Solutions for precise control and monitoring of production processes

Users obtain a full range of force–displacement measurement systems from one source

Kistler extends its maXYmos product family and presented the newly developed maXYmos NC for electromechanical joining modules at Automatica 2014 in Munich, Germany. Visitors also experienced precise joining and testing with the maXYmos BL, specifically designed for hand presses. Kistler’s full range of measurement systems facilitates end-users’ needs and acts as a single integrated source. This allows customers to operate a consistent systems approach for all applications in production – from the manual workstation through to a fully-controlled joining system.

Intelligent sequence control – Enhancing precision
With both manually operated and automatic pressing processes, product efficiency is only assured in a zero-defect environment. The XY monitors from Kistler's maXYmos series enable customers to evaluate production processes, allowing them to operate with process-integration, which enhances consistency and maximizes quality assurance. Faults throughout the production line can be detected early and the relevant product parts removed in good time – increasing product efficiency and avoiding unwanted downtime. Customers are able to conserve resources and increase quality assurance and product safety – ultimately saving substantial time and cost.

A further development to the maXYmos family, the maXYmos NC (numeric control), joining processes can also be monitored and controlled through system integration.

The maXYmos NC evaluates and documents the XY courses of joining and press-fitting processes in connection with the NC joining modules and the associated servo amplifier IndraDrive. Due to the form of the measurement curves, each stage of the production and assembly line – and even the entire product – can be monitored and controlled via SERCOS III all in real-time. In this way, optimum cycle times can be achieved with the highest degree of repeat accuracy and unplanned downtimes reduced, allowing for increased machine availability which accelerates the overall production process.
For actuation of NC joining modules, Kistler has also developed an integrated and user-friendly sequence control system for the maXYmos NC. Programs for press-fitting parts can be created through the intuitive user interface of the touch display, removing the need to be dependent on an external control system. Highly complex processes can be illustrated simply and effectively.

Visitors at the show will be able to witness the intuitive operability and the clear display of the maXYmos systems. The uniform operational interface in XY monitoring enables rapid integration into existing or newly planned systems. External measurement points – such as piezoelectric sensors for calibration or reference measurement – can also be connected at a later time thanks to the diversity of the interface. This ensures the greatest flexibility, both during the installation process and for ongoing data analysis.

Quality assurance for processes on hand presses
Kistler will also present an additional product from the maXYmos range at Automatica in Munich – the maXYmos BL for hand presses. In non-automated operations, this ensures that the processes are performed with reproducible quality using a sequence pre-programmed in the device – irrespective of who is operating the system. Visitors at Automatica will learn how the highly developed piezoelectrical sensor and the clear monitoring enable rapid good/bad feedback and immediate correction or removal of faulty parts. With integrated or upgraded process control, zero-defect production of end-products is possible for each individual manufacturer, regardless of operating personnel.

NC joining systems for reduced power consumption
Kistler's NC joining systems support the automotive and automotive supplies industries in reducing power consumption in series production. This is achieved thanks to their higher level of efficiency when compared to pneumatic or hydraulic processes.
The savings potential of the electrical process is up to 77 percent when compared to hydraulic systems and up to 90 percent when compared with pneumatic process. Production costs fall due to the low cost of system maintenance, which is less than an hour per system per year. The processes implemented with the NC joining systems in assembly and product inspection can be precisely controlled due to the integrated servo amplifier.

Alos, due to the measuring range switchover of the NC joining systems and the simple measuring program switchover which is possible, different components can be produced on one and the same machine. The NC joining systems are installed quickly, as the systems are tested by Kistler prior to installation, enabling operational throughput to be maximized.