 55 kn 100 kn 200 kn Rated force pull 3 kn 7,5 kn 16,5 kn 30 kn 60 kn Stroke** 250 mm 250 mm 300 mm 300 mm 300 mm Max. speed** 300 mm/s 220 mm/s 200 mm/s 200 mm/s 85 mm/s Max. short-term 10% of rated force overload Positional repeatability < ± 0,01 mm under load**** Sensors Load cell 0,5 10 kn 1,25 25 kn 2,75 55 kn kn kn Rated force 10 kn 25 kn 55 kn 100 kn 200 kn Accuracy < +/- 0,5 % of rated force,pressing Resolver x x x x x Resolution 0,0012 mm 0,0004 mm 0,0004 mm 0,0005 mm 0,0003 mm Electrical Protection class Motor/drive IP54 (as component) Mains supply see axis controller Climatic conditions + 10 to + 40 C, from 40 C performance loss, max. 55 C; air moisture < 75%**, without condensation *Recommended operating range 5-100% **Specials on request.(colour, stroke, speed,..) ***Zero position of drive is the reference (marked) position + 3 mm ****in thermal transient condition

7 Data sheet TOX -Electric Power Module EPMK 10, 25, 55, 100, 200, 400 kn Optional with brake for category 4 safety requirements For CAD files, please visit us at J A1 A2 I B U T R M*** K*** G W ØC X ØD P ØY ØV L ØH ØF A N Dimensions Order No. Type Stroke kg EPMK xM8x M12x1, EPMK xM8x ,5 M22x2 48, EPMK , xM10x M30x EPMK xM12x M30x EPMK xM16x M39x , EPMK ± xM24x M64x Nominal force [kn] A A1 A2 B C D Ff7 G H I J K L M N P R T U Vg6 W X Y Specifications EPMK EPMK EPMK EPMK EPMK EPMK ***** Mechanical Rated force* push 10 kn 25 kn 55 kn 100 kn 200 kn 400 kn Rated force pull 3 kn 7,5 kn 16,5 kn 30 kn 60 kn 400 kn Stroke** 250 mm 250 mm 300 mm 300 mm 300 mm 300 mm Max. speed** 300 mm/s 250 mm/s 200 mm/s 200 mm/s 85 mm/s 40 mm/s Max. short-term 10% of rated force overload Positional repeatability < ± 0,01 mm under load**** Sensors Load cell 0,5 10 kn 1,25 25 kn 2,75 55 kn kn kn kn or kn Rated force 10 kn 25 kn 55 kn 100 kn 200 kn 400 kn Accuracy < +/- 0,5 % of rated force,pressing Resolver x x x x x x Resolution 0,0012 mm 0,0004 mm 0,0004 mm 0,0005 mm 0,0003 mm 0,0015 mm Electrical Protection class Drive IP54 (as component) Mains supply see axis controller Climatic conditions + 10 to + 40 C, from 40 C performance loss, max. 55 C; air moisture < 75%**, without condensation *Recommended operating range 5-100% **Specials on request. (colour, stroke, speed,..) ***Zero position of drive is the reference (marked) position + 3 mm ****in thermal transient condition *****EPMK 400 only with Axis Controller line-x available Weight approx

8 Data sheet TOX -Electric Power Module EPMR 55, 100 kn For CAD files, please visit us at D2 D1 C2 C1 C4 X Q C M*** K*** G W F3 F4 F2 F1 ØY ØV L ØJ ØH F C3 N E2 E1 A A1 A2 A3 B U T R P Dimensions Order no. Type Stroke Nominal force [kn] A A1 A2 A3 B C C1 C2 C3 H7 C4 H7 D1 D2 E1 E2 F F1 ±0,02 F2 F3 F4 G H J EPMR , , , EPMR , , , , , Order no. Type Stroke K L M N P Q R T U Vg6 W X Y EPMR M24x1, EPMR M24x1, Weight approx. kg Specifications EPMR EPMR Mechanical Rated force* push 55 kn 100 kn Rated force pull 16,5 kn 30 kn Stroke** 100 mm 100 mm Max. speed** 120 mm/s 120 mm/s Max. short-term overload 10% of rated force Positional repeatability under < ± 0,01 mm load**** Sensors Load cell 2,75 55 kn kn Rated force 55 kn 100 kn Accuracy < +/- 0,5 % of rated force,pressing Resolver x x Resolution 0,00025 mm 0,0003 mm Electrical Protection class Drive IP54 (as component) Mains supply see axis controller Climatic conditions + 10 to + 40 C, from 40 C performance loss, max. 55 C; air moisture < 75%**, without condensation *Recommended operating range 5-100% **Specials on request. (colour, stroke, speed,..) ***Zero position of drive is the reference (marked) position + 3 mm ****in thermal transient condition The tightly toleranced (H7) keyways on the mounting flange provide for precise alignment of the drive with respect to the direction of travel. The height and position of the drive can be precisely adjusted using spacer plates and keys

