Even smarter and more precise joining

In the new 2164A NCFx Pro joining modules, users can choose between two sensor technologies: a piezoelectric force sensor with an especially wide, flexible measuring range and increased overload protection, or a strain-gauge-based (DMS) force sensor. Both sensors are integrated directly in the tool holder of the servo press - right where the joining force is applied.

Compared with their predecessors, the new joining modules are slimmer, faster and optimally designed for future functional enhancements such as predictive maintenance. The NC electromechanical joining modules are also available as an angled design for limited installation spaces.

A basic principle in measurement technology says that the closer a measurement is taken to the point of action, the more accurate the results will be. This is equally true for joining systems whose sensors check whether the system is applying the correct force. Thanks to telemetry, the force sensors on the new electromechanical joining modules in the NCFx Pro series from Kistler are integrated in the tool holder, more precisely on the ram, now, exactly where the joining force is generated.

The transmission from the sensor to the electronics in the joining module housing is purely digital. Data are transmitted via an EtherCAT interface to the maXYmos NC process monitoring system from Kistler. This digital communication offers several advantages: it is less susceptible to interference while offering extensive diagnostic options and direct access to additional sensor data, such as the built-in temperature sensors. What's more, cable length no longer affects measurement accuracy, system stability is further improved, and sources of error are minimised.

Thanks to the new sensor position and digital data transmission, the energy-efficient servo presses achieve a new level of precision for applications in the electronics industry, medical technology and the automotive industry. "Especially in steering, chassis, and axle assemblies or other safety-relevant components, precision and reliability are core requirements for our customers. The new product family offers crucial advantages here," reports Alexander Muller, who is responsible for these joining systems at Kistler.

Flexibility through piezoelectric measurement technology

The strain gauge (DMS) force sensors cover measurement ranges from 2 to 120 kN, while the piezoelectric force sensors cover ranges from 0.05 to 120 kN. Depending on the sensor, seven predefined measuring ranges can be used with the piezoelectric sensors via maXYmos NC process monitoring system. This selection enables more accurate measurements while offering high overload protection, particularly in the smaller measuring ranges. Users also benefit from reduced spare parts inventory and flexible system adjustment without re-calibration.

Both joining-module variants - with either piezoelectric or strain gauge (DMS) force sensors - are designed with a 20 percent overload reserve. This reserve provides additional safety if the actual joining force is higher than expected. Both sensors are mechanically compatible, can be easily exchanged or reordered from 2 kN and can be returned for calibration. An optional DAkkS calibration is already in preparation. Thanks to plug-and-play, the sensors are automatically recognised, including their sensitivity and measuring ranges. This avoids errors during commissioning and greatly simplifies handling.

Simplified integration and commissioning

At speeds of 250 to 500 millimetres per second, the new NCFx Pro electromechanical joining modules from Kistler achieve significantly higher cycle rates and thus increased productivity in automated manufacturing processes. They also feature a more compact design that allows for smaller centre distance and reduces space requirements, simplifying integration into existing machine concepts.

Another advantage is that, up to 60 kN, only a single cable is required to connect the motor for commissioning. The new servo amplifiers ctrlX DRIVE are also more compact and save additional space in the control cabinet. A safety-zone box for the functions SMES, SMST2 and safe limited speed is no longer necessary.

The joining module itself also features a plug-and-play architecture, allowing users to commission it quickly and without extensive parameterisation. The externally located lubrication port enables simple maintenance and connection to a central lubrication system.

Forward-thinking: an accelerometer for future predictive maintenance functionality is already integrated.