TOX SoftWare Facts und Features TOX SoftWare is a new, interactive Software Suite with completely integrated controls and monitoring functions specifically designed for press applications. The user will be able to quickly define and configure new projects without the knowledge of any programming language. The TOX SoftWare Software Suite consists of four modules: WORX CONNECT DIAG WEB 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. 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 projectwizard will aid in the initial setup and assist in the project layout. Projects can be saved and copied as templates for future use. DIAG diagnostics environment The DIAG Module contains all necessary tools to set up local and remote diagnostics. This is the environment for commissioning and troubleshooting with integrated jog functions, simulation screens, communication-test and system calibration tools. WEB information environment This Multimedia area offers all the datasheets, manuals, CAD-Templates and 3-D animations of the entire TOX PRESSOTECHNIK product range. Integrated web browser technology will link the user directly to the TOX PRESSOTECHNIK Website, FAQ and download areas. CONNECT communication environment The CONNECT-Module contains HMI templates which can be tailored to the specific applications. All necessary software and hardware drivers can be configured to the user defined communication protocol allowing easy integration into existing control architectures and setup for communicating SPC data. User friendly Easy Configuration Integrated Documentation Platform Independent Supports all common Interfaces Manual mode screen Automatic mode screen Automatic setup 12
SoftwareSuite The programming interface Communication TCP/IP Internet Profibus Interbus I/O RS 232/ RS 485 Programming The press 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 press sequence Control the process Monitoring TOX SoftWare offers a superior process monitoring utility which allows the display and editing of the recorded press-cycle with complex envelope curves or simple windows which can be easily placed over the curve by a touch of the screen area. SPC-Data can be archived, visualized and edited for further processing. Commissioning An online mode enables the user to monitor all controller functions and I/O in real time for commissioning and troubleshooting purposes. Master curve function Scope function I/O monitor Jog function TOX SoftWare Editing HMI Configuration Process Monitoring Function 13
TOX -Single Axis Controller EDC Compact Status displays LED X2-com-Terminal Programming port 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 X1 Servo feedback X10 Profibus/Interbus X7 Ethernet TOX -Single Axis Controller EDC Compact: The TOX -Single Axis Controller EDC Compact controls and monitors all functions of any TOX -Servo Press System. The TOX -Controller EDC Compact is a single axis CNC with integrated servo amplifier. Compact design with front facing connections Comprehensive programming and diagnostic functions Digital position feedback with 500 µs sample rate Electrical isolation between controller and amplifier Integrated safety functions for motor and servo amplifier Safety category level 3; with additional components safety category level 4 Two (2) power ratings IP54 on request The EDC Compact controller specific features: Parameter style programming of all press or joining applications (online and offline) Display of process results including status Setting an unlimited number of Force- and Displacement limits Date and Time Stamp Graphic analysis of press- or joining results Commissioning function Calibration function Functional test of load cell On board memory for up to 32 applications On board memory for up to 1500 press- or joining results Storage of several press configurations EDC Compact standard interfaces: Ethernet Barcode reader Profibus 2nd load cell interface (analog) RS 232 Other field bus interfaces are RS 485 supported Partial list of pre-configured function blocks: Spindle specific data Pressing or Joining Displacement - Position All Hardware data: - Force - Force - Holding Homing sequence with: - Speed - Speed - SPC Data Handling - Speed - Current limits Transition speed Intermediate and Final Values - Acceleration/ - Position Deceleration - Position - Current draw Process Monitoring - Relative Position - Force TOX SoftWare: The TOX SoftWare is shipped with each and every TOX -Servo Press System. The TOX SoftWare is specifically designed to set-up and program the EDC Compact. System requirements: PC (min. Pentium III) 128 MB RAM Operating System WIN2000 (or higher) Ethernet or RS232 interface 14
TOX -Servo-Press-Systems 125,6 118 55,5 7 273,5 206,5 243,9 277,4 285 310,8 10,5 2,5 7 53,25 Advantages: Simple Setup Our TOX -Servo Press Systems are designed to be an "out of the box" solution, cutting engineering and assembly time to a minimum. - standard bolt mounting pattern - quick disconnects on both ends - "plug and play" - standard industrial power input 380VAC - 480VAC - fast and easy exchange of force transducers - two (2) force transducers possible (Redundancy) Maintenance TOX -Servo Press Systems are designed to reduce maintenance requirements to a minimum thus ensuring uptime and production throughput. - maintenance free brush-less DC Servo Motor - extended lubrication intervals - integrated diagnostics - maintenance free planetary gearbox Planetary Roller Screw Longest life time Highest power density Highest transmission speed Highest static capacity Highest efficiency Highest rigidity High revolutions with up to 6000 min -1. Our planetary roller screw is designed to the highest standards in the industry ensuring the highest life expectancy under full load cycles. TOX -EDC Elements of a Planetary Roller Screw, providing compact design. 15
Design of TOX -Electric Power Module EPMK Press forces from 1 200 kn Scope of delivery TOX -ElectricDrive Set TOX -Electric Power Module or TOX -Electric Power Curver Cable set consisting of motor cable and sensor cable Controller Ballast resistor Accessories Grease gun for re-greasing the TOX -ElectricDrive Systems, Greasing intervals and amount according to the manual, suitable for 400g TOX -Special grease cartridge 400g TOX -Special grease cartridge 16
Block diagram: Use of the TOX -ElectricDrive System. EDC Ballast resistor Emergency switch button Standard Interface, Profibus Optional interface, Interbus Safety category 3 + UB X31 Rext X10 X11/X12 X40 X50-52 I/O X2 X7 X13 X1 X20 RS232 programming Ethernet, programming, process data Resolver/force transducer Power PC Spindle Emergency switch Emergency switch box with a delay of approx. 150-500 ms. Control, digital, PLC Green: Scope of delivery TOX -Electric- Drive Set Red: supplied by customer Special solutions Complete panel in IP54. Customer specific solutions possible on request. System comparison of hydraulic machines and TOX -ElectricDrive Systems Hydraulic machine Electromechanical Servo machine Installation work of each individual component High Low Additional accessories, hydraulic units, valves Many No Error sources during installation High due to the amount of components Low Flexibility stroke Only manual, / dead stops With PC or PLC Flexibility force Only manual / pressure With PC or PLC Flexibility speed Only manual / regulator With PC or PLC Flexibility acceleration No With PC or PLC Transition speeds between approach- / No Freely programmable power stroke Monitoring stroke Yes, with optional monitoring equipment Yes Monitoring force Yes, with optional monitoring equipment Yes Freely programmable sequences No Yes Cycle time optimization variable via controller No Integrated in sequence Constraints by cables (e.g. radius) No Obey minimum cable radius Constraints by hoses (e.g. radius) High, hose type, minimum radius No Danger caused by high voltages No Yes Danger caused by high air- or oil-pressures Yes No Emission issues caused by air or oil High No Communication interfaces, effort! Extra modules, additional work and cost Included, standard Profibus Extra module, additional cost and space Yes Ethernet No TCP/IP Interbus Extra module, additional cost and space Yes, optional instead of Profibus PLC Yes Yes Inputs/Outputs Extra module, additional cost and space Eight (8) I/O's - expandable Protection class IP 54 IP 54 possible Accessories 17