9 The Servo Spindle in operation Robot guided clinching tongs EPMR 55 used in TOX -Robotic tongs TZ for joining sheet metal EPMR 55 Application: Metal joining with TOX -Round Joint (see brochure: TOX - Joining Systems) Option: Terminal box for starting the compensating slide and the spray lubrication equipment, and manual initiation for spraying a lubricant on to the joining area, if required. TOX -Robot tongs TZ (see brochure: TOX -Tongs) Option: Robot coupling TOX -Electric PowerKurver EPC 90 kn Servo-Drive-Unit with planetary roller screw in combination with our proven TOX -PowerKurver cam activated press design. The large opening angle allows for easy access to tooling. Self-locking Long lifetime Freely programmable opening angles, up to 90. Applications: Clinching Clamping Marking Robot Applications Advantages: Part accessibility Top loading Clamping and Clinching at the same time Accessories such as for TOX - PowerKurver type KK are possible (see TOX -PowerKurver catalog). Ordering example: EPC Version number Opening angle Press force (kn) Electric Power Curver

10 The line-q and line-x idea Between the servo drive and the servicing, parameter setting and visualization, there is always an axis-controller. The functions and interfaces available depend on the type of the axis-controller. Ethernet Option: 24 V DC brake PC/Laptop or IPC for operating and process monitoring Fieldbus I/O Servo motor Resolver signal Control for parameter setting and commissioning For the TOX -ElectricDrive, one may select between two single axis controllers, line-q or line-x. Both lines are identical in their mechanical design and differ only with regards to the number of features. Axis-Controller (Ill.: line-x) Load cell signal Complete program line-q Short lead time Limited in the number of functions and customer interfaces The first choice if the extensive list of functions is sufficient. Spindle (Ill.: EPMK) Complete program line-x Nearly unlimited number of functions with custom interfaces possible. The best choice if the extensive list of functions is already sufficient or can be expanded by the TOX service experts. NETWORK TOX software Ethernet Interbus/ServiceNet/Profibus RS 232/485 PLC TOX -Axis-Controller line-q Q TOX -Axis-Controller line-x X Standard Data bus RS 232 / RS 485 Ethernet TCP / IP Fieldbus Profibus-DP Standard Data bus Fieldbus Ethernet TCP/IP Profibus-DP CanOPEN Optional Interbus instead of Profibus Other Fieldbus available over Gateway, e.g. DeviceNet, ControlNet, Ethernet IP Analog 0-10 V, alternative to Profibus Digital 8 inputs / 8 outputs expandable to 32 Optional Other Fieldbus available over Gateway, e.g. Interbus, DeviceNet, ControlNet, Ethernet IP Analog 0-10 V; two available with one free Digital 8 inputs / 4 outputs expandable to

11 TOX -Axis-Controller line-q and line-x TOX -Axis-Controller: the central intelligence Both freely programmable axis controllers are single axis controllers with integrated logic and servo amplifier. They control and monitor all functions of the TOX -ElectricDrive system. Advantages include the highly dynamic processing of pressing programs and fast reaction to variations in the process. During and after production, the process data can be taken from the controller for further processing or documentation. Configuration and Programming with the TOX SoftWare All parameters, configuration and program functions residing inside the controller will be accessed with the software module TOX -Worx in the software package TOX software. The TOX software is delivered with each TOX -ElectricDrive. The following system requirements are necessary to access the TOX software in the axis controller: TOX software in the axis controller: (Industrial) PC (Pentium III) Operating system WIN2000 or higher Java Runtime Common Characteristics: Faster commissioning, Plug and Work Extensive programming and diagnostic functions Parameter programming of processes (online and offline) Pre-configured and pre-calibrated Maintenance-free Display and monitoring of forcetravel progressions Graphical process analysis Display of process results including status, date and time stamp Target position with monitoring of force limits Target force with monitoring of position limits Window monitoring Sequential control Run according to PLC standard values PLC function blocks e.g. Siemens S7 Deflection compensation Abstract from the standard function library: - Force and/or travel controlled commands - Functions for process control and process data recording - Graphical displays - Processing of input signals as well as definition and setting of output signals - Taring and continuous monitoring of force sensors Quality data management over Ethernet and Fieldbus Commissioning function without PLC Input and allocation of calibration values of the force sensors Integration of external force sensors (DMS and 0-10 V are possible) Functional test of load cells Highest safety category possible (see page 2) Axis controller and ballast resistor can be installed in any applicable standard enclosure Electric connections are provided with plugs Integrated overload functions for motor and servo amplifier Electrical isolation between controller and amplifier 3-cable technology Protection degree IP20, can be extended to IP54 Compact design with direct AC supply and integrated resolver and motor connection For spindle operation, including process monitoring a PC is not required The circuit diagrams are included with the operating manuals. On request, we can provide an info CD including wiring examples, TOX soft- Ware, PLC building blocks and the operating manual immediately after receipt of the order

12 TOX -Axis-Controller line-q Q Status displays LED X2-com-Terminal Programming port X30 AC Input X31 Ballast resistor X40 Category 3 safety X50/X51 Digital Input/Output Status displays LED I/O X13/X14 Active/passive transducer X6 I/O Expansion X4/X5 Encoder input COM 2/3 RS 232 (e.g. barcode input) X3 Encoder output X10 Profibus/Interbus X1 Servo feedback X20 Motor plug X7 Ethernet Special properties of line-q Stores last 1000 process data sets Memory for about 25 processes (for TOX standard workflows) Digital force regulation with 0.5 ms sample rate of 0,5 ms Four controllers are allocated according to spindle sizes and are specially matched to their capacity ranges Customized interfaces are possible within a limited scope Special solutions Complete panel in IP54. Customer specific solutions possible on request. General data and installation requirements Operating conditions Circuit type with grounded star-circuit unlimited use IT-net Follow instructions for special measures! Standards Conformity CE Low voltage directive (73/23/EWG) Approvals UL 508C Power Conversion Equipment (File-No ) Enclosure Enclosure type IP20 not in the connecting area of the Contact protection according to type 1 motor side connectors. Climatic conditions Operation* IEC/EN K3 ( C) Derating of rated output current C: 1,5%/ C air moisture max. 95%, without condensation *Attention: In case of an installation at 1000 m above sea level the reduction of the nominal current will be 15%/1000 m

13 TOX -Single Axis Controller line-q Q 125, , ,5 206,5 243,9 277, ,8 10,5 2,5 7 53,25 Easy installation due to compact cabinet design The TOX -Axis-Controller has been designed for optimized integration. - Standard industrial power input: 3 x 480 V (+5% ; -25%) = V AC 50/60 Hz - Dimensions of controller W/H/D: 273.5/310.8/ mm - Dimensions of ballast resistor W/H/D: 30/60/355 mm - Built-in depth of switch cabinet: 300 mm Standard interfaces Ethernet Profibus or Interbus RS 232 RS 485 Block diagram Use of the TOX -ElectricDrive System Simplified presentation. line-q Ballast resistor Standard Interface, Profibus + UB X31 Rext X10 X2 X7 RS 232 programming process data Ethernet, programming, process data PC Emergency switch button light grille/protective door Optional interface, Interbus delayed to category 3 switching-off X11/X12 X40 X50-52 I/O X13 X1 X20 Force sensor Resolver Motor Servo drive Ordering description: EDC2 See offer or order confirmation for precise description. Emergency switch undelayed Emergency switch box with a delay of approx ms. as per risk analysis and afterrunning test Control, digital, PLC Green: Scope of delivery TOX - ElectricDrive Set Red: supplied by customer

14 TOX -Axis-Controller line-x X Pluggable Axis controller Pluggable modules Basic appliance Mains connection Pluggable I/O connections CANonBOARD Profibus module Ethernet TCP/IP module Analog Inputs/ Outputs Digital I/O Mains filter Mounting socket Axis controller Motor connection Memory module Safety module Diagnostic interface Resolverconnection By plugging the axis-controller to or off the mounting base, it can be quickly connected or replaced. The plug-in system of the modules makes them easy to select and to change: Safety Bus (communication) Intelligence Special properties of line-x Storage of the last 500 process data records Digital force regulation with sampling rate of 1ms Memory for about 270 processes (for TOX standard workflows) Six controllers are allocated according to spindle sizes and are specially matched to their capacity ranges Customized interfaces are generally possible Special solutions Complete panel in IP54. Customer specific solutions possible on request

15 Functions and possibilites of line-x X Exclusive properties of line-x Integrated PLC functionality, IEC Envelope curve monitoring Controlling remaining bottom thickness for clinching (quality dimension X) Integration of external distance sensorics All modules are pluggable Customized fault diagnostics are possible Customized functions are possible Current volume of special function library Process jumps: process calling, subprocess calling With process jumps it is possible to define jumps into other processes during and/or at the end of a process. Spindle data By adding this function, you can change the spindle data on the fly while the process is running. At the end of the process, the spindle data will be reset to the default value. This gives you the possibility to work with additional force sensors on one spindle. Stopping the process By adding this function, the process is stopped. This is useful in combination with the conditional check function. Conditional check function (start-, target-, end condition) Based on a selectable source (IO, Fieldbus, variable). This function gives you the possibility to define multiple conditional targets within a process. Set and evaluate integer and/or real variables This function is used to define an integer and/or real variable for the conditional check function. General data and installation requirements Operating conditions Circuit type with grounded star-circuit unlimited use IT-net Follow instructions for special measures! Standards Conformity CE Low voltage directive (73/23/EWG) Approvals UL 508C Power Conversion Equipment (File-No ) Enclosure Enclosure type EN IP20 not in the connecting area of the NEMA 250 Contact protection according to type 1 motor side connectors. Climatic conditions Operation* IEC/EN EN K3 ( C) Derating of rated output current C: 2,5%/ C max. 85%, without condensation air moisture *Attention: In case of an installation at 1000 m above sea level the reduction of the nominal current will be 15%/1000 m

16 TOX -Axis-Controller line-x X Mounting dimensions Mounting plate Mains filter for EPM x a Size of the TOX -Electric Power Module Dimensions a (mm) Weight (kg) EPMx ,3 EPMx 025 EPMx 055 EPMx ,1 Size of the TOX - Electric Power Module Dimensions (mm) a b b1 b2 e c1 d g m Weight (kg) EPMx ,5 12,5 26,5 EPMx Standard industrial power input: 3 x V (+0% ; -0), Nominal power at 400 V AC 50/60 Hz - Dimensions of ballast resistor W/H/D: 30/60/355 mm - Built-in depth of switch cabinet: 400 mm Blocks diagram Use of the TOX -ElectricDrive-System. Simplified diagram. line-x Ballast resistor Standard Interface, Profibus X105 MXI1 MMI MXI2 Ethernet, programming, process data PC Emergency switch button light grille/protective door approx ms delay Safety category 3 MSI X4, X5 I/O X3 X7 X105 Force sensor Resolver Motor Servo drive Emergency switch undelayed Emergency switch box with a delay of approx ms as per risk analysis and afterrunning test Control, digital, PLC green: Scope of delivery TOX - ElectricDrive Set red: supplied by customer

17 TOX SoftWare Facts and Features for line-q and line-x User friendly Easy configuration Integrated documentation Designed for touch screen use Platform independent Supports all common interfaces Several user levels The TOX SoftWare consists of the programs: Server (connection from the PC to the axis controller), WORX and HMI. TOX SoftWare WORX Project environment The WORX-Module has pre-configured, ready to use press function blocks which can be customized to the individual application. A dialog based project-wizard will aid in the initial setup and assist in the project layout. Projects can be saved and copied as templates for future use. TOX SoftWare is a new, interactive Software Suite with completely integrated controls and monitoring functions specifically designed for all applications. Worx-Project management line-x The user will be able to quickly define and configure new projects without the knowledge of any programming language. Operating interface and software are programmed by TOX and may be adapted in conformity with customer s request. The Windows based user interface has a familiar look and feel enabling quick and easy navigation through the projects. The Explorer-style menu layout supports easy administration of press programs and file handling. Abstract from the function library line-x Programming The process cycle is configured by selecting process specific function blocks from a menu, building a press sequence. No CNC code programming knowledge is required. Click on the Menu function block Enter the required parameters Start the process Control the process Worx Diagram line-x Commissioning An online mode enables the user to monitor all controller functions and I/O in real time for commissioning and troubleshooting purposes. Curve mapping I/O Display Jog function

18 TOX SoftWare HMI HMI-communication environment (HMI = Human-Machine-Interface) The TOX SoftWare includes an HMI for the operator to control and visualize the process. The user platform can be adapted by the user. It is also possible to configure a data export in this part of the software. Manual operation picture line-q Adaptable screen surface Messages can be freely defined (errors, information, status, etc.) Manual / Automatic screen Diagnostic screen with logbook Process data export in Excel-compatible CSV format for quality management Counter (total, IO,NIO, maintenance intervals) Protected against unlicensed change access by authorization Special screens with additional information can be integrated (e.g. temperature indicators, travel measuring systems and the like) Backup of all parameters by pressing a button TTM(TOX Touch Menue) line-q Diagnostic module line-q

19 TOX SoftWare HMI with line-q Q Process control using the window technique Graphics module line-q Monitoring of a force/travel progression of a process with defined windows. + An almost unlimited number of force/travel windows can be defined. Sequential control expanded process administration and simplified conversion scenario Sequence module line-q + Piecepart-specific parameter change by pressing a button and selection of another sequence + Maximum number of processes limited only by the hard drive capacity + Dynamically controlled process flow with IO/NIO statement + Highly efficient manual workplaces thru single cycle control possibility Process data export in graphics module line-q

20 TOX SoftWare HMI with line-x X Monitoring The HMI collects the complete force/travel diagrams and evaluates them with the help of freely programmable windows and/or envelope curves. The values can be zoomed and displayed in different ways. SPC Data can be archived (SPC: statistic process control). Clinching module with envelope curve line-q Simple teach-in mode + Automatic teaching of the processes and the force limits in the target window and the envelope + no programming, just parameter setting + automatic scaling of diagrams Process monitoring using envelope curves The envelope curve determines by two limit curves the path of the force/travel progression + Full monitoring within the set point and target windows, i.e. the force/travel characteristics curve can not fall outside the upper and lower limits + Selection possibility! For curves deviating from the envelope, these options apply: process will continue until target window is reached stop process Clinching module process parameter line-q Clinch module for the modern sheet metal joining technology Precise control of the quality dimension X (remaining bottom thickness after the clinching process) in consideration of the machine deflection. Irregularities in production (fluctuations in sheet metal thickness, fluctuations in surface condition...) could otherwise cause fluctuations of the dimension X. e Control dimension "X" + active stabilization of variances technical optimum achieved with an accuracy of ± 0,04 mm + the X dimension is assured independent of material combination and properties Point diameter Pressing module process parameter line-q Pressing module for highly flexible pressing procedures + Cockpit function due to complete parameter setting on one screen + High precision possible, for example, by the integration of different piecepart specific deflection values in the process flow + High repetitive accuracy, for example, by the possible compensation of dimensional fluctuations of piecepart lengths + Complex process flows can be realized (several jump function, sub-process calling etc.)

21 Control Options for line-q and line-x IP54 enclosure For axis controller package, including fan or cooling unit. Specifications according to TOX Standards. Special executions available on request (Example see picture page 12 and 14). Safety Controls All the following control variants are type-examination tested. Basic Controls: Cycle initiation over 2-hand buttons. Both switches must be held down during the complete cycle. Visualization over IPC with swivel arm to be mounted on pressframe with flange selectively from above or below. Options to Basic Controls: Function safe return stroke. The return stroke of a press takes place automatically after completing the press cycle. The switches do not have to be held down during the return stroke. Function safe speed. The drive extends with a maximum speed of 10 mm/s. The controls can be activated with a 1-hand switch or foot switch. Control with protective door: Cycle initiation by 1-hand switch or foot switch The pressing process is only started if the protective door is closed Light Curtain Controls: Safety guarding and controlling version Two operating modes are available: 1. The light curtain has no controlling function. Cycle initiation over 1-hand switch or foot switch. 2. The light curtain has a controlling function. Cycle initiation after end of light curtain interruption (so-called Talot control) Special executions (on request): Software integration of external components, e.g. sensors for temperature, travel, etc. Activation of additional motions, e.g. for a sliding table, a guarding door, etc. Industrial PC from TOX : the sturdy alternative to usual PC systems Execution IPC with stainless housing, rack mount version High speed IPC in panel mount version Terminal: embedded IPC rack as panel mount Touchscreen 12.1 inch TFT (SVGA) 12.1 inch TFT (SVGA) 17 inch TFT (SXGA) 12.1 inch TFT (SVGA) Operating system Windows XP TOX Linux Software TOX software TOX software Terminal with reduced function, for line-q only Mass storage 40 GB HD 512 MB CF Card Interfaces 2x USB (one front connection), 1 x Ethernet 10/100 Base- T RJ-45, 2 x PS/2, 1 x COM1 RS232, 1 x VGA-CRT, 1 x LPT 2 x USB (one front connection) 1 x Ethernet 10/100 Base- T RJ-45 2 x PS/2 1 x COM1 RS232 1 x VGA-CRT 1 x LPT 4 x USB (two front connections) 1 x Ethernet 10/100 Base-T RJ-45 Ambient temperature +5 C C +5 C C +5 C C In contrast to a terminal, the Industrial PC (IPC) allows additional programs to be installed. Particularly rugged based on solid state circuitry. Offline operation is not possible with this terminal

22 Accessories Grease gun for re-greasing the TOX -ElectricDrive Systems It is a must for the reliable operation of the spindle. Order no.: ZFP Greasing intervals and amount according to the manual, suitable for 400g TOX -Spindle grease cartridge. 400g TOX -Special grease cartridge Order no.: ZFE Automatic lubrication for TOX -ElectricPower Module Possible on request. Calibration equipment type ZKE For the re-calibration of the TOX - ElectricPower Module. The interval for the re-calibration is fixed by customer s quality management. Includes: - Precision force sensor 10, 50, 100 or 200 kn - Digital display unit - Shockproof power cord - Calibration certificate - Aluminum case Applications From the TOX building blocks to special machines Planning and design of complete presses and special machines. TOX PRESSOTECHNIK helps you solve your production demands with the application of specific solutions made with components from our standard product line. Realization of electro-mechanic presses of utmost safety level (see page 2) and tested by the German Employer s Liability Insurance Association. TOX -Press series PC With 2-column ram guide, EPMK 100 with brake, protective hood with exhaust fan, safety 2-hand controls, function safe direction with operator guarding and touch screen IPC with TOX software see picture page

23 Applications TOX -Press series PC With 2-column ram guide, for pressing and pulling operation, EPMK 400 with brake, protective hood with exhaust fan, safety controls with function safe speed, stroke initiation via 1-hand key or foot pedal TOX -Automatic station C-frame type CEJ with CER stand, EPMR 55, TOX -Clinching tools and TOX lube spray equipment TOX -Press series MB with 2-column ram guide, base UUM, EPMK 55 with brake, safety control with protective door and 1-hand key with function safe speed for inching operation with open protective door and TOX software TOX -Automatic station series CMB With linear guided ram mounted in the C-frame, UUM table, EPMK 100, control for automatic operation with touch screen IPC with TOX software TOX -Press series MAG With 4-column ram guide, EPMK 100 with holding brake, slide table with locking cylinder, UUM of welded construction, safety control with protective door and 1-hand key or foot pedal, with touch screen IPC with TOX software TOX -Automatic station C-frame type CEB with CER stand, EPMK 55 positioning cylinder for CEB, EPMK 55 for pressing and pulling operation, EPMK 10 preload axis with external force sensor

24 Product Range TOX -Powerpackage TOX -PowerKurver TOX -ElectricDrive Our Worldwide Sales and Service Network TOX -FinePress TOX -Presses TOX -Controls, TOX -Monitoring TOX -Joining- Systems TOX -Tongs TOX -Piercing and Marking TOX GMBH & PRESSOTECHNIK CO. KG Riedstraße 4 D Weingarten Tel. +49 (0) 7 51 / Fax +49 (0) 7 51 / info@tox-de.com TOX -Fastener- Insertion TOX -Production Systems Subject to technical alternations. 